description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 09/776,523, filed Feb. 2, 2001.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
This invention relates in general to braces for joint support, and in particular to an exteriorly positionable anatomical brace having a pivoting joint assembly with multi planar hinging for accurate alignment of joined limb structures in relation to each other, and additionally having an infinitely-adjustable, cable-controlled limb extension regulator.
Both injury and disease can affect the health, well-being, and operability of various joints of the human body. Chief among such joints are the knee and elbow where disease such as osteo-arthritis can curtail normal activity or where an injury such as a sports-related abuse or impact can prevent or severely limit continued activity. One manner of treating such joint conditions and/or preventing or reducing the severity of sports related injuries is to fit the wearer with an appropriate brace whereby a pivotal support member is positioned adjacent the affected joint and held in place usually by cuffs situated around limb structure sites above and below the supported joint. As is apparent, the cuffs are responsible for stabilizing the support member and therefore must be well secured to their associated limbs. In addition to requiring proper limb structure embrace by cuffs, a joint brace also requires a joint pivoting assembly that supports, stabilizes, and protects the actual joint itself while pivotally joining the cuffs. Thus, in the knee joint for example, the joint pivoting assembly of the brace most beneficially should pivot in one bending or extension plane while also permitting multi planar motion such that the lower leg beneath the knee can be moved in a normal manner and the upper and lower leg structures can align with each other in a natural manner. Further, it many times is desirable to be able to precisely and infinitely limit or regulate the distance of the pivotal extension plane at the knee while allowing natural bendability and normal multi planar motion up to the controlled extension distance. Unfortunately, however, present braces generally are not able to offer multi-planar alignment capabilities or infinite extension control, thereby requiring a user to endure single-plane pivotability along with either a self-limit or pre-set limit of limb extendability. In view of such restrictions, it is apparent that a need is present for a joint brace that permits substantially natural limb movement in conjunction with limb extension control as indicated for particular limb care.
Consequently, a primary object of the present invention is to provide a joint brace having a joint assembly with multi planar hinging for accurate alignment of joined limb structures in relation to each other.
Another object of the present invention is to provide a joint brace having an infinitely-adjustable limb extension regulator for limiting limb extension as indicated for a particular user.
These and other objects of the present invention will become apparent throughout the description thereof which now follows.
BRIEF SUMMARY OF THE INVENTION
The present invention is an exteriorly positionable anatomical brace for stabilizing a uniting pivoting joint such as a knee joint disposed between a first and second limb structure of a living being. The brace comprises an upper frame member and a lower frame member joined together by a pivoting joint member, with each such frame member having secured thereon a respective cuff for encompassing a portion of each limb structure above and below the joint. Retention of the brace in place at the joint site is preferably accomplished with respective upper and lower securement members each wrapping around a respective limb structure in alignment with and not encompassed by the cuff. The pivoting joint member comprises two opposing pivoting assemblies each positionable on one side of the anatomical joint of a wearer to thus join the upper and lower frame members together. Each of these assemblies includes a forward arm member and a rearward arm member each having an upper end and a lower end, with these ends connected respectively to the upper frame member and the lower frame member. Specifically, the upper ends of each arm are individually mounted within a spherically-pivotal socket in connection with the upper frame member, while the lower ends of each arm likewise are individually mounted within a spherically-pivotal socket in connection with the lower frame member. As is apparent, these individual spherical mounts permit the selection of differing pivot ratios at a total of eight sites (four sites per lateral and per medial side) to thereby enable the upper and lower frame members to assume many different angular relationships with each other. Because of the availability of such a vast number of relationship combinations, the frame members of the brace becomes substantially self-aligning with each individual joint encounter among many wearers, thus accomplishing simulation of actual limb movement and angular interrelations thereof as natural individual limb-structure correlations are maintained.
As earlier noted, proper joint care many times requires limited or regulated limb extension, with such control emanating at the pivoting joint member. While prior art controls typically include inserts of a predetermined size for placement in the base path of upper and lower frame travel, the limb extension regulator of the present invention is a cable, preferably fabricated of braided metal strands, extending between each rearward arm member and the upper frame member. A cable-length adjuster, preferably externally accessible, is provided for infinitely adjusting the length of cable available between the arm member and frame member to thereby regulate extendability of the brace-bearing limb. Most preferably, a visible measurement scale is provided for each cable such that available cable length on each side of the joint is adjusted to be substantially identical. In addition to being infinitely length-adjustable, the cable additionally provides a modicum of elasticity such that cessation of limb travel produces a less dramatic limb impact, but, instead, a gentler limb-extension termination for the wearer. The brace here defined therefore substantially simulates natural joint behavior along with extension control as individually indicated.
BRIEF DESCRIPTION OF THE DRAWINGS
An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which:
FIG. 1 is a perspective lateral view of a knee brace with upper and lower cuffs of respective upper and lower frame members in place on a patient leg shown in phantom;
FIG. 2 is a perspective medial view of the knee brace of FIG. 1 ;
FIG. 3 is a lateral perspective view of the upper cuff and upper frame member only of FIG. 1 in disassociated relationship;
FIG. 4 is a medial perspective view of the upper cuff and upper frame member only of FIG. 3 ;
FIG. 5 is a rear perspective view of the upper cuff and upper frame member of FIG. 1 in place on a leg;
FIG. 6 is an interior perspective view of a portion of the upper cuff of FIG. 1 ;
FIG. 7 a is an interior side elevation view of the upper cuff of FIG. 4 ;
FIG. 7 b is a schematic interior side elevation view of the cuff of FIG. 7 a showing tensioning thereof;
FIG. 7 c is a top plan view along line 7 c — 7 c of FIG. 7 a;
FIG. 8 is an inner perspective view of the joint assembly and respective portions of joined upper and lower frame members of FIG. 1 ;
FIG. 9 is an exploded perspective view of the joint assembly and frame members of FIG. 8 ;
FIGS. 10 a and 10 b are perspective views of the inner and outer sides of the joint assembly of FIG. 8 ; and
FIG. 11 is an exploded perspective view of the joint assembly of FIG. 10 a.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIGS. 1-5 , a knee brace 10 is shown ( FIG. 1 ) in place on a leg 12 of a human being. The brace 10 has an upper frame member 14 and a lower frame member 16 , with each such frame member 14 , 16 having secured thereon a respective cuff 18 , 20 for disposition about the limb structures above and below the knee joint 22 . Each cuff 18 , 20 is an arcuate wall structure, which non-limitedly can be fabricated of a polymer plastic, for juxtapositioning with the respective limb structures as shown. A snap-in protective patella cup 24 can be included as shown for specific impact absorption that may occur at the patella of the knee joint 22 .
The knee brace 10 is retained in place on the leg 12 with respective upper and lower securement members 26 , 28 each respectively wrapping around an adjacent rear portion of the leg 12 . While FIGS. 2-5 show only the upper securement member 26 , it is to be understood that the following description thereof applies equally to the lower securement member 28 . Thus, the securement member 26 includes a medial piece 30 and a lateral piece 32 each attached at outside edges thereof to an elastomeric central piece 34 disposed behind the medial and lateral pieces 30 , 32 . Respective inside edges 40 , 42 of the medial and lateral pieces 30 , 32 are provided with eyelets 44 through which is intertwined a length of non-elastomeric lace 46 in substantially the same manner as a shoe is laced to thereby permit the drawing of each inside edge 40 , 42 toward each other. As would be recognized by the skilled artisan, hook-and-loop connectors (e.g. VELCRO) or other appropriate engagers can be employed in place of the length of lace 46 . Finally, the elastomeric central piece 34 is secured along a generally central vertical length 48 thereof to a liner section (not shown) situated behind the central piece 34 to thereby permit elasticized movement of the medial and lateral pieces 30 , 32 .
The lateral piece 32 is releasably secured respectively to the upper cuff 18 and the upper frame member 14 , and the medial piece 30 is releasably secured to the upper frame member 14 and the medial condyle 52 , all by way of respective quick-release tab members 54 situated within respective slots 56 . As shown, each tab member 54 is provided with a finger-receiving pressure button 58 which, when depressed, permits removal of the tab member 54 from the slot 56 . In operation, the brace 10 is placed at the limb site of a user and positioned about the involved limb structures. Upon first placement of the brace 10 , the lace 46 is tightened to appropriate tightness while the central piece 34 increases surface area on the leg 12 to disperse pressure and prevent pull from the leg 12 such that the cuff 18 is properly maintained in place. Once such lacing is accomplished the first time, re-lacing is not required during brace use. Specifically, when a user wishes to remove the brace, the user simply presses inwardly on the pressure buttons 58 of only laterally, or, preferably, only medially, situated tab members 54 to release these tab members 54 from their respective slots 56 and remove the brace 10 from the leg 12 . It is important to note that the above-described tab-member release does not require increased tension on the leg and therefore is both safe and comfortable. Subsequent re-positioning of the brace 10 merely requires placement thereof as previously situated and re-connection of the earlier disengaged tab members 54 into respective slots 56 . This re-connection requires no contact with, or re-adjustment of, the lace 46 or the central piece 34 , and thereby assures proper brace placement without awkward, and very possibly incorrect, orientation of the brace 10 . Because the medial connection involves connection to the medial condyle 52 which is, of course, at the hinge point of the upper and lower frame members 14 , 16 , a closer positioning of the securement member 26 to the body joint is permitted, thereby improving joint support. While a lateral condyle 60 does not bear a connector member, it is to be understood that such construction could be provided if desired.
Construction of the cuffs 18 , 20 is illustrated in FIGS. 6-7 c . Both the upper cuff 18 and lower cuff 20 are substantially identical in construction except for overall size since, of course, the lower cuff 20 encompasses a smaller-diameter limb portion below the knee joint 22 . As shown particularly in FIGS. 6 and 7 a with respect to the upper cuff 18 , whose following description also applies to the lower cuff 20 , the cuff 18 has two tensioning strip members 62 , integral therewith and disposed within respective non-continuous sleeves 64 , 66 that are structurally a part of the cuff 18 and that converge toward each other medially. Each strip member 62 , which preferably is fabricated of titanium, stainless steel, or similar material possessing similar tensioning properties, continues medially into a cuff mount 68 that functions to secure the cuff 18 to the upper frame member 14 . Finally, a respective exteriorly-accessible threaded screw 70 extends into each strip member 62 for adjusting tension in each strip member 62 and simultaneously adjusting the arc defined by the upper cuff 18 . Thus, clockwise turning of the screw 70 incrementally draws the lateral end of the strip member 62 medially for arcuately tightening the cuff 18 , while counter clockwise turning of the screw 70 incrementally releases the lateral end of the strip member 62 for arcuately loosening the cuff 18 . Operationally, the brace 10 is fitted to a patient by encompassing the cuffs about the respective limb structures above and below the knee joint 22 as seen in FIG. 1 . Once the upper cuff 18 is situated about the limb structure, the screws 70 are threadingly advanced to thereby cause movement of the lateral end of the cuff 18 , as illustrated in FIGS. 7 b and 7 c , against the limb structure as the strip members 62 are forced to bend toward the encompassed limb structure. Continued screw advancement increases tightening of the cuff 18 against the encompassed limb structure to thereby accomplish superior anchoring of the brace 10 and consequent stabilization of the knee joint 22 . As earlier noted, the lower cuff 20 is constructed in the same manner as the upper cuff 18 and therefore encompasses and embraces the limb structure below the knee joint 22 in like fashion.
Referring to FIGS. 8-11 , the pivoting assembly 72 uniting the upper and lower frame members 14 , 16 is illustrated. The assembly 72 includes an upper housing 74 and a lower housing 76 that fit, respectively, into a complementarity shaped opening 78 of the upper frame member 14 and a complementarity shaped opening 80 of the lower frame member 16 . Once so positioned, respective caps 82 , 84 are held in place with conventional set screws 86 passing respectively through apertures 88 a , 88 b and 90 a , 90 b . Those skilled in the art however will recognize that the housings 74 and 76 can be formed unitary with the frame members 14 and 16 . The lateral condyle 60 resides between the assembly 72 and the knee joint 22 . Both the upper and lower housings 74 , 76 have two respective openings 92 a , 92 b and 94 a , 94 b each having respective sidewalls 96 shaped to nest a spherical shape. Disposed between two openings 92 b , 94 a of the housings 74 , 76 is a forward arm member 98 having generally perpendicularly angled first and second ends 100 a , 100 b directable toward the openings 92 b , 94 a . In like manner, a rearward arm member 102 having generally perpendicularly angled first and second ends 104 a , 104 b is disposed between two openings 92 a , 94 b of the housings 74 , 76 such that the ends 104 a , 104 b are directable toward the openings 92 a , 94 b . A cable assembly 106 includes a cable 108 extending from the upper housing 74 to an upper edge portion 110 through an aperture 112 of the rearward arm member 102 , and is provided with a conventional set screw 114 at one end thereof for extending or shortening the length of the cable 108 disposed between the rearward arm member 102 and upper housing 74 . Such length adjustment is accomplished with an Allen wrench inserted into the enterable channel 116 leading to the set screw 114 . Because the upper housing 74 resides within the upper frame member 14 , the cable 108 functions as a joint extension limiter to determine the travel distance of the upper frame member 14 from the joint and thus the pivotal distance of the upper and lower frame members 14 , 16 in relation to each other. An opening 126 can be provided in the cap 82 such that the progressive placement of the cable 108 can be observed exteriorly and such placement can be made identical for both the lateral and medial sides. Two additional benefits are provided by the cable 108 in that, first, infinite pivot-distance adjustability, as opposed to prior-art pre-sized stop members, allows great flexibility in leg extension, and, second, the cable itself has a dampening, or minimal stretch, effect that results in a softer extension stop and a consequent reduced risk of joint trauma.
As earlier described, the sidewalls 96 of the openings 92 a , 92 b and 94 a , 94 b are shaped to nest spherical forms. As clearly illustrated in FIG. 11 , spherical sockets 118 a , 118 b, 118 c , 118 d are disposed in these openings 92 a , 92 b and 94 a , 94 b in the constructed assembly 72 , and each such socket accepts one respective perpendicularly angled end of forward and rearward arm members 98 , 102 . Each angled end 100 a , 100 b , 104 a , 104 b has an aperture 120 there through which mates with a transverse aperture 122 of each socket 118 a , 118 b , 118 c , 118 d such that respective pins 124 can pass through such mated apertures and retain the angled ends 100 a , 100 b , 104 a , 104 b within the sockets 118 a , 118 b , 118 c , 118 d . Because of the spherical interface between each socket 118 a , 118 b , 118 c , 118 d and each sidewall 96 , multi planar movement of the upper and lower frame members 14 , 16 in relation to each other can be accomplished. In particular, the different pivot points thus provided allow different pivot ratios as needed for both lateral and medial sides to thereby simulate actual knee joint movement. This is, of course, in contrast to parallel planar hinges as found in the prior art where the knee joint and limb structures of a user are forced to adapt to knee brace construction instead of the knee brace adapting to the needs of the user. The present knee brace 10 , because of the multi planar and potentially differing pivot ratios and consequent multi planar movement capabilities of the lower frame member 16 in relation to the upper frame member 14 , provides automatic tibia alignment and automatic anatomical changes over time by accommodating anatomical differences among users. These properties accomplish all-important positive three-point positioning at the quadriceps muscle, the gastrocnemius (calf) muscle, and the knee joint itself. In this manner, stabilization and support of a uniting pivoting joint occurs economically, through an “off-the-shelf” brace, and, simultaneously, most effectively through continual self-alignment capabilities combined with sound limb-structure stability.
While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | A brace for stabilizing a joint such as a knee disposed between a first and second limb structure. The brace includes upper and lower frame members, cuffs for encompassing a portion of each limb structure, and a uniting pivoting joint member. The joint member includes two opposing pivoting assemblies, with each including a forward and a rearward arm member each having upper and lower ends spherically-pivotally connected to the upper and lower frame members for enabling multiple angular relationships. The pivoting assembly can include a limb extension regulator, preferably a cable, extending between the rearward arm member and the upper frame member to permit infinitely adjustable extendability of the brace-bearing limb. Most preferably, a visible measurement scale is provided for precise extension distances. | 0 |
BACKGROUND OF THE INVENTION
Tag axles are known in the art and are used as an expedient for reducing the per-axle load in a vehicle, Generally, when a vehicle is loaded, whether it be a dump truck, concrete mixer truck, or other load-carrying vehicle, the axle weight can be increased beyond that permissible for over-the-highway travel. This can result in damage to the highway and the truck and can create a hazard to the operator of an overloaded vehicle. A tag axle can be used to further distribute the vehicle and payload weight. The tag axle is loaded to relieve the other axles, and to that extent the load is relieved on the remaining axles, the per-axle weight is brought within that permitted by the various state laws for over-the-highway travel.
Unfortunately, tag axles in present use tend to be cumbersome and ineffective. Existing tag axles are mounted in such a way that when the wheels are moved downwardly into ground engagements, the limits of vertical movement of the tag axle are so limited that, in many cases, when the vehicle is moving under uneven terrain the tag axle bottoms out on the frame, and weight is lifted off the rear axles and tandem axles and transferred excessively onto the tag axle causing the tag axle wheels to dig into the ground. This is called "ploughing", and is an inherent result of many of the presently used tag axles because there is insufficient vertical movement for the tag axle before bottoming out on the frame.
Moreover, the air brakes and other associated power equipment for operating the air brakes are mounted in such a way on the tag axle as to interfere with normal and expected operation of the tag axle. In supporting the tag axle so that it can move vertically to cushion the load at the rear of the vehicle it is common present practice to use the large, weight-contributing structures which tend to limit normal operation of the tag axle.
In the present invention the purpose is to eliminate the previously used constructions which consisted of large centering guides, cross braces and blocks for guiding the wheels, as well as the inapt location of the air brake power actuation equipment, and substitute in its place a much simpler, cleaner construction in which the tag axle is supported and guided laterally by means of elevated guide means located one at each side of the frame and having rollers which engage in tracks or other bearing structures. In this way, the primary object of the invention is achieved, which is to permit minimized unsprung tag axle weight and a construction that avoids ploughing, i.e., digging into the ground when the vehicle is moved over irregular terrain and in which the components are more protected and less obstructive to normal vertical movement of the tag axle.
However, the means for guiding the wheels is greatly improved in that the wheels are permitted to move freely in a vertical sense, and one wheel can even move in a limited vertical sense relative to the other, to provide for normal encountering with chuck holes, potholes, and the like. At the same time, the wheels are prevented from moving laterally back and forth sidewise of the frame, and one wheel is prevented from advancing relative to the other along the length of the frame. Thus, the tag axle is prevented from pivoting about a vertical axis but can move perpendicularly, to allow for normal cushioning of the vehicle. But lateral movement of the wheels, i.e. movement horizontally to the frame, either side to side at the frame, or front to back of the frame, is totally prevented.
Each of the wheels includes a fender, and the fenders are braced for vertical movement with the wheel, the bracing being accomplished also through the tag axle.
It is possible, therefore, with existing vehicle structure, to take what is a commonly available tag axle. invert its normal position, weld to the existing frame a downwardly and rearwardly projected leverage system for supporting the tag axle, and then suspend the tag axle in a normally retracted position by means of springs located one on each side of the rails of the frame. Each side of the axle is then actuated by an associated air bag to effect downward movement of the wheels (rotatably supported on the tag axle) into ground engagement and thereby to distribute the vehicle load.
Other objects and features of the present invention will beome apparent from a consideration of the following description, which proceeds with reference to the accompanying drawings.
DRAWINGS
FIG. 1 is an isometric view of a front discharge concrete mixer unit having the present invention installed thereon;
FIG. 2 is a rear view looking from the rear of the vehicle and illustrating details of the tag axle construction;
FIG. 3 is an enlarged detail view illustrating the tag axle in retracted position; and,
FIG. 4 is a view similar to FIG. 3, but illustrating the tag axle in its operation position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a vehicle designated generally by reference numeral 10, consists of a front discharge concrete mixer unit described in complete detail in several issued patents, one of the principal ones of which is the now expired J. Jack Willard U.S. Pat. No. 2,859,949, issued Nov. 11, 1958, entitled "FORWARD DISCHARGING TRANSIT CONCRETE MIXER. "
Briefly, the front discharge mixer truck 10 consists of a bowl 12 which is mounted on a frame 14 and having a front axle 16 with ground engaging wheels 18,20 and tandem axles 24,26 each having a pair of wheels 28 and 30. Connecting the frame 14 to the tandem axles is a tandem axle support flange 31 and a pivot 32 for an axle beam 34. Stub axles (not shown) project from opposite ends of beam 34 to provide the anti-friction bearings on which are mounted the respective pairs of wheels 28,30.
At the front end of the vehicle 10 is a cab 36 and an extendable chute 38. Concrete, at the time of discharge, emerges from the forward open end 40 of the bowl 12 and is discharged into a hopper 42 with a discharge opening directed into the chute 38. The bowl is supported by means of stanchion 44 having rollers which engage a bearing collar 46 on the drum to rotatably support the forward end of the drum and the rear portion of the drum is rotatably driven and supported by a rear stanchion 48. The drum is rotated by means of a chain or gear arrangement, the particular arrangement shown herein consisting of a gear box 50 and transmission 52 which is driven by a power takeoff from engine 54.
Referring now to FIGS. 2, 3, and 4, there is shown a tag axle 56 having a pair of wheels 58 and 60, one pair at each of opposite ends of the tag axle. Tag axle 56 also includes two upright arms 62,64, each having an anti-friction roller bearing 66 in operative slideable engagement with bearing surfaces 68,70 secured to frame 14 so that tag axle 56 can move in a vertically upward and downward direction indicated by double arrow headed line 72. At the same time, the tag axle is prevented from moving in a horizontal direction indicated by the double arrow headed line 74 (FIG. 2) and the axle is prevented from moving in either direction indicated by double arrow headed line 76 about a vertical axis. Slight movement is permitted in a vertical sense by the right-hand pair of wheels 58 relatively to the left-hand pair 60 to compensate for chuck holes and the like so that the truck will not be caused to tilt as it moves over rougher terrain. This relative vertical movement is, however, quite slight and limited in its nature.
Referring to FIGS. 2, 3, and 4, the tag axle 56 is supported on a pair of articulated arms 78 and 80, 78 being secured by rivets 82 or the like to framerail 84 and arm 80 having pivot connection to 86. The tag axle 56 is supported at end 88 of arm 80 which is biased to the upward or raised position indicated in FIG. 3 by a pair of springs 90 which are stretched between a channel 94 secured to arm 78 and a second channel 96 operatively secured to the underside of lever 80. Thus, the tag axle is held in a raised position, FIG. 3, until one of a pair of air-actuated bellows, or air bags 91, 92 is energized to lower the wheel sets 58,60 into engagement with ground 100 (FIG. 4). Each wheel of the pairs of wheels 58 has a fender section 102 which is operatively secured to its associated upright arm 62,64 (FIG. 2).
As viewed in FIG. 2, the side rails 84 of the frame are fastened together by means of a cross-brace 104 which is disposed just to the rear of rear-mounted engine 54.
Above the level of the cross-brake 104 is a rear bumper 108.
One of the important advantages of the present invention is that the tag axle 56 can move up or down in the direction indicated by the double headed arrow line 72 in FIG. 2 and without interfering with any of the existing structure of the vehicle. Thus, the cylinders 112 which are the power cylinders for operating the brakes (not shown) associated with the pairs of wheels 58,60, can be disposed at a lower level on the tag axle 56 which is inverted (in a vertical sense) from the conventionally mounted tag axles so that the tag axle and its associated equipment can move upwardly and downwardly through a substantial distance and without interfering or engaging with surrounding truck structure. The tag axle 56 can move up and down under high loads; while the vehicle is going up inclines, the tag axle 56 is enabled to move upwardly sufficiently and without coming into contact with the chassis of the truck so that no part of the truck weight is transferred off wheels 28,30 and onto wheels 58,60. This avoids the "ploughing" effect common in previously employed tag axle arrangements.
The air bags 91,92 permit the pairs of wheels to move up and down in a vertical sense (line 72) and such movement is permitted because the wheels 66 have anti-friction roller bearing against the opposed bearing surfaces 68,70 of guide plates secured to rails 84. Thus, the wheels are efficiently guided in a vertical sense permitting shock absorbing vertical movement, but the wheels are prevented from moving in a lateral sense indicated by line 74 in FIG. 2 or rotating about a vertical axis (line 76, FIG. 2). One set of wheels 58 can move to a slight extent relative to the other set of wheels 60 to compensate for chuck holes and depressions while the other is on level ground, thus permitting the slight movement of one set of wheels relative to the other. Consequently, the truck does not tend to tip. It should be borne in mind, however, that this relative vertical movement of one set of wheels over the other is slight, in the order of only 3 or 4 inches or so.
OPERATION
In operation, the vehicle 10 is loaded with concrete, the charge being received in rotatable bowl or drum 12 and the driver of the vehicle then proceeds to the building site where the concrete is to be discharged. In transit, the bowl continuously rotates at a slow but controllable speed in order to keep the concrete from "setting up," and maintaining a substantially constant slump value for the load.
Should the load on front axle 16 and tandem axles 24,26 be excessive so as to approach the upper limit of permissible axle loading or upper limit determined by so-called "bridging" law, then the tag axle 56 is actuated to relieve some of the load on these other three axles, this being accomplished by energizing or actuating the air bags 91,92. When the air bags 91,92 are inflated to the desired extent, the arm 80 is pivoted downwardly about 86, bringing the tag axle 56 and wheels 58,60 in a downward direction and causing the wheels 58,60 to come into ground support 100 at which time a part of the load of the vehicle is transferred onto the tag axle 56 and correspondingly relieving at least some of the load on the remaining axles 16,24,26. In this way, the per-axle loading of 16,24,26 is relieved, thus making the load manageable and within the axle-loading limitations prescribed by state law for over-the-highway vehicle transit of the load.
Movement of the tag axle is permitted in a vertical sense, but other movements of the tax axle, either in a horizontal sense (indicated by double arrow headed line 74) or torsional sense (indicated by the arrows 76) is prohibited by means of the anti-friction wheels 66 which are carried by arms 62,64 and secured to the tag axle 56. Movement of the anti-friction wheels 66 on the opposed bearing surfaces 68,70 precludes movement of the wheels except in a vertical sense, while permitting only slight differential vertical movement of each set of wheels 58,60 at the opposite sides of the truck.
Because there are no obstructing sections of the frame, rear bumpers, and other such support components by reason of the unique construction and placement of the tag axle 56, such tag axle 56 can move through a greater vertical extent, and avoid obstructions and bottoming out relative to the frame. This permits a movement through a substantial vertical extent, and by avoiding bottoming out of the tag axle on the frame because of the unique "inverted" positioning of the axle relative to the frame, there is no transfer of excess vehicle loads onto the tag axle such as would normally occur should bottoming out take place while the vehicle is going on an incline. Whenever the tag axle does bottom out on the frame, the rear axle wheels are sometimes literally raised off the ground, and thus all of the weight of the vehicle is borne by the front axle and the tandem axle. This result is entirely obviated in the present invention because of the unique inverted or "upside down" placement of the tag axle so that neither the brake actuator components, the axle itself, or any of the associated structure is likely to come into engagement with the frame. The length of arms 62,64 multiplies the resisting torque of bearings 66 to inadvertent and unwanted movement of the tag axle 56 except in its prescribed vertical movement. The efficiency of such arrangement over the previous gripping of tag axle 56 is apparent. There is less opportunity, or, more correctly, no opportunity for the mounting, shock absorbing, or other truck related tag axle structure to come into engagement with the frame, or interfere with the desired scope of vertical movement required for proper tag axle operation.
When the pressure in air bags 90,91,92 is relieved, the springs 90 retract the tag axle 56 and associated wheels 58,60, causing them to raise vertically to the position shown in FIG. 3. The fenders 102 for the wheels, being attached one to each of the arms 62,64 is likewise raised to transport position. Altogether, the improvement obtained results in a more economical tag axle construction because of the greatly reduced weight at the cantilevered end of the truck: the tag axle 56 can move through a greater vertical scope and without having any of the associated structure come into engagement with the ground 100 or other vehicle components. More efficient guidance is provided and at a higher level, making it more efficient by increasing the lever arm for the guidance roller 66 (note the substantial length from the center line of the tag axle 56 to the point of engagement between roller 66 with the opposed bearing surfaces 68,70, in FIG. 2), and consequently the guidance is more precise and appropriate to the type of movement expected from the tag axle 56.
Although the present invention has been illustrated and described in connection with a few example embodiments, it will be understood that these are illustrative of the invention and are by no means restrictive thereof. It is reasonably to be expected that those skilled in this art can make numerous revisions and adaptations of the invention, and it is intended that such revisions and adaptations will be included within the scope of the following claims. | A tag axle is mounted to the frame at the rear of a vehicle on an articulated linkage which extends downwardly and rearwardly. Springs bias the tag axle and its bearing-supported wheels in an upward direction. The tag axle is actuated downwardly by two air bags, one at each end of the tag axle. The tag axle provides vertical support at the rear of the vehicle through the air bag actuators. The tag axle is guided vertically by means of two upright arms, one at each side of the frame, and including anti-friction roller bearings and associated tracks which permit free vertical movement of the tag axle but prohibit lateral and torsional, and limit differentially vertical, movement of the wheels. A greater vertical movement of the tag axle is permitted because of the location and disposition of the tag axle and associated components, thereby preventing ground-bottoming or ploughing by any component at the rear portion of the vehicle. The total package is lighter and more compact to reduce weight and cost. | 1 |
BACKGROUND
[0001] Field
[0002] The present disclosure generally relates to a color conversion substrate, a method of fabricating the same, and a display device including the same. More particularly, the present disclosure relates to a color conversion substrate able to obtain long-term stability in quantum dots (QDs) and a superior degree of color conversion efficiency in the color conversion substrate, a method of fabricating the same, and a display device including the same.
[0003] Description of Related Art
[0004] A light-emitting diode (LED) is a semiconductor device formed of a compound such as gallium arsenide (GaAs) to emit light when an electrical current is applied thereto. The LED uses a p-n junction semiconductor structure into which minority carriers, such as electrons or holes, are injected, such that light is generated by the recombination of electrons and holes.
[0005] The characteristics of LEDs include low power consumption, a relatively long lifespan, the ability to be mounted in cramped spaces, and strong resistance to vibrations. LEDs are commonly used in display devices and in the backlight units of display devices. Recently, research into applying LEDs to general illumination devices has been undertaken. In addition to monochromatic LEDs, such as red, blue, or green LEDs, white LEDs have also come onto the market. In particular, a sharp increase in demand for white LEDs is anticipated, in line with the application of white LEDs to vehicle lighting devices and general lighting devices.
[0006] In the field of LED technology, white light is commonly generated using two main methods. The first method to generate white light includes disposing monochromatic LEDs, such as red, green, and blue LEDs, adjacently to each other such that various colors of light emitted by the monochromatic LEDs are mixed. However, color tones may change depending on the environment in which such devices are used, since individual monochromatic LEDs have different thermal or temporal characteristics. In particular, color stains may occur, making it difficult to uniformly mix different colors of light. The second method to generate white light includes applying a fluorescent material to an LED and mixing a portion of initial light emitted by the LED and secondary light of which wavelength has been converted by the fluorescent material. For example, a fluorescent material generating yellowish-green or yellow light may be used as a light excitation source on a blue LED, whereby white light can be produced by mixing blue light emitted by the blue LED and yellowish-green or yellow light excited by the fluorescent material. At present, the second method of realizing white light utilizing a blue LED and a fluorescent material is generally used.
[0007] Recently, quantum dots (QDs) have been used for color conversion to produce white light. QDs generate relatively strong light within a narrow wavelength, the light being stronger than light generated from a typical fluorescent material. In general, a QD-LED backlight unit generates white light by irradiating blue light emitted by a blue LED onto yellow QDs, and applies the white light to a liquid crystal display (LCD) as backlight. LCDs using such a QD-LED backlight unit have high potential as new displays, since the characteristics of such LCDs include superior color reproduction unlike those using a traditional backlight using LEDs only, the ability to realize full color comparable to that of organic light emitting diodes (OLEDs), as well as lower fabrication costs and higher manufacturing productivity than OLED TVs.
[0008] However, when QDs are continuously exposed to oxygen and moisture in an external air gap, defects may be formed on the surface of QDs, leading to problems, such as reduction in color conversion efficiency and change in color coordinates. Therefore, it is important to ensure the thermal stability of QDs and isolate QDs from the external air gap in order to apply QDs to a display device as a color (wavelength) conversion material.
RELATED ART DOCUMENT
[0009] Patent Document 1: United States Patent Application Publication No. 20120113672 (May 10, 2012)
BRIEF SUMMARY
[0010] Various aspects of the present disclosure provide a color conversion substrate able to obtain long-term stability and a superior degree of color conversion efficiency in quantum dots (QDs) and a superior degree of color conversion efficiency in the color conversion substrate, a method of fabricating the same, and a display device including the same.
[0011] According to an aspect, a color conversion substrate includes: a thin glass plate; a QD coating layer disposed on one surface of the thin glass plate; a light guide plate disposed to face the QD coating layer, wherein a light-emitting diode (LED) is disposed on a side of the light guide plate; and a sealant disposed between the thin glass plate and the light guide plate to isolate the QD coating layer from an external environment.
[0012] The QD coating layer may have an embossed pattern on a surface thereof facing the light guide plate.
[0013] The thin glass plate may have an embossed pattern on the other surface thereof.
[0014] The light guide plate may implemented as a glass light guide plate or a polymer light guide plate.
[0015] The sealant may be formed of a frit when the light guide plate is the glass light guide plate or is formed of an epoxy when the light guide plate is the polymer light guide plate.
[0016] The color conversion substrate may further include a moisture absorber disposed between the QD coating layer and the sealant.
[0017] According to another aspect, a color conversion substrate includes: a first thin glass plate; a QD coating layer disposed on the bottom surface of the first thin glass plate; a second thin glass plate in close contact with the bottom surface of the QD coating layer; a sealant disposed between the first thin glass plate and the second thin glass plate to isolate the QD coating layer from an external environment; and a light guide plate disposed under the second thin glass plate. An LED is disposed on a side of the light guide plate.
[0018] The QD coating layer may have an embossed pattern on the bottom surface thereof.
[0019] The first thin glass plate may have an embossed pattern on the top surface thereof.
[0020] The second thin glass plate may have an embossed pattern on the bottom surface thereof.
[0021] The sealant may be formed of a frit.
[0022] The color conversion substrate may further include a moisture absorber disposed between the QD coating layer and the sealant.
[0023] According to further another aspect, a display device includes: the above-stated color conversion substrate; a display panel disposed over the color conversion substrate; and an LED disposed on a side of the light guide plate of the color conversion substrate, and serving, together with the color conversion substrate, as a side emitting backlight unit.
[0024] The display panel may be implemented as a liquid crystal display (LCD) panel.
[0025] According to yet another aspect, a method of fabricating a color conversion substrate includes: forming a QD coating layer by coating a thin glass plate with a paste containing QDs; disposing a second thin glass plate or a light guide plate in a position facing the thin glass plate such that the QD coating layer is sandwiched between the second thin glass plate or the light guide plate and the thin glass plate; and hermetically bonding a periphery of a surface of the thin glass plate to a periphery of a surface of the second thin glass facing the surface of the thin glass plate or to a periphery of a surface of the light guide plate facing the surface of the thin glass plate by means of a sealant.
[0026] The operation of forming the QD coating layer may include forming an embossed pattern on the surface of the QD coating layer while adjusting the degree of curing the paste.
[0027] The sealant may be applied on the thin glass plate in the operation of forming the QD coating layer or may be applied on the second thin glass plate or the light guide plate in the operation of disposing the second thin glass plate or the light guide plate.
[0028] The sealant may be formed of a frit or an epoxy.
[0029] The method may further include disposing a moisture absorber around the QD coating layer.
[0030] As set forth above, a frit material and an epoxy material having superior sealing characteristics are applied as a sealant. It is therefore possible to protect the inner QD coating layer from both moisture and oxygen, thereby obtaining long-term stability of the QDs.
[0031] In addition, according to the present disclosure, the pattern formed on the surface of the QD coating layer scatters light that has been emitted by the LEDs and guided by the light guide plate before the light is wavelength-converted by the QDs. This enables the light to be additionally wavelength-converted, thereby improving color conversion efficiency. Furthermore, a pattern is formed on one surface of the thin glass plate exposed to air, with the QD coating layer formed on the other surface of the thin glass plate. It is possible to reduce the amount of light totally reflected from the interface between the thin glass plate and the air while the light is passing through the thin glass plate after passing through the QD coating layer. This can consequently increase the color conversion efficiency using the QDs and, furthermore, can reduce the number of LEDs used as a light source and the amount of energy consumed, whereby a high-efficient environmentally-friendly display device can ultimately be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a cross-sectional view schematically illustrating a color conversion substrate and a display device including the same according to an exemplary embodiment;
[0033] FIG. 2 illustrates simulated light diffusion patterns in a case in which an embossed pattern is formed on the surface of a QD coating layer (left) and a case in which the surface of the QD coating layer is flat (right); and
[0034] FIG. 3 is a cross-sectional view schematically illustrating a color conversion substrate and a display device including the same according to another exemplary embodiment.
DETAILED DESCRIPTION
[0035] Reference will now be made in detail to a color conversion substrate, a method of fabricating the same, and a display device including the same according to the present disclosure, embodiments of which are illustrated in the accompanying drawings and described below, so that a person skilled in the art to which the present disclosure relates could easily put the present disclosure into practice.
[0036] Throughout this document, reference should be made to the drawings, in which the same reference numerals and symbols will be used throughout the different drawings to designate the same or like components. In the following description, detailed descriptions of known functions and components incorporated herein will be omitted in the case that the subject matter of the present disclosure is rendered unclear by the inclusion thereof.
[0037] As illustrated in FIG. 1 , a color conversion substrate 100 according to an embodiment is configured to convert the color (wavelength) of a portion of light emitted by one or more light-emitting diodes (LEDs) used as a backlight source of a display device, for example, a liquid crystal display (LCD). According to the present embodiment, the color conversion substrate 100 is disposed to the rear of a display panel 20 such as an LCD panel, and forms, together with one or more LEDs (hereinafter referred to as “LEDs”) 10 , an LCD backlight unit (BLU) radiating light toward the display panel 20 . Although not illustrated in the drawings, each of the LEDs 10 may include an LED body and an LED chip. The LED body is a structure having a hollow portion in a specific shape, providing a structural space for accommodation of the LED chip. The LED body has wires and a lead frame by which the LED chip is electrically connected to an external power source. The LED chip is a light source emitting light when an electrical current is applied thereto by the external power source, is mounted on the LED body, and is connected to the external power source via the wires and the lead frame. The LED chip is implemented as a forward junction of an n-semiconductor layer that provides electrons and a p-semiconductor layer that provides holes. In the present embodiment, the backlight unit is implemented as a side emitting backlight. Accordingly, the LEDs 10 are disposed on one side of the color conversion substrate 100 to emit light toward the color conversion substrate 100 .
[0038] In this manner, the color conversion substrate 100 according to the present embodiment forming the backlight unit of the display panel 20 together with the LEDs 10 includes a thin glass plate 110 , a quantum dot (QD) coating layer 120 , a light guide plate 130 , and a sealant 140 .
[0039] The thin glass plate 110 protects the QD coating layer 120 disposed on the bottom surface thereof (when referring to FIG. 1 ). In addition, the thin glass plate 110 serves as a path along which light emitted by the LEDs 10 passes or exits in the direction of the display panel 20 disposed above the thin glass plate 110 . In addition, the thin glass plate 110 is bonded to the light guide plate 130 by the sealant 140 , thereby isolating the QD coating layer 120 from the external environment. The thin glass plate 110 may formed of a material selected from among, but is not limited to, silicate glass, silica glass, borosilicate glass, and non-alkali glass, with a thickness of 0 . 3 mm or less. According to the present embodiment, the thin glass plate 110 provided as above can reduce the thickness of the color conversion substrate 100 , thereby reducing the thickness of the display device.
[0040] According to the present embodiment, a pattern 111 having an embossed structure is formed on the top surface of the thin glass plate 110 , i.e. the surface of the thin glass plate 110 facing the display panel 20 . Although the pattern 111 is illustrated as having a semicircular cross-section in the present embodiment, this is merely illustrative, and the pattern 111 may have a variety of cross-sectional shapes.
[0041] The pattern 111 formed on the top surface of the thin glass plate 110 as above can reduce the amount of light that is totally reflected from the interface between the thin glass plate 110 and air while the light is passing through the thin glass plate 110 . This can consequently increase the color conversion efficiency of QDs in the QD coating layer 120 and, furthermore, can reduce the number of LEDs 10 used as the light source and the amount of energy consumed, whereby a highly-efficient environmentally-friendly display device can ultimately be realized.
[0042] The QD coating layer 120 is disposed on the bottom surface of the thin glass plate 110 . In addition, the QD coating layer 120 is hermetically sealed by the thin glass plate 110 , the light guide plate 130 and the sealant 140 , thereby being prevented from being exposed to the air. According to the present embodiment, it is possible to protect the QD coating layer 120 from both moisture and oxygen, thereby obtaining long-term stability in the QD coating layer 120 . The QDs of the QD coating layer 120 convert the wavelength of light emitted by the LEDs 10 , thereby generating wavelength-converted light, i.e. fluorescent light. According to the present embodiment, since the LEDs 10 are implemented as blue LEDs, the QD coating layer 120 may be formed of a QD material converting the wavelength of a portion of light emitted by the blue LEDs 10 into yellow light.
[0043] According to the present embodiment, a pattern 121 having an embossed structure is formed on the bottom surface of the QD coating layer 120 , i.e. on the surface of the QD coating layer 120 facing the light guide plate 130 . Although the embossed pattern 121 has a triangular cross-section as illustrated in FIG. 1 , the embossed pattern 121 may have a variety of other shapes. Thus, the shape of the pattern 121 formed on the QD coating layer 120 is not limited to any specific shape. The embossed pattern 121 is formed on the bottom surface of the QD coating layer 120 through which light guided by the light guide plate 130 enters the QD coating layer 120 , and thus serves to scatter the light to be wavelength-converted by the QD coating layer 120 . This consequently enables additional wavelength conversion, thereby improving color conversion efficiency.
[0044] FIG. 2 illustrates simulated light diffusion patterns demonstrating the effects of the pattern 121 formed on the surface of the QD coating layer 120 . It is apparent that light is diffused in the case in which the pattern 121 is formed on the surface of the QD coating layer 120 (left), whereas substantially no light is diffused in the case in which the surface of the QD coating layer is flat (right).
[0045] The light guide plate (LGP) 130 is disposed to face the QD coating layer 120 . The light guide plate 130 and the thin glass plate 110 are bonded by means of the sealant 140 , thereby sealing the QD coating layer 120 . In addition, the light guide plate 130 distributes light that is incident thereto after being emitted by a point light source of the LEDs 10 , uniformly over the entire area of the display panel 20 . That is, the light guide plate 130 guides the light emitted by the LEDs 10 in the direction of the QD coating layer 120 and the display panel 20 .
[0046] According to the present embodiment, the light guide plate 130 may be implemented as a glass light guide plate or a polymer light guide plate. In addition, the thickness of the light guide plate 130 may be 1.0 mm or less.
[0047] The sealant 140 is disposed between the thin glass plate 110 and the light guide plate 130 . Specifically, the sealant 140 is disposed between the bottom periphery of the thin glass plate 110 , laterally spaced apart from the QD coating layer 120 on the bottom surface of the thin glass plate 110 and the top periphery of the light guide plate 130 corresponding to the bottom periphery. The sealant 140 disposed between the thin glass plate 110 and the light guide plate 130 is in a shape encircling the side surfaces of the QD coating layer 120 , serving, together with the thin glass plate 110 and the light guide plate 130 , to isolate the QD coating layer 120 from the external environment. When the light guide plate 130 is implemented as a glass light guide plate, the sealant 140 may be formed of a frit having superior ability in being bonded to the thin glass plate 110 and the glass light guide plate. When the light guide plate 130 is implemented as a polymer light guide plate, the sealant 140 may be formed of an epoxy.
[0048] The color conversion substrate 100 according to the present embodiment may include a moisture absorber 150 within an enclosed space defined by the thin glass plate 110 , the sealant 140 , and the light guide plate 130 . When the moisture absorber 150 is disposed adjacently to the QD coating layer 120 within the enclosed space defined by the thin glass plate 110 , the sealant 140 , and the light guide plate 130 , the moisture absorber 150 can prevent the QD coating layer 120 from being exposed to moisture, thereby further improving long-term stability of the QD coating layer 120 .
[0049] Hereinafter, a color conversion substrate according to another exemplary embodiment will be described with reference to FIG. 3 .
[0050] FIG. 3 is a cross-sectional view schematically illustrating the color conversion substrate according to the another embodiment and a display device including the same.
[0051] As illustrated in FIG. 3 , a color conversion substrate 200 includes a first thin glass plate 210 , a QD coating layer 120 , a second thin glass plate 230 , a sealant 140 , and a light guide plate 240 .
[0052] The first thin glass plate 210 may formed of one material selected from among, but is not limited to, silicate glass, silica glass, borosilicate glass, and non-alkali glass, with a thickness of 0.5 mm or less, like the thin glass plate ( 110 in FIG. 1 ) according to the former embodiment. In addition, a pattern 211 having an embossed structure is formed on the top surface of the first thin glass plate 210 . Descriptions of the functions and effects of the pattern 211 identical to those of the pattern ( 111 in FIG. 1 ) of the thin glass plate 110 according to the former embodiment will be omitted.
[0053] The QD coating layer 120 is disposed on the bottom layer of the first thin glass plate 210 . Descriptions of the QD coating layer 120 identical to the QD coating layer ( 120 in FIG. 1 ) according to the former embodiment will be omitted.
[0054] The second thin glass plate 230 is in close contact with the bottom surface of the QD coating layer 120 . The thickness and type of the second thin glass plate 230 may be identical to those of the first thin glass plate 210 . A pattern 231 having an embossed structure 231 is disposed on the bottom surface of the second thin glass plate 230 . The pattern 231 faces the light guide plate 240 . The pattern 231 disposed on the bottom surface of the second thin glass plate 230 facing the light guide plate 240 increases lengths of paths along which light guided by the light guide plate 240 travels. This can consequently increase the contact between the light and the QD coating layer 120 , thereby further increasing color conversion efficiency.
[0055] Unlike the former embodiment, the sealant 140 according to the present embodiment is disposed between the first thin glass plate 210 and the second thin glass plate 230 in order to isolate the QD coating layer 120 from the external environment. The sealant 140 may be formed of a frit having superior ability to be bonded to the first thin glass plate 210 and the second thin glass plate 230 .
[0056] According to the present embodiment, the second thin glass plate 230 is bonded to the first thin glass plate 210 by means of the sealant 140 , thereby sealing the QD coating layer 120 disposed on the bottom surface of the first thin glass plate 210 . Due to this configuration, the light guide plate 240 is disposed under the second thin glass plate 230 in order to guide light emitted by LEDs 10 in the direction of the QD coating layer 120 .
[0057] As in the former embodiment, the color conversion substrate 200 according to the present embodiment includes a moisture absorber 150 disposed between the QD coating layer 120 and the sealant 140 .
[0058] Hereinafter, a method of fabricating a color conversion substrate according to an exemplary embodiment will be described. The reference numerals in FIG. 1 and FIG. 3 will be referred to for the components of the color conversion substrate.
[0059] First, a QD coating layer 120 is formed by coating a thin glass plate 110 with a paste containing QDs. In this case, a pattern 121 in an embossed structure may be formed on the surface of the QD coating layer 120 by adjusting the degree of curing the paste. In addition, a pattern 111 in an embossed structure may be formed on the surface of the thin glass plate 110 facing away from the surface coated with the paste.
[0060] Afterwards, the light guide plate 130 or a second thin glass plate 230 having a pattern 231 is disposed in a position facing the thin glass plate 110 such that the QD coating layer 120 is sandwiched between the light guide plate 130 or the second thin glass plate 230 and the thin glass plate 110 . At this time, after the QD coating layer 120 is formed on the thin glass plate 110 , a sealant 140 may be applied on the periphery of the thin glass plate 110 laterally spaced apart from the QD coating layer 120 or may be applied on the periphery of the second thin glass plate 230 or the light guide plate 130 that faces the thin glass plate 110 .
[0061] Before the thin glass plate 230 or the light guide plate 130 is disposed in the position facing the QD coating layer 120 , a moisture absorber 150 may be applied to on thin glass plate 110 between the QD coating layer 120 and the applied sealant 140 , around the QD coating layer 120 .
[0062] Finally, the thin glass plate 110 and the second thin glass plate 230 or the thin glass plate 110 and the light guide plate 130 are bonded to each other by firing the sealant 140 disposed therebetween, whereby the method of fabricating a color conversion substrate according to the present embodiment is completed.
[0063] It is preferable that the sealant 140 be formed of a frit when bonding the thin glass plate 110 and the second thin glass plate 230 or the thin glass plate 110 and the light guide plate 130 formed of glass. It is preferable that the sealant 140 be formed of an epoxy when bonding the thin glass plate 110 and the light guide plate 130 formed of a polymer.
[0064] In addition, when the QD coating layer 120 is sealed by bonding the thin glass plates 110 and 230 , the light guide plate 240 is disposed under the thin glass plate 230 , whereby light emitted by the LEDs 10 disposed on the side of the light guide plate 240 is guided to the QD coating layer 120 .
[0065] The foregoing descriptions of specific exemplary embodiments of the present disclosure have been presented with respect to the drawings. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and obviously many modifications and variations are possible for a person having ordinary skill in the art in light of the above teachings.
[0066] It is intended therefore that the scope of the present disclosure not be limited to the foregoing embodiments, but be defined by the Claims appended hereto and their equivalents.
DESCRIPTION OF REFERENCE NUMERALS
[0067] 100 , 200 : color conversion substrate
[0068] 110 : thin glass plate
[0069] 120 : quantum dot (QD) coating layer
[0070] 130 , 240 : light guide plate
[0071] 140 : sealant
[0072] 150 : moisture absorber
[0073] 210 : first thin glass plate
[0074] 230 : second thin glass plate
[0075] 111 , 121 , 211 , 231 : pattern
[0076] 10 : LED
[0077] 20 : display panel | The present invention relates to a substrate for color conversion, a manufacturing method therefor, and a display device comprising the same and, more specifically, to a substrate for color conversion for not only securing the long-term stability of quantum dots but also exhibiting excellent color conversion efficiency, a manufacturing method therefor, and a display device comprising the same. To this end, the present invention provides a substrate for color conversion, a manufacturing method therefor, and a display device, the substrate for color conversion comprising: a thin plate glass; a coating layer for quantum dots formed on one surface of the thin plate glass; a light guide plate disposed to face the coating layer for quantum dots, a light emitting diode being disposed on the sides thereof; and a sealing material which is formed between the thin plate glass and the light guide plate and which blocks the coating layer for quantum dots from the outside. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatuses for controlling negative pressure in internal combustion engines. More particularly, the present invention pertains to apparatuses for controlling negative pressure in internal combustion engines that are provided with brake boosters, which use negative pressure to improve braking force.
2. Description of the Related Art
Brake boosters have become widely used in vehicles to decrease the required pressing force of the brake pedal. A typical brake booster uses negative pressure, which is produced in an intake passage downstream of a throttle valve, as a drive source. In other words, negative pressure is communicated to the brake booster through a communicating pipe connected to the downstream side of the throttle valve. Negative pressure corresponding to the pressed amount of the brake pedal acts on a diaphragm, which is incorporated in the brake booster, and increases the braking force.
However, internal combustion engines such as diesel engines do not control the amount of air intake during operation. Thus, it is difficult to produce negative pressure at the downstream side of the throttle valve. In such cases, vacuum pumps are provided to produce negative pressure for the brake booster.
Japanese Unexamined Patent Publication No. 61-21831 describes an apparatus that produces negative pressure for the brake booster when the vacuum pump malfunctions. The apparatus slightly closes the throttle valve to produce negative pressure at the downstream side of the throttle valve. The negative pressure is communicated to the brake booster.
However, the employment of a vacuum pump increases the engine load and degrades the fuel efficiency.
Furthermore, in engines that perform stratified charge combustion, stoichiometric air-fuel mixture is supplied to the vicinity of an ignition plug in a cylinder. The other portions of the cylinder are provided with only air. Hence, the throttle valve is substantially completely opened during normal running conditions. As a result, practically no negative pressure is produced at the downstream side of the throttle valve. This causes the negative pressure communicated to the brake booster to be insufficient.
SUMMARY OF THE INVENTION
Accordingly, it is an objective of the present invention to provide a provide an internal combustion engine that produces sufficient negative pressure for a brake booster when performing stratified charge combustion.
To achieve the above objective, the present invention provides an apparatus for controlling brake force of a vehicle movable based on rotation of an engine with a plurality of cylinders. Each of said cylinders has a combustion chamber that receives fuel from a fuel injector and air from an air intake passage. The air and fuel are mixed and combusted in the combustion chamber. The engine selectively performs a stratified charge combustion and a uniform charge combustion. The stratified charge combustion mode is selected to increase the amount of the air and the fuel supplied to the engine and improve a combusting state of the engine. The apparatus includes a brake booster for increasing said brake force in accordance with negative pressure applied thereto. The brake booster is actuated by the negative pressure an amount of which is greater than a predetermined amount. A restricting means restricts airflow in the air intake passage to generate the negative pressure that is supplied to the brake booster. A fuel injector directly injects the fuel into the cylinder to set the engine to perform the stratified charge combustion. A measuring means measures the amount relating to the pressure applied to the brake booster. A determining means determines the amount relating to the pressure in the brake booster being smaller than a predetermined value. An actuating means for actuating the restricting means to apply the negative pressure to the brake booster when the amount relating to the pressure in the brake booster is smaller than the predetermined value. The actuating means converts a running condition of the engine from the stratified charge combustion to the uniform charge combustion.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a diagrammatic drawing showing an apparatus for controlling negative pressure in an engine according to a first embodiment of the present invention;
FIG. 2 is an enlarged cross-sectional view showing the cylinder engine;
FIG. 3 is a schematic drawing showing the brake booster;
FIG. 4 is a flowchart illustrating the negative pressure control routine executed by the ECU;
FIG. 5 is a flowchart illustrating the negative pressure control routing that continues from FIG. 4;
FIG. 6 is a flowchart illustrating the negative pressure control routine that continues from FIGS. 4 and 5;
FIG. 7 is a flowchart illustrating the uniform charge combustion control routine;
FIG. 8 is a flowchart illustrating the negative pressure control routine executed by the ECU in a second embodiment according to the present invention;
FIG. 9 is a flowchart illustrating the negative pressure control routine that continues from FIG. 8; and
FIG. 10 is a map showing the relationship between the engine speed and the acceleration depression amount with respect to the assumed intake pressure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of an apparatus for controlling negative pressure in an internal combustion engine according to the present invention will now be described with reference to the drawings.
As shown in FIG. 1, an engine 1 is provided with, for example, four cylinders 1a. The structure of the combustion chamber of each cylinder 1a is shown in FIG. 2. As shown in these drawings, the engine 1 has a cylinder block 2 that accommodates pistons. The pistons are reciprocated in the cylinder block 2. A cylinder head 4 is arranged on top of the cylinder block 2. A combustion chamber 5 is defined between each piston and the cylinder head 4. In this embodiment, four valves (first intake valve 6a, second intake valve 6b, and two exhaust valves 8) are provided for each cylinder 1a. The first intake valve 6a is provided with a first intake port 7a while the second intake valve 6b is provided with a second intake port 7b. Each exhaust valve 8 is provided with an exhaust port 9.
As shown in FIG. 2, the first intake port 7a is a helical port that extends in a helical manner. The second port 7b extends in a straight manner. Ignition plugs 10 are arranged at the middle of the cylinder head 4. High voltage is applied to each ignition plug 10 by an ignitor 12 though a distributor (not shown). The ignition timing of the ignition plugs 10 is determined by the output timing of the high voltage sent from the ignitor 12. A fuel injection valve 11 is arranged near the inner wall of the cylinder head at the vicinity of each set of first and second intake valves 6a, 6b. The fuel injection valve 11 is used to inject fuel directly into the associated cylinder 1a and enables both stratified charge combustion and uniform charge combustion.
As shown in FIG. 1, the first and second intake ports 7a, 7b of each cylinder 1a are connected to a surge tank 16 by a first intake passage 15a and a second intake passage 15b, which are defined in an intake manifold 15. A swirl control valve 17 is arranged in each second intake passage 15b. The swirl control valves 17 are connected to, for example, a step motor 19 by a common shaft 18. The step motor 19 is controlled by signals sent from an electronic control unit (ECU) 30. The step motor 19 may be replaced by an actuating member controlled by the negative pressure in the intake ports 7a, 7b.
The surge tank 16 is connected to an air cleaner 21 through an intake duct 20. An electrically controlled throttle valve 23, which is opened and closed by a step motor 22, is arranged in the intake duct 20. The ECU 30 sends signals to drive the step motor 22 and open and close the throttle valve 23. The throttle valve 23 adjusts the amount of intake air that passes through the intake duct 20 and enters the combustion chambers 5. The throttle valve 23 also adjusts the negative pressure produced in the intake duct 20.
A throttle sensor 25 is arranged in the vicinity of the throttle valve 23 to detect the opening angle (throttle angle TA) of the valve 23. The exhaust ports 9 of each cylinder 1a are connected to an exhaust manifold 14. After combustion, the exhaust gas is sent to an exhaust pipe (not shown) through the exhaust manifold 14.
A conventional gas exhaust recirculation (EGR) mechanism 51 recirculates some of the exhaust gas through an EGR passage 52. An EGR valve 53 is arranged in the EGR passage 52. The EGR passage 52 connects the downstream side of the throttle valve 23 in the intake duct 20 to an exhaust duct. The EGR valve 53 includes a valve seat, a valve body, and a step motor (all of which are not shown). The opening area of the EGR valve 53 is altered by causing the step motor to intermittently displace the valve body with respect to the valve seat. When the EGR valve 53 opens, some of the exhaust gas sent into the exhaust duct enters the EGR passage 52. The gas is then drawn into the intake duct 20 via the EGR valve 53. In other words, some of the exhaust gas is recirculated by the EGR mechanism 51 and returned to the air-fuel mixture. The recirculation amount of the exhaust gas is adjusted by the opening amount of the EGR valve 53.
As shown in FIGS. 1 and 3, a brake booster 71 is provided to enhance the braking force of the vehicle. The brake booster 71 increases the pressing force of the brake pedal 72. The pressing force is converted to hydraulic pressure and used to actuate brake actuators (not shown) provided for each wheel. The brake booster 71 is connected to the downstream side of the throttle valve 23 in the intake duct 20 by a connecting pipe 73 and actuated by the negative pressure produced in the duct 20. A check valve 74, which is opened by the negative pressure produced in the intake duct 20, is provided in the connecting pipe 73 (FIG. 3). The brake booster 71 includes a diaphragm, which serves as an actuating portion. One side of the diaphragm communicates with the atmosphere. The negative pressure produced in the intake duct 20 and communicated through the connecting pipe 73 acts on the other side of the diaphragm. A pressure sensor 63 is arranged in the connecting pipe 73 to detect the pressure in the brake booster 71, or the brake booster pressure PBK (absolute pressure value).
The ECU 30 is a digital computer provided with a random access memory (RAM) 32, a read only memory (ROM) 33, a central processing unit (CPU) 34, which is a microprocessor, an input port 35, and an output port 36. A bidirectional bus 31 connects the RAM 32, the ROM 33, the CPU 34, the input port 35, and the output port 36 to one another.
An acceleration pedal 24 is connected to an acceleration sensor 26A. The acceleration sensor 26A generates voltage proportional to the degree of depression of the acceleration pedal 24. This enables the acceleration opening ACCP to be detected. The voltage output by the acceleration sensor 26A is input into the input port 35 by way of an analog to digital (A/D) converter 37. The acceleration pedal 24 is also provided with a complete closure switch 26B, which detects whether the acceleration pedal 24 is not pressed at all. The closure switch 26B outputs a complete closure signal XIDL set at one when the acceleration pedal 24 is not pressed at all and outputs a complete closure signal XIDL set at zero when the acceleration pedal 24 is pressed. The output voltage of the closure switch 26B is also input into the input port 35.
A top dead center position sensor 27 generates an output pulse when, for example, the piston in the first cylinder 1a reaches the top dead center position. The output pulse is input into the input port 35. A crank angle sensor 28 generates an output pulse each time a crankshaft of the engine 1 is rotated by a crank angle CA of 30 degrees. The output pulse sent from the crank angle sensor 27 is input into the input port 35. The CPU 34 reads the output pulses of the top dead center position sensor 27 and the crank angle sensor 28 to compute the engine speed NE.
The rotational angle of the shaft 18 is detected by a swirl control valve sensor 29 to measure the opening area of the swirl control valves 17. The signal output of the swirl control valve sensor 29 is input into the input port 35 by way of an A/D converter 37.
The throttle sensor 25 detects the throttle angle TA. The signal output of the throttle sensor 25 is input into the input port 35 by way of an A/D converter 37.
An intake pressure sensor 61 is provided to detect the pressure in the surge tank 16 (intake pressure PiM). The intake pressure PiM detected by the intake pressure sensor 61 when the engine 1 is started is substantially equal to the atmospheric pressure PA. Thus, the intake pressure sensor 61 also detects atmospheric pressure.
A coolant temperature sensor 62 is provided to detect the temperature of the engine coolant (coolant temperature THW). A vehicle speed sensor 64 is provided to detect the speed of the vehicle (vehicle speed SPD). The signal outputs of the sensors 61, 62, 64 are input into the input port 35 by way of A/D converters 37. The signal output of the pressure sensor 63 is also input into the input port 35 by way of an A/D converter 37.
The running condition of the engine 1 is detected by the throttle sensor 25, the acceleration sensor 26A, the complete closure switch 26B, the top dead center position sensor 27, the crank angle sensor 28, the swirl control valve sensor 29, the intake pressure sensor 61, the coolant temperature sensor 62, the pressure sensor 63, and the vehicle speed sensor 64.
The output port 36 is connected to the fuel injection valves 11, the step motors 19, 22, the ignitor 12, and the EGR valve 53 (step motor) by way of drive circuits 38. The ECU 30 optimally controls the fuel injection valves 11, the step motors 19, 22, the ignitor 12 (ignition plugs 10), and the EGR valve 53 with control programs stored in the ROM 33 based on signals sent from the sensors 25-29, 61-64.
Control programs stored in the apparatus for controlling negative pressure in the engine 1 will now be described with reference to the flowcharts shown in FIGS. 4-6. A routing executed to control the negative pressure communicated to the brake booster 71 by controlling the throttle valve 23 (the step motor 22) is illustrated in FIGS. 4-6.
When entering the routine, the ECU 30 first determines whether the engine 1 is presently performing stratified charge combustion in step 100. If stratified charge combustion is not being performed, the ECU 30 determines that the engine 1 is presently performing uniform charge combustion. This indicates that problems related with negative pressure are unlikely to occur. In this case, the ECU 30 proceeds to step 112.
In step 112, the ECU 30 computes the basic throttle angle TRTB from the present detecting signals (the acceleration opening ACCP, the engine speed NE, and other parameters). The ECU 30 refers to a map (not shown) to compute the basic throttle angle TRTB. The ECU 30 proceeds to step 113 and sets the final target throttle angle, or throttle opening area TRT, by subtracting the present throttle closing angle TRTCBK from the basic throttle angle TRTB. The ECU 30 then temporarily terminates subsequent processing. The ECU 30 then temporarily terminates subsequent processing. When the ECU 30 jumps from step 100 to step 112, the value of the throttle closing angle TRTCBK is set to zero. Thus, the basic throttle angle TRTB is set equal to the final target throttle opening area TRT.
In step 100, if it is determined that the engine 1 is performing stratified charge combustion, the ECU 30 proceeds to step 101. At step 101, the ECU 30 subtracts the most recent brake booster pressure PBK, which is detected by the pressure sensor 63, from the atmospheric pressure PA to obtain the pressure difference DPBK.
In step 102, the ECU 30 determines whether the present vehicle speed SPD is equal to or higher than a predetermined speed (e.g., 20 km/h). If the vehicle speed SPD is lower than the predetermined speed, the ECU 30 continues the stratified charge combustion mode and proceeds to step 103 to execute the throttle angle control (stratified charge brake control).
In step 103, the ECU 30 determines whether the flag XBKIDL that indicates the execution of the stratified charge brake control is set at one. The execution flag XBKIDL is set at one when producing negative pressure while performing the stratified charge combustion mode. If the execution flag XBKIDL is set at zero, that is, if the stratified charge control is not in process, the ECU 30 proceeds to step 104.
In step 104, the ECU 30 determines whether the present pressure difference DPBK is smaller than a predetermined negative pressure value tKPBLK (e.g., 300 mmHg), which initiates the stratified charge brake control. If the pressure difference DPBK is smaller than the negative pressure value tKPBLK, the ECU 30 proceeds to step 105.
In step 105, the ECU 30 sets the execution flag XBKIDL to one to enter the stratified charge brake control mode. The ECU 30 then proceeds to step 106 and computes the closing compensation angle a. To obtain the closing compensation value a, the ECU 30 refers to a map such as that shown in FIG. 7. In the map, the closing compensation angles a are indicated in correspondence with values that are obtained by subtracting the value of the pressure difference DPBK from the target negative pressure value tKPBKO (e.g., 350 mmHg). If the pressure difference DPBK is much smaller than the predetermined negative pressure value tKPBKO (i.e., if the subtracted value is large), the closing compensation angle a is set at a large value to increase the closing speed of the throttle value 23. On the contrary, the closing compensation angle a is set at a small value to decrease the closing speed of the throttle valve 23 when the pressure difference DPBK approaches the predetermined negative pressure value tKPBKO (i.e., when the subtracted value is small).
In step 107, the ECU 30 renews the throttle closing angle TRTCBK to a value obtained by adding the present closing angle compensation value a to the throttle closing angle TRTCBK of the previous cycle and then proceeds to step 112. In step 112, the ECU 30 computes the basic throttle angle TRTB. Then, in step 113, the ECU 30 sets the final target throttle opening area TRT by subtracting the present throttle closing angle TRTCBK from the basic throttle angle TRTB. Afterward, the ECU 30 temporarily terminates subsequent processing. Accordingly, if the ECU 30 carries out steps 103 to 107, the increasing value obtained by subtracting the throttle closing angle TRTCBK is set as the final target throttle opening area TRT.
In step 104, if the pressure difference DPBK is equal to or greater than the negative pressure value tKPBLK that initiates the stratified charge brake control, the ECU 30 jumps to step 112. In this case, stratified charge brake control is not executed.
If the execution flag XBKIDL is set at one in step 103, the ECU 30 proceeds to step 108 and determines whether the pressure difference DPBK exceeds the negative pressure value tKPBKO that terminates the stratified charge brake control. If it is determined that the pressure difference DPBK does not exceed the negative pressure value tKPBKO, the ECU 30 proceeds to step 106. The ECU 30 carries out steps 106, 107 and then proceeds to step 112 to compute the basic throttle angle TRTB. Subsequently, in step 113, the ECU 30 sets the final target throttle opening area TRT to a value obtained by subtracting the present throttle closing angle TRTCKB from the basic throttle angle TRTB. Afterward, the ECU 30 temporarily terminates subsequent processing. Accordingly, in this case, the value obtained by subtracting the presently increasing throttle closing angle TRTCBK is set as the final target throttle opening area TRT.
If it is determined that the pressure difference DPBK exceeds the negative pressure value tKPBKO in step 108, the ECU 30 proceeds to step 109 to decrease the throttle closing angle TRTCBK (and increase the target throttle opening area TRT). At step 109, the ECU 30 renews the throttle closing angle TRTCKB to a value obtained by subtracting a predetermined closing angle compensation value b (b is a constant value) from the throttle closing angle TRTCBK of the previous cycle.
In step 110, the ECU 30 determines whether the throttle closing angle TRTCBK corresponds to a value of zero. If it is determined that the throttle closing angle TRTCBK does not correspond to a value of zero, the ECU 30 proceeds to step 112 to compute the basic throttle angle TRTB. Subsequently, in step 113, the ECU 30 sets the final target throttle opening area TRT to a value obtained by subtracting the present throttle closing angle TRTCBK from the basic throttle angle TRTB. Afterward, the ECU 30 temporarily terminates subsequent processing. Accordingly, in this case, the value obtained by subtracting the presently decreasing value of the difference between the throttle closing angle TRTCBK and the basic throttle angle TRTB is set as the final target throttle opening area TRT.
If the throttle closing angle TRTCBK corresponds to a value of zero in step 110, the ECU 30 proceeds to step 111. At step 111, the ECU 30 sets the execution flag XBKIDL to zero to terminate the stratified charge brake control mode. The ECU 30 then carries out steps 112, 113 and temporarily terminates subsequent processing. When the ECU 30 proceeds from step 111 to step 112, the value of the throttle closing angle TRTCBK is set at zero. Thus, the basic throttle angle TRTB is set equal to the final target throttle opening are TRT.
In step 102, if the present vehicle speed SPD is equal to or higher than the predetermined speed, the ECU 30 proceeds to step 114 to temporarily perform uniform charge combustion while executing throttle angle control (uniform charge combustion brake control).
In step 114, the ECU 30 determines whether the present pressure difference DPBK is smaller than the negative pressure value tKPBKLS at which the uniform charge brake control is initiated (e.g., 300 mmHg). If it is determined that the pressure difference DPBK is equal to or greater than the negative pressure value tKPBKLS, there is no need to produce negative pressure. In this case, the ECU 30 jumps to step 120. If the pressure difference DPBK is smaller than the negative pressure value tKPBKLS, the ECU 30 determines that negative pressure is insufficient and proceeds to step 115. At step 115, the ECU 30 sets the execution flag XBKDJ at one to execute uniform charge combustion control.
In step 116, the ECU 30 adds one to the count value CBKDJ of a counter in an incremental manner.
In step 117, the ECU 30 determines whether the count value CBKDJ is greater than a predetermined value (eight in the embodiment). The predetermined value corresponds to the period of time that is necessary to stabilize the brake booster pressure DPBK when performing uniform charge combustion. If the count value CBKDJ is greater than the predetermined value of eight, the ECU 30 proceeds to step 119. If the count value CBKFJ is not yet greater than the value of eight, the ECU 30 proceeds to step 118. In step 118, the ECU 30 determines whether the present pressure difference DPBK is greater than the negative pressure value tKPBKSO at which the uniform charge combustion brake control is terminated (e.g., 350 mmHg). If the brake booster pressure DPBK is equal to or lower than the negative pressure value tKPBKSO, the ECU 30 returns to step 115. This is repeated until the count value CBKDJ becomes greater than the predetermined value of eight or until the brake booster pressure DPBK becomes greater than the negative pressure value tKPBKSO. In other words, the uniform combustion mode is continued until the negative pressure becomes sufficient.
When the count value CBKDJ becomes greater than the predetermined value of eight or when the brake booster pressure DPBK becomes greater than the negative pressure value tKPBKSO, the ECU 30 proceeds to step 119 to terminate the uniform charge combustion. In step 119, the uniform charge combustion flag XBKDJ is set at zero.
When the ECU 30 proceeds to step 120 from step 114 or step 119, the ECU 30 clears the count value CBKDJ to zero. The ECU 30 then proceeds to steps 112, 113 and subsequently terminates subsequent processing.
In the negative pressure control routine, the pressure difference DPBK is computed from the atmospheric pressure PA and the brake booster pressure PBK. When the pressure difference DPBK is smaller than the negative pressure value tKPBKL that initiates stratified charge brake control or the negative pressure value tKPBLKS that initiates uniform charge brake control, the close control of the throttle valve 23 is performed. If the vehicle speed SPD is lower than the predetermined speed SPD, the ECU 30 executes negative pressure control when the stratified charge combustion is performed. If the vehicle speed SPD is equal to or greater than the predetermined speed, the ECU 30 executes negative pressure control when the uniform charge combustion is performed.
The uniform charge combustion control routine for computing various parameters when controlling negative pressure during uniform charge combustion (uniform charge brake control) will now be described with reference to FIG. 7.
When entering this routine, in step 201, the ECU 30 reads various detecting signals, such as the degree of acceleration pedal depression ACCP and the engine speed NE. In step 202, the ECU 30 determines whether the flag XBKDJ indicating execution of the uniform charge brake control is set at one. If the flag XBKDJ is not set at one, the ECU 30 determines that uniform charge combustion is not being performed and terminates subsequent processing. If the flag XBKDJ is set at one, in step 203, the ECU 30 computes the target fuel injection amount TAU for uniform charge combustion, the target ignition timing SA, the target throttle angle TA, the target EGR opening area EGRT, and the basic fuel injection timing AINJ.
Accordingly, in the uniform charge combustion control routine, when the flag XBKDJ is set at one, various parameters for uniform charge combustion are computed. Based on these parameters, the actuators (the fuel injection valve 11, the ignitor 12, the step motor 22, the EGR valve 53, etc.) are controlled.
In this embodiment, it is determined whether there is a need to produce negative pressure to actuate the brake booster 71 (steps 104, 112). If it is determined that negative pressure must be produced, the close control of the throttle value 23 is carried out. The closing of the throttle valve 23 produces negative pressure and ensures the actuation of the brake booster 71.
When determining whether it is necessary to produce negative pressure for the actuation of the brake booster 71, the ECU 30 computes the pressure difference DPBK by subtracting the brake booster pressure PBK, which is detected by the pressure sensor 63, from the atmospheric pressure PA. When the pressure difference DPBK is smaller than the negative pressure value tKPBKL, which initiates stratified charge brake control, or the negative pressure value tKPBKLS, which initiates uniform charge brake control, the ECU 30 executes the close control of the throttle value 23 (negative pressure producing control).
When traveling at a high altitude, the decrease in the atmospheric pressure PA causes the brake booster pressure PBK to be lower than when traveling at a low altitude. Accordingly, the brake booster pressure PBK may be low while the actual negative pressure for actuating the brake booster 71 is insufficient. However, in this embodiment, the closing control of the throttle valve 23 is executed to produce negative pressure when the pressure difference DPBK, is smaller than the reference value (negative pressure value tKPBKL for initiating stratified charge brake control or the negative pressure value tKPBKLS for initiating uniform charge brake control). This always guarantees sufficient negative pressure for the actuation of the brake booster 71 even when the atmospheric pressure PA fluctuates such as when traveling at high altitudes.
When the vehicle speed SPD is equal to or greater than the predetermined speed and the brake booster pressure DPBK is lower than the uniform charge brake control initiating negative pressure value tKPBKLS, the combustion is forcibly switched from stratified charge combustion to uniform charge combustion. This avoids insufficient negative pressure when opening the throttle valve 23 to increase speed during stratified charge combustion. The required negative pressure that corresponds to the running state of the engine is achieved and actuation of the brake booster 71 is guaranteed.
Furthermore, the engine 1 returns to stratified mode combustion when a predetermined time period elapses after switching to uniform charge combustion. This prevents degradation in the duel efficiency due to continued uniform charge combustion. The predetermined time period is the time necessary to produce sufficient negative pressure for the brake booster 71. Thus, the engine 1 readily returns to stratified charge combustion after producing as much negative pressure as possible for each running state of the engine.
The engine 1 forcibly returns to stratified charge combustion when the brake booster pressure DPBK becomes greater than the uniform charge brake control terminating pressure value tKPBKSO. In this case, the engine 1 returns to stratified charge combustion regardless of the elapsed time period. This enables the engine 1 to readily return to the stratified charge combustion after the negative pressure becomes sufficient. As a result, fuel efficiency is enhanced.
Furthermore, the closing control of the throttle valve 23 is executed if the pressure difference DPBK is smaller than the reference value (negative pressure value tKPBKL for initiating stratified charge brake control or negative pressure value tKPBKLS for initiating uniform charge brake control), and the closing control is terminated if the pressure difference DPBK becomes greater than a larger reference value (negative pressure value tKPBKO for terminating stratified charge brake control or negative pressure value tKPBKSO for terminating uniform charge brake control). In other words, the reference value has a hysteresis. This prevents hunting caused by the pressure difference DPBK becoming smaller than the reference value and then equal to or greater than the reference value in a repetitive manner. Repetitive execution and non-execution of the closing control does not take place.
Although the opening area of the intake passage is narrowed to produce negative pressure, an electronically controlled throttling mechanism that includes the throttle value 23 and the step motor 22 is employed as a means to guarantee negative pressure. Thus, conventional devices are used to produce negative pressure. This lowers costs.
In this embodiment, when increasing the throttle closing angle TRTCBK, the throttle closing angle TRTCBK is renewed by adding the presently set closing angle compensation value b to the throttle closing angle TRTCBK of the previous cycle. The closing angle compensation value a is set at a large value if the pressure difference DPBK is much smaller than the negative pressure value tKPBKO for terminating stratified charge brake control. Therefore, the closing speed is high immediately after the initiation of the closing control. This readily guarantees negative pressure.
If the pressure difference DPBK approaches the negative pressure value tKPBKO for terminating stratified charge brake control, the closing angle compensation value a is set at a small value. Thus, when a certain time elapses after starting the closing control, the closing speed decreases. This suppresses overshooting of the closing action and the negative pressure. As a result, a state in which the intake air amount is small due to the continuance of the close control regardless of the negative pressure being sufficient is avoided. This prevents undesirable combustion.
A second embodiment according to the present invention will now be described. To avoid a redundant description, like or same numerals are given to those components that are like or the same as the corresponding components of the first embodiment.
In the first embodiment, when the vehicle speed SPD is equal to or higher than the predetermined speed and the brake booster pressure DPBK is smaller than the negative pressure value tKPBKLS that initiates uniform charge brake control, the engine 1 switches to uniform charge combustion from stratified charge combustion. After the predetermined time period elapses, the engine 1 returns to stratified charge combustion. Thus, after returning to stratified charge combustion, the engine 1 may again return to uniform charge combustion when the above conditions are satisfied. Such repetition may result in hunting.
This embodiment copes with such problems. A portion of the negative pressure control routine executed by the ECU 30 is shown in the flowcharts of FIGS. 8 and 9.
In step 102, which is shown in FIG. 4, if the vehicle speed SPD is equal to or higher than the predetermined speed, the ECU 30 proceeds to step 114. In step 114, the ECU 30 determines whether the present pressure difference DPBK is smaller than the negative pressure value tKPBKLS at which the uniform charge brake control is initiated (e.g., 300 mmHg). If it is determined that the pressure difference DPBK is equal to or greater than the negative pressure value tKPBKLS, there is no need to produce negative pressure. In this case, the ECU 30 jumps to step 309. If the pressure difference DPBK is smaller than the negative pressure value tKPBKLS, the ECU 30 determines that negative pressure may be insufficient. In this case, the ECU 30 proceeds to step 301.
At step 301, the ECU 30 determines whether the uniform charge brake control history flag XBKDJM is set at zero. The history flag XBKDJM indicates whether there is a history of uniform charge brake control being carried out and indicates whether to prohibit returning to the uniform charge brake control. When returning to the uniform charge brake control is prohibited, the history flag XBKDJM is set at one. If returning is allowed, the history flag XBKDJM is set at zero. If the history flag XBKDJM is set at one, uniform charge brake control will not be carried out. In this case, the ECU 30 proceeds to step 309. If the history flag XBKDJM is set at zero, the ECU 30 proceeds to step 302.
In step 302, the ECU 30 sets the uniform charge brake control execution flag XBKDJM at one. The ECU 30 also sets the history flag XBKDJM at one.
In step 303, the ECU 30 adds one to the count value CBKDJ of the counter in an incremental manner. In step 304, the ECU 30 computes the assumed pressure difference DPMTAK. The assumed pressure difference DPMTAK is set and stored as the uniform charge assumed pressure difference DPMTAKM. The uniform charge assumed pressure difference DPMTAKM refers to the difference of the assumed intake pressure PMTAK with respect to the atmospheric pressure PA when performing uniform charge combustion. As shown in FIG. 10, the assumed intake pressure PMTAK is obtained through a map, plotted by experiment results, by referring to the degree of acceleration pedal depression ACCP and the engine speed NE. In the map, if the degree of acceleration pedal depression ACCP is small, the assumed intake pressure PMTAK is small and the assumed pressure difference DPMTAK is large.
In step 305, the ECU 30 sets and stores the brake booster pressure DPBK as the uniform charge brake booster pressure DPBKM.
In step 306, the ECU 30 determines whether the count value CBKDJ is greater than a predetermined value (eight in the embodiment). The predetermined value corresponds to the period of time that is necessary to stabilize the brake booster pressure DPBK when performing uniform charge combustion. If the count value CBKDJ is greater than the predetermined value of eight, the ECU 30 temporarily terminates uniform charge combustion and proceeds to step 308.
If the count value CBKDJ is not yet greater than the value of eight, the ECU 30 proceeds to step 307. In step 307, the ECU 30 determines whether the present pressure difference DPBK is higher than the negative pressure value tKPBKSO at which the uniform charge combustion brake control is terminated (e.g., 350 mmHg). If the brake booster pressure DPBK is not higher than the negative pressure value tKPBKSO, the ECU 30 returns to step 302. This is repeated until the count value CBKDJ becomes greater than the predetermined value of eight or until the brake booster pressure DPBK becomes greater than the negative pressure value tKPBKSO. In other words, the uniform combustion mode is continued until the negative pressure becomes sufficient.
When the count value CBKDJ becomes greater than the predetermined value of eight or when the brake booster pressure DPBK becomes greater than the negative pressure value tKPBKSO, the ECU 30 proceeds to step 308 to terminate the uniform charge combustion. In step 308, the uniform charge combustion flag XBKDJ is set at zero.
When the ECU 30 proceeds to step 309 from steps 114, 301, or 308, the ECU 30 clears the count value CBKDJ to zero.
In step 310, the ECU 30 computes the present assumed pressure difference DPMTAK (when the uniform charge combustion is terminated). The assumed pressure difference is obtained by comparing the assumed intake pressure PMTAK when performing uniform charge combustion to the atmospheric pressure PA in the same manner as in step 304.
In step 311, the ECU 30 determines whether the value obtained by subtracting the uniform charge assumed pressure difference DPTAKM, which has been stored in step 304, from the assumed pressure difference DPMTAK, which has been computed in step 310, is greater than a predetermined value (in this embodiment, 50 mmHg). In other words, the ECU 30 determines whether it has become easier to produce negative pressure by switching to uniform charge combustion than in the previous cycle. If the value obtained in step 311 is greater than a predetermined value, the ECU 30 proceeds to step 313 to switch to uniform charge combustion.
At step 313, the ECU 30 sets the uniform charge brake control history flag XBKDJM to zero. This enables the engine 1 to enter uniform charge combustion. Afterward, the ECU 30 proceeds to step 112, which is described in the first embodiment.
If the computed value in step 311 is not greater than the predetermined value, the negative pressure produced in the present combustion mode is almost the same as the negative pressure produced by performing uniform charge combustion. In this case, the ECU 30 proceeds to step 312.
In step 312, the ECU 30 determines whether the value obtained by subtracting the present brake booster pressure DPBK from the uniform charge brake booster pressure DPBKM is greater than a predetermined value (in this embodiment, 50 mmHg). In other words, the ECU 30 determines whether the present brake booster pressure DPBK is decreasing greatly with respect to the uniform charge brake booster pressure DPBK. If the computed value is greater than 50 mmHg, this indicates that the negative pressure has already been used due to the depression of the brake pedal. In this case, the ECU 30 proceeds to step 313 to allow switching to uniform charge combustion.
In step 313, the ECU 30 sets the uniform charge brake control history flag XBKDJM as zero. This enables the ECU 30 to return to uniform charge brake control. If the value obtained in step 312 is not greater than 50 mmHg, the ECU 30 determines that further negative pressure need not be produced. In this case, the ECU 30 proceeds to step 112 without changing the history flag XBKDJM, which is set at one.
In addition to the advantageous effects obtained in the first embodiment, the following advantageous effects may also be obtained through this embodiment.
In the first embodiment, the engine 1 returns to stratified charge combustion regardless of the brake booster pressure DPBK after uniform charge combustion has been carried out for a predetermined period of time. Thus, if the acceleration pedal is depressed after re-entering stratified charge combustion, the negative pressure becomes insufficient. In this case, the engine 1 immediately returns to uniform charge combustion. Accordingly, there is a possibility that uniform and stratified charge combustion are alternated repeatedly. However, in this embodiment, if the engine 1 returns to stratified charge combustion from uniform charge combustion, the ECU 30 decides whether it is better to remain in the stratified charge combustion or to return to the uniform charge combustion to ensure the required negative pressure. Accordingly, this prevents hunting and stabilizes the operation of the engine 1.
Although only two embodiments of the present invention has been described so far, it should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. More particularly, the present invention may be modified as described below.
(1) In the illustrated embodiment, an electronically controlled throttle mechanism is used as the negative pressure producing means. The throttle mechanism includes the throttle value 23 arranged in the intake duct 20, and the step motor 22 serving as an actuator for opening and closing the throttle value 23. However, an idle speed control (ISC) mechanism may be used as the negative pressure producing means. Such an ISC mechanism includes an idle speed control valve arranged in an intake passage that bypasses the throttle value 23 and an actuator for opening and closing the control valve.
The EGR mechanism 51 provided with the EGR valve 53 and other parts may also be employed as the negative pressure producing means.
Negative pressure producing mechanisms other than those shown in the drawings may also be employed. For example, a mechanical throttle valve that is linked to the acceleration pedal may be used in lieu of the electronically controlled throttle valve.
(2) In the illustrated embodiment, the computation of the closing compensation angle a enables the closing speed of the throttle valve 23 to be variable. However, the closing speed may be constant. Furthermore, in the preferred and illustrated embodiment, the fuel injection timing is altered when executing the closing control while performing stratified charge combustion. However, the closing control may be eliminated.
(3) The present invention is applied to the cylinder injection type engine 1 in the illustrated embodiment. The present invention may also be applied to an engine that performs stratified charge combustion and weak stratified charge combustion. For example, the present invention may be applied to an engine that injects fuel beneath the intake valves 6a, 6b provided in the associated intake ports 7a, 7b. The present invention may also be applied to an engine that injects fuel directly into the cylinder bores (combustion chambers 5) from injection valves arranged near the intake valves 6a, 6b. As another option, the present invention may be applied to an engine that does not perform stratified charge combustion.
(4) In the illustrated embodiment, helical type intake ports are employed to produce swirls. However, the swirls do not necessarily have to be produced. In such case, parts such as the swirl control valve 17 and the step motor 19 may be eliminated.
(5) The present invention is applied to a gasoline engine in the illustrated embodiment. However, the present invention may also be applied to other types of engines such as diesel engines.
(6) In the illustrated embodiment, the atmospheric pressure PA is detected by the intake pressure sensor 61. However, an atmospheric pressure sensor may be provided to detect the atmospheric pressure.
Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | An apparatus for controlling brake force of a vehicle is disclosed. Each cylinders of a vehicle engine has a combustion chamber that receives fuel from a fuel injector and air from an air intake passage. The engine selectively performs a stratified charge combustion and a uniform charge combustion. The stratified charge combustion mode is selected to increase the amount of the air and the fuel supplied to the engine and improve a combusting state of the engine. The apparatus further includes a brake booster for increasing the brake force according to the negative pressure applied thereto. The brake booster is actuated by the negative pressure an amount of which is greater than a predetermined amount. Airflow in the air intake passage is restricted to generate the negative pressure. A fuel injector directly injects the fuel into the cylinder to set the engine to perform the stratified charge combustion. An electronic control unit (ECU) measures the an amount relating to the pressure applied to the brake booster. The ECU actuates the motor means to apply the negative pressure to the brake booster when the amount is smaller than the predetermined value and converts the driving condition of the engine from the stratified charge combustion to the uniform charge combustion. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
REFERENCE TO MICROFICHE APPENDIX
Not Applicable
TECHNICAL FIELD
The present invention relates generally to construction hardware, and more particularly to an improved fastener apparatus for metal roofing and steel building construction.
BACKGROUND INFORMATION AND DISCUSSION OF RELATED ART
Fasteners for use in roofing and steel building construction currently include the ring shank self-sealing nail, the self sealing hex head. Manufacturers of these fasteners recommend these said existing fasteners be replaced every five years. This replacement is necessary because the rubber seals used on these fasteners are damaged by the sun's UV Rays due to their exposed nature. In addition, snow falls and lands on the rooftop, and gravity causes the snow to slide downhill which builds up against the vertical walls of the hex head and increases in weight. Eventually the weight of the snow and ice overwhelms the holding power of the existing fasteners and with the aid of gravity the snow and ice unload, violently sliding over the existing fasteners and causing damage to the fasteners and their seals.
U.S. Pat. No. 6,764,262 to Hargis discloses a weatherproof fastener having a shank and head, the latter formed with a recess in its lower surface. A gasket is positioned in the recess, which it partially fills until the screw is employed to joint two elements and the gasket is compressed so that it fills the entirety of the recess, thereby preventing to ingress of undesirable materials. Hargis fails to consider the solid connection between the said head and said shank create a “T” shape, which when the fastener is applied at any off angle other than perfectly vertical, will allow the ingress of undesirable materials to the underside of the head as it becomes exposed to sliding snow and ice and UV Rays. When the fastener is applied at an off angle one side will touch the workpiece and the opposite side will rise up creating a gap between the workpiece and the outer rim of said head, therefore allowing the ingress of said materials.
The foregoing patents reflect the current state of the art of which the present inventor is aware. Reference to, and discussions of, these patents is intended to aid in discharging Applicant's acknowledged duty of candor in disclosing information that may be relevant to the examination of claims to the present invention. However, it is respectfully submitted that none of the above-indicated patents disclose, teach or suggest, show or otherwise render obvious, either singly or when considered in combination, the invention described and claimed herein.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an improved fastener apparatus for use in roofing and steel building construction. The inventive fastener provides a self-adjusting and automatically self-leveling head which is separate from the threaded shank portion. Said head portion provides a frusto-hemispherical head, a curved outer surface, a base portion, a peripheral edge, and a hollow center having in the form of a rounded annular cup, said rounded annular cup center is wider and near vertical at the uppermost portion which curves and narrows towards horizontal at the lower portion, and is designed to accept a separate threaded shank portion to be inserted through the hollow center of said head portion. Said shank portion having threads at the first end, and a rounded ball head at the second end, and a flat top surface bearing a tool fitting. When combined said annular cup head portion and said rounded ball shank portion create a free moving ball joint which allows the free moving head to self level under compression of installation regardless of which angle the threaded shank portion is installed. Said Head portion has a downwardly-appending lip portion which extends from the peripheral edge and defines an annular recess in the base portion, the annular recess having a flat upper surface which transitions into a vertical downwardly-appending lip portion, said vertical transfers into a annular wall at approximately 100 to 110-degrees, said annular wall ends in a curved lowermost bottom of the annular lip portion, said bottom of the lip portion is substantially flat, said flat bottom of the downwardly appending lip portion curves and transfers into an upwardly-appending peripheral edge, said peripheral edge of the lip portion slopes outward at approximately 110-degrees, said peripheral edge at 110-degrees transfers into the frusto-hemispherical head. Said recess and downwardly appending lip portion should be deep enough to accommodate a large seal and said threaded shank should be free of threads so when combined the seal can properly seat around the shank and create a water tight seal.
The inventive self leveling head feature will address the fastener head perimeter and downwardly-appending lip portion from scratching the painted workpiece during installation. Since the first portion of the seal will make contact with the workpiece as it is being fastened, this portion of the seal will begin to compress and will provide resistance, the remaining portion of the seal that has not made contact with the workpiece will not have any resistance and is free to make contact with the workpiece which will adjust the free moving head to a level position before final compression of the seal occurs, the entire head will then be flush and level.
A second thin seal should also be inserted between said rounded ball head of the threaded shank portion, and the rounded cup portion of said free flowing head which contains the recess. The addition of this second seal is mainly to provide a barrier between said ball and said cup which create the self adjusting head in order to stop rusting and electrolysis, and secondarily to stop the ingress of water into the recess through the two separate said cup and ball portions which combine to create the entire head of the self-leveling fastener.
The individual heads of the inventive fastener should combine to create one head, and be as low profile as possible to reduce friction between the fastener and unloading snow and ice which can shear the head of the fastener and tear the entire fastener from the installed position. As the afore mentioned Hex Head fasteners create a catch which causes a build-up of snow and ice, whereas the vertical sides and high profile of the Hex fasteners head actually catch snow and ice and stop it from naturally unloading off the roof due to the pull of gravity.
The lip should have six specific features to it. The first is on the inside of the lip, the top 20% of the annular recess is vertical in order to catch the top portion of the seal and stop it from expanding wider which will cause instantaneous resistance between the seal and the workpiece in order to self level the head, the second 70% portion of the annular recess wall transitions into a 110-degree sloping wall which gets wider as it nears the bottom of the lip allowing the seal to slowly expand and fill the recess, the third 10% portion is rounded so the seal escaping the recess and under the lip is not pinched or cut by the inside of the recess wall, the bottommost portion of the lip is substantially flat and substantially wide to accommodate a portion of seal and to create a scratch barrier between said lip and said workpiece being fastened, the bottommost said flat portion transitions into a rounded portion which removes any sharp edges that may scratch the workpiece being fastened, and the outer peripheral edge slopes up towards the main body of the fastener head at a 110-degree angle, this section creates a horizontal V-shaped cavity which accommodates the excess seal that escapes from the recess to be protected from unloading snow and ice as it resides within the horizontal V-shape created between the workpiece and the peripheral edge at a 110-degree angle of the edge. The purpose of this inventive recess lip portion is to work in unison with the seal, the workpiece, and the free moving head of the fastener, to self-level the head portion regardless of the angle the threaded portion is installed. As the fastener is installed the seal located inside the recess makes first contact with the workpiece and is sandwiched between said free moving head and said workpiece being fastened, the seal is then slightly compressed and begins to expand in an outward direction, the short top 20% vertical wall of the lip portion is designed to stop the seal from expanding wider as it makes contact with said vertical recess wall, this contact transitions the expansion of the seal from a sideways motion into a downward direction, this contact also creates immediate and increased resistance from the seal which causes the free moving head portion to self-level itself with the aid of said resistance. Once said free moving head has self leveled with the aid of said short vertical wall and increased resistance from the seal, the lowermost portion of the seal is allowed to gradually expand along the angled 110-degree mid portion and fill the remaining recess. The extreme bottommost portion of the inner recess wall is rounded and will not damage the rubber seal as it expands at an acceptable rate for the composition of the rubber seal, and eventually escaping from the recess which provides a scratch barrier between the lip of the fastener head and the workpiece being fastened. Further, the substantially flat and substantially wide bottom of the lip portion is designed to accommodate escaping seal and aid in the self-leveling aspects of said free moving head, also creating a scratch barrier between said lip portion and said workpiece. And the final portion of the downwardly-appending lip portion is the peripheral edge, it is designed at a 110-degree outward angle to accommodate a small amount of seal which may completely escape from the recess and even beyond the lip portion of the recess to stop the ingress of undesirable materials and water.
The separation of said threaded shank portion with a rounded ball head, and said head portion with rounded cup, combine and create a ball joint which allows the threaded shank portion to spin during installation and the free moving head portion to be held by the installer without said head portion spinning in the installers fingers, further, as the head and seal make contact with said workpiece being fastened the rubber seal contained inside the recess is not subjected to extreme twisting and binding which causes damage to the seal during installation.
It is therefore an object of the present invention to provide an improved fastener that can withstand the elements.
It is another object of the present invention to provide a new and improved fastener that provides easier installation for the operator.
It is another object of the present invention to provide a new and improved fastener that protects the seal from extreme forces under the installation process including twisting, binding, rolling and heat generated by the friction caused during the final seating of installation.
It is another object of the present invention to provide a new and improved fastener in which the head self levels and provides a tighter seal in order to stop the ingress of undesirable materials under the head which the existing fasteners that have a solid head to shank connection cannot provide.
A further object of the present invention is to provide a novel fastener that will not scratch the painted surface of the workpiece due to the self leveling aspect of the separated head and shank.
An even further object of the present invention is to provide a novel fastener that will not cause rusting and electrolysis between the fastener head and the workpiece.
Other novel features which are characteristic of the invention, as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawing, in which preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawing is for illustration and description only and is not intended as a definition of the limits of the invention. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming part of this disclosure. The invention resides not in any one of these features taken alone, but rather in the particular combination of all its structures for the functions specified.
There has thus been broadly outlined the more important features of the invention in order that the detailed description thereof that follows 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 additional subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based readily may 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.
Certain terminology and derivations thereof may be used in the following description for convenience in reference only, and will not be limiting. For example, words such as “upward,” “downward,” “left,” and “right” would refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as “inward,” and “outward” would refer to directions toward and away from, respectively, the geometric center of a device or area and designated parts thereof. References in the singular tense include plural, and vise versa, unless otherwise noted.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The invention will be better understood and objects other than those set fourth above will be come apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein.
FIG. 1 includes illustrations 1 -A and 1 -B, are a side elevation view of this inventive fastener fully assembled and installed.
FIG. 1-A is a side elevation view of this fastener with the threaded shank portion installed in a vertical position.
FIG. 1-B is a side elevation view of the fastener with the threaded shank portion installed at an off angle of approximately 20-Degrees from vertical, noting that the free flowing head portion has self leveled automatically and equal pressure has been applied to the seal.
FIG. 2 includes illustrations 2 -A, 2 -B and 2 -C, and is a side elevation view of this fastener.
FIG. 2-A is a side elevation view of the individual components in an unassembled position.
FIG. 2-B is the individual components of this inventive fastener assembled, with the threaded shank installed in a 20-degree off vertical angled position.
FIG. 2-C is also the individual components assembled, but with the threaded shank installed in a vertical position.
FIG. 3 is a top elevation view of the head of this inventive fastener.
FIG. 4 is a side elevation view in a cross section of the fastener apparatus.
FIG. 5 is a side elevation view in an enlarged close up of the downwardly-appending lip portion with its individual features that form the annular recess wall.
FIG. 6 includes illustrations 6 -A, 6 -B and 6 -C, and is a side elevation view used as an example of existing solid connecting head and shank head technology that cannot
FIG. 6-A is a side elevation view of existing solid connecting head and shank head technology installed at the vertical position, which is the only acceptable position for this solid “T-shaped” design.
FIG. 6-B is a side elevation view of existing solid connecting head and shank head technology installed at a 15-degree off of vertical angle.
FIG. 6-C is a side elevation view of existing solid connecting head and shank head technology installed at a 25-degree off of vertical angle.
FIG. 7 includes illustrations 7 -A, 7 -B and 7 -C, and is a cross section side elevation view used as an example to illustrate the proper seating of the seal as it is installed, as it secures itself around the center shank, and how the recess wall works as the fastener tightens down into a completely installed position
FIG. 7-A sows the seal in an uncompressed state prior to the seal making contact with the workpiece.
FIG. 7-B illustrates how the seal has begun to compress and the recess wall causes the seal to secure itself around the center of the shank.
FIG. 7-C shows the seal in a final installed position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 7 , wherein like reference numerals refer to like components in various views, there is illustrated therein a new and improved fastener apparatus, generally denominated 100 herein.
FIG. 1 includes two illustrations 1 -A and 1 -B and is a side elevation view of this new invention 100 installed. FIG. 2 , includes three illustrations 2 -A, 2 -B and 2 -C is a cross section side elevation view detailing the individual components which make up the completed fastener 100 unassembled ( 2 -A) and assembled vertically ( 2 -B) and assembled showing the free moving threaded shank at an off angle ( 2 -C). FIG. 3 is a top plan view of the fastener head. FIG. 4 is a side elevation view in a cross section which details the individual claims and is the embodiment of the invention. FIG. 5 is a side elevation view in a cross section and is a close up of the individual features that create the recess wall and self leveling head portion. FIG. 6 is a side elevation view and is a example illustration of an existing one piece fastener with a solid head and shank connection. FIG. 7 is a side view elevation and includes three illustrations 7 -A, 7 -B and 7 -C, showing the fastener being installed and details how the recess wall works in unison with the seal and properly seats under compression.
This inventive fastener 100 includes four portions, the threaded shank portion 50 , the free moving head portion 75 , an upper seal 6 , and a lower recess seal 7 , which combine together and create a self-leveling headed fastener 100 . The threaded shank portion 50 is inserted through a nylon or rubber upper seal 6 , then through the free moving head portion 75 , and finally through the rubber recess seal 7 . The fastener threaded shank portion 50 includes a frusto-hemispherical head 1 , having a flat top surface 2 bearing a tool fitting, a curved ball bottom 3 , and a threaded shank 9 , and a smooth thread-less portion on the shank 8 . A shank portion 50 is connected to the free moving head portion base portion 80 , the shank portion bearing screw threads 9 and a tip portion 90 as is well known in the art. The threaded shank portion 50 and the free moving head portion 75 each contain circular outer surfaces, FIGS. 3-5 .
Further, this fastener also has a free moving head portion 75 , which has a frusto-hemispherical head 5 , a hollow center formed in a rounded cup shape 4 , a flat base portion 17 , and a peripheral edge 16 . A downwardly-appending lip portion 30 extends from the peripheral edge 16 and defines an annular recess 40 in the free moving head base portion 75 . The annular recess 40 has a flat upper surface created by two pieces defined as the threaded shank portion 50 and the free moving head portion 75 , more particularly numbered as features 17 and 18 . The lip portion 30 has a 110-degree angled outer edge 10 , a curved lower edge 15 , a substantially wide and flat bottom 11 , and an inner edge which is curved at the bottom 10% 14 , a 70% mid portion which is angled at 110-degrees 13 , and a vertical 20% upper portion 12 terminating in the annular recess flat upper surface 17 .
The threaded shank portion 50 and the free moving head portion 75 combine to create a ball joint to allow the fastener to self-level the head regardless of the angle the shank portion 50 is installed off vertical. The ball 3 on the bottom of the head 80 on the threaded shank portion 50 combines with the cup 4 on the free moving head 75 and creates a durable head that can rotate to any position up to 30-degrees off vertical and allow the head 75 to self level under compression of installation. The free moving head portion 75 also aids the installer to hold the free moving head tightly in their fingers without the head spinning in their fingers causing friction burn, while the threaded shank portion 50 spins inside the center of the free moving head 75 , further, the free moving head does not spin therefore the seal within the recess does not spin or bind and the seal is not damaged during installation.
A thin nylon or rubber seal 6 is installed between the ball 3 of head 80 and the cup 4 of the free moving head 75 to stop the ingress of water into the ball joint ( 3 and 4 ) which will cause rusting and electrolysis, further to stop the ingress of water into the recess 40 via the ball 3 and cup 4 .
The rounded or convex head shape 1 of the threaded shank portion 80 , and the convex free moving head portion 75 is also convex and low profile to reduce friction between unloading snow and ice and the head of the fastener to reduce head shear.
The peripheral edge 16 is located below the mid point near the bottom of the head 75 for the purpose of creating a ramp 5 to direct snow and ice over the top of the head which will apply a downward force as snow and ice slide over the head 75 , and will not allow the unloading snow and ice to ingress under the head 75 and cause uplift.
The recess 40 is designed to accommodate a rubber seal 7 that when in an uncompressed state said seal 7 fills the recess 40 from the threaded section of the shank 9 to the vertical wall 12 of the annular recess downwardly appending lip portion 30 , under compression the vertical wall 12 stops the top portion of the rubber seal 7 from expanding laterally from center and causes the rubber seal to instead compress and close the seal towards the center and seat around the smooth unthreaded portion 8 of the shank 50 .
The annular mid portion of the recess wall at an angle of 110-degrees 13 allows the lower portion of the seal to compress and transition from an inward motion towards the center 8 at the top portion of the seal, to an outward motion at a gradual rate towards the downwardly appending lip portion 30 . The unique design compresses the seal around the center of the shank 8 to block the ingress of water through the ball 3 and the cup 4 into the recess area 40 .
The lowermost portion of the annular lip portion 30 is rounded 14 so the seal is not cut or pinched by an otherwise shape edge.
The bottom of the downwardly appending lip portion 30 is substantially flat and wide 11 in order to allow a small portion of seal to escape the confines of the recess 40 and create a scratch barrier between the lip portion 30 and the workpiece being fastened 19 .
The outer edge of the lip portion 15 is rounded to allow a small portion of seal 7 to entirely escape the lip portion 30 without being cut or pinched.
Completing the recess lip portion 30 the outer edge is angled outwards away from center at 110-degrees 10 from the lowermost curve 15 up to the peripheral edge 16 , and is designed to create a “V” shape laterally 95 to protect exposed seal from damage due to unloading snow and ice pushing the seal over the heads peripheral edge 16 and therefore tearing it off. The “V” shape is created by the edge of the fastener at 110-degrees 10 and the workpiece 19 .
The above disclosure is sufficient to enable one of ordinary skill in the art to practice the invention, and provides the best mode of practicing the invention presently contemplated by the inventor. While there is provided herein a full and complete disclosure of the preferred embodiment of the invention, it is not desired to limit the invention to the exact construction, dimensional relationships, and operation shown and described. Various modifications, alternative constructions, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features and the like.
Therefore, the above description and illustrations should not be construed as limiting the
Therefore, the above description and illustrations should not be construed as limiting the scope of the invention, which is defined by the appended claims. | Fastener apparatus including a self-adjusting and automatically self-leveling head separate from a threaded shank portion. An embodiment of the apparatus provides a self-leveling head portion defining an annular conical recess and lip portion sized to receive a seal. A threaded shank resides within an annular cup center of the self-leveling head and has a thread-free portion seated by the compressed seal creating a water tight seal. | 5 |
RELATED APPLICATIONS
This is a continuation-in-part of co-pending application Ser. No. 918,492, filed June 23, 1978 (now abandoned), which is a continuation of application Ser. No. 775,244, filed Mar. 7, 1977 (abandoned).
DESCRIPTION
This invention relates to an improved irrigation pipe gate valve, and has for an object thereof the provision of a new and improved irrigation pipe gate valve.
Another object of the invention is to provide a gate valve which dissipates energy of water flow to minimize soil erosion.
A further object of the invention is to provide a gate valve which has a slide that can be cocked to divert water toward the center of the nearest furrow.
Another object of the invention is to provide a gate valve having a slide movable to an open position by vacuum in an irrigation pipe.
Another object of the invention is to provide a gate valve having a slide provided with stops preventing accidental closing by pressure of water.
Another object of the invention is to provide a gate valve having a resilient frame having a sealing lip allowing a slide to open easily but which will not creep toward a closed position.
Another object of the invention is to provide a gate valve slide which is elongated so that it can be inserted endwise through an opening in a frame, turned and pulled back into the opening with a tapered front end to facilitate its movement through the frame while preventing slide from being pushed back into the pipe.
Another object of the invention is to provide a gate valve mounted on a recessed lip portion of a pipe and in which no part of the slide extends beyond the pipe when a slide is in its open position.
Another object of the invention is to provide a gate valve having a slide adjustable to vary flow and with large passages to allow debris to pass therethrough.
In the drawings:
FIG. 1 is a fragmentary, perspective view of an irrigation pipe having a plurality of improved gate valves forming one embodiment of the invention;
FIG. 2 is an enlarged, fragmentary, vertical sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is an enlarged, fragmentary, partially sectional, perspective view of one of the gate valves of FIG. 1;
FIG. 4 is an enlarged, fragmentary, horizontal sectional view taken along line 4--4 of FIG. 1;
FIGS. 5-8 are sectional views of the pipe and one of the valves being installed in the pipe; and
FIG. 9 is an enlarged, horizontal, sectional view of an improved gate valve forming an alternate embodiment of the invention.
Identical improved gate valves 10 forming specific embodiments of the invention are mounted in cup-like, recessed or indented opening portions 12 in an irrigation pipe 14. Each valve includes a softly resilient rubber or neoprene grommet-like frame 16 and a rigid slide 18 of a tough plastic, such as, for example, polyurethane. Each slide has a tubular body portion 20, which is generally elliptical in transverse cross-section, with a flange or lip 22 forwardly tapered to facilitate insertion of the slide through the frame, rear face of the flange 22 being abrupt to prevent accidentally pushing the slide inwardly out of the frame. The slide has two pairs of large, diametrically opposite circular inlet holes or ports 24, which admit water in opposed streams to somewhat dissipate its energy to help prevent soil erosion. A post-like handle 26 braces the elongated sides of the body 20. An inner end plate or bottom 28 closing the inner end of the slide has a somewhat wide flange 30, which acts as a valve closure member and as a stop to prevent outward movement of the slide out of the frame. Longitudinally spaced pairs of ribs 32 act as detent-like stops to hold the slide in selected positions of adjustment relative to the frame. The slide can be adjusted longitudinally relative to the frame to any of a large number of positions varying from fully open to fully closed. Also, the slide may be adjusted between a center position in which the slide is perpendicular to the frame and a cocked position directing the water at an acute angle to the pipe, as illustrated in FIG. 4, to direct the water toward the nearest of furrows 34, 36 and 38.
The frame 16 has an endless or generally annular, cup-shaped groove 40 fitting closely on and sealing to planar lip portion 42 and curved transition portion 44 of the indented opening 12. Bevelled lip portion 46 is pressed by water pressure tightly and sealingly against the curved transition portion 44. The frame has a planar inner face 46 and a narrow, thin sealing lip 48 fitting tightly on the body portion 20 of the slide.
To install the valve, with the frame 16, out of the opening 12, the lower edge of the flange 30 of the slide 18 is inserted into the opening 12, as shown in FIG. 5. Then the slide is pivoted to insert the rest of the flange into the opening and the slide is pushed fully into the pipe with a wire hook 60 attached to the slide, as shown in FIG. 6. Then the frame 16 is installed. With the components in the positions thereof shown in FIG. 7, the slide is pulled up by the wire hook, is cocked, and is partially drawn through the frame, as shown in FIG. 8. Then the outer end of the slide is snapped fully through the frame. The front locking edge 22 of the slide is wider than the opening in the frame so that it is very difficult to move the edge 22 straight through the opening in the frame.
The slide 18 will open under vacuum and prevent failure of the aluminum pipe due to a vacuum condition. The slide cannot be displaced toward closing under pressure due to the ribs 32 on the sides. The sealing lip 48 allows the slide to be opened easily, but is more difficult to close. This is an advantage since the slide wall will not "creep" to a closed position under gated pipe operating pressures. The tapered front edge 22 of the slide aids in easy installation. The slide has a wedge portion 29 adjacent the flange 30 to wedge into the frame to completely close the opening even under low water pressure.
Embodiment of FIG. 9
An improved gate valve 110 forming an alternate embodiment of the invention is identical to the gate valves 10, except that a grommet-like frame 116, which is like the frame 16, except that the frame 116 includes two semi-ratchet sealing lips 148 rather than the single semi-ratchet lip 48 of the frame 16 so that a slide 118 will stay in a set position at very high operating pressures. The lips 148 are spaced apart the same distance that each adjacent pairs of ribs 132 on the ends of the ellipse are spaced. To give the ratchet effect, each rib 148 has a planar, inner face 149, a land 151 and a bevelled, outer face 153 of substantially the same slope as inner sides 155 of the ribs 132. The width of each of the lands 151 is substantially the same as the distance between each adjacent pair of the ribs 132. The faces 149 are perpendicular to the longitudinal axis of the gate so that it is somewhat difficult to push the ribs 132 outwardly past the lands (in the closing direction) while it is much easier to push the ribs 132 inwardly in an opening direction. The grommet being of elastic material compresses to permit such movement. | An irrigation pipe laying crosswise of a series of furrows has gate valves mounted in its side spaced to match each furrow. Each gate valve includes a generally elliptical, elastomeric, grommet-like frame fitting on the periphery of a recessed lip portion of the pipe defining an opening, and also includes a tubular slide slidable in the frame between a closed position and three open positions, one perpendicular to the pipe and two others cocked to either side to direct water to the outer of the three furrows. | 5 |
TECHNICAL FIELD
The present invention relates to a knitted textile that is foamed with an elastomeric latex composition to create a textile-elastomer composite, the composite being particularly preferable for transfer or film-coating to create an artificial leather substrate. In particular, the knitted textile-elastomer composite exhibits improved compressibility, pliability, and drape, characteristics that are commonly associated with high quality leather.
DISCUSSION OF THE PRIOR ART
Polymer latexes (e.g., polyurethane and acrylate) have been utilized in a variety of ways, most notably as coatings or finishes on fabric surfaces. Such latexes may provide, for example, a barrier to potentially adverse environmental conditions. Furthermore, leather substitutes have also been produced through the use of waterborne polymer latexes. Such substitutes provide an alternative to more expensive, genuine leather articles. Such artificial leather substrates must exhibit the suppleness and appearance that are characteristic of genuine leather, and must withstand heavy and repeated use within automobile and furniture upholstery, for example.
Previous polyurethane-based leather substitute products include composites produced through the reaction of a polyurethane latex and an acid-generating chemical (specifically, hydrofluorosilicic salts). Such a composition is disclosed in U.S. Pat. No. 4,332,710, to McCartney, entirely incorporated herein by reference. McCartney teaches heat-activated coagulation of a polyurethane latex in conjunction with only an acid-generating chemical, such as salts of hydrofluorosilicic acid. Such a composition and method present some difficulties, primarily in the use of an acid-generating chemical alone to provide ionic coagulation. This two-component system often results in a non-uniform distribution in the textile substrate and can form stringy structures, which are unattractive as suede leather substitutes. Of particular concern are the environmental and safety issues associated with the use of hydrofluorosilicic acid salts, which are highly discouraged within the industry but which are patentee's preferred acid-generating chemicals.
Other prior teachings involving polymer latex heat-activated coagulation include U.S. Pat. No. 4,886,702 to Spek et al. The '702 patent discloses a method utilizing a composition comprising a waterborne polymer latex (including polyurethane and acrylate), a cloud-point surfactant coagulant, and a blowing agent, which evolves gas during heating. However, such a composition does not produce preferable leather-like textile products due to the stiff hand that results from the effect of the blowing agent. Second, the preferred blowing agent is freon, which is being phased out of production due to its deleterious environmental impact. Third, the coagulation process requires the addition of acid and/or salt compounds, which have the potential to coagulate the latex mixture prior to contact with a textile substrate, thus resulting in a non-uniform dispersion on the substrate surface. Last, the shelf-life of patentees' composition is, at a maximum, only eight hours in duration, thereby placing certain limitations on manufacturing flexibility.
Furthermore, U.S. Pat. No. 4,171,391, to Parker, teaches polyurethane latex coagulation within an aqueous ionic or acid bath. Because the determining factors are the type and amount of ionic material (or acid) and the rate of diffusion of such a constituent from the bath to the substrate material, such a procedure is difficult to control. As a result, there is a lack of consistent uniform dispersion and coagulation from one textile substrate to another. Particularly with heavier fabric substrates, the necessary contact times may be as long as 30 minutes, translating into high costs for the manufacturer and, ultimately, the consumer.
These shortcomings indicate a need, then, within the industry, for improved leather-like textile-elastomer composites, which are relatively inexpensive to make, which have a more realistic appearance and improved aesthetic qualities when transfer or film-coated, and which have an overall better performance over the prior art.
SUMMARY
This invention concerns a leather-like textile-elastomer composite, and a method of producing this composite, the method comprising the sequential steps of:
(a) providing a knitted textile fabric;
(b) foam-coating the knitted fabric with a liquid elastomer composition, the elastomer composition comprising:
(i) a waterborne, anionically-stabilized polymer latex;
(ii) an acid-generating chemical;
(iii) a cloud-point surfactant; and
(iv) a foam-stabilizing surfactant,
wherein sufficient gas is incorporated into the liquid elastomer composition to produce a foamed elastomer composition;
(c) heating the coated textile to an initial temperature to effectuate a uniform dispersion and cause coagulation of said elastomer composition over the textile fabric; and
(d) subsequently heating the coagulated fabric to a temperature higher than the temperature utilized in step (d) in order to dry, but not destroy, the coagulated elastomer over the fabric.
The addition of step (e), in which the textile-elastomer composite is subsequently transfer or film-coated, results in a high quality artificial leather substrate that exhibits the compressibility, pliability, and drape that are characteristic of genuine leather articles.
It is thus an object of the invention to provide an improved, more aesthetically pleasing leather-like fabric-elastomer composite. The term fabric-elastomer composite refers to an article comprised of a knitted textile fabric, which has been coated on at least one side with an elastomer composition. An object of the invention is to provide a composite that has a more realistic, leather-like appearance and is more aesthetically pleasing when transfer or film-coated. Another object of the invention is to provide a method of producing a leather-like article which includes environmentally safe, nontoxic, low odor, noncombustible chemicals. Yet another object of this invention is to provide leather-like composites, which when transfer or film-coated, are suitable for all intended uses in which a user requires or desires a faux-leather substrate.
Perhaps most importantly, the inventive method and composition impart a soft, fine-structured coagulum leather-like finish to fabrics which is comparable to, if not better than, leather-like finishes produced with organic solvent-borne systems (such as those described in U.S. Pat. No. 4,886,702, noted above). Thus, the inventive method and composition provide the means to produce, in a very safe manner, a fabric-elastomer composite having a desirable suppleness and appearance, which, when transfer or film-coated, effectively simulates a genuine leather article.
The term fabric-elastomer composite refers to an article comprised of two layers, wherein one layer is a knitted textile fabric, and the second layer is an elastomeric coating that has been applied to at least one side of the knitted fabric. The second, elastomeric layer is partially incorporated into the knitted textile, creating a seamless transition between the two layers. As noted above, the inventive foamed elastomer composition comprises five materials: a waterborne polyurethane latex, an acid-generating chemical, a cloud-point surfactant, a foam-stabilizing surfactant, and sufficient gas to produce the foamed product.
An anionically stabilized polymer latex is an emulsion or dispersion formed from a polymer, an anionic surfactant, and water. Polyurethane, acrylic, or polyurethane-acrylic latex is preferable, but any waterborne anionically stabilized polymer latex may be used. The preferred latexes are those having at least a 30% solids content. One preferred example of a polyurethane latex is EX-62-655 (40% solids), available from Stahl. A suitable polyurethane-acrylic latex is Paranol T-6330 (50% solids), available from Parachem. Examples of suitable anionic surfactants for use in the polymer dispersion include, but are not limited to, poly-acrylic acid copolymers, sodium laurel sulfate, aryl or alkyl benzene sulfonates, such as, but not limited to, the proprietary Rhodacal DS-10 (from Rhodia). In addition to the anionic surfactant and water, a nonionic surfactant may also be included in the polymer dispersion. Examples of a nonionic surfactant include polyvinyl alcohol and ethoxylated surfactants, such as Pluronic F-68 (from BASF). Also well known in the art is the incorporation of carboxyl or sulfate groups into the backbone of the polymer in order to help stabilize the latex. The waterborne criterion is of utmost importance within this invention primarily to insure that potentially environmentally harmful organic solvents are not present within the elastomer composition.
The term acid-generating compound denotes a chemical which is not an acid at room temperature, but which produces an acid upon exposure to a heat source. Examples include, but are not limited to, ammonium acid salts like ammonium sulfate and ammonium phosphate, and organic acid esters. One particularly suitable class of compounds that both meet this description and that provide superior results with little or no harmful environmental impact are organic acid esters. Some specific types of these compounds include ethylene glycol diacetate, ethylene glycol formate, diethylene glycol formate, triethyl citrate, monostearyl citrate, a proprietary organic acid ester available from High Point Chemical Corporation under the tradename Hipochem AG-45, and the like. The most preferred compound is ethylene glycol diacetate, available from Applied Textile Technologies under the tradename APTEX™ Donor H-plus.
The term cloud-point surfactant is intended to encompass any surface-active agent that becomes less water soluble upon exposure to higher temperatures. This type of surfactant easily binds with the polymer latex upon gelling and facilitates the uniform coagulation of the latex over the entire contacted textile substrate. Specific surfactants that meet such requirements include poly(ethylene) oxides, poly(ethylene/propylene) oxides, polythio ethers, polyacetals, polyvinylalkyl ethers, organo-polysiloxanes, polyalkoxylated amines, or any derivatives of these listed compounds, with the preferred being polyalkoxylated amines, available from Clariant under the tradename Cartafix U™.
The term foam-stabilizing surfactant includes any surface-active agent that improves the ability of the inventive composition to entrain, and retain, air. Particular examples include, but are not limited to, alkyl benzene sulfates and sulfonates (Rexoprene series from Emkay Chemical) like sodium laurel sulfate (also sold under the name Stephanol AM from Stepan Corporation), sodium dioctyl sulfosuccinate, dodecyl benzene sulfonate, alkyl amine oxides (Unifroth series from Unichem Corp.), alkyl phosphates (Synfac series from Milliken Chemical), ammonium stearate (Henkel), water-soluble cellulose derivatives (Hercules Inc.), and Alkasurf DAP-9 (Rhodia).
The proportions required within the inventive elastomer composition are based upon the ratio of weights between the latex and each of the remaining components. For instance, ratios between the latex and each of the other components (namely, the acid-generating compound, the cloud-point surfactant, and the foam-stabilizing surfactant) should be in the range of 5:1 to 200:1, with preferred ranges of from about 10:1 to about 50:1. The Examples below further illustrate the utilization of such ranges of weight ratios.
The gas associated with the foam production is selected from the group consisting of atmospheric air, mixtures of oxygen, nitrogen, and hydrogen, and the like. Atmospheric air is preferred as an inexpensive and readily available source. The gas is incorporated at a pressure in the range of 1 pound per square inch (gauge) to 100 pounds per square inch (gauge), with a preferred range of about 25 p.s.i.g. to about 50 p.s.i.g. The acceptable weight ratio of air to latex within the composition is in the range of 0.1:1 to 50:1, with a preferred range of 3:1 to 8:1.
The air, or other gas, is incorporated into the foam by mechanical agitation. The air-incorporation process, commonly called foaming, may be accomplished through any accepted procedure. Examples, not intended as limitations, include whipping with a Hobart mixer or a Gaston Systems mechanical foamer. The foamed elastomer composition can then be applied with screen coating, knife coating, parabolic foam coating, and the like, without any limitation intended.
It has been found that incorporating air into (or foaming) the inventive composition offers several benefits over conventional application methods. First, the amount of elastomer applied to the textile substrate is less than the amount that would be used in a dip application, thus resulting in cost savings to manufacture. Secondly, because the incorporated air reduces the density of the inventive composition, the substrates that are produced following coagulation have aesthetic properties that more closely resemble leather. In addition, the air incorporated into the foam increases the volume of the coating, improving application and creating an improved surface for transfer coating. Finally, the manufacturer has greater control over the application of the elastomer. As a result, the foam mixture does not have to be applied to both sides of the fabric, as it would be with a dip application. Further, the degree of penetration of the foam into the textile substrate can also be controlled.
Subsequently, the elastomer-coated textile fabric is heated. This heating step generates an acid and gels the cloud-point surfactant, which then uniformly coagulates the inventive latex over the entire substrate. The temperature required to initiate the reaction depends on the particular acid-generating compound utilized. However, in general, the requisite temperature should be at least 80° C., with a high temperature being about 130° C.
The boiling point of water is the preferred temperature, particularly where a steam application (and most preferably a saturated steam application of 100° C. to 110° C. at sea level) is used. Such conditions are preferred because moist heat (steam) provides the most effective exposure for the elastomer composition. The presence of moisture permits a greater level of control over the reaction since the addition of dry heat generally vaporizes the aqueous portion of the inventive latex, which promotes the undesirable formation of a continuous polymer film. The latex must remain moist in order for proper and uniform coagulation to ensue. Therefore, the elastomer composition preferably must contain water during the entire reaction. An exposure time of from about 1 minute to about 10 minutes, in a steam application, may be used. The preferred exposure time is about 2 minutes in a steam application. The utilization of a steam heating step again provides a distinct advantage over the prior art by retaining strictly aqueous solvent reaction conditions.
Alternatively, the coated fabric may also be exposed to rapid heating by a microwave or radio frequency heat source, which does not provide an appreciable loss of moisture to the overall elastomer composition. An exposure time of from about 1 second to about 1 minute in a microwave application may be used.
Yet another alternative is to expose the coated fabric to heating by a convection heat source. Preferably, the temperature should be raised slowly to allow the coating to coagulate prior to dry and prevent the coating from cracking. An exposure time of from about 10 seconds to about 10 minutes in a convection oven may be used.
After the first heating step, the textile-elastomer composite is dried, preferably by high convection, low temperature heating (preferably, but not limited to, less than 130° C.) or by microwave heating in order to prevent continuous film formation on the fabric surface. The second heating step is engineered to dry the composite without destroying the coagulation of the elastomer composition.
The knitted textile fabric utilized within the inventive process should be comprised of any synthetic fibers. As merely examples, and not intended as limitations, the textile fabric may be constructed from fibers of polyester, nylon (-6 or -6,6), polyolefins, polylactic acid, spandex, and the like. The preferred knit fabric is made of polyester, and most preferably polyethylene terephthalate yarns. The knitted textile can be produced using a variety of constructions, including warp knit constructions (such as raschel and tricot) and weft knit constructions (such as circular and flat knit). The most preferred construction is a tricot construction, which uses three bars to create the fabric. The most preferred yarn sizes and types for each bar are as follows: bars 1 and 2 contain a monofilament yarn having a denier equal to or less than 300 denier, and bar 3 contains a multifilament yarn having a combined denier equal to or less than 300 denier. For example only, and not as limitation, bar 3 could incorporate a two-ply yarn, in which each ply has a denier such that, when the deniers of the two plies are combined, the combined denier for the multifilament yarn is in the range of 300 denier or less. Bar 3 produces the face of the finished fabric, while bars 1 and 2 produce act as “ground” yarns on the back of the finished fabric. The preferred number of courses per inch is in the range of 60, and the preferred number of wales per inch is in the range of about 40. However, course and wale counts can range plus or minus 40% from the preferred values listed above.
The textile fabric may be treated with dyes, colorants, pigments, ultraviolet absorbers, softening agents, soil redisposition agents, lubricating agents, antioxidants, flame retardants, rheology agents, and the like, either before foaming or after, but with a preference for such additions before foaming. Within the elastomer composition, there may be incorporated any of the above-listed textile additives, as well as lubricating agents or cross-linking agents. One particularly desired agent is a softening/soil redisposition/lubricating additive Lubril QCX™, available from Rhône-Poulenc. Desirable pigments include PP14-912 and PP14-905 available from Stahl.
It has been found that sanding or napping the fabric prior to the application of the elastomeric composition will improve the hand of the fabric-elastomer composite and will improve the adhesion between the fabric and the composition. In addition, the sanding or napping process has been found to impart, in the fabric-elastomer composite, a suede-like feel on the effective back of the composite. It is believed that sanding is most preferable for knit fabrics.
In addition, in some circumstances, it may be desirable to subject the finished fabric to a calendering process. Calendering improves the adhesion characteristics of the final product (that is, the three-layer fabric-elastomer composite that has also been transfer coated). The calendering process produces a feel similar to that of suede on the effective back of the transfer-coated fabric-elastomer composite. Calendering can be achieved on any equipment designed for such purpose, including, but not limited to, a Briem calender having a heated drum width of approximately 20 inches. Because the settings for temperatures, pressures, and speeds are all related to one another, a range of appropriate settings could be used to achieve the desired effect. For example, one such preferred setting involves a temperature of 150° F., a pressure of 40 kg/cm 2 , and a speed of 2 yards/minute.
After calendering, the fabric-elastomer composite is subjected to either transfer or film coating to create a three-layer composite structure that resembles genuine leather in both appearance and tactile characteristics. In both transfer and film coating, the additional coating is applied in contact with the elastomer coating. The technical face of the textile becomes the effective back of the three-layer composite. The transfer coating process involves the application of a plurality of individual layers of polyurethane (typically, at least two, but up to five or more) to a paper backing. The coatings are then adhered to the fabric-elastomer composite, and the paper backing is removed, resulting in a three-layer leather-like product in which the third layer refers to a plurality of individual layers that are applied together to the already produced two-layer composite. The film coating process involves adhering a sheet-like film substrate to the fabric-elastomer composite, typically using adhesives and heat to laminate the film to the composite. The term “film” is used to mean any thin, sheet-like substrate, comprising either a metallic substrate, a polymeric or plastic film, or a felt-like or flocked textile substrate.
The inventive composite may be utilized as upholstery fabric for furniture or in automobiles; within garments or apparel; or for any other purpose in which a textile leather substitute is desired.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the inventive composite is set forth in the following Examples.
EXAMPLE 1
A tricot knit, having 60 courses per inch and 39 wales per inch, was created using 20 denier monofilament polyester in bar 1 , 20 denier monofilament polyester in bar 2 , and a one-ply 100 denier, 100 filament (1/100/100) polyester yarn in bar 3 . The fabric was sanded on the technical back with a 0.028 inch gap. The technical face of the fabric was then sanded with a 0.018 inch gap. The fabric was dyed using disperse dyestuffs to achieve a desired color. Subsequently, the technical back of the fabric was wetted out and then foam-coated with the elastomer composition (i.e. polyurethane) described herein. The foam coating was applied with a knife-over-slot method, off the pin coater. The speed of application was 15 yards per minute (ypm). Following the application of the elastomeric foam, the fabric passed through a tenter-oven having a series of nine temperature zones, in which the elastomeric foam was allowed to uniformly coagulate over the fabric surface without over-drying the fabric. The temperature of the zones was set as follows: Zone 1 at 250° F., Zones 2 and 3 at 275° F., Zone 4 at 300° F., Zones 5 through 8 at 350° F., and, Zone 9 at 275° F. The fan speed was set on low for Zones 1 through 5 and on high for Zones 6 through 9 . The peel strength of the resulting fabric-elastomer composite was tested using a Sintech 1/S machine in accordance with ASTM Test Method D413 (Book 9.01). The test results showed a peel strength of less than 2 pounds per inch.
EXAMPLE 2
A knit sample was prepared with the same construction as that of Example 1 and in the same manner described in Example 1. The knit fabric was then subjected to a calendering process on a Briem calender with a drum having an approximately twenty-inch width. The calendering process was accomplished at a speed of 2 yards per minute, a pressure of 40 kg/cm 2 , and a temperature of 150° F. The peel strength of the resulting calendered fabric-elastomer composite was tested using a Sintech 1/S machine in accordance with ASTM Test Method D413 (Book 9.01). The test results showed a peel strength of 6.4 pounds per inch, more than three times the peel strength of the non-calendered sample, as described in Example 1.
The Kawabata Evaluation System
A specialized, quantitative measure of pliability, compressibility, and softness—the Kawabata Evaluation System—was utilized, and shall be described below.
The Kawabata Evaluation System (“Kawabata System”) was developed by Dr. Sueo Kawabata, Professor of Polymer Chemistry at Kyoto University in Japan, as a scientific means to measure, in an objective and reproducible way, the “hand” of textile fabrics. This is achieved by measuring basic mechanical properties that have been correlated with aesthetic properties relating to hand (e.g., slickness, fullness, stiffness, softness, flexibility, and crispness). The mechanical properties that have been associated with these aesthetic properties can be grouped into five basic categories for purposes of Kawabata analysis: bending properties, surface properties (friction and roughness), compression properties, shearing properties, and tensile properties. Each of these categories is comprised of a group of related mechanical properties that can be separately measured.
The Kawabata System uses a set of four highly specialized, custom-developed measuring devices. These devices are as follows:
Kawabata Tensile and Shear Tester (KES FB1)
Kawabata Pure Bending Tester (KES FB2)
Kawabata Compression Tester (KES FB3)
Kawabata Surface Tester (KES FB4) KES FB1 through 3 are manufactured by the Kato Iron Works Co., Ltd., Div. of Instrumentation, Kyoto, Japan. KES FB4 (Kawabata Surface Tester) is manufactured by the Kato Tekko Co., Ltd., Div. of Instrumentation, Kyoto, Japan. The results reported herein required only the use of KES FB1, KES FB2 and KES FB4.
For the testing relating to the characteristics of compressibility, pliability, and drape described herein, only Kawabata System parameters relating to the properties of compression, bending, and shearing stiffness were used.
The complete Kawabata Evaluation System is installed and is available for fabric evaluations at several locations throughout the world, including the following institutions in the U.S.A.:
North Carolina State University
College of Textiles
Dep't. of Textile Engineering Chemistry and Science
Centennial Campus
Raleigh, N.C. 27695
Georgia Institute of Technology
School of Textile and Fiber Engineering
Atlanta, Ga. 30332
The Philadelphia College of Textiles and Science
School of Textiles and Materials Science
Schoolhouse Lane and Henry Avenue
Philadelphia, Pa. 19144
Additional sites world-wide include The Textile Technology Center (Sainte-Hyacinthe, QC, Canada); The Swedish Institute for Fiber and Polyrher Research (Molndal, Sweden); and the University of Manchester Institute of Science and Technology (Manchester, England).
The Kawabata Evaluation System installed at the Textile Testing Laboratory at the Milliken. Research Corporation, Spartanburg, S.C. was used to generate the numerical values reported herein.
KAWABATA BENDING TEST PROCEDURE
A 20 cm×20 cm sample was cut from the web of fabric to be tested. Care was taken to avoid folding, wrinkling, stressing, or otherwise handling the sample in a way that would deform the sample. The die used to cut the sample was aligned with the yarns in the fabric to improve the accuracy of the measurements. The samples were allowed to reach equilibrium with ambient room conditions prior to testing unless otherwise noted.
The testing equipment was set-up according to the instructions in the Kawabata Manual. The machine was allowed to warm-up for at least 15 minutes before samples were tested. The amplifier sensitivity was calibrated and zeroed as indicated in the Manual. The sample was mounted in the Kawabata Heavy Duty Pure Bending Tester (KES FB2) so that the cloth showed some resistance but was not too tight. The fabric was tested in both the course and wale directions, and the data was automatically recorded by a data acquisition program running on a personal computer. The coefficient of bending for each sample was calculated by a personal computer-based program that merely automated the prescribed data processing specified by Kawabata, and the results were recorded with measurements taken when the samples were flexed in opposite directions.
EXAMPLE 3
Prior Art
The Heavy Bending test (KES FB2) was used to measure the force required to bend the fabric-elastomer composite approximately 150 degrees. The fabric sample was created by using the construction of Fabric 1, but rather than foaming the elastomer composition onto one side of the fabric, the fabric was dipped into the elastomer composition, nipped between nip rolls to effect penetration and pick-up control, and then dried. The dip-coated fabric-elastomer, produced as described herein, required a force of 1.9 grams force cm 2 per centimeter in the course (fill) direction and 1.5 gfcm 2 /cm in the wale (warp) direction.
EXAMPLE 4
The fabric-elastomer composite of Example 1 (having been subjected to foam coating on one side only) was tested according to the Heavy Bending Test described above. The foam-coated fabric-elastomer composite required a force of only 0.9 gfcm 2 /cm in the course direction and 0.9 gfcm 2 /cm in the wale direction. This result indicates that the foam-coated fabric-elastomer of Example 1 is softer and more pliable than the dip-coated fabric-elastomer of Example 3.
EXAMPLE 5
Prior Art
The dip-coated fabric-elastomer described in Example 3 was subjected to compression testing on the Kawabata Compression Tester (KES FB3) using the “standard measurement” technique. The gear speed of the red gear was set at 1 mm/50 seconds, the Fm speed was set at 5.0, the stroke select was set at 5 mm, the sens speed was set at 2×5, and the time lag was set at “standard.” A gap distance of 2.5 was used. The compression test measures the resilience or “body” of a fabric sample, by comparing the % difference between the gauge of the non-compressed sample with the gauge of a sample under a controlled compression. The fabric-elastomer composite exhibited a compression rate of 13.7%.
EXAMPLE 6
The fabric-elastomer composite of Example 1 was subjected to compression testing on the Kawabata Compression Tester (KES FB3) using the “standard measurement” technique. The gear speed of the red gear was set at 1 mm/50 seconds, the Fm speed was set at 5.0, the stroke select was set at 5 mm, the sens speed was set at 2×5, and the time lag was set at “standard.” A gap distance of 2.5 was used. The compression test measures the resilience or “body” of a fabric sample, by comparing the % difference between the gauge of the non-compressed sample with the gauge of a sample under a controlled compression. The fabric-elastomer composite exhibited a compression rate of 39.6% (close to a 300% improvement as compared to the fabric-elastomer composite of Example 3).
EXAMPLE 7
Prior Art
A 200 g sample of the fabric-elastomer composite of Example 3 was subjected to the “Standard Measurement” of the Shear Test (KES FB1) on the Kawabata machine. The sens control was set at 2×5, and the elongation measurement was 25 mm. The shear control was in the “set” position, rather than the “variable” position. The Shear Test gives an indication of the stiffness and resistance a sample has when subjected to opposing parallel forces. The numerical values that are produced in this test, as measured in the warp and fill directions, increase in direct relation to the stiffness of the fabric (high value, high stiffness). The fabric-elastomer composite of Example 3 exhibited a measured stiffness of 10.5 gf/cm degree in the fill direction and a measured stiffness of 7.0 in the warp direction.
EXAMPLE 8
A 200 g sample of the fabric-elastomer composite of Example 1 was subjected to the “Standard Measurement” of the Shear Test (KES FB1) on the Kawabata machine. The sens control was set at 2×5, and the elongation measurement was 25 mm. The shear control was in the “set” position, rather than the “variable” position. The Shear Test gives an indication of the stiffness and resistance a sample has when subjected to opposing parallel forces. The numerical values that are produced in this test, as measured in the warp and fill directions, increase in direct relation to the stiffness of the fabric (high value, high stiffness). The fabric-elastomer composite of Example 4 exhibited a measured stiffness of 6.7 gfcm 2 /cm degree in the fill direction and a measured stiffness of 9.0 in the warp direction. This difference, particularly in the fill direction, indicates a lesser degree of stiffness (i.e., a softer composite). | The present invention relates to a process for producing a knitted textile material that, when transfer or film-coated, is suitable for use as an artificial leather substrate. The inventive procedure involves (a) producing an elastomer composition of at least four ingredients (an anionically-stabilized waterborne polymer dispersion, an acid-generating chemical, a cloud-point surfactant, and a foam-stabilizing surfactant); (b) incorporating sufficient gas into the liquid mixture to generate a spreadable foam; (c) applying the foam onto a porous knitted textile substrate; (d) heating said foamed fabric until the elastomer coagulates over the fabric substrate; and (e) drying the resultant composite without destroying the coagulated structure. The resultant composite obtains a pliability, compressibility, and drape that is similar to that of leather and a surface that is suitable for transfer or film-coating to produce artificial leather. The composite may be utilized as upholstery fabric in furniture or in automobiles, apparel, and the like. | 3 |
PRIORITY
The present application is related to, claims the priority benefit of, and is a continuation application of, U.S. patent application Ser. No. 13/562,602, filed Jul. 31, 2012 and issued as U.S. Pat. No. 9,132,010 on Sep. 15, 2015, which is related to, claims the priority benefit of, and is a continuation application of, U.S. patent application Ser. No. 11/997,139, filed May 14, 2008 and issued as U.S. Pat. No. 8,231,646 on Jul. 31, 2012, which is related to, claims the priority benefit of, and is a U.S. national stage application of, International Patent Application Serial No. PCT/US2006/029223, filed Jul. 28, 2006, which is related to, and claims the priority benefit of, U.S. Provisional Patent Application Ser. No. 60/703,422, filed Jul. 29, 2005. The contents of each of these applications are hereby incorporated by reference in their entirety into this disclosure.
BACKGROUND
The concept of myocardial salvage through coronary sinus intervention dates back to the nineteenth century. The objective has been to increase the flow of oxygenated blood to the ischemic myocardium by perfusing the coronary bed retrogradely from the coronary sinus; i.e., coronary retroperfusion. To date, a number of retroperfusion methods have been developed. Pressure-controlled intermittent coronary sinus occlusion (PICSO) has been used in conjunction with a balloon-tipped catheter positioned just beyond the orifice of the coronary sinus with the proximal end connected to a pneumatic pump that automatically inflates and deflates the balloon according to a preset cycle. Synchronized retrograde perfusion, SRP and simplified retroperfusion are other techniques that actively pump arterial and venous blood in the former and the latter, respectively. The left ventricle-powered coronary sinus retroperfusion technique has focused on driving left ventricular blood into the coronary sinus through a surgically created left ventricle to coronary sinus shunt.
Prior studies have shown the efficacy of venous retroperfusion. It has been demonstrated that (1) coronary venous bypass-graft (CVBG) or percutaneous in situ coronary venous arterialization (PICVA) permit survival in the presence of LAD arterial ligation as compared with the uniform non-viability of just LAD arterial ligation without retroperfusion; (2) retroperfusion is effective because it perfuses all layers of the heart, including the subendocardium; and (3) considerable recovery of regional myocardial function with low regional capillary blood flows and low levels of retrograde arterial outflow provide evidence for possible oxygen delivery via the intramyocardial venous plexus.
The CVBG or PICVA procedure has a number of advantages over the conventional coronary artery bypass graft (CABG) procedure, including: (1) approximately 20% of revascularization candidates have angiographically diffuse atherosclerotic changes with poor runoff or small coronary arteries which makes arterial bypass or percutaneous coronary angioplasty (PTCA) unlikely to succeed. In those cases, CVBG may be the procedure of choice. Furthermore, the runoff for the coronary veins are significantly larger than those of arteries and hence the surgical implementation is much easier as is the improved patency of the graft. (2) The coronary venous system of the heart rarely undergoes atherosclerotic changes. This reduces the problem of restenosis that is commonly evident with the CABG procedure and should reduce the need for multiple surgeries throughout the patient's lifespan. (3) The CVBG is surgically easier to implement than the CABG procedure and does not require cardiac arrest and the use of extracorporeal circulation. The CVBG procedure can be implemented in the beating heart with the use of a cardiac restrainer. This reduces the surgical risks and ensures quicker recovery, which is particularly important in the elderly and the severely ill patients.
To emphasize the importance of this field in terms of numbers, there are about 1.4 million annual incidences of myocardial infarction in the U.S. and an equal number in Western Europe. Approximately 20% of those patients are not good candidates for bypass because of diffuse coronary artery disease. Those patients have little treatment options other than heart transplant. The number of heart transplants is meager, however, at 2,000 in 2005. Many of those patients progress to heart failure where the cost of treatment of is very high ($40 billion annually in US representing 5.4% of total health care cost). The prospect of a device to treat those patients is great in terms of lives saved as well as costs reduction associated with heart failure.
Thus, a need exists in the art for an alternative to the conventional techniques of treating heart failure using retroperfusion such that the technique should be minimally invasive, easy to use and understand, simple to implement and effective in producing desired results.
BRIEF SUMMARY
The present disclosure relates generally to controlling blood pressure, including devices and methods for controlling blood pressure using a retrograde cannula.
The present disclosure provides devices and methods for assisting in the proper retroperfusion of various organs (e.g., brain, eye, etc.) but in particular the heart. A general goal is to develop a coronary venous retroperfusion cannula that will provide perfusion of the coronary bed retrogradely through the coronary sinus with arterial blood generated from a peripheral artery with no need for a pump. The cannula will be introduced from the axillary or femoral vein under local anesthesia and the proximal end, which consists of a graft, will be anastomosed to the axillary or femoral artery, respectively. Furthermore, the cannula will initially impose a significant pressure drop (approximately 50 mmHg) due to inflation of a balloon or an obstruction (stenosis) made of resorbable material, and hence will only transmit a fraction of the arterial pressure to the venous system. The intermediate pressure can be used to arterialize the venous system for 2 to 3 weeks and can then be raised to arterial pressure by release of the stenosis.
In the case of a resorbable material, as the material resorbs over a several week period, it will reduce the pressure drop and hence transmit more of the arterial pressure to the venous system. This addresses a major problem with coronary venous retroperfusion, which is the sudden increase in pressure (venous to arterial) that results in vessel edema and hemorrhage. Here, a novel cannula is presented which provides a gradual increase in pressure to allow the venous system to arterialize. The gradual increase in pressure allows arterializations of the venous system, which prevent vessel rupture. Some of the advantages of the present disclosure include, but are not limited to: (1) design of a cannula with a stenosis that will provide the desired initial pressure drop and ensure undisturbed flow into the coronary venous system; (2) pre-arterialization of the venous system to prevent edema and hemorrhage, (3) elimination of the need for a pump as blood is delivered from the patient's artery; (4) percutaneous delivery of the system with no need for open heart surgery; and (5) delivery of cannula in the beating heart to eliminate cardiac arrest such as in bypass surgery.
Since the coronary veins do not develop arteriosclerosis, it is desirable to use these vessels as conduits for revascularization. More than 60 years ago, Roberts et al. suggested the use of coronary veins as conduits to deliver oxygenated blood in a retrograde manner in animal studies. Five years after this seminal study, Beck and colleagues performed the coronary retroperfusion procedure in humans. The method was abandoned, however, due to the high mortality rate from the edema and hemorrhage that result due to the elevated pressure. Furthermore, graft clots and atherosclerotic changes occur in the venous vessels in response to the abrupt change in pressure, which lead to progressive venous obliteration.
In order to remedy these difficulties, the present disclosure avoids increasing the pressure in the coronary vein from venous (10-20 mmHg) to arterial values (100-120 mmHg) in a single step. Instead, a cannula is presented that regulates the pressure in the venous system over time to a more gradual increase in pressure. This procedure allows the venous vessels to arterialize and the vessel walls to thicken in order to decrease the stress and prevent rupture of the post capillary venules. Furthermore, the gradual increase in pressure will decrease the injury response and subsequently reduce the atherosclerotic changes of the large epicardial veins.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cannula within a vessel wall in which at a distal end, an external expandable balloon anchors the cannula in the coronary vein, while an internal balloon provides the necessary obstruction to cause a drop in pressure according to an exemplary embodiment of the present disclosure, wherein further impedance electrodes are placed distally to locally size the coronary sinus while additional electrodes are placed internal to the balloon for sufficient inflation and hence occlusion of the vein according to the distal size measurement;
FIG. 2A shows a detailed version of a cannula's multi-lumen catheter with inner and outer balloons according to an exemplary embodiment of the present disclosure;
FIG. 2B shows cross-sectional views of exemplary embodiments of multiple lumens within a cannula according to exemplary embodiments of the present disclosure;
FIG. 3A shows a cannula inserted into the coronary sinus via the axillary vein according to an exemplary embodiment of the present disclosure;
FIG. 3B shows an embodiment of a cannula containing a resorbable stenosis according to an exemplary embodiment of the present disclosure;
FIG. 4A shows a minimally invasive surgical insertion of a retroperfusion cannula with direct puncture of the axillary vein and catheterization into the coronary sinus according to an exemplary embodiment of the present disclosure;
FIG. 4B shows the cannula of FIG. 4A after the graft is fixed in position at the coronary sinus;
FIG. 4C shows the cannula of FIG. 4A as the axillary artery is prepared and the proximal side of the graft is anastomosed to the axillary artery;
FIGS. 5A and 5B show the implantation of the auto-retroperfusion cannulae in the axillary and femoral regions; and
FIGS. 6A and 6B show a distribution of selective perfusion territories wherein Zone 1 corresponds to retroperfusion at the level of LAD interventricular anterior vein, which corresponds to the anterior and lateral wall of the left ventricle, and wherein Zone 2 is at the level of the obtuse marginal circumflex vein, and Zone 3 is at the level of the posterolateral circumflex vein.
DETAILED DESCRIPTION
The present disclosure describes a cannula for acute and chronic retroperfusion that is designed for percutaneous insertion into the coronary sinus and proximally connecting to the subclavian artery. This allows retroperfusion of oxygenated blood through the coronary venous system to decrease an acute ischemic area during an acute myocardial infarction event.
An exemplary embodiment of the disclosure, illustrated in FIG. 1 , shows a cannula 100 within a vessel wall 140 , with the proximal portion (not shown) being a graft. The distal portion of the cannula includes a catheter 101 with an expandable external balloon 121 . The catheter may be made of any appropriate material used in the art, such as polyurethane, silicone rubber, or other appropriate polymeric material. The distal end may also contain pressure sensors 124 for monitoring purposes and impedance electrodes 123 for measuring the vessel and sizing the external balloon 121 accordingly.
The external expandable balloon 121 anchors the cannula in the coronary vein. Additionally, the external balloon prevents backflow of blood leaving the cannula. In this embodiment, a second, internal balloon 122 serves to provide the pressure drop required for gradual arterialization of the vein. The balloons may be made of any material suitable for their function, including but not limited to, polyethylene, latex, polyestherurethane, or combinations thereof. The balloons may be connected to secondary lumens within the cannula, which are, in one embodiment, connected to percutaneous ports emerging from the proximal end of the cannula. The percutaneous ports may be used to inflate or deflate the balloons during retroperfusion. In one exemplary embodiment, the internal balloon 122 may be removed completely via the secondary lumen when vein arterialization is complete. As in the embodiment illustrated in FIG. 1 , an external balloon and an internal balloon may be concentric to each other. In other embodiments, the internal and external balloons may be located on distinct portions of the cannula.
Some exemplary embodiments may contain two tetrapolar sets of electrodes 123 to measure the vessel near the distal tip 120 of catheter and to size the balloon accordingly. The selective region of the coronary sinus can be sized using these excitation and detection electrodes as described in more detail within the pending patent application, “System and Method for Measuring Cross-Sectional Areas and Pressure Gradients in Luminal Organs,” U.S. patent application Ser. No. 10/782,149, filed on Feb. 19, 2004, which is incorporated by reference herein in its entirety. In that application, a description is provided of a conductance catheter that is used to determine size of blood vessels.
In embodiments of the cannula that do not include impedance electrodes, the sizing of the exterior balloon may also be accomplished based on the compliance of the balloon measured ex vivo and in vivo. This method requires the calibration of the balloon volume and hence diameter in vitro subsequent to in vivo. This alternative method avoids the need for electrodes and impedance sizing but may be less accurate.
Once the lumen size of the applicable region of the coronary sinus is determined, the balloon is expanded accordingly. It is recalled that a vein is rather compliant at lower pressures and hence an appropriate diameter is selected to maintain the cannula lodged into the lumen. For acute applications, saline may be used to fill the balloon. For longer term applications, gels or silicones may be used to fill the balloon.
FIG. 2A shows the distal portion of the cannula 200 within the vessel wall 240 . The body of the cannula houses two or more lumens with a variety of possible configurations, some of which are shown in FIG. 2B . In the embodiment illustrated, the cannula contains a primary lumen 203 and multiple secondary lumens 204 . The secondary lumens may connect to an expandable exterior balloon 221 and/or interior balloon 222 . The secondary lumen may also contain pressure sensors that allow internal monitoring of the cannula during retroperfusion.
The primary lumen 203 is the conduit that allows the oxygenated blood flow derived from an artery to flow into the coronary sinus. The lumen of the catheter is designed to provide an optimal stenosis geometry for the desired initial pressure drop and to ensure undisturbed flow in the coronary venous system. In various embodiments, the secondary lumens 204 may be used for a variety of different purposes, such as inflation, deflation, and removal of interior and exterior balloons, coronary sinus pressure measurement, cannula pressure measurement, and drug delivery. In one exemplary embodiment, the secondary lumens 204 are operatively coupled with proximal extensions that branch from the graft body in such way that they are employed as percutaneous access ports.
FIG. 3A presents a detailed illustration of an exemplary embodiment of a cannula, with its proximal end being a graft 302 , that contains a stenosis which causes a drop in the pressure of blood passing through the cannula. The stenosis can be imposed by inflation of a balloon that partially occludes the lumen or by imposing a resorbable material within the lumen. A variety of materials may be used to construct the resorbable stenosis, such as, for example, polyols and magnesium alloy. The most widely used polyols are mannitol, sorbitol and maltitol. Mannitol is used in the description of the examples herein. A mold of the computed shape will be used to construct the stenosis using computer-assisted design while the magnesium alloy geometry will be sculpted by laser from a single tube. Mannitol is a naturally occurring nonreducing acyclic sugar compound widely used in foods, pharmaceuticals, medicine and chemical industries. Crystalline Mannitol exhibits a very low hygroscopicity, making it useful in products that are stable at high humidity.
Mannitol is often added in dried protein formulations as the bulking agent as it has the tendency to crystallize rapidly from aqueous solutions. It has recently been shown that acetylsalicylic acid, which is an active ingredient of aspirin, can be mixed with Mannitol without affecting its properties. This is ideal as it will provide antithrombotic properties to prevent coagulation of blood during the resorption of the stenosis. Alternatively, magnesium alloys may be used which are currently used in drug-eluting bioabsorbable stents. Magnesium is a natural body component with beneficial antithrombotic, antiarrythmic and antiproliferative properties. The degradation rate of magnesium alloy has been shown to be linear and complete after 2-3 months. The use of degradable magnesium alloys leads to electronegative and therefore, hypothrombogenic surfaces. As an essential element, slowly degrading magnesium should not harm tissue, particularly since magnesium solutions up to 0.5 mol/l are well tolerated if given parenterally. The mechanical properties and corrosion of magnesium alloys are quite controllable under physiological conditions and match the requirements for degradable stenosis. The stenosis mold 330 is then inserted into the catheter portion of the cannula very close to the proximal inlet. The graft 302 may then be glued at this junction as shown in FIG. 3A .
It should be noted that the resorption rate of mannitol is a function of molecular weight, crystallinity, and particle size. The compound is prepared so that it will resorb in approximately 8 weeks. The magnesium alloys have been shown to resorb within 8-12 weeks.
For balloon occlusions, the desired occlusion is obtained by measurement of pressure at the tip of the cannula during inflation of the balloon. Once the desired intermediate pressure is obtained, the balloon volume is finalized. The patient is allowed to arterialize at the pressure for some time. At the end of such period (typically 2-3 weeks), the occlusion is removed by deflation of the balloon. In an exemplary embodiment, the inner lumen containing the inner balloon may be removable and hence withdrawn.
The cannula is intended for insertion from either the axillary 341 or femoral (not shown) veins into the coronary sinus. The proximal graft 302 is anastomosed to the adjacent artery 342 . The graft may be made of any biocompatible, nonresorbable polymer with the necessary strength to support the surrounding tissue and withstand pressure from blood flow and the necessary flexibility to form an anastomosis with between the artery and the vein within which the cannula is housed. For example, a material such as GORE-TEX (polytetraflouroethylene) is suitable for use in the graft. In exemplary embodiments, the total length of the graft is approximately 6 cm and that of the attached catheter is 8-10 cm, but they may be of any lengths such that their dimensions allow an anastomosis between the human coronary sinus and the subclavian artery to be made. Access ports 306 which connect to and are in fluid contact with the secondary lumens branch off of the proximal graft 302 in some embodiments.
The diameter within the cannula will, in certain exemplary embodiments, be approximately 4 mm, but may be of any diameter such that the cannula allows sufficient blood flow and can be accommodated by the relevant vessels. The geometry of the stenosis will be varied to ensure an approximately 50 mm Hg pressure drop and a sufficient entrance length into the coronary vein to ensure fully developed flow.
To perform automatic retroperfusion using the present cannula, the axillary vein 441 and the axillary artery 442 are exposed as shown in FIGS. 4A-C . The same procedure may be performed using the femoral vein 543 and the femoral artery 544 as shown in FIGS. 5A and 5B . The distal end portion of the cannula 400 is then introduced into the axillary vein 441 . This may be done using the well-known Seldinger technique, which includes passing the cannula over a guide wire under fluoroscopy. The distal end portion of the cannula is then directed (via fluoroscopy, direct vision, transesophageal echocardiogram, or other suitable means) through the vasculature (e.g., the subclavian vein and the superior vena cava) and into the right atrium of the heart. The distal end portion of the cannula is further advanced through the right atrium and into the coronary sinus 446 , which is the coronary vein. When the distal end portion of the cannula reaches the desired location in the coronary sinus, measurement of the sinus is made and the external balloon is inflated accordingly.
Next, an anastomosis 405 of the proximal graft portion 402 of the cannula and the artery 442 may be accomplished by suturing the graft section to the axillary artery as shown in FIG. 4C . This approach could be used for long term arterialization of the coronary venous system, which can replace coronary artery bypass graft.
Alternatively, the autoretroperfusion cannula can be inserted by percutaneous puncture (under local anesthesia) in the axillary vein 541 and axillary artery 542 and both ends connected through a quick connector 545 . This procedure may also be performed using the femoral vein 543 and artery 544 , as shown in FIG. 5B . This procedure can be used for acute patients or for short periods of arterialization of the coronary veins to stabilize the patient as a bridge to another procedure.
Once the cannula is in place, normal antegrade blood flow continues as usual, but oxygenated blood will be automatically retroperfused through the cannula to the ischemic myocardium via the coronary sinus. The oxygenated blood flow through the cannula occurs throughout the cardiac cycle with a pulsatile flow pattern, but with a peak flow and pressure at the end of systole and the beginning of diastole. Back-flow of blood into the right atrium from the coronary sinus is prevented by the balloon.
It should be noted that the aforementioned procedures can be done under local anesthesia. Depending on the patient's particular condition, auto-retroperfusion can last for minutes, hours, days, or months. During retroperfusion, the secondary lumens can be used for coronary sinus pressure measurement and the delivery of drugs, cells, genes, or growth factors. It is expected that the access ports 406 , which are fluidly connected with the secondary lumens, and the graft section will be subcutaneous.
As this method is based on selective retroperfusion, there is a relationship between the site of the coronary sinus where the cannula is anchored and the region of the heart requiring treatment. FIGS. 6A-6B show several zones of interest. Zone 1 651 , shown from an anterior view in FIG. 6A and from a posterior view in FIG. 6B , corresponds to retroperfusion at the level of the LAD interventricular anterior vein, which corresponds to the anterior and lateral wall of the left ventricle. This is the largest area of the left ventricle to be perfused and hence clinically the most relevant. This area is the most distal to the coronary sinus and can be determined by sizing of the vein through the impedance electrodes. Zone 2 652 covers the level of the obtuse marginal circumflex vein and is more proximal to the coronary sinus. Zone 3 653 covers the level of the posterolateral circumflex vein, which is the smallest area of the left ventricle to be perfused and is the most proximal to the coronary sinus. Hence, the position of the catheter, which can be determined by sizing of the vein through impedance measurements, can determine the perfusion territory. This will serve as a clinical strategy to treat patients with LAD or LCx disease.
While various embodiments of devices for controlling blood perfusion and methods of using the same have been described in considerable detail herein, the embodiments are merely offered as non-limiting examples of the disclosure described herein. It will therefore be understood that various changes and modifications may be made, and equivalents may be substituted for elements thereof, without departing from the scope of the present disclosure. The present disclosure is not intended to be exhaustive or limiting with respect to the content thereof.
Further, in describing representative embodiments, the present disclosure may have presented a method and/or a process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth therein, the method or process should not be limited to the particular sequence of steps described, as other sequences of steps may be possible. Therefore, the particular order of the steps disclosed herein should not be construed as limitations of the present disclosure. In addition, disclosure directed to a method and/or process should not be limited to the performance of their steps in the order written. Such sequences may be varied and still remain within the scope of the present disclosure. | Devices and methods for controlling blood perfusion pressure. In an exemplary device for controlling blood perfusion pressure within a vessel of the present disclosure, the device comprises an elongated body having a lumen, a proximal end configured for placement in a first area having a first blood pressure, and a distal end configured for placement in a second area having a second blood pressure, partial occluder positioned within the lumen of the elongated body between the proximal end and the distal end, the partial occluder configured so not to fully occlude a blood vessel, wherein the partial occluder is configured to equalize the first blood pressure at the first area with the second blood pressure at the second area. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to vane-type camshaft phasers for varying the phase relationship between crankshafts and camshafts in internal combustion engines; more particularly, to such phasers wherein a front cover plate clamps and seals against a stator; and most particularly, to a phaser having an improved front cover plate.
BACKGROUND OF THE INVENTION
[0002] Camshaft phasers, also referred to herein simply as a cam phaser, for varying the phase relationship between the crankshaft and a camshaft of an internal combustion engine are well known. A prior art vane-type phaser generally comprises a plurality of outwardly extending vanes on a rotor interspersed with a plurality of inwardly extending lobes on a stator, forming alternating advance and retard chambers between the vanes and lobes. Engine oil is supplied via a multiport oil control valve (OCV), in accordance with an engine control module, to either the advance or the retard chambers as required to meet current or anticipated engine operating conditions. In a typical prior art vane-type camshaft phaser a front cover clamps and seals against a stator to prevent internal oil leakage across the rotor arms.
[0003] A first known front cover is made from powdered metal steel and typically requires significant secondary high-level precision machining, deburring, grinding, and cleaning. Packaging requirements necessitate the front cover geometry to have thin sections that are typically difficult to execute in powdered metal tooling. Especially a section of the cover that interfaces with a bias spring in the assembled cam phaser is prone to cracking because of its thin cross-section. Typically, powdered metal front covers are manufactured to have a thickness of about 7 mm.
[0004] A second known front cover is die cast from aluminum, requires secondary high-level precision machining, and includes a steel insert at a lock pin seat wear interface. Compared to the first known front cover, the aluminum front cover provides mass savings and is not prone to cracking at the interface with the bias spring. However, the aluminum die cast front cover must be thicker than the powdered metal steel front cover, since additional length for adequate stator bolt thread engagement into aluminum threads is needed. This additional length is not acceptable for some applications where packaging is tight. A typical minimum thickness for a die cast aluminum front cover where the threads are cut directly into the aluminum is about 9 mm. Furthermore, the aluminum front cover typically clamps against the stator by tightening the bolts in several locations thereby generating local clamp load points. These local clamp loads may cause deflection to occur in the span of the cover between the bolts. Such deflection of the front cover may reduce the effective clamp load between cover and stator and may increase localized end clearances on top of the rotor arm, which in turn may increase internal oil leakage across the rotor arms.
[0005] What is needed in the art is an improved front cover that fulfills the packaging requirements.
[0006] What is further needed in the art is an improved front cover that effectively spreads the clamp load further out, reducing cover deflection and improving the effective clamp load between cover and stator.
[0007] It is a principal object of the present invention to provide mass reduction while providing a rigid sealing surface.
[0008] It is a further object of the present invention to enable the use of aluminum for manufacturing the front cover of a cam phaser to be packaged in the tightest application by increasing the thread strength of the bolt bores.
SUMMARY OF THE INVENTION
[0009] Briefly described, a vane-type camshaft phaser in accordance with the invention for varying the timing of combustion valves in an internal combustion engine includes a rotor having a plurality of vanes disposed in a stator having a plurality of lobes and a front cover plate that clamps and seals against the stator lobes. The front cover plate in accordance with the invention is die cast from aluminum followed by precision machining. The front cover plate includes four bolt bores for receiving stator bolts and a well that receives a hardened, ground bushing functioning as a lock pin seat. Formed steel threaded inserts are press fitted into the bolt bores of the aluminum front cover plate. This adds the required strength to the stator bolt threads to enable a shorter thread engagement, which in turn enables a thinner aluminum front cover plate that may be packaged in tight applications where prior art aluminum front covers cannot be used due to their greater thickness.
[0010] The steel threaded inserts not only provide a higher stiffness but also have a flanged shape that effectively spreads the clamp load generated during the tightening of the stator bolts further out preventing local clamp load points and, consequently, reducing cover deflection over the span of the front cover plate. Reduced cover deflection results in an improved effective clamp load between cover and stator and reduced oil leakage from valve timing advance and valve timing retard chambers formed by the rotor and the stator.
[0011] Furthermore, by utilizing steel inserts having a higher strength than aluminum materials, mass savings, and consequently manufacturing costs savings, compared to prior art powdered metal front covers are achieved by enabling the use of aluminum as material for the front cover plate while fulfilling packaging requirements for tight applications. Still further, the use of steel threaded inserts in accordance with the present invention enables the design of an aluminum die cast front cover plate that has the potential to work with the currently existing envelope at current or lower costs and that enables the use of the existing bias spring.
[0012] Therefore, the addition of steel threaded inserts pressed into the aluminum die cast front cover plate in accordance with the invention solves the problem of aluminum threat strength and localized clamp loads and, therefore, overcomes the shortcomings of prior art aluminum die cast front covers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0014] FIG. 1 is an exploded isometric view of a vane-type camshaft phaser in accordance with the invention;
[0015] FIG. 2 is an exploded isometric top view of a front cover plate in accordance with the invention;
[0016] FIG. 3 is an isometric top view of the front cover plate with steel threaded inserts installed in accordance with the invention;
[0017] FIG. 4 is an exploded isometric bottom view of the front cover plate in accordance with the invention;
[0018] FIG. 5 is an isometric bottom view of the front cover plate with steel threaded inserts installed in accordance with the invention; and
[0019] FIG. 6 is a cross-sectional view of the front cover plate taken through a bore and a lock pin seat in accordance with the invention.
[0020] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1 , a vane-type cam phaser 10 in accordance with the invention includes a rear cover 12 having bores 14 for receiving bolts 16 . The heads of bolts 16 are received in countersinks in rear cover 12 and the threaded ends of bolts 16 are received in front cover plate 20 . A pulley or sprocket 18 is formed integrally with a stator 22 , also referred to as a stator/sprocket. Pulley or sprocket 18 is typically used for engaging a timing chain or belt (not shown) operated by an engine crankshaft (not shown). Stator 22 is provided with a plurality of inwardly extending lobes 24 circumferentially spaced apart for receiving a rotor 26 including outwardly extending vanes 28 which extend into the spaces between lobes 24 . Hydraulic advance and retard chambers are thus formed between lobes 24 and vanes 28 as known in the art. Each rotor vane 28 is provided with an axial groove along the vane tip for receiving a resilient seal element 32 for sealingly wiping a cylindrically concave inner wall of stator 22 . Likewise, each stator lobe 24 may be provided with an axial groove along the lobe tip for receiving a resilient seal element 32 for sealingly wiping a cylindrically convex outer wall 33 of the hub of rotor 26 .
[0022] Rear cover 12 and front cover plate 20 clamp against stator lobes 24 at opposite sides. Bolts 16 extend through bores 14 included in rear cover 12 and through bores 34 positioned in stator lobes 24 and the threaded ends of bolts 16 are received in threaded inserts 202 press fitted into bores 204 of cover plate 20 . A hub of a target wheel 52 passes through front cover plate 20 and is fixed to rotor 21 for rotation therewith. Target wheel 52 spins in front of a sensor creating timed pattern of high/low signals for the purpose of sensing and/or controlling the position of phaser 10 . A coiled bias spring 36 is disposed in a central well 38 formed in rotor 26 and is anchored to front cover plate 20 by tang 42 for urging rotor 26 to a predetermined rest position relative to the position of the stator, for example, fully retarded at engine shutdown. A locking pin mechanism 44 is received in a longitudinal bore 46 formed in an oversize vane 28 of rotor 26 . A well 206 formed in front cover plate 20 (shown in FIGS. 4 through 6 ) receives bushing 48 of locking pin mechanism 44 and is utilized as lock pin seat. Locking pin mechanism 44 may rotationally lock and unlock rotor 26 to and from stator 22 . In installation to an engine camshaft, cam phaser 10 is secured via a central bolt (not shown).
[0023] Referring now to FIGS. 2 and 3 , an improved die cast aluminum front cover plate 20 of a camshaft phaser 10 in accordance with the invention has a generally circular shape with a generally circular central opening 208 and extends longitudinally from an outer surface 216 to an inner surface 218 for a thickness 220 . A groove 210 for receiving tang 42 of bias spring 36 ( FIG. 1 ) extends for a distance from central opening 208 towards the outer perimeter 214 of front cover plate 20 and is formed in outer surface 216 during the die casting process and later machined. A window 236 leading to groove 210 is machined into front cover plate 20 . A lip 212 for guiding bias spring 36 extends into central opening 208 proximate to groove 210 . Front cover plate 20 includes bores 204 positioned in indentations 222 and proximate to outer perimeter 214 . Bores 204 are also positioned to be in line with stator bores 34 included in stator lobes 24 , as shown in FIG. 1 . If stator 22 includes four lobes 24 and thus four bores 34 as shown in FIG. 1 , front cover plate 20 includes four bores 204 for receiving four bolts 16 . In a currently preferred embodiment, bores 204 are machined into front cover plate 20 . Bores 204 and indentations 222 are designed to receive steel threaded inserts 202 . Bore 204 receives knurled shaft 226 and flange 228 rests in indentation 222 . Additional indentations 224 in outer surface 216 may be included in front cover plate 20 to enable mass reduction while still providing a rigid sealing surface.
[0024] Threaded inserts 202 include shaft 226 , flange 228 , and threaded axial bore 232 . Threaded inserts 202 are in a currently preferred embodiment manufactured from steel. The shaft 226 is provided with knurls 230 , a series of small ridges or grooves on the surface of shaft 226 , that enable to press fit steel threaded inserts 202 into bores 204 . Knurls 230 support press fitting steel threaded inserts 202 into bores 204 and, thus, the convenient subassembly of front cover plate 20 , and eliminate the need to grind or otherwise extensively machine the inner surface of bores 204 to receive the inserts 202 . Flange 228 horizontally extends from shaft 226 orthogonally in all directions.
[0025] While flange 228 is shown to have a “D” shape, flange 228 may have any desired shape, such as circular, rectangular, square, hexagonal etc. Threaded bore 232 extends through shaft 226 and flange 228 and receives the threaded end of bolt 16 shown in FIG. 1 . The length 234 of threaded bore 232 and, therefore, the length of steel threaded insert 20 , is determined by the size of bolts 16 , since the thread length needs to have at least the same value as the diameter of the received bolt. Thus, for example, if bolt 16 is a size M6 with a diameter of 6 mm (millimeters), length 234 of threaded bore 232 preferably should be at least 6 mm. Since indentations 222 are designed such that flange 228 of steel threaded insert 202 is level with outer surface 216 of front cover plate 20 when installed, thickness 220 of cover plate 20 has nominally the same value as length 234 of threaded bore 232 and, thus, of steel threaded insert 202 . Consequently, thickness 220 of front cover plate 202 needs to be at least 6 mm if, for example, M6 bolts 16 are used. With a minimal possible thickness 220 of 6 mm, front cover plate 20 is suitable for applications where packaging requirements necessitate a maximum thickness 220 of, for examples 7 mm.
[0026] Referring now to FIGS. 4 through 6 , front cover plate 20 includes a well 206 formed in inner surface 218 for receiving bushing 48 of locking pin mechanism 44 (shown in FIG. 1 ). Well 206 is utilized as a lock pin seat for locking pin mechanism 44 . Since camshaft phaser 10 is exemplary shown in FIG. 1 to include only one locking pin mechanism 44 , front cover plate 20 is shown in FIGS. 5 and 6 to include only one well 206 . As can be seen, well 206 is positioned in relative close proximity to one of bores 204 . As can be seen in FIG. 6 , cover plate 20 is designed such that steel threaded insert 202 can be positioned in indentation 222 formed in outer surface 216 without interfering with well 206 formed in inner surface 218 . This enables the use of front cover plate 20 with currently existing manufacturing envelopes.
[0027] By utilizing steel threaded inserts 202 as in a currently preferred embodiment the problem of aluminum thread strength found in prior art die cast aluminum front covers is solved and, consequently, a more compact (smaller thickness 220 ) die cast aluminum front cover plate 20 is enabled, allowing for packaging of cam phaser 10 in tighter applications where prior art aluminum front covers will not fit. By allowing for a smaller thickness 220 steel threaded inserts 202 enable a mass savings compared to prior art front covers.
[0028] Furthermore, by horizontally extending shaft 226 and, thus, diameter of bore 204 , flange 228 effectively spreads a clamp load created during tightening of bolts 16 beyond the diameter of bolt 16 . Consequently, utilizing steel threaded inserts 202 enables the clamp load to be evenly distributed throughout an area surrounding bore 204 preventing local load points. Thus, deflection of front cover plate 20 is reduced and the overall effective clamping load of the front cover against the stator, compared to prior art die cast aluminum front covers, is improved.
[0029] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims. | A die cast aluminum front cover plate for application in a vane-type camshaft phaser includes a plurality of bores and a plurality of steel threaded inserts press fitted into the bores. Steel threaded inserts add the required strength to the stator bolt threads to enable a shorter thread engagement, which in turn enables a thinner aluminum front cover plate that may be packaged in tight applications where prior art aluminum front covers cannot be used due to their larger thickness. The steel threaded inserts not only provide a higher stiffness but also have a flanged shape that effectively spreads the clamp load generated during the tightening of the stator bolts further out preventing local clamp load points and, consequently, reducing cover deflection over the span of the front cover plate. | 8 |
RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 488,180 of Michael L. Robertson, filed Apr. 25, 1983 now U.S. Pat. No. 4,510,854, and entitled COMPACT BARBECUE OVEN. Application Ser. No. 488,180 is incorporated into this application by reference.
BACKGROUND OF THE INVENTION
This invention relates in general to ovens for cooking food, and more particularly to a compact barbecue oven.
Barbecued foods have traditionally been prepared over open fires, and while this procedure may be acceptable for an occasional back yard barbecue, it is not suitable for the preparation of barbecued foods on a large scale commercial basis. Indeed, open fires are most inefficient, and require an exceptionally large surface area to cook foods in even reasonable quantities. Many restaurants that specialize in barbecue foods utilize commercial barbecue ovens for preparing their foods. These ovens often contain a rotisserie for supporting a large quantity of food in a relatively confined space, and have some type of firebox or burner arrangement. Indeed, the true barbecue flavor can only be obtained when a wood-burning firebox is employed, and in some of these ovens the firebox is located in the actual oven chamber, while in others the firebox is located remote from the oven chamber. In either case, the oven occupies a considerable amount of floor space and may not be suitable for restaurants that do relatively modest business in barbecue foods. Furthermore, many barbecue ovens of current manufacture derive most of their heat from expensive fuels such as natural or liquid petroleum gas or from other energy sources such as electricity.
SUMMARY OF THE INVENTION
One of the principal objects of the present invention is to provide a barbecue oven that is highly compact and occupies relatively little floor space. Another object is to provide a barbecue oven that contains within its oven chamber a firebox in which wood may be burned to provide the food as it is cooked with the true barbecue flavor. A further object is to provide a barbecue oven which enables smoke to accumulate in the region where the food is supported within the oven. An additional object is to provide a barbecue oven of the type stated that is simple in construction and inexpensive to manufacture. These and other objects and advantages will become apparent hereinafter.
DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which form part of the specification and wherein like numerals and letters refer to like parts wherever they occur -
FIG. 1 is a perspective view of a compact barbecue oven constructed in accordance with and embodying the present invention;
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1;
FIG. 3 is a sectional view of the oven taken along line 3--3 of FIG. 2; and
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3 and showing primarily the firebox.
DETAILED DESCRIPTION
Referring now to the drawings, a highly compact barbecue oven B includes a cabinet 50 that houses or otherwise supports all of the major components of the oven B. Among those components are a rotisserie 52 located in the upper portion of the cabinet 50, a firebox 54 located in the lower portion of the cabinet 50, and a burner 56 positioned to direct a flame into the firebox 54.
The cabinet 50 possesses a box-like configuration in that it has four corners formed by left and right side walls 62, 64, a top wall 66, a bottom wall 68, a back wall 70, a front wall 72, all of which are joined rigidly together into the box-like configuration. In addition, the cabinet 50 has a vertical partition wall 74 which is located between and parallel to the side walls 62, 64, it being closer to the latter than the former. The partition wall 74 extends upwardly from the bottom wall 68, and near the top wall 66 a small portion of the partition wall 74 flares outwardly toward the side wall 64 to form a flue chamber 76. The partition wall 74 divides the interior of the cabinet 50 into an oven chamber 78 and equipment compartment 80, the former being between the partition wall 74 and the left side wall 62, while the latter is between the partition wall 74 and the right side wall 64. The back wall 70 behind the equipment compartment 80 is perfectly flat and extends from the top wall 66 to the bottom wall 68. However, behind the lower portion of the oven chamber 78 the rear wall 70 is offset forwardly somewhat, it having an oblique section and a short vertical section which provides a recess 82 at the rear of the cabinet 50. The left side wall 62, the top wall 66, the front wall 72 and the partition wall 74 are all heavily insulated, as it is that portion of the back wall 70 which closes the oven chamber 78. By reason of the offset at the lower end of the back wall 70, the upper portion of the oven chamber 78 is somewhat deeper that the lower portion.
The upper portion of the oven chamber 78 contains the rotisserie 52 which revolves on an axle 84 that extends between and is supported on the left side wall 62 and the partition wall 74. Indeed, the axle 84 extends through the partition wall 74 and into the equipment compartment 80 where it is connected to a motor 86 which turns the rotisserie 52.
The firebox 54, on the other hand, is in the lower portion of the oven chamber 78 generally in front of the short vertical section at the lower end of the back wall 70. The firebox 54 possesses a cylindrical configuration, and accordingly has a longitudinal or side wall 90 that is cylindrical and two end walls 92 and 94. All three of the walls 90, 92 and 94 are spaced from the walls 62, 66, 68, 70, 72, and 74 which enclose the oven chamber 78. More specifically, the end wall 92 faces the left side wall 62, but is spaced from it, whereas the other end wall 94 faces the partition wall 74, yet is spaced from it. The cylindrical side wall 90 has its axis horizontal and parallel to the back wall 70 and front wall 72, and generally the bottom wall 68 as well, but is spaced from each of those walls. Thus, all three of the firebox walls 90, 92 and 94 are exposed to the oven chamber 78.
The firebox 54 is suspended in the oven chamber 78 from a heat shield 96 which is formed from sheet metal and extends across the lower part of the oven chamber 78 from the left side wall 62 to the partition wall 74, it being attached at its ends to both. The shield 96 includes an upper portion which is presented horizontally within the oven chamber 78 generally above the firebox 54, a rear portion which is presented vertically in the chamber 78 behind the upper rear quadrant of the firebox 54, and an oblique intermediate portion which extends between the upper and rear portions. The cylindrical side wall 90 of the firebox 54 is attached to the vertical rear portion of the heat shield 96, but the horizontal upper portion is spaced upwardly away from the cylindrical side wall 90.
The cylindrical side wall 90 of the firebox 54, in the region thereof that is presented toward the oblique portion of the heat shield 96, is provided with a longitudinally directed slot 98 that extends substantially the full length of the side wall 90. The slot 98 permits smoke to escape from the interior of the firebox 54 and enter the oven chamber 78 to flavor food on the rotisserie 52. While the slot 98 opens into the oven chamber 78, it is nevertheless obscured from above by the heat shield 96 and also by a deflector plate 100. The latter is attached to the top of the cylindrical wall 90 and projects rearwardly, generally horizontally, toward vertical portion of the heat shield 96, yet is spaced from the heat shield 96. Smoke escaping from the slot 98 is thus directed rearwardly by the deflector plate 100 and thence forwardly by the heat shield 96, so that it passes upwardly along the cabinet front wall 72 into the region of the rotisserie 52.
The firebox 54 also has a sleeve 102 which extends from its right end wall 94 to and indeed through the partition wall 74. The interior of the sleeve 102 opens into the portion of the firebox 54 enclosed by the cylindrical side wall 90, as well as into the equipment compartment 80, where it accommodates the burner 56 which may be a conventional type gas conversion burner having a tube from which the fire is emitted. That tube projects into the sleeve 102. When ignited, the burner 56 directs a flame into the sleeve 102 and the larger interior portion of the firebox 54 enclosed by the cylindrical side wall 90. The air for maintaining combustion within the firebox 54 enters the firebox 54 through the burner 56 and the sleeve 102. The burner 56 is under the control of a thermostat which senses the temperature in the upper portion of the oven chamber 78.
Finally the firebox 54 has a door 104 which is actually an arcuate segment of the cylindrical side wall 90. The door 104 in effect occupies the front upper quadrant of the firebox 54 and extends substantially the full distance between the two end walls 92 and 94. It is hinged along its lower margin to the remainder or fixed portion of the side wall 90, so that when opened, it swings forwardly toward the cabinet front wall 72 and then downwardly. Near its upper margin at each end, the door 104 has an angle bracket attached with a cutout 106 where a removable handle may be engaged with the door 104 to swing the door 104 to its open position. The handle is, of course, short enough to clear the heat shield 96 as the door 104 swings to its open position. The door 104 also has a bracket 108 which projects forwardly from it when the door 104 is in its closed position. Of course, when the door 104 is open, logs may be loaded into the firebox 54, and these logs will be ignited when burner 56 is energized.
The cabinet 50 also includes a baffle wall 110 which extends through the oven chamber 78 in the space between the rotisserie 52 and the firebox 54 and at its ends is attached to the left side wall 62 and the partition wall 74. While the baffle wall 110 extends laterally to the side wall 62 and partition wall 74, its front margin is spaced from the front wall 72 and its rear margin is spaced from the back wall 70. Actually, the rear margin is located opposite the oblique section of the back wall 70, that is the section at the recess 82, and the baffle wall 110 is inclinded downwardly to that section of the back wall 70. In other words, the baffle wall 110 is itself oblique, but it is not pitched at an angle as great as the oblique section of the back wall 70. The baffle wall 110 is insulated much like the walls 62, 66, 68, 70, 72, and 74 which enclose the oven chamber 78.
The front wall 72 of the cabinet 50 includes an upper opening 112 which is located opposite to the rotisserie 52 generally at the elevation of the axle 84 thereof and a lower opening 114 at the elevation of the door 104 to the firebox 54, the former being normally occupied by a door 116, while the latter is normally occupied by a door 118. The two doors 116 and 118 are hinged to the cabinet front wall 72 along the lower margins of their respective openings 112 and 114, and thus swing downwardly and outwardly when opened. However, when closed the doors 116 and 118 in effect form a continuation of the front wall 72, and like the remainder of the front wall 72, they are insulated. Each door 116 and 118 has an insulated handle 120 for grasping it and also a pair of manually operated latches 122 for holding it in its closed position. In addition, the lower door 118, on its inside face is fitted with a bar 124 which, when the door 118 is closed, bears against the bracket 108 on the firebox door 102 to insure that the firebox door 104 is closed. Indeed, unless the firebox door 104 is closed, the bracket 108 on that door will interfere with the bar 124 on the lower cabinet door 118 as the lower door 118 is moved to its closed position, and thus will prevent the lower door 118 from reaching its fully closed position. In other words, by reason of the bracket 108 on the firebox door 104 and the bar 124 on the lower cabinet door 118, the lower cabinet door 118 cannot be closed until the firebox door 104 is fully closed. Of course, when the two doors 118 and 104 are open, logs may be loaded into the firebox 54.
The cabinet back wall 70 at its vertical lower section carries a circulating fan 126 including an electric motor 128 and an inside fan blade 130 and an outside fan blade 132. Both the outside fan blade 132 and the motor 128 are located in the recess 82, and when the motor 128 is in operation, the blade 132 directs a stream of cool air across the motor 120, keeping it at a reasonably low operating temperature. The inside fan blade 130, on the other hand, is located within the oven chamber 78 directly behind the firebox 54, and when the motor 128 is in operation, the blade 130 directs heated air from within the oven chamber 78 across the bottom of the firebox 54 generally through the space between the firebox 54 and the cabinet bottom wall 68, as well as across the top of the heat shield 96 generally through the space between the heat shield 96 and the baffle wall 110.
At the lower end of the partition wall 74 is a drain pipe 134 which extends through the equipment compartment 80 for draining grease which collects on the cabinet bottom wall 68. Indeed, the cabinet bottom wall 68 slopes slightly downwardly to the drain pipe 134.
The cabinet top wall 66 in the region above the equipment compartment 80 is provided with a flue opening 136 which opens into the flue chamber 76. A conventional flue pipe fits to the flue opening 136.
To place the oven in operation, the upper cabinet door 116 is opened and food is inserted through its opening 112 and placed onto the rotisserie 52. When the desired amount of food is loaded, the door 116 is again closed. The lower cabinet door 118 is also opened to expose the firebox 54 and its door 104 is likewise opened. Logs are inserted through the lower opening 114 into the firebox 54, whereupon the firebox door 104 is closed as is the cabinet door 118 behind it. Indeed, the cabinet door 118 will not shut until the firebox door 104 is in its fully closed position.
Once the firebox 54 has received a supply of logs, the burner 56 is ignited. It directs a flame through the sleeve 102 and into the larger interior portion of the firebox 54 where the flame impinges on the logs and ignites them. When the combustion is capable of sustaining itself, the burner 56 shuts off. The air for supporting the combustion enters through the burner 56 and the sleeve 102.
The combustion within the firebox 54 heats the cylindrical side wall 90 as well as the end walls 92 and 94 on the firebox 54, and the heated side wall 90 in turn radiates and conducts heat to the heat shield 96. The inside face blade 130 of the circulating fan 126 causes air within the oven chamber 78 to flow across the back of the cylindrical side wall 90 for the firebox 54, the air going both upwardly and downwardly. The downwardly directed stream flows beneath the cylindrical side wall 90 and then upwardly across the front of the cylindrical wall 90, whereupon it rises through the space between the cabinet front wall 72 and the baffle wall 110. The upwardly directed stream flows over the heat shield 96, whereupon it likewise rises through the space between the cabinet front wall 72 and the baffle wall 110. Some of the circulating air also passes across the end walls 92 and 94 of the firebox 54. Of course, the air as it flows across the walls 90, 92 and 94 of the firebox 54 and likewise across the rear and top of the heat shield 96 is heated and undergoes a significant rise in temperature. It also acquires smoke which pases outwardly from the slot 98 of the firebox 54.
The heated and smoke-laden air issues from the space between the cabinet front wall 72 and the baffle wall 110 and heats the upper portion of the oven chamber 78 where the rotisserie 52 is located, the temperature of the air being hot enough to cook food that is on the rotisserie 52 which revolves. The smoke, on the other hand, imparts a barbecue flavor to the food. Some of the heated air is exhausted through the flue chamber 76 and flue opening 136, to be discharged into a flue which is connected with that opening. However, most of the air passes downwardly through the space between the cabinet back wall 70 and the baffle wall 110 and returns to the inside fan blade 130 which recirculates it past the firebox 54 and its heat shield 96 as previously described.
This invention is intended to cover all changes and modifications of the example of the invention herein chosen for purposes of the disclosure which do not constitute departures from the spirit and scope of the invention. | A highly compact oven for preparing barbecued foods on a commercial basis includes a cabinet having a vertical partition wall that divides its interior into an oven chamber and an equipment compartment, and doors which provide access to the oven chamber. In addition, the oven has a rotisserie for supporting foods in the upper portion of the oven chamber opposite one of the doors, and this rotisserie is turned by a motor in the equipment compartment. A cylindrical firebox in which wood is burned is located in the lower portion of the oven chamber opposite another of the doors to provide the heat required for cooking the food and the smoke for imparting the barbecue flavor to that food. Food on the rotisserie is shielded from the firebox by a baffle wall which extends across the oven chamber, yet has its margins spaced from the front and back walls, so that heated air and smoke circulate freely between the region of the firebox and the region of the rotisserie. Moreover, the firebox is exposed to the oven chamber along its cylindrical side wall and end walls, so that maximum transfer of heat to the circulating air occurs. Wood that is placed within the firebox is ignited by a burner that is located in the equipment compartment and projects its flame through a sleeve that extends between the firebox and the vertical partition wall. | 0 |
BACKGROUND OF THE INVENTION
This invention is directed to a coupling for tubing. More specifically, this invention is directed to a heat recoverable metal coupling for metal tubing.
A variety of heat recoverable metal couplings have been developed for joining tubing and the like together for such applications as aircraft hydraulic systems and the like. One such device is disclosed in Harrision et al, HEAT RECOVERABLE METALLIC COUPLING, Ser. No. 410,314, filed Oct. 29, 1973, which is assigned to the assignee of the present invention and is incorporated herein by reference. Other forms of such couplings include those with smooth bores, serrated bores, toothed inserts and the like. The bodies of these heat recoverable metallic coupings are often tapered at the ends to reduce the stress loading on the tubing positioned in the coupling under bending loads. By tapering the ends of the coupling, the coupling is more able to flex and distribute the load over a broader area of the tubing. This prevents or significantly reduces failure of the tubing as a result of high stress concentration.
Although high bending stress may be substantially reduced by tapering the ends of the coupling member, the flexing of tubing at the coupling causes relative movement between the ends of the coupling and the underlying tubing. This relative motion is generally longitudinal in nature and causes chafing, fretting and galling of the tubing over a period of time. This working of the tubing is especially acute in aircraft and other applications where vibration occurs for continued periods of time. The roughened, pitted area thus formed results in points of high stress concentration in the tubing which, through continued flex cycling, lead to the propagation of cracks through the tube wall eventually resulting in tube failure. Unsatisfactory attempts have been made to eliminate or reduce the amount of chafing which occurs at the ends of the coupling members. Lubricants have been applied to the interface between the coupling and tubing as an attempt to reduce the friction at the interface. It remains that certain gall prone materials are subject to the eventual failure at locations near the end of metallic couplings because of the relative motion between components.
SUMMARY OF THE INVENTION
The present invention is designed to eliminate relative motion at the ends of heat recoverable metal couplings as a means for preventing chafing, fretting or galling of the tubing associated therewith to avoid eventual tube failures. To accomplish this end, a heat recoverable metallic coupling is here disclosed which includes a body having a generally cylindrical section and stress distribution sections extending from the generally cylindrical section to rigid collars. The entire structure is of a heat recoverable nature and usually is of unitary construction, although a composite construction using a liner of another metal or material is feasible and would be desirable in certain applications, as, for instance, where a substance corrosive to the heat recoverable metal is to be contained in the tubing.
The stress distribution sections provide a transition from the thick-walled cylindrical section to thin-walled ends of the stress distribution sections. At the generally cylindrical section, the body is in most instances more rigid than the tubing with which the coupling is to be employed. At the ouher ends of the stress distribution sections, the walls of the coupling are thin and the coupling is at least as flexible as the tubing. Thus, each end of the coupling provides an area of increasing strength such that the tubes extending into the coupling will experience stress loading from flexure of the tubing over a broad area rather than concentrated at a rigid edge of an untapered coupling.
The stress distribution sections further provide a strength gradient with respect to tensile and compressive loading. Again, the tensile and compressive strengths of the coupling decrease from the comparatively rigid cylindrical sections to the thin-walled ends. At the thin-walled ends, the compressive and tensile strengths of the coupling are less than those of the tubing with which the coupling is to be employed.
The collars located outwardly of the stress distribution sections have a transverse wall thickness which is substantially greater than the thin-walled ends adjacent thereto. The thickness and recovered inside dimension of each collar provide recovery hoop strength to tightly grip the tube extending therethrough. The recovery hoop strength is designed to create sufficient friction between each collar and the adjacent section of tubing to overcome the linear flexural strength of each composite stress distribution section. The linear flexural strength is that strength tending to create relative longitudinal motion between the coupling and the underlying tubing when the tubing is subjected to flexure. In other words, the gripping of the tubing is such that the collars will not slide longitudinally along the tubing during flexure of the tubing. Thus, compression and elongation is experienced inwardly of the collars in the stress distribution sections. As a result, little or no relative longitudinal motion between the coupling and the tubing is experienced. Thus, it has been found that the amount of chafing, fretting or galling can be either eliminated or reduced to an inconsequential amount by the application of the present invention.
Accordingly, it is an object of the present invention to provide an improved heat recoverable metallic coupling.
It is another object of the present invention to provide a heat recoverable metallic coupling which reduces the incidence of chafing, fretting and galling of the tubing extending therethrough.
It is a further object of the present invention to provide a heat recoverable metallic coupling wherein the outermost portions of the coupling do not move relative to tubing extending therethrough durig flexing of that tubing.
Moreover, it is an object of the present invention to provide improved heat recoverable couplings which do not concentrate bending stress or substantially weaken the tubing extending therethrough.
Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a coupling assembled with tubing according to the present invention.
FIG. 2 is a cross-sectional elevation taken along line 2--2 of FIG. 1.
FIG. 3 is an end view of the coupling.
FIG. 4 is a cross-sectional end view taken along line 4--4 of FIG. 2.
FIG. 5 is an elevation, partially in section, of an unrecovered coupling including an insert according to the present invention.
FIG. 6 is an elevation, partially in section, of the embodiment of FIG. 5 recovered about the tubing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, the coupling is illustrated as a hollow member 10 fabricated from a heat recoverable metallic material. The hollow member 10 is of unitary construction. However, composite structures may also be employed without departing from the invention concepts of the present invention. It is further to be understood that the present invention may be in the form of a T-shaped member or other member capable of accepting three or more incoming tubes. Furthermore, only a single opening may be employed at one end of the hollow body to form an end cap.
The hollow member 10 includes a main, substantially cylindrical hollow body section 14. In the present embodiment, a substantially cylindrical bore 12 extends the length of the hollow member 10. The bore may include serrations or teeth such as disclosed in Harrison et at, HEAT RECOVERABLE METALLIC COUPLING, Ser. No. 410,314, filed Oct. 29, 1973, or be completely smooth. Two annular teeth 13 are associated with each side of the coupling. It has been found that the teeth 13 substantially improve the sealing capabilities of the coupling.
At either end of the main, substantially cylindrical hollow body section 14, stress distribution sections 16 and 18 extend longitudinally from the cylindrical section to collars 26 and 28. The stress distribution sections 16 and 18 each include a tapered portion 20 and a thin-walled section 22 in the present embodiment. The tapered portions 20 act to distribute the resistance to bending of the hollow member 10 when the tubes extending into the hollow member 10 are strained under a bending load. The walls of the tapered portions 20 offer decreasing resistance to the strain imposed by the tubes because of the decreasing cross section of the walls of the tapered portion 20. This allows distribution of the load across a greater length of the tubes to prevent fatigue failure at a specific high stress point at the edge of a stiff untapered coupling.
The thin-walled portions 22 extend from the tapered portion 20 to the collars 26 and 28. The length of each thin-walled portion 22 is preferably approximately one-fifth to equal to the outside diameter of the thin-walled portion. The bore of the thin-walled portion 22 is generally smooth, although properly designed inward projections may be incorporated. The thin-walled sections 22 act to extend the relatively flexible ends of the tapered portion 20 to eliminate the edge formed by more conventional couplings at the end of similar tapered portions. The conventional couplings tend to promote chafing, fretting or galling because of relative longitudinal motion at the ends of the coupling between the coupling and the tubing extending therethrough. The thin-walled sections remove the ends of the coupling away from the heavier portions of the taper.
The collar 26 and 28 are located at the extended ends of the thin-walled sections 22. The collar 26 and 28 are substantially thicker in transverse crosssection than the thin-walled sections 22. These collars 26 and 28 are also of heat recoverable metallic material and are sized to tightly conform to the tubing positioned within the coupling upon heat recovery of the collars. The collars 26 and 28 may have a transverse wall thickness which is equal to the thickness of the main wall portion of the coupling. However, in most applications, it is not necessary to have a collar as thick as the main wall portion.
The relative longitudinal holding capacity of the collars 26 and 28 based on the hoop strength of the collars 26 and 28 and the stress induced by the recovery of the undersized collars about the tubing the designed to exceed the longitudinal force that can be transmitted by elastic deformation of the thin-walled sections 22. Consequently, the collars 26 and 28 will remain fixed relative to the tubing regardless of the flexure of the tubing. With the tubing strained in a bending mode, the thin-walled sections 22 experience elastic deformation thereby allowing the tubing to flex relative to the main, cylindrical hollow body section 14 without displacing the collars. The thin-walled sections 22 also have a flexural strength which is no greater than that of the tubing with which the coupling is to be employed. If the strength of the thin-walled sections 22 were greater than the tubing, the tubing would be excessively stressed at the ends of the coupling which could result in early failure of the tubing. A gradual decrease in the bending moment in the tubing from a maximum stress at the coupling ends to zero near the center is necessary for good flex life. Thus, it will be apparent that the function of the thin-walled extensions between the tapered sections and the collars is to permit the collars to move with the tubing as it bends and also to transmit linear stress to the tapered sections so thay they will also move with tubing. In this way, all, or nearly all, relative motion between the tubing and coupling is eliminated.
The heat recoverable porperties of a hollow member 10 are advantageous for both the main, hollow body portion 14 and the collars 26 and 28. The main, hollow body portion 14, when recovered about tubes, such as shown in the figures as 30 and 32, prevents longitudinal extraction of the tubes from the coupling and provides a seal to prevent leakage of high pressure fluid which may be contained within the tubing through the coupling. At the same time, the recovery of the collars 26 and 28 acts to retain the collars in position on the tubing 30 and 32 such that no chafing, fretting and galling will occur.
One specific example of employing the nickeltitanium alloy on one-half inch OD tubing (1.27 cm.) includes thin-walled sections having a thickness from 0.010 inches to 0.020 inches (0.025 cm. to 0.051 cm.). The outside diameter of the main body portion 14 is 0.70 inches (1.78 cm.) while the collars 26 and 28 have an outside diameter of 0.60 inches (1.52 cm.). The relaxed bore diameter of the coupling is 0.470 inches (1.20 cm.). An alloy of nickel and titanium such as disclosed in Harrison et al, HEAT RECOVERABLE METALLIC COUPLING, Ser. No. 410,314, filed Oct. 29, 1973, has been found to comply with the requirements of the present invention.
To illustrate the use of composite construction of the present invention, FIGS. 5 and 6 show the employment of a substantially cylindrical insert 34 having inwardly extending teeth 36. The inwardly extending teeth are intended to further deform the underlying tubes 30 and 32 as can be seen in the recovered view, FIG. 6. Thus, the insert illustrated is designed as a means for further increasing the holding capacity of the coupling. Inserts designed to accomplish other functions such as galling the inner ends of the tubes 30 and 32 are also contemplated by the present invention. A more detailed description of such inserts is provided in Martin, Composite Coupling, Ser. No. 608,209, filed Aug. 27,1975, which is assigned to the assignee of the present invention and is incorporated herein by reference. The insert disclosed is shown to be shorter in length than the overall length of the heat recoverable coupling member. However, where the insert is designed as a means for preventing corrosive action between the heat recoverable coupling and the tubing, it is advantageous to have the insert extend beyond the ends of the heat recoverable coupling. In the latter instance, the insert is preferably of a flexible or structurally weak nature in order that the advantages obtained by the rigid location of the collars 26 and 28 will not be compromised.
Thus, a coupling is provided which reduces or eliminates longitudinal motion between flexing tubes and the associated coupling and reduces the maximum bending stress experienced by the tubing at the coupling. In this way, chafing, fretting or galling of the tubing at the outer ends of the coupling is avoided. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein described. The invention therefore, is not to be restricted except by the spirit of the appended claims. | A coupling of heat recoverable metallic material for joining tubular members and other cylindrical substrates. The couplings include a hollow member having at least one opening for receipt of a tube. This hollow member is designed to eliminate relative motion between the ends of the member and the tubing during flexure of the tubing and coupling assembly. This elimination of such relative motion is accomplished by incorporating thin-walled sections at each end of the hollow member with collars located outwardly of the thin-walled sections. The collars tightly grip the tubing to prevent relative motion between the collar and the tubing while the thin-walled sections allow flexural response of the coupling to the flexure of the tubing itself. | 8 |
This is a continuation of application Ser. No. 778,932, filed Mar. 18, 1977, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of the coloring of continuous synthetic filaments in the form of tow for conversion into yarn having the color known as "heather".
2. Description of the Prior Art
As used herein, the term "heather" which is a well known term of art, will refer to a product in the form of a yarn ultimately formed from staple and which has a color which is formed from the blending of white and colored pieces of staple or staple having white and colored portions thereon. Such heather yarns are conventionally used in the formation of fabrics for wearing apparel and the like, although, of course, many type of end uses are possible. While the term "heather" generally refers to the color, it has also become conventional to designate the product as heather.
There are currently two commercial methods for the production of heather. In the first method, a continuous synthetic fiber, such as, acrylic or polyester, although other synthetics may be used, which fiber is in the form of tow, is cut into staple and preformed into sliver. It is understood that the terms "staple" and "sliver" are well known and in particular, "sliver" refers to a rope formed from staple which has been blended sufficiently to give the rope some cohesiveness so that it may be further treated.
The sliver thus formed is then wound onto a bobbin which generally weighs from about 8 to 10 kg, although more or less weight can be used per bobbin depending on the particular type process which is going to be used as well as the type of synthetic fiber and its own weight. In any event, such bobbins are conventionally referred to as "tops".
A number of such tops are then placed onto a creel which may accommodate 16 or more of the tops. The sliver from each of the tops are then simultaneously (all the ends) fed through a gill box to form an extremely thin sheet which is referred to as a "lap". The lap is sufficiently thin so as to substantially expose most of the fibers to the subsequent processing.
This lap is then printed on one side by passing the lap between a print roll having a plurality of raised portions, generally in the form of a spiral thereon, and a second roll which is coated with an absorbent material and which is impregnated with dye. As a result, that side of the lap which contacts the impregnated roll is printed with a design pattern corresponding to that of the print roll. Moreover, because the print roll is in pressurized contact with the absorbent covering of the impregnated roll, the design pattern essentially impregnates through the thickness of the lap.
The design generally printed onto the lap results in the individual filaments of the sliver which, as noted, are formed from blended pieces of staple, having colored and uncolored portions. That is to say, the uncolored portions are the color of the original fiber which is essentially white.
The thus printed lap is then gathered, typically through a funnel type gathering device, and collected into essentially a single rope and treated using the usual dye fixation procedures, washing treatments, drying treatments, etc., such treatments being conventional and depending on both the type of dye and type of synthetic fiber that is being used.
After the fixation and subsequent processing treatments, the rope must then be reformed into sliver. The sliver is then formed into tops again for shipment to the processing center for the conventional blending treatments to prepare the yarn.
One of the significant disadvantages of the above process which is commonly referred to as the "Vigereux" process, is the fact that it can only be used to treat sliver, i.e., material which has been precut into staple. Thus, the process is completely unsuitable and cannot be used with tow, which is a rope formed from the fibers which are in continuous filament form
The basic reason for this is that tow cannot be treated by passing through a gill box because it is formed from continuous filament rather than from staple. Consequently, tow cannot be formed into a thin lap as can sliver. Also, tow as it comes from the manufacturer, has a crimp in it which results from the manufacturing process. Thus it has been thought that because of the inability to form tow into a lap, one cannot achieve the substantial impregnation of all of the fibers as is required in the Vigereux process to produce a suitable product for forming into heather.
The second method for forming heather is by cutting two, formed from continuous filaments, into staple, converting the staple into sliver, and then forming the sliver into tops. The tops are then subjected to a "package or unit type" dyeing operation wherein the individual tops are placed into sealable containers and are dyed in much the same way as in the conventional "package dyeing" procedure. This results, of course in the tops being 100 percent dyed with the particular color being used.
The thus dyed tops are fixed, washed, dried, etc., using conventional procedures and these dyed tops are then creeled with an appropriate number of undyed white tops, depending on the ultimate color blend which is desired in the heather. The ends of all of these creeled tops are then subjected to blending through a series of gills, blenders, etc., for preparation into a yarn.
The disadvantages of this process are apparent since the ultimate blending is obtained by taking sliver of one color and/or sliver of another color and uncolored sliver and blending these individual pieces. The pieces of sliver are relatively large and consequently, the homogeneity of the resulting heather is not particularly good due to the large splotches of color which will occur.
Turning again to the Vigereux process, a number of other disadvantages attend the utilization of this process. For example, it is relatively slow because of the necessity of using the gill box. The gill box essentially separates the fibers of the sliver in such a way that a suitably thin lap can be formed. This is, however, an extremely slow process and consequently, the speed of the subsequent printing step is controlled by the speed of the gill box treatment.
Another problem is the fact that, in the Vigereux process, extensive breaks in the form of "wrap-arounds" on the print wheel occur. This is primarily due to the fact that the lap is extremely thin and is composed of cut fibers. Thus, many fiber ends pass through the print roll and covered roll and the chances for the ends catching on to the roll and wrapping around the roll are very high.
Moreover, since, in the Vigereux type process, one is feeding a series of 16 or more different ends of sliver into the machine, and this sliver is composed of cut fibers, from time to time, due to a slight catch in the tops, the sliver will pull apart or break. This, like the "wrap-arounds" necessitates shutting down of the machine in order to tie the slivers or remove the wrap-arounds.
In practice, two workers are required to monitor the Vigereux process at all times. One of the workers monitors the print roll to continually remove any small wrap-arounds which are formed so as to avoid their expanding into large wrap-around. The other worker is required to continuously monitor the creel so as to repair any breaks in the sliver.
With respect to the second process described hereinabove, one of the major disadvantages is that it is essentially a bulk type dyeing process. That is to say, the tops are placed within a chamber and dye stuff in a relatively large volume of solvent is forced through the tops under pressure. In dyeing processes of this type, the efficiency of the dye usage is relatively poor. After the dyeing operation, not all of the dye is exhausted from the dyeing liquid. However, this dyeing liquid is no longer usable and is generally discarded. Consequently, the process is quite expensive considering the amount of dye wasted in the process, the large amount of energy required and the large amount of solvent or water wasted.
Another problem of this process is the fact that it creates pollution problems. Thus, the used dyestuff solution must be discarded and, assuming that the solvent is water, it will generally be disposed of in conventional sewage. However treatment may be required to properly prepare it for entry into the sewage system.
In the event that an organic solvent system is used, the solvent cannot be dumped but rather, must be recovered. Also, of course, such organic solvents create air pollution problems and cannot be vented to the atmosphere. Also, organic solvents, are relatively expensive and, consequently, processes are usually required in the overall treatment to recover as much of the solvent as possible. This, of course, adds to the overall expense of the process.
Finally, because dyestuffs diluted in large volumes of solvent, are utilized in this type process, relatively large volumes are constantly being treated and this is another disadvantage of the process, since larger equipment is needed.
Also, in this unit dyeing type of process, when it is desired to change colors, the down-time is quite extensive since all of the equipment must be completely cleaned and all contamination of the old dyestuff must be removed from the dye tanks. This is a fairly intricate process and requires a significant amount of time in practice.
One important aspect of the so-called "package-dyeing" system is that when a mixture of dyestuffs is to be used to achieve a given color, the dyes must be compatible with respect to their exhaust rates from the dye bath. That is to say, their exhaust rate curves must be similar. If they are not compatible and do not have the same or similar exhaustion rates, uneven dyeing will occur.
Consequently, the choice of dyestuffs for use in such combinations is quite limited with this process and often result in the necessity of utilizing relatively expensive dyes in order to obtain the appropriate compatibility.
A major problem attendant both to the Vigereux type process as well as the unit or package dyeing type process described above is the fact that they both treat sliver which is formed from staple and cannot be utilized to treat tow. This has a significant effect on acrylic fiber when it is desired to have a "high bulk yarn". In producing such a high bulk, the bulk is usually imparted to the acrylic fiber at the time of cutting it into staple. Thus, the bulk is imparted to the undyed fiber.
However, in both the Vigereux and the unit dyeing process, the staple is ultimately dyed and thus must necessarily be subjected to dye fixation treatments. Such treatments usually involve heating of the sliver. As a result of this second heating the original high bulk which was imparted to the fiber is destroyed. Consequently, a heather product having high bulk cannot be produced by either the Vigereux or the unit dyeing process because of the necessity of the subsequent dye fixation treatments which destroy the high bulk previously imparted to the fiber.
It is also possible, with acrylic fibers, to produce heather utilizing the so-called "tunnel dyeing" technique. This enables acrylic fiber to be dyed in the form of tow. However, the fiber passed through the "tunnel dyeing" process, which is a conventional process, is completely dyed with the particular color.
However, the tunnel dyeing technique has a number of disadvantages, one of which is the fact that because of the speed of the process and the narrowness of the dyeing chamber where the dye is aged and steamed after being applied to the fiber, the dyes often do not set exactly properly. Thus, for example, if one is using a dye composition composed of several colors, the tow exiting the chamber will often be observed to have spots of the individual colors thereon rather than a blend of the colors. This is due to the fact that the exact steaming or other finishing treatment conditions were not sufficient for each of the individual colors. While it is possible to subsequently blend the thus dyed material in such a manner as to obliviate the inhomogeneity resulting from the dyeing, when another batch of tow is treated in an attempt to obtain the same color, it cannot be done since it is virtually impossible to duplicate the non-homogeneity that occurred in the previous batch.
Also, of course, with respect to the tunnel dyeing technique, in order to form the heater product, an ultimate blending of individual slivers must be effected as with the unit dyeing treatment.
SUMMARY OF THE INVENTION
Applicants have discovered a method for producing heather which can be utilized directly on continuous filament in tow form without having to first cut the tow into staple and form sliver therefrom and then treat the sliver. As a result, the present process avoids all of the disadvantages of the prior known processes utilized for producing heather and further is faster, more economical, and produces a more homogeneous heather product than the prior art processes.
Particularly, the present process is a method for applying a color to continuous synthetic fibers in the form of tow wherein the tow is first spread into a flattened sheet, color is applied to the flattened sheet in a first predetermined design pattern to one side of the sheet so as to impregnate the color into the depth of the sheet and then color is applied in a second predetermined design pattern to the other side of the sheet so as to impregnate the color into the depth of the sheet from the other side.
This process is carried out on an apparatus which is composed of means for spreading the tow into a flattened sheet, first means for applying color to one side of the sheet in the first predetermined design pattern and to impregnate the color into the depth of the sheet and second means for applying color to the other side of the sheet in a second predetermined design pattern and so as to impregnate the color into the depth of the sheet, the second means being positioned subsequent to the first means.
The tow which is produced by the present process is quite unique in that it is formed from continuous filaments which have intermittent colored and uncolored portions along their lengths.
More particularly, the method of the present invention involves utilizing dye application stations which are composed of a print roll having raised portions thereon, a second roll disposed opposite the print roll and in pressurized contact therewith, which second roll has an absorbent outer covering thereon for retaining coloring agent or a dye and means for impregnating the absorbent covering. By passing the sheet of tow through or between these two rolls, an appropriate pattern corresponding to that of the predetermined design pattern is imprinted and impregnated into the depth of the sheet on the side of the sheet contacting the impregnated covering. The thus printed tow is then sent to a second dye station wherein the positioning of the rolls is opposite to that of the first dye station so that the pattern is produced on the other side of the sheet and is also impregnated into the depth of the sheet.
Thereafter, the thus printed or colored tow, the continuous fibers of which have intermittent colored and uncolored portions along their lenghts, is subjected to the conventional dye fixation, scouring, washing, drying, etc. techniques after which it may be cut into staple and processed in the usual manner to produce heater.
By virtue of the fact that the present process treats tow as opposed to sliver, a number of significant and highly unexpected advantages result. Thus, for example, as compared to the Vigereux process, the present process is much faster, and in fact, can be run twice as fast or perhaps even more than twice as fast as the Vigereux process. The reason for this is that tow is substantially stronger since it is composed of continuous filaments as opposed to cut up filaments as is sliver. Moreover, because a gill box is not utilized to form the flattened sheet, the process can also be run faster since the gill box, as noted hereinbefore, is a relatively slow treatment for forming the sliver into an extremely thin sheet. Also, the extensive breaks in the form of "wrap-arounds" and breaks in the sliver which are attendant the Vigereux process do not occur in the present process since the tow is in continuous filament form. This further results in the fact that only one operator is required to monitor the present process as opposed to the two operators required for the Vigereux type process.
With respect to the bulk type dyeing process discussed hereinabove, the present process is advantageous in that because the fibers have splotches or intermittent color along their length as opposed to being completely dyed one color and having to be subsequently blended with sliver of another color, a more more homogeneous heather product is ultimately obtained. The reason for this is that one is dealing with much smaller units of colored and uncolored fiber. Additionally, all of the dye is effectively utilized in the present process since there is no concern with exhaustion of the dyestuff as there is no immersion of the material into the dyestuff contained in a liquid. This results in a significant saving in dyestuff. Moreover, it avoids the pollution problems which are attendant the use of large volumes of water or organic solvents generally encountered with the bulk type dyeing process. Also, of course, the extensive down time for change of colors which is required with the bulk type dyeing process is not encountered with the present process since it is much easier to merely clean the rolls, change absorbent coverings and proceed with treatment with the new color.
Finally, a very significant improvement and advantage of the present process as opposed to both the Vigereux and bulk type dyeing processes is the fact that one can obtain a heather product having high bulk. Thus, the present process treats the acrylic fiber in the form of continuous filament, and dyes it and subjects the filaments to the dye fixation treatments prior to its being cut into staple. Consequently, there are no subsequent heat treatments after the high bulk treatment as in the prior art processes and the resulting heather product will retain the high bulk given to it during the staple cutting process.
Moreover, considering the bulk dyeing process, since the present process does not utilize the exhaustion technique of the dyes, one can use two or more inexpensive dyes since they need not be compatible with respect to their exhaustion rate curves.
As opposed to the "tunnel dyeing" technique which is utilized for tow, the dye inhomogeneities which occur with this process do not occur with the present process and consequently it is much easier to produce uniformity from one run of tow to another.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the process flow scheme of the present invention and the apparatus of the present invention.
FIG. 2 is a drawing of a segment of a single continuous filament from tow colored by the process of the present invention.
FIG. 3 is a photograph of one side of a sheet of tow colored by the process of the present invention.
FIG. 4 is the opposite side of the sheet of FIG. 3 which is colored with the process of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the process of the present invention is carried out according to the scheme shown and the apparatus depicted therein. Particularly, means for spreading tow is depicted generally at 10 which comprises a conventional sequence of rollers such that the tow generally in the form of a somewhat crimped rope as it is received from the producer at 12 is fed in the direction shown by arrow A into a plurality of rollers designated generally as 14 and through overhead rollers 16, 18 and turning roller 20, into press rollers 22 whereby the tow at 24 is formed into a relatively flat sheet. As the tow proceeds from rollers 14 to and through rollers 22, it is gradually spread apart to form the relatively flat sheet. Rollers 22 may be any type of opposing rollers, although generally, rollers having longitudinal ribs along their longitudinal axis are used. These are the usual type of feeding rollers used in textile processing machinery.
The tow 24, after it has passed rolls 22, is in the form of a sheet which is approximately 1/32 to 1/2 inch thick. It should be understood, that the tow cannot be formed into a completely flat or extremely thin sheet, as can sliver fed from a creel of tops. This is because it is composed of continuous filaments and, as manufactured, has a multiplicity of crimps along the length of the fibers which are produced due to the nature of the method of manufacture of tow. Thus, sheet 24 is actually a relatively thick sheet with a relatively rough surface due to the variation in thickness as well as the crimps which are present in the tow.
Thereafter, the two in sheet form 24 proceeds through a first coloring or printing station 26 wherein the side of the tow sheet indicated as B is imprinted with a predetermined design pattern.
Coloring station 26 is composed of a print roller 28 which has a plurality of raised portions thereon in the form of a preselected or predetermined design pattern. Typically, this roll is made of metal and preferably of stainless steel, since the latter is easily cleaned for color changes. Preferably, the raised portions of the roll are in the form of spirals running circumferentially about the periphery of the roll and longitudinally along the longitudinal axis of the roll. Most preferably, there are four such raised portions as can be evidenced from viewing the roll in cross-section as is shown in FIG. 1, although an increased number of such spirals may also be used depending on the particular type of dye or color coverage of the tow sheet 24 which is desired. Also, of course, the pitch of the spirals may be varied, again, depending on the end pattern and coverage desired.
As shown, print roll 28 is an undriven roll and is mount on a spring loaded roll positioning device such that roll 28 can be moved in either direction along the double arrow indicated as C by adjusting handle 30.
Pad roll 32 is a driven roll and has a covering of an absorbent material thereon. The covering may be any type of absorbent material which will absorb a dye, however, preferably an all wool covering is utilized.
Roll 32 is in a fixed position, i.e., it is not movable along the direction shown by double arrow C and is only slightly spaced apart or in actual contact with print roll 28 so that sheet 24 can pass between the two rolls. It is thus clear that adjustment device 26 can be adjusted so as to vary the amount of pressure or contact between print roll 28 and pad roll 32. Also, by virtue of the pressurized contact of print roll 28, sheet 24, and covered roll 32, rotation of roll 32 is used to convey the sheet past the dye station. Of course, other conventional means of conveying sheet 24 through the process can be used.
Opposing roll 32, on the opposite side from print roll 28, is dye transfer roll 34 which typically has a resilient coating thereon, e.g., rubber. A portion of dye transfer roll 34 is immersed in dye reservoir 36 and rotates therein for the purpose of picking up dye and transferring the picked up dye to pad roll 32.
Dye transfer roll 34 is undriven, however, it is attached to spring loaded adjustment means 38 which are similar to means for the purpose of moving dye transfer roll in either direction along the double arrow designated as D. As a result, the degree of pressure of dye transfer roll 34 against pad roll 32 can be varied by appropriate adjustment utilizing adjustment means 38.
Consequently, because of the absorbent coating or covering about pad roll 32, and utilizing means 38, dye transfer roll 34 can be adjusted so as to press against the absorbent covering of roll 32 to a greater or lesser degree. The covering of roll 32 after a few turns is completely saturated or impregnated with the dye transfer red thereto by roll 34, and by varying the pressure exerted by dye transfer roll 34, one can obtain a squeegee type effect which serves the purpose of controlling the amount of dyestuff impregnated in the covering. Thus, by applying more pressure with dye transfer roll 34, more of the dye will be squeezed from pad roll 32 and will drip back into reservoir 36 and this will have an overall effect of decreasing the amount of dye ultimately transferred to side B of sheet 24. Conversely, by decreasing the pressure of dye transfer roll 34 on pad roll 32 roll 32 will retain more dye and consequently more dye will be transferred to side B of sheet 24.
It is also thus seen that the adjustment means 26 attached to print roll 28 serves a different purpose from adjustment means 38 attached to dye transfer roll 34. Thus, adjustment means 26 serves only to maintain pressurized contact between roll 28, sheet 24 and roll 32. As roll 32 is driven in the appropriate direction, it in turn serves to move sheet 24 between rolls 32 and 28. Moreover, the raised portions or ribs on roll 28 as it is turning will press into sheet 24 and, in turn press the corresponding portions of the sheet contacted by the raised portions into the absorbent covering of roll 32. This server to transfer or print the dyestuff impregnated into the covering of roll 32 onto and into side B of sheet 24 in those areas corresponding to the raised portions of roll 28.
It is understood, of course, that other means would be easily ascertainable by the skilled artisan with respect to either adjusting the relative pressures of the rolls against one another or for impregnating the covering of roll 32 with the dye mix.
It is further noted that inasmuch as this is essentially a printing type of operation as opposed to a vat dyeing type of mechanism, the dyestuff in reservoir 36 is in the form of a relatively thick paste, i.e., has a relatively small amount of solvent or liquid.
It is as a result of this that the dye utilization in the present process is highly efficient since there is essentially no dye thrown away due to any type of dye exhaustion or depletion of the bath. As dye is continually transferred to the sheet, the amount of dye in reservoir 36 decreases and it is merely required to add additional dye paste thereto to maintain an appropriate level of paste therein. It is further easy for the operator to calculate, based on the knowledge of the total length of tow to be treated, decreases process speed, coverage, etc., the rate of paste utilization. It is merely required to add additional dye paste from time to time thereto to maintain an appropriate level of paste therein. It is easy for the operator, based on the above factors, to accurately estimate exactly how much dye paste will be required for the total run so that very little residual dye paste will remain in the reservoir at the end of the given run.
After traversing the first dye station, the sheet of tow printed on side B proceeds to a second dye station designated generally as 40.
Referring now to FIG. 3, a photograph of side B of the tow sheet as it emerges from the first dye station is shown. It can be seen that the dye, which in this case was dark brown, has been printed in essentially a diagonal pattern traversing the width of the sheet.
It is further noted that at the first print station, it is not just those fibers which may happen to be on the surface of side B of the sheet which are exposed to the dye. Because of the pressure between rolls 28 and 32 and the absorbent and resilient character of the covering of roll 32, the dye actually impregnated into the thickness of the sheet and generally will impregnate a substantial portion if not all of the sheet thickness. The pressures of the relative rolls are adjusted in order to assure such depth of penetration as is required. This impregnation is important since it assures that substantially all of the individual fibers will have dye transferred thereto.
Dye station 40 is essentially the same as the first dye station with the exception that the rolls are in reverse order. That is to say, they are in position so as to apply dye to the opposite side of the sheet of tow designated as side E.
Particularly, dye station 40 is composed of print roll 42 having pressure adjusting means 44 attached thereto for adjusting roll 42 in either direction along the arrow designated as F.
Opposite print roll 42 is pad roll 46 which also has an absorbent coating thereon. Roll 46 is a driven roll. On the opposite side thereof is dye transfer roll 48 which is partially immersed in reservoir 50 and has pressure adjustment device 52 attached thereto in order to adjust dye transfer roll 48 in either direction along the arrow designated as G.
This dye station operates in essentially the same manner as the first dye station, the only difference being that due to the opposite juxtaposition of the rolls as compared to the first dye station, the predetermined design pattern corresponding to the pattern on print roll 42 will be transferred to side E of the sheet of tow 24 since it is this side which comes into contact with covered roll 46.
It is clear further from the utilization of these two dye stations, that one may use either the same design pattern on each of rolls 28 and 42 or may vary the design patterns depending on the specific results intended. For example, one may use a spiral design pattern similar to that on roll 32 with the exception that the spirals travel in the direction opposite to those of roll 28. Also, one may use a greater or lesser number of such spirals or vary the pitch of the spirals again depending on the specific end result desired.
Additionally, one may use a different color dye in the second dye station from that used in the first dye station. Whether or not this is done will depend on the final heather effect desired.
FIG. 4 is a photograph of tow sheet 24 showing side E after it has emerged from dye station 40. In this particular case, a print roll was utilized in dye station 40 which also had spiral ribs similar to those of print roll 28 at the first dye station although the width of the raised portions was less than that of those of roll 28 and the pitch was opposite so that a crisscross pattern between the imprint on side B and the imprint on side E was obtained. Again, of course, the rolls in print station 40 are adjusted appropriately so as to assure substantial penetration of the dyestuff transferred onto side E from pad roll 46.
After proceeding through dye station 40, the sheet of tow is transferred over rolls 54 and through collector 56, which is generally a funnel, to reform the sheet into a rope. The rope of reformed tow is designated as 58. It then traverses around change of direction rolls 60 and through placement rolls 62 which are merely opposing rolls having a slot therebetween which are attached to beam 64 which moves back and forth in the direction indicated by arrow H so as to direct the rope back and forth into container 66. This rope retrieval system is conventional in the art and is used merely for uniformly disposing the rope into container 66. It is noted that container 66 is on dolly system designated as 68 which, as roll 62 move back and forth in the direction of double arrow H, moves perpendicular to that direction so as to assure a uniform disposition of the rope, both widthwise and lengthwise, into the container.
Since generally the length of tow thus treated will be much greater than can fit on one container, as is conventional in treatment of textile fabrics in rope 4, when one container is full, additional containers are then placed onto the dolly to receive the further processed tow although the rope is never cut after the entire run is treated, the containers may be suitably transferred to the appropriate dye fixation, washing and drying equipment as is conventional in the art for the particular type of dyestuff and type of fabric being treated.
The amount of dye coverage of the tow, generally referred to as percentage of coverage (this percentage can be either lengthwise of the sheet or of the individual fibers, since the percentage would be equivalent in either case) is controlled by four factors:
(1) by the width and number of ribs on the print roll;
(2) by the pressure of the print roll against the second covered roll; and
(3) by the pressure of the dye transfer roll against the second covered roll; and
(4) by the concentration of the dyestuff paste.
It is, of course, not desired to completely cover all of portions of each of the fibers of the tow with the dye, but rather to obtain somewhat less than 100% coverage. Thus, these factors should be selected to achieve a coverage of from about 10 to 95% of the surface of the fibers in the tow. Preferably the amount of coverage is from 12 to 85%. However, it is clear that much of the adjustment depends on the actual end product which is desired and this would initially be set before starting the actual processing run by making small test samples and adjusting appropriately. Such adjustment would be within the skill of the artisan operating the process.
Referring now to FIG. 2, a diagram representation of a series of fibers selected from tow colored by the present process are shown. The representation of the fibers is greatly magnified in order to show the intermittent spacing of the colored portions which are designated as X as distinguished from the uncolored portions designated as Y. When the individual fibers of the tow are actually viewed under magnification (about 5-10×), it is seen that the fibers along the length possess intermittent portions of colored areas and uncolored white areas which is the original color of the tow as it is received prior to treating with the present process. The length of the colored portions will vary somewhat since it will be appreciated that the sheet of tow which is being processed is quite uneven and the control over the intermittent spacing is not exact. Nevertheless, the colored areas will be intermittently broken by white areas and the amount of such intermittent spacing will further depend on the particular amount of coverage for which the process was initially set.
It is further noted that the colors of the various X portions may vary from one to another if, in the original process, the color of the dye in one dye station was different from that of another. The ultimate step in treating the dyed tow will be a blending operation and consequently the final color obtained will be an appropriate blend of the uncolored or white portion of the tow, and the various colored portions whether they be all the same color or different colors. The important aspect, however, of the tow product as it emerges from the present process is the fact that it remains in the form of continuous filaments as opposed to sliver formed from staple. It is because of this that the subsequent processing steps are simplified.
What is important, however, is the fact that since the individual pieces of staple formed from the dyed tow each possess splasches of color as opposed to being either completely colored or uncolored, the ultimate product possesses significantly greater homogeniety as compared with products produced by prior art processes.
As will be further seen, it is possible in the present process to include additional dye stations other than the two shown although from a commercial point of view it would generally appear to be less desirable since at come point combining so many colors or imprints would lead to disadvantages in the color desired by the ultimate blending. For most commercial purposes and colors of the heater product which would normally be desired, two dye stations would be sufficient.
It will also be further seen with respect to the points and rolls at which pressure may be applied at the dye stations that the pressure may be applied from other rolls, i.e., one may also utilize the dye transfer roll to apply additional pressure to the contact between the print roll and the pad roll and consequently a number of modifications of this type may be made. Also, of course, it is possible to make the print roll rather than the pad roll a driven roll although we have found it preferable to retain the pad roll as the driven roll in the system. Such variations are readily apparent to the skilled artisan.
Referring again to FIG. 1, the apparatus of the present invention comprises a means for spreading tow into a flattened sheet; a first means which constitutes the first dye station for applying and impregnating color to and into one side of the sheet in a predetermined design pattern; and a second means which constitutes the second dye station for applying and impregnating color to and into the other side of the sheet in a predetermined design pattern, which second means or second dye station is positioned subsequent to the first dye application means or dye station.
More particularly, both the first and second dye application stations comprise a print roll having raised portions on the surface thereof in the form of the desired design pattern; a second roll which is positioned opposite to the print roll and in rotatable contact therewith so as to create a space for feeding a flattened sheet of tow therebetween, the second roll having an absorbent outer covering thereon; means for driving at least one of the rolls and preferably the second roll and means for impregnating the covering with dye. The relationship of the print roll and second roll of the second dye station is opposite that of the corresponding rolls of the first application means for dye station.
The apparatus may further comprise means for adjusting the pressurized contact of the print roll against the second roll and the impregnation means may comprise a dye transfer roll which is partially immersed in a dye reservoir and which is in rotatable contact with the second roll. It is further possible and preferred that the dye transfer roll possess means for adjusting its pressure against the second or covered roll.
Additionally, it is noted that the present process and apparatus may be utilized to treat any type of synthetic continuous filament which can be embodied in tow form. Thus, typically, synthetic fibers such as nylon, polyester, acrylics, polyacetals, as well as many other known types of synthetic fibers can be treated. Understandably, the dye systems which would be utilized will depend on the particular type of synthetic fiber which is being treated as will the subsequent dye fixation, washing, drying, etc. steps. | A method is disclosed for applying color to continuous synthetic fibers in the form of tow comprising the steps of first spreading the tow into a flattened sheet, applying color in a first predetermined design pattern to one side of the sheet so as to impregnate the color into the depth of the sheet to a given depth, and then applying color in a second predetermined design pattern to the other side of the sheet so as to impregnate the color into the depth of the sheet from the other side. The thus treated tow is suitable for forming into blended yarn, commonly known as "heather". An apparatus is also disclosed for accomplishing the above treatment and continuous fibers in the form of tow having intermittent portions of said fibers colored are also disclosed. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to batteries and, more particularly, to intercell connectors for batteries.
In general, batteries comprise a housing containing multiple cells in an acid electrolyte. The housing is generally manufactured of a rubber or plastic material, and the cells are generally formed of lead and lead oxide plates. Each cell is physically separated from the adjacent cell within the housing by employing, for example, intersecting barrier walls spaced apart within the housing to form an individual cavity for each cell. The cells are electrically interconnected to provide the desired battery voltage, and a cover is provided which is attached to the top of the housing in a manner which is intended to seal the cells within their respective cavities.
To provide a reliable battery, it is necessary to prevent gases which develop within each cell during the operation of the battery from leaking into adjacent cells. In the construction of prior art batteries, it has been found that the intercell electrical connections provide a path for intercell gas leakage. This is particularly true when the batteries are subjected to thermal shock tests as required by many military specifications. Such shock testing tends to cause the materials used to interconnect and to seal the various cells to separate, producing voids which permit intercell gas leakage.
Accordingly, it is an object of the present invention to provide a new and improved battery.
It is another object of the present invention to provide a battery having improved intercell connectors which minimize intercell gas leakage.
It is yet another object of the present invention to provide an improved method of interconnecting cells of a battery.
SUMMARY OF THE INVENTION
The foregoing and other objectives of the invention are accomplished by providing a battery housing having intersecting vertical barrier walls which form multiple cavities within the housing. Each cavity has an opening defined by the top surface of the barrier walls, and a battery cell is mounted within each cavity.
Lead bars are provided which are formed into links which straddle the top of the barrier wall and electrically interconnect adjacent cells. Grooves are provided along the inner surfaces of each link adjacent the barrier wall, where each groove is substantially parallel to the top surface of said wall. The outer surfaces of each link are knurled.
A liquid sealant is applied to the portion of each link straddling the respective wall, whereby the sealant flows into the grooves under the force of capillary action and provides a gas tight seal in the space between the inner surface of each link and the respective barrier wall. The sealant also flows into the multiple indentations of the knurl and adheres to the outer surface of each link.
A cover is provided having intersecting recesses corresponding to the intersecting barrier walls of the housing. The cover is bonded to the housing using an adhesive such as epoxy resin, whereby the top surfaces of the barrier walls including the outer surfaces of the links are adhesively bonded within the recesses of the cover. The sealant adhering to the outer surface of each link provides a gas-tight seal between that outer surface and the adhesive.
Other objects, features and advantages of the invention will become apparent from a reading of the specification taken in conjunction with the drawings in which like reference numerals refer to like elements in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a battery housing employed in the present invention, showing the battery cells and interconnecting bars positioned within the housing;
FIG. 2 is a left side view in cross-section of FIG. 1, taken along the line 2--2 of FIG. 1, showing the position of one set of interconnecting bars in relation to a barrier wall in the housing of FIG. 1;
FIG. 3 is a side view of one of the interconnecting bars of FIG. 2, showing the side of the bar facing toward the barrier wall;
FIG. 4 is another side view of the interconnecting bar of FIG. 3, showing the side of the bar facing away from the barrier wall;
FIG. 5 is a perspective view, partially cut-away of the set of interconnecting bars of FIG. 2 after the bars have been heated to form a link;
FIG. 6 is a bottom view of a battery cover employed in the present invention;
FIG. 7 is a cross-sectional view of the cover of FIG. 6, taken along the line 7--7 of FIG. 6; and
FIG. 8 is a cross-sectional view showing the link of FIG. 5 after the battery cover has been assembled to the battery housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2 there is shown a battery housing 10 having interior vertical walls 12 which intersect to form six cavities 14. The housing may be formed of rubber or a plastic material such as polypropylene. Mounted within each cavity 14 is a battery cell 16. Each cell 16 is fastened within the housing 10 using epoxy 17 or other suitable adhesive. Projecting above each cell 16 is an L-shaped bar 18, preferably formed of lead. The bottom leg 20 of each bar 18 is electrically and mechanically connected to a terminal 22 of the respective cell, as shown in FIG. 2. Generally, the terminal 22 is also formed of lead, and the bar 18 may be attached to the terminal 22 by locally heating and melting together the respective parts.
As shown in FIGS. 1 and 2, the bars 18 are positioned in adjacent pairs on opposite sides of the walls 12. As described below, the top portions of adjacent pairs of bars 18 are heated and melted together to form an interconnecting link between adjacent cells. From the pattern of bars 18 shown in FIG. 1, it may be appreciated that the interconnecting links described above serve to electrically interconnect the six battery cells 16 in a series circuit. Terminal posts 24 and 26 are electrically connected to the negative and positive ends, respectively, of the series circuit, and serve as the output terminals of the battery.
FIG. 3 is a side view of one of the bars 18, showing side 28 of the bar 18 which faces the barrier wall 12 in the view of FIG. 2. A top portion 30 of the side 28 is tapered as shown in FIG. 2, and the ends 32 of the side 28 are chamfered as shown in FIG. 1. Generally triangular shaped grooves 34 are provided in the surface of the side 28. In a preferred embodiment, the grooves 34 are each approximately ten-thousandths of an inch wide and approximately ten-thousandths of an inch deep, and are spaced apart approximately one-hundred and twenty-five thousandths of an inch. The grooves 34 are parallel to each other and are substantially parallel to the top surface of the bar 18.
FIG. 4 is another side view of one of the bars 18, showing side 36 of the bar 18, which faces away from the barrier wall 12 in the view of FIG. 2. A portion of the surface of the side 36 is provided with a pattern of multiple indentations 38, which may be formed by knurling the surface, or by a similar operation.
To electrically interconnect the various cells 16, forms (not shown) are fitted over the top ends of the lead bars 18, and heat is applied to these ends. The top ends of the bars 18 melt and flow together over the top of the wall 12, forming an interconnecting link 40 which straddles the wall 12 as shown in FIG. 5.
To ensure that gases developed in one cell 16 cannot leak into adjacent cells, it is necessary to ensure a gas tight seal between the wall 12 and the sides 28 of the link 40. In the present invention, this is accomplished by applying a liquid sealant to the links 40 in such a manner that the sealant is drawn under the force of capillary action into the grooves 34 which are substantially parallel to the top surface of the wall 12. In a preferred embodiment, the battery housing 10, including the cells 16 and the formed links 40 is inverted and dipped into a shallow tray containing the sealant, whereby the portions of the links 40 including the grooves 34 and the knurls 38 are submerged in the sealant.
A sealant which has been found to be suitable for use in the present invention is a two part liquid mixture manufactured by Reliance Universal, Inc., Brea, Calif. The mixture consists of 10 parts by volume of a base material, part number 851-W018-3 and 1 part by volume of an activator, part number 853-CO18-164. The weight per gallon is approximately ten pounds for the base material and approximately eight pounds for the activator. The viscosity is approximately 60 K.U. @ 77° F. for the base material and is approximately Q-V (Gardner-Holt scale) for the activator.
It has been found that the grooves 34 act as capillaries and that the sealant is drawn into these grooves and hardens to form a reliable gas-tight seal between the sides 28 and the wall 12, as shown by the areas designated 41 in FIG. 8. The sealant also flows into the multiple indentations 38 and forms a strong bond to the sides 36 of the link 40, as shown by the areas designated 43 in FIG. 8.
To enclose the individual cells 16 within their respective cavities 14, a cover 42 is provided, as shown in FIGS. 6 and 7. The bottom surface of the cover 42 includes intersecting recesses 44 which correspond in position to the top surfaces of the intersecting barrier walls 12 of the housing 10 when the cover 42 is attached to the top of the housing 10. Widened portions 46 of the recesses 44 are provided in locations corresponding to the positions of the links 40.
In a preferred embodiment of the invention, the cover 42 is assembled to the housing 10 in the following manner. The cover 42 is placed on a flat surface with the bottom side facing upward. A liquid epoxy adhesive 48 is dispensed into the recesses 44. The housing 10, including the cells 16 and the links 40, is then inverted and placed over the cover 42. The top portions of the walls 12 and the links 40 are submerged in the epoxy 48 as shown in FIG. 8. When the epoxy 48 hardens, the sealant in the areas 43 acts to provide a reliable gas-tight seal between the sides 36 of the link 40 and the epoxy 48. In a preferred embodiment, the epoxy adhesive 48 is a two part mixture comprising equal parts of a resin and a hardener manufactured by Reliance Universal, Inc., Brea, Calif. The resin, Part Number 850-CO18-234, weighs approximately twelve pounds per gallon and has a maximum viscosity of 6500 CPS at 77° F. The hardener, Part Number 853-BO18-174, weighs approximately twelve pounds per gallon and has a maximum viscosity of 9000 CPS at 77° F.
In an alternate embodiment of the invention, after the links 40 are formed from the bars 18, they are chemically treated to remove surface oxides. The surface oxides may be removed from the lead links 40 using one of a number of chemical compounds such as hydrogen peroxide or chromic acid. The top portions of the walls 12 and the links 40 are then directly submerged in the epoxy 48 (previously dispensed into the recesses 44 of the cover 42) without applying any sealant in the areas 41 or 43 of the links 40.
It has been found that when the links 40 are treated to remove surface oxides, the epoxy 48 is able to flow into the grooves 34 by capillary action, and the epoxy 48 also is able to flow into and adhere to the multiple indentations 38 on the sides 36 of the link. Accordingly, in this embodiment, the epoxy 48 provides the seal between the sides 28 of the link 40 and the wall 12, as well as between the sides 36 of the link 40 and the walls of the widened portion 46 of the recesses 44.
While there has been shown and described preferred embodiments of the invention, it is to be understood that various other adaptations and modifications may be made within the spirit and scope of the invention. It is thus intended that the invention be limited in scope only by the appended claims. | An improved method of interconnecting cells in batteries is disclosed, where the cells are connected using lead links which straddle the walls separating the cells in the battery housing. Grooves are provided in the surfaces of the links which are adjacent the walls and multiple indentations are provided in the opposite surfaces of the links. The links are coated with a sealant which flows into the grooves under the force of capillary action and forms a gas tight seal between cells. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. under §119(e), to Provisional application number U.S. 61/867,319, filed on Aug. 19, 2013, which is incorporated by reference in its entirety and made part of this specification.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a water filtering device that fits over roof rain gutters, also known as gutter guards, that repels debris from entering the gutter while at the same time allowing rainwater to pass through the filter therefore preventing the gutter to become blocked.
[0003] Roof gutters or eaves troughs are narrow channels used to collect rainwater shed by roof systems in order to move the rainwater to a downspout for the purpose of either diverting the rainwater away from the structures' foundation to avoid water erosion and water damage, or to collect the rainwater for water harvesting. Generally, there are four categories of roof gutter guards; 1) devices that fit inside a gutter to prevent the blockage of water by the debris, 2) devices that fit over the gutter as with large holes (commonly referred to as screens or diamond hole or drilled hole devices) to block debris and allow water to flow through, 3) devices that fit over gutters with a solid cover and slots allowing debris to fall off while water surface tension pulls the water through a front slot, 4) devices that fit over the gutter with small holes (referred to as mesh or micromesh systems) to block debris and allow water to be pulled through by surface tension devices.
[0004] Regarding the mesh filtering type of roof gutter guard, the filtering material holes can be small enough to not allow water to pass freely through due to water's surface tension properties and molecular adhesion forces. Therefore to allow water to be pulled through the filtering material, the use of surface tension devices that touch or designed into the filtering mesh are used while still keeping out debris and leaves. Two such examples of prior art of a small hole filtering devices are U.S. Pat. No. 7,310,912 incorporated herein by reference, and U.S. Pat. No. 6,951,077 B1 incorporated herein by reference.
[0005] There exists unlimited combinations of roof types, roof styles, roof slopes, gutter types, gutter sizes, gutter guard materials, rainwater downpour rates, leaf sizes and shapes, debris sizes and shapes, and weather severity to name a good portion of factors that affect a gutter guard's performance. With known prior art on mesh based gutter guards, commonly used techniques to pull or draw water through the mesh utilizing frame rails, mesh designs, or material strips that touch the mesh from underneath that causes the surface tension and adhesion forces to be reduced which allows the water to be drawn through the mesh into the gutter.
[0006] There exists undesirable conditions with the current prior art on mesh based gutter guards which are 1. The mesh does a poor job in capturing the water during high flow conditions (like heavy rainfall and high pitch roof systems), 2. The support frames that suspend the mesh from underneath require holes or channels in greater size to allow water to pass thereby weakening the frame and causing it to bend, 3. The support frames contain horizontal surfaces that hold water and moisture that promote moss and algae growth which can cause blockage of the filtering mesh and therefore water runoff.
[0007] The present invention is a debris repelling filtering device (also known as a gutter guard) that provides improvements on existing prior art and associated products by 1) reducing the filtering media's water's tension and adhesion properties, 2) improved debris repelling technology, 3) improving frame strength and performance, 4) reducing moss and algae growth conditions, and 5) increased installation adaptability.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0008] FIG. 1 is a top down elevation view of the present invention.
[0009] FIG. 2 is a top angle view of a portion of the present invention as installed on as installed on a gutter and roof system.
[0010] FIG. 3 is a side view of the present invention using the flat wing as installed on gutter.
[0011] FIG. 4 is a side view of the present invention using the bend wing as installed on gutter.
[0012] FIG. 5 A is a front view detail on the filtering media raised ridges of present invention.
[0013] FIG. 5 B is a front view detail of the filtering media's raised ridge with an angled slope of the side wall.
[0014] FIG. 5 C is a front view detail of the filtering media's raised ridge with a vertical slope of the side wall.
[0015] FIG. 5 D is a front view detail of the filtering media raised ridge with a narrow distance between the raised ridges.
[0016] FIG. 5 E a is a front view detail of the filtering media raised ridge with a wide distance between the raised ridges.
[0017] Figured 6 is a side view of the filtering media of present invention.
[0018] Figured 7 is a top angle view of the filtering media installed on main body frame of present invention.
[0019] Figured 8 is the filter media top surface raised ridge surface design of present invention.
[0020] Figured 9 A is an exploded side view of the present invention.
[0021] Figured 9 B is a complete side view of the present invention.
[0022] Figured 10 is a side view of the flat wing design of present invention.
[0023] Figured 11 is a side view of the bend wing design of present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The objects for the present invention for the debris repelling media support system may be accomplished in the following manner: The present invention may have three components consisting of a main body frame ( 23 ), a filtering media ( 13 ), and one of several different widths rear wing ( 15 )( 16 ) attachments.
[0025] The main body frame is configured with a front lip connection plane area ( 20 ) for attaching the filtering media ( 13 ) and to allow for connection to the gutter surface ( 29 ). The frame contains a center recessed curved louver support area that supports the filter media, and the frame has a rear connection plane area ( 21 ) for attaching both the filtering media ( 13 ) and the rear wing attachment ( 18 ). The front lip connection plane area ( 20 ) is configured as a flat extended area that is designed to rest upon and attach to the gutter. The filtering media is attached to the front lip connection plane area ( 20 ), then the filter media ( 13 ) rests upon the top of the curved louvers ( 19 ), then the media is attached to the rear filter media connection plane area ( 36 ). The design of the attachment shelf that connects the filtering media to the main body connection plan ( 34 ) extends slightly over the front connection plane and the puts a slight downward pressure on the filtering media allows for the device to maintain a tight media fit over the entire curved louver support area ( 12 ).
[0026] In addition, when the rear wing section ( 16 ) is attached to rear screen connection plane area ( 21 ), the rear wing section extends slightly over the rear connection plane area ( 20 ) causing a slight downward pressure on the filtering media which allows for the device to maintain a tight media fit. The upward curved louver design ( 19 ) allows for upward force to hold the filtering media ( 13 ) in a tight configuration and also repels downward forces on the frame and filtering media. The louver design is a vertical upward curved louver ( 19 ) that produces a ridged support frame, having little horizontal surfaces for water to catch upon, and having an unobstructed path for rainwater to flow from the filtering media into the gutter.
[0027] The described main body frame ( 23 ) on this present invention is made from a one piece design of either folded material or molded material. The curved louvers arise from a supporting shelf that is recessed below the filtering mesh to allow for the louver top edge height ( 43 ) to face upward and on the same plane as the both the front ( 42 ) and rear ( 43 ) media connection plane. The louver ( 12 ) is curved upward to produce an arch-like effect on the filtering media with the peak of the curve ( 19 ) in the center of the top of the louver. The main body frame ( 23 ) is designed to accept a rear wing attachment of different designs and lengths at the rear media connection plane area ( 36 ).
[0028] The present invention consists of a filtering media ( 13 ) component the attaches to the main body frame ( 23 ) and is supported underneath by the curved louvers ( 12 ). The filtering media's top surface( 48 ) is shaped with many raised ridges ( 14 ) that run from front ( 46 ) to rear ( 47 ) and that have a curved S-shape design ( 49 ) in which the ridges are equal distance from each other ( 50 ) and also parallel ( 44 ) as the S-shape is viewed from side to side ( 51 ). The raised ridges ( 14 ) have both an angle upward ( 52 ) side and a rounded top ( 53 ) appearance.
[0029] The filtering media is supported by the curved louvers that touches the underneath of the filter media in multiple places. The design of the S-shape pattern ( 49 ) on the filter media crosses the vertical louvers in a horizontal-like directions therefore causing a left to right flow of rainwater. The raised ridges' tops ( 53 )( 14 ) are in sufficient height to allow for leafs and debris to be suspended above the filtering media that causes rainwater to flow underneath the debris and into the media. The raised ridges are in close enough proximity to each other to allow for the suspended debris not to interfere with the media filtering of the rainwater. The filtering media rests upon louvers ( 12 ) and is attached to the main body ( 23 ) at the front ( 42 ) and rear ( 41 ) connection plan in such a fashion that a slight downward force is placed up the filtering media resulting in a tight fit of the filter media.
[0030] The wing sections ( 15 )( 16 ) of the present invention is designed to attach to the main body frame in a permanent connection at the rear connection plane ( 36 ) of the main body frame ( 23 ). The different size wings allows for the present invention to be installed in multiple ways to the roof fascia ( 32 ) or roof deck system ( 28 ) that is required to accommodate the many different types of gutters and roofs. The wing can be designed in either a flat wing shape ( 16 ) or a bent wing shape ( 15 ) where each is attached to the main body in the same manner. The wing's attachment area ( 18 ), also described as the front of the wing, is configured to fit over the filtering media ( 13 ) and the main body rear connection plane area ( 36 ) and be connected in a permanent manner by crimping to the main body frame.
[0031] The wing rear area takes the configuration of either flat end ( 17 ) for bent end ( 38 ) and is used to secure the present invention to the roof system. The flat wing can be of different length from front to rear and contains a folded hem ( 17 ) at the rear. The bend wing can be of different length from front to rear and contains an upward bend ( 38 ) at the rear.
[0032] The present invention when installed on a standard gutter system keeps debris and leafs out of the gutter and allows rainwater (also known as water) to flow inside the gutter without the gutter becoming blocked by the debris. As the rainwater falls, it gets both the roof wet and the present invention's filtering media wet (also known as device) and thereby reducing the surface tension of the filtering media. Rainwater on the roof travels downward toward the gutter and comes in contact with the device, and as the water flows vertically across the filter media the waer goes thought device's filtering media more effectively due to the S-shape raised ridges and through the louvers that don't block or impede water flow.
[0033] During this time, the filtering media's raised S-shape media design ( 49 ) forces the water flow to break its vertical flow pattern into a non-vertical flow pattern, by directing the water path either in a left or right direction. This non-vertical flow pattern has three purposes, first it slows down the water flow to allow for increase time to allow the water to filter through the media, second it forces the vertical water flow to come in contact with the non-vertical direction side of the raised ridges allowing the forward velocity of the water to assist in drawing the water into the media, and third, by changing the water's vertical direction, the water is drawn across the top of the top of the curved louver supports that are underneath the media, which draws the water into the media. During this third event, the angle of which the water is flowing across the louver support is not perpendicular to the top of the louver, but at a continuous changing angle which increases the water siphoning effect into the filtering media. These three described events work together to achieve an increase flow siphoning effect and water flow through the filtering media during both light rain water flow and heavy rain water flow.
[0034] After the water enters the filtering media, it falls directly into the gutter without contacting the horizontal frame support louvers. The louvers act like thin bridges to support the screen and frame, while producing no horizontal surface for water to rest upon or build up on. The lack of a horizontal surface below the filtering media is an important design feature to prevent moss and algae build up. With no horizontal surface under the mesh to retain water, algae and moss growth will be reduced therefore increasing the effectiveness of the device over such current prior art designs which all have substantial horizontal surfaces under the filtering media.
[0035] The curved louver design assists in the ridge frame design by using a cantilever ( 37 ) approach to resist downward forces on the device. The downward forces put pressure on the device to bend or collapse, mostly by the roof weight resting upon the back of the device or by heavy debris falling on the device. The cantilever louver design ( 37 ) resists the downward force and therefore can support a heavier roof system, like Spanish tile or concrete tile, or extreme pressures on the device caused by a high pitched roof system such as 12/12 pitch roof with slate tiles or wood shakes. This resistance by the cantilever effect of the curved louver causes the device's filtering media to remain tight against the main body frame, which is important to not allow the filtering media to loose contact with the underlying frame. Should this occur, the filtering effect of the media is reduced due to the loss of the siphoning effect caused by the underlying frame no longer able to contact the underneath of the filtering media. This bending of frame and subsequent loss of contact between the media and the frame caused by downward forces does not occur in the present invention, but does occur in other such current prior art designs which frames do bend under modest downward force. | A gutter filtering device constructed to be mounted on top of a gutter opening and to extend from the front to the rear, and to attach to the front lip of the gutter. The gutter filtering device comprises a main body frame portion supporting a filtering media, a front mounting portion and a rear wing mounting portion. The main body frame portion is comprised of louvers that supports and holds a filtering media. The front mounting portion comprises a bending of the main body frame that folds over and crimps to the front end of the filtering media. The rear mounting portion comprises a separate rear wing folded over and crimpled to rear portion of the main body frame. The filtering media's top surface is shaped with many front to rear raised ridges in an repeating S-shape pattern that are parallel and form a consistent pattern from left to right. | 4 |
[0001] This application is a divisional application of our allowed and copending U.S. patent application with the Ser. No. 11/111,085, which was filed Apr. 20, 2005 which claims the benefit of U.S. provisional patent application Ser. No. 60/564,905, which was filed Apr. 23, 2004, both of which are incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] Water treatment, especially as it relates to removal and destruction of perchlorate.
BACKGROUND OF THE INVENTION
[0003] Excessive concentrations of perchlorate in the environment, and especially in water consumed by human is highly problematic as perchlorate is known to interfere with iodide uptake into the thyroid gland. Dysregulation of iodide uptake is often manifested in disruption of thyroid functions, leading to several problems, including impaired regulation of energy metabolism, problems associated with development of fetus and young children, and in some cases even promotion of tumor growth. Despite the known dangers of perchlorate, California has currently no established drinking water standard or maximum contaminant level (MCL) for perchlorate. Instead, the department of health and safety (DHS) refers to an action level for perchlorate of 6 micrograms per liter (μg/L), which is expected to become the MCL.
[0004] It is well known in the art to capture perchlorate from potable water using an anion exchange resin. However, resins are expensive and typically only concentrate and transfer the problem from the water source to the eluent. Moreover, many anion exchange resins will capture other anions, including sulfate, nitrate, and bicarbonate. To circumvent non-specific binding of other anions, perchlorate specific anion exchange resins may be used. For example, suitable anion exchange resins include SYBRON™ SR-6 and 7, LEWITT™ 6362, PUROLITE™ A 520E, A 530 E, A 600 E and A 850 E or Rohm & Haas' AMBERLITE™ PWA 2 and IMAC 555 HP.
[0005] Despite the relatively high selectivity of certain resins towards perchlorate, various difficulties nevertheless remain. Among other things, competing anions are often present in 100- to 1000-fold (and even higher) molar excess, and will therefore still capture substantial quantities of non-perchlorate anions. Consequently, most of these resins cannot be effectively regenerated by simple methods such as brine or caustic treatments, but require relatively cumbersome regeneration methods (e.g., high temperature and pressure treatment with tetrachloroferrate as described in U.S. Pat. No. 6,448,299 and U.S. Pat. Appl. 2003/0222031). Other methods, such as on-column destruction of perchlorate by an aqueous solution of titanium-(III)-oxalate complexes require addition of alcohols to accelerate the perchlorate destruction reaction, as described in U.S. Pat. No. 6,358,396. The use of titanium (III) to reduce perchlorate to chloride was also reported by Cope et al., J. Chem. Soc. A; 301 (1967), and again by Lui et al., Inorg. Chem. 23, 3418, (1984). Though attractive at first sight, such methods typically fail to remove sulfate and bicarbonate from the resin, as these methods will only reduce perchlorate to chloride. Thus, as neither carbonate, bicarbonate, nor sulfate are reducible with titanium (III), the exchange medium requires additional regeneration by alternative techniques to remove carbonate, bicarbonate, sulfate, and nitrate. Furthermore, the '396 patent teaches that organic chelating agents (e.g., oxalate) are necessary to stabilize the titanium (IV) and prevent hydrolysis to titanium dioxide. Consequently, such methods are of limited commercial value due to the relatively low concentrations of titanium (III) species used for the reaction, and the slow rate of reduction even at relatively high concentrations of perchlorate ions.
[0006] Electrochemical generation and regeneration of Ti (III) from Ti (IV) in sulfuric acid and methanesulfonic acid are described respectively by Bandlish in U.S. Pat. No. 5,266,173 and Harrison in U.S. Pat. Nos. 5,246,553, 5,409,581, and 5,679,235. In these patents, titanium (III) is used for the mediated electro-organic synthesis of aromatic amines and other compounds. Foller et al also describe in U.S. Pat. No. 5,250,162 the electrochemical generation of Ti (III) in the context of the manufacture of titanium dioxide.
[0007] Therefore, although numerous methods and configurations for perchlorate destruction are known in the art, all or almost all of them suffer from one or more disadvantages. Consequently, there is still a need to provide improved compositions, methods and devices for perchlorate destruction.
SUMMARY OF THE INVENTION
[0008] The inventors discovered that Ti (III) assisted perchlorate destruction can be significantly accelerated using methanesulfonic acid (and related acids that increase solubility of Ti (III)). Using such systems, perchlorate can be eluted from a resin using concentrated methanesulfonic acid containing Ti (IV) to form an eluent, which is then electrochemically reduced to Ti (III) that destroys perchlorate to chloride in a known reaction. It should be particularly appreciated that contemplated methods can be employed with both, non-selective anion exchange resins as well as with perchlorate selective ion exchange resins. In preferred aspects, and especially where non-selective anion exchange resins are used, the non-perchlorate anions are eluted with brine while perchlorate remains tightly bound, and the so partially regenerated resin is then treated with the optionally Ti(IV)-containing methanesulfonic acid, while perchlorate specific exchange resins may be directly eluted with the methanesulfonic acid.
[0009] It should be especially appreciated that contemplated methods, configurations, and/or devices provide numerous advantages. Among other things, the rate of reaction for perchlorate to chloride in methanesulfonic acid and/or related acids that increase solubility of Ti (III) is significantly higher as compared to other solvents. Moreover, the perchlorate destruction may be performed at ambient pressure, even without a heating step and/or addition of organic accelerants or chelators (e.g., oxalic acid, EDTA, etc.).
[0010] The inventors have further discovered that contemplated methods and devices can be used for processes in which perchlorate and nitrate are captured by ion exchange resins (e.g., PWA 2 and IMAC 555), and especially when both, perchlorate and nitrate, are present in potable or other waters that require treatment. In such processes, the ion exchange resin can be eluted and/or regenerated with an alkylsulfonic acid, and most preferably with methanesulfonic acid that additionally comprises one or more dissolved salts of titanium. Eluted nitrate will then rapidly react with titanium (III) to generate ammonia or an ammonium salt in the methanesulfonic acid, and periodic transfer of the anolyte from the anolyte compartment to the catholyte compartment will allow electrochemical destruction of any ammonia that may have built up in the catholyte compartment.
[0011] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention along with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 is a schematic of one exemplary configuration according to the inventive subject matter.
[0013] FIG. 2 is a graph depicting perchlorate concentrations in the effluent of a perchlorate selective ion exchange column in response to the following treatments (a) control—no treatment, (b) regeneration with TiOSO4, (c) regeneration with 3.7 M MSA and NaMS, (d) regeneration with 4.0 M sulfuric acid.
[0014] FIG. 3 is a graph depicting perchlorate concentrations in effluent during regeneration of a perchlorate selective resin.
[0015] FIG. 4 is a schematic of one exemplary configuration for the generation of titanium (III) ions according to the inventive subject matter.
[0016] FIG. 5 is a graph depicting perchlorate concentrations during reduction with titanium (III) dissolved in various media.
[0017] FIG. 6 is a graph depicting perchlorate concentrations during reaction with titanium (III) in the presence of 0.02 M oxalate ions.
[0018] FIG. 7 is a graph depicting the rate of perchlorate destruction with titanium (III) in various media.
[0019] FIG. 8 is a graph depicting the pseudo 1st order rate of reaction of FIG. 7 correcting for titanium (III) concentration in the respective media.
DETAILED DESCRIPTION
[0020] The inventors discovered that Ti (III)-assisted perchlorate destruction can be significantly accelerated using acids that increase solubility of titanium ions, and particularly using sulfamic acid and/or methanesulfonic acid (MSA). Such destruction has sufficiently fast kinetics to allow the reaction to be run at ambient conditions, and even in the presence of non-perchlorate ions. Still further, it is preferred that contemplated acids will allow facile elution of the perchlorate from the column (and/or in a less preferred aspect, on-column destruction).
[0021] In one exemplary aspect of the inventive subject matter, perchlorate is eluted from a resin that is specific for perchlorate. It should be recognized that in such methods the concentration of non-perchlorate anions is significant. As depicted in FIG. 1 , potable water (or wash solutions from contaminated soil, etc.) contaminated with perchlorate, sulfate, nitrate, and/or bicarbonate is fed via stream (1) through perchlorate specific exchange resin (A). Perchlorate is adsorbed onto the resin along with other anion species. Once the ion exchange resin has bound a predetermined quantity of perchlorate and/or other anionic species, or once the resin has exhausted perchlorate binding capacity, perchlorate ions begin to appear in the effluent (2) of the ion exchange column. At this point, the ion exchange column can be switched out of service (e.g., flow of potable water is stopped or the flow is fed to a second column), for example, by diverting stream (1) to a second ion exchange resin (not shown).
[0022] The Resin (A) is then regenerated by passing a relatively concentrated solution of MSA anions containing titanium (IV) ions via line 3, typically removing about 80% of the perchlorate adsorbed on to the ion exchange resin. The regenerant (eluent) is fed via line 4 to the cathode compartment of an electrochemical cell (B), that is divided by a separator (e.g., ion exchange membrane such as NAFION, or microporous or macroporous separators such as GORETEX; not shown). Once elution is completed, the ion exchange resin is rinsed with water from wash stream (7) to form waste stream and (8), and is then ready for service as perchlorate adsorber.
[0023] In electrochemical cell B, Ti (IV) ions are reduced to Ti (III), and the reduced solution is then transferred via line (5) to separate tank (C) where the perchlorate reacts with the so generated titanium (III) to produce chloride. Once the perchlorate concentration is sufficiently reduced, the MSA solution is ready for use as a regenerant of an ion exchange column (e.g., via recycling line (6)). It should be particularly noted that nitrate ions present in the regenerant solution will also be reduced by titanium (III) to ammonia.
[0024] Alternatively, in another exemplary aspect of the inventive subject matter, perchlorate is eluted from a resin that is non-specific for perchlorate (e.g., PUROLITE's A 520 E, or Rohm-Hass IMAC 555®. Such resins are nominally a nitrate selective resins, however exhibit a significantly greater affinity for perchlorate than nitrate. Therefore, it should be recognized that non-perchlorate anions can be eluted with a eluent that will not (or to a significantly lesser degree) elute the perchlorate from the resin. For example, brine can be employed to remove nitrate, sulfate, and/or bicarbonate.
[0025] With further reference to FIG. 1 and a non-specific resin, it is contemplated that once the anion exchange resin (A) is saturated with perchlorate, regeneration is performed with brine to remove nitrate, sulfate, bicarbonate, and other anions using brine lines 10 and 11. After brine elution, the resin A is further regenerated by passing a relatively concentrated solution of MSA anions containing titanium (IV) ions to remove perchlorate. Once more, about 80% of the perchlorate adsorbed on to the ion exchange resin can be removed using such procedure. The ion exchange, once rinsed with water via lines (7) and (8), is ready for service as a perchlorate absorber, and the MSA eluent is then processed as described above. With respect to the brine regeneration, it should be noted that there are numerous manners of regenerating brine known in the art, and all of those are contemplated suitable herein. However, especially preferred methods of brine regeneration are described in our U.S. provisional patent application with the Ser. Nos. 60/535,209, which was incorporated by reference into the priority application with the Ser. No. 60/564,905, which is also incorporated by reference herein.
[0026] Alternatively, it should be recognized that contemplated configurations and methods may also be implemented as a retrofit in an already existing ion exchange plant. Most typically, such plant will include a non-selective anion exchange resin to which perchlorate, nitrate, and other anions are bound. Upon regeneration with brine (or other eluent), the perchlorate and at least some of the nitrate and can be re-captured on a perchlorate selective resin (e.g., A 530 E, or PW2A, commercially available from Purolite or Rohm & Haas, respectively). Once bound, the perchlorate may then be eluted and/or destroyed using an acid that increases metal solubility, and most preferably a solution that comprises MSA, an MSA salt, sulfamic acid, and/or sulfuric acid, and that further includes Ti (III) and/or Ti (IV). Depending on the particular configuration and solution, the Ti (IV) may be electrochemically converted to Ti (III), which then destroys perchlorate to thereby produce chloride. The ion exchange resins may then be rinsed (e.g., with water that may be recovered), and the spent salts can then be concentrated.
[0027] Therefore, it should be recognized that an anion exchange resin (e.g., perchlorate specific or non-specific) to which perchlorate is bound can be regenerated with methanesulfonic acid and/or a methanesulfonic acid salt, which typically includes at least one of a Ti(IV) and a Ti (III) ion. Alternative MSA salts also include those comprising at least one of an alkali metal, an alkaline earth metal, and a transition metal. Viewed from another perspective, it should be recognized that the anion exchange resin to which perchlorate is bound may be regenerated by contacting the resin with at least one of an acid and a salt of the acid, wherein the acid increases solubility of a metal ion.
[0028] Of course, it should be recognized that the eluting acid need not be limited to MSA, and that numerous alternative acids also appropriate. For example, MSA may be modified such as to increase or decrease the pKa (e.g., via halogenation or alkylation of the methyl group), or soluble polymers having alkylsulfonic acid groups may be used. Still further alternative acids include relatively strong acids forming stable anions (e.g., sulfuric acid), and/or electrochemically relatively inert acids (e.g., sulfamic acid), and all reasonable combinations thereof. Furthermore, suitable acids may include inorganic anions to compete off the bound perchlorate, and/or include complexing agents. It should be noted that the preferred concentrations of the eluting acid is relatively high, and particularly preferred concentrations of MSA and/or sulfamic acid are at least 30% of saturation, more typically at least 50% of saturation, and most preferably between about 70% and 100% of saturation. Thus, and viewed from another perspective, suitable eluents will have at least 0.2M concentration of the eluting acid, more typically at least 0.5M, even more typically at least 1.0M, and most typically at least 1.5M (and higher, including 2M, 3M, 4M, 5M) concentration of the eluting acid. Depending on the particular concentration and other factors, the pH of the eluting solution will therefore be acidic (less than pH 5, and more typically less than pH 3, and most typically less than pH 1), and most commonly be in the range of between about 2 and −1.0, more typically between 1.0 and −1.0, and most typically between −0.5 and −1.0.
[0029] With respect to the titanium, it should be noted that the Ti (IV) may be added to the MSA at any time so long as at another time Ti (III) will react with the perchlorate to form a chloride anion. Thus, reduction of perchlorate may occur on the column, in the catholyte, and/or in a separate reaction vessel. Additionally, it should be recognized that shuttle redox compounds may be present if desired. It should further be recognized that at least in some instances the presence of chloride ions in the solution may reduce the rate of reduction of perchlorate. Consequently, it should be appreciated that chloride may be removed from the solution (e.g., periodically) by methods well known in the art. For example, chloride may be removed by passing the spent reductant solution through the anolyte of the electrochemically cell and converting the chloride ions to chlorine gas. Alternatively, in a less preferred aspect, chloride could be precipitated as an insoluble salt (e.g., by the addition of silver). On the other hand, as described in published U.S. Pat. App. No. 2003/0222031, which is incorporated by reference herein, perchlorate may also be eluted and then non-electrolytically destroyed using a iron catalyzed reaction in which ethanol is oxidized and perchlorate is reduced (preferably using a FeCl 3 /HCl solution).
[0030] Therefore, it should be especially appreciated that a method of perchlorate destruction includes a step of reacting the perchlorate in a solvent comprising titanium (III) and at least one of methanesulfonic acid and a methane sulfonic acid salt to thereby form chloride and at least some Ti (IV). Most typically, the Ti (III) is electrochemically generated from Ti (IV) using electrodes and configurations well known in the art. However, in alternative aspects, the electrochemical generation of Ti (III) may also be performed using a chemical reducing agent, which may or may not be generated on an electrode. Such Ti (III)-assisted perchlorate destruction is particularly advantageous as the solvent significantly accelerates the reaction as demonstrated below. Thus, viewed from yet another perspective, it should be recognized that perchlorate destruction using titanium (III) in solution can be accelerated by adding methanesulfonic acid, sulfuric, and/or sulfamic acid to the solution at a concentration effective to accelerate the perchlorate destruction.
EXAMPLES
Preparation of Ion Exchange Media ICA
[0031] Purolite® A-530E perchlorate selective ion exchange media was weighed into a 2.5 cm diameter 15 cm tall ion exchange column (e.g., Kontes™, Chromaflex™). For the following experiments, 20 g of media was used, resulting in a total bed depth of approximately 6 cm. The media was used as received with no preconditioning. Deionized water was poured onto the media to assist initial packing, and a layer of liquid was maintained over the media following initial packing. After loading, the media was split into two parts, equal by weight. The media was then designated ICA-1, ICA-2. The ICA-2 media was further subdivided into two equal parts which were designated ICA-2 and ICA-3. Media under test was reloaded into the column, while media reserved for later experiments was stored in a beaker of deionized water under ambient conditions.
[0032] Media: 20 g Purolite® 530E ion exchange resin; Media ID: ICA; Initial Perchlorate Load: 100 ppm. Approx 75.0 mg/g; Test 6-IC: Media: ICA-1, 10 g. Eluent: sodium methanesulphonate (NaMS)/methanesulfonic acid (MSA). In column, one-pass, 4.6 l. Test 7-IC: Media: ICA-1, 10 g. Eluent: Na-MS/MSA. In column, one pass, 1.9 l. Test 8-IC: Media: ICA-1, 10 g. Eluent: Ti3-MS/MSA. In column, recirculating, 5 hr. Test 9-IC: Media: ICA-1, 10 g. Eluent: Ti-4-OSO4/OH/MSA. In column, 1.15 l, 2 passes. The results are graphically depicted in FIG. 2 . Here, the first line (solid circles) refers to 3.7M MSA, 0.2M Na + , the second line (plus symbol) refers to TiOSO4, the third line (x-symbol) refers to Ti (III) methane sulfonate/MSA, and the fourth line (star symbol) refers to initial loading.
Preparation of Ion Exchange Media ICB
[0033] Purolite®A-530E perchlorate selective ion exchange media was weighed into a standard 2.5 cm diameter 15 cm tall ion exchange column (e.g., Kontes™, Chromaflex™). 40 g of media were used with a bed depth of approximately 12 cm. The media was used as received, with no preconditioning. de-ionized water was poured onto the media to assist the initial packing, and a layer of liquid was maintained over the media following the initial packing. After loading, the media was split into two parts, equal by weight. The media were then designated ICB-1, ICB-2. Media under test was re-loaded into the column, while media reserved for later experiments was stored in a beaker of DI water, under ambient conditions.
[0034] Media: 40 g Purolite® 530E ion exchange Resin; Media ID: ICB; Initial Perchlorate load: 100 ppm. Approx 60 mg/g; Test 1-ICB: Media ICB-1, 20 g. Eluent: TiOSO 4 /H 2 SO 4 . Re-circulating; overnight; Test 2-ICB: Media ICB-1, 20 g. Eluent: NaMS (0.2 M)/MSA.(3.7 M) In column, one pass, 4.2 l (Same 6-IC); Test 3-ICB: Media ICB-1, 20 g. Eluent H2SO4.(4 M) In column, one pass, 4.7 l. The results are graphically depicted in FIG. 3 , and the figure legend denotes the respective conditions.
Exemplary Systems for Ti (IV) Reduction and Perchlorate Destruction
[0035] Methanesulfonic acid: A solution of methanesulfonic acid (70%) 100 ml, 28.17 g of titanium oxysulfate, and 100 ml of water were ion exchanged and stirred at a temperature 70° C. overnight until all the solid had dissolved and the solution became clear. This solution of Ti (IV) was introduced into the cathode compartment of an electrochemical cell as shown in FIG. 4 . Here, membrane F was Nafion® 350, the cathode E a high surface area glassy carbon felt, and the anode D a Platinized titanium mesh. The anolyte in this cell was 20% methanesulfonic acid. Catholyte and anolyte were circulated past the electrodes using respective catholyte and anolyte tanks A and B, respectively, and pumps G and H.
[0036] A current of 2 Amps (570 A/m 2 ) was passed until, according to theory, 100% of the Ti (IV) was converted into Ti (III). The final concentration of the catholyte solution was 0.51 M of Ti (III) and 35% methanesulfonic acid. To this solution, 0.2466 g perchloric acid was added to give a solution containing 1.233 g/l perchlorate. The solution was agitated at room temperature and the progress of the reaction was followed by monitoring the perchlorate concentration as depicted in FIG. 5 . At the end of 70.5 hours, residual perchlorate concentration was 585 ppb, equivalent to a 99.95% destruction. Throughout the reduction of perchlorate and of titanium (III) air was excluded by sparging with nitrogen
[0037] Sulfuric Acid: A solution of sulfuric acid (98%) 40 ml, a quantity 29.3 g of titanium oxysulfate-sulfuric acid powder TiOSO4*H2SO4 and 60 mls of water were ion exchanged and stirred overnight until all the solid had dissolved. This solution of Ti (IV) was introduced into the cathode compartment of an electrochemical cell FIG. 4 . The membrane was Nafion 350, the cathode a high surface area glassy carbon felt and the anode a Platinized titanium mesh. The anolyte in this cell was 20% sulfuric acid. A current of 2 Amps were passed until according to theory all the titanium (IV) was converted into Ti(III). The final concentration of the solution was 0.445 M of Ti(III) and 40% sulfuric acid. To this solution 0.123 g perchloric acid was added to give a solution containing 1.23 g/l perchlorate. The solution was agitated at room temperature, the progress of the reaction was followed by monitoring the concentration as depicted in FIG. 5 . At the end of 93 hours the residual concentration was 80 ppm a perchlorate destruction of 94%. Throughout the reduction of perchlorate and titanium (III), air was excluded by sparging with nitrogen.
[0038] Ti (III) MSA: A solution of methanesulfonic acid (70%) 350 ml, a quantity 10 g of Ti metal powder and 350 ml water were ion exchanged and heated at 65° C. for several days to produce a solution of 0.17 M Ti (III) methanesulfonate in 35% MSA. To a 100 ml aliquot of this solution 0.087 g of perchloric acid was added to give a solution containing 0.87 g/l perchlorate. The solution was agitated at room temperature and the progress of the reaction was followed by monitoring the concentration as depicted in FIG. 5 . At the end of 69 hours the residual concentration was 126 ppb a 99.99% perchlorate destruction. Throughout the reduction of perchlorate and titanium (III), air was excluded by sparging with nitrogen
Ti (III)-Assisted Nitrate Destruction
[0039] A solution was prepared by dissolving 0.1009 g NaNO 3 and 12.41 g HCl into water in a volumetric flask marked at 50 mL. The solution was transferred to a 125 mL dark glass bottle and left tightly capped. Subsequently 11.47 g TiCl 3 was added (volume about 9.6 mL) to bring the total volume to approximately 60 mL. The rate of disappearance of nitrate with time was monitored by taking 1000 microliter samples and quenching them with 100 microliter of 30% H 2 O 2 which reacts rapidly with the titanium (III). Care was taken to keep the reaction vessel tightly capped when samples were not being taken, and samples were taken in such a way as to minimize as much as possible the exposure of the contents to air. Samples were analyzed via gradient separation using an hydroxide eluent on the IC (AS11 column), with UV detection at 210 nm. Virtually all the nitrate was destroyed within 6 hours as shown in the table below.
[0000]
TIME (HR)
PPM AS NO 3
0
950
2
105
4
45
6
23
23
15
Comparative Example 1
[0040] To a solution of 0.2 M oxalic acid 0.25 M TiCl 3 was added. This solution was split in three equal parts to the second and third parts ethanol was added at a concentration of 25 and 50% respectively. To each of them 0.1 M ClO 4 was added. The progress of the reactions was followed by monitoring the perchlorate concentration. The respective destruction for these three conditions were 21, 20, and 18% after 26 hours at a rate of 0.75, 0.74, and 0.067 g/l/hr as depicted in FIG. 6 .
Comparative Example 2
[0041] To a solution of 0.2 M oxalic acid 0.25 M TiCl3 was added and 1 M HCl. To each of them 0.02 M ClO4 was added. The progress of the reactions was followed by monitoring concentration. As can be seen from FIG. 6 , the addition of ethanol to the solution of titanium (III) chloride and oxalic acid the reaction rate is comparatively slow when compared with the use of Titanium (III) MSA at a much lower and realistic concentration of perchlorate in solution. In comparative example 2 the perchlorate concentration is 0.02 M and again, as depicted in FIG. 5 , the rate of perchlorate destruction is much slower than in the examples above where methanesulfonic acid is the dissolving species for titanium.
[0042] The rate of reaction is best seen as a function of perchlorate concentration, as is shown in FIG. 7 , and by normalizing the results for initial Ti (III) concentration as shown in FIG. 8 . The fastest rate of reaction, once the titanium concentration is compensated for, is that of the experiment in which the counter ion to the titanium (III) is the methanesulfonate anion (as opposed to a mixture of sulfate and methanesulfonate ion). It should, however be noted that the fastest rates of perchlorate destruction are observed when perchlorate is destroyed with titanium (III) in methanesulfonic acid whether or not it is ion exchanged with sulfuric acid.
[0043] Thus, it should be recognized that the inventors discovered a method of regenerating an ion exchange resin (e.g., perchlorate selective ion exchange resin) to which perchlorate is bound, wherein the resin is contacted with a regenerant comprising methanesulfonic acid and titanium (IV). Optionally, the regenerant may also include sulfamic acid and/or sulfuric acid. In another step, the Ti (IV) in the regenerant is electrochemically reduced to Ti (III), and in still a further step, reduction of the perchlorate to chloride is performed using the Ti (III), wherein the reduction may be performed in a chemical reactor. The ion exchange resin is then rinsed with a rinse fluid to complete regeneration of the ion exchange resin. Where desirable, sodium chloride brine may be passed through the ion exchange resin to thereby convert the ion exchange resin from the methanesulfonate form to the chloride form.
[0044] Alternatively, the resin may be also be contacted with a regenerant comprising Ti (IV) methanesulfonate salts and Ti (III) methanesulfonate salts to thereby elute the perchlorate, wherein at least part of the perchlorate is reduced by the titanium (III) in the regenerant. In a further step, the Ti (IV) in the regenerant is electrochemically converted to Ti (III). Optionally, the anion exchange resin may then be rinsed with water (which may be recovered), and the Ti salts and/or brine salts may be concentrated.
[0045] Thus, specific embodiments and applications of perchlorate destruction from water and other sources have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Furthermore, where a definition or use of a term in a reference, which is incorporated by reference herein is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. | Perchlorate is removed and effectively destroyed in devices and methods that employ a eluting solvent in which the anion of an acid solubilizes Ti (III), which may be electrochemically generated or added in situ. Using such solvents, destruction of perchlorate is unexpectedly and several orders of magnitude faster than using solvents without solubilizing acids. In most preferred aspects, the solubilizing acid is methane sulfonic acid and/or sulfamic acid, and Ti (III) is electrochemically generated. Perchlorate destruction will then result in formation of Ti (IV), which may be present in the eluent in a subsequent elution. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application Ser. No. 60/686,948 filed on Jun. 1, 2005, which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was made in part with Government support under National Institutes of Health Grant GM031001 and General Clinical Research Center Grant M01 RR00833. The Government has certain rights in the invention.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
The Compact Disc Appendix (CD Appendix), which is a part of the present disclosure, includes files designated “Table 1” having 294 pages and a size of 953 KB, “Table 2” having 299 pages and a size of 969 KB, “Table 3” having 145 pages and a size of 470 KB, “Table 4” having 299 pages and a size of 970 KB, and “Table 5” having 299 pages and a size of 969 KB. The tables, each having over 50 pages, comprise the atomic coordinates of exemplary crystal structures. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner of that material has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright. The subject matter of the CD Appendix is incorporated herein by reference in its entirety. 00001
LENGTHY TABLES
The patent contains a lengthy table section. A copy of the table is available in electronic form from the USPTO web site (http://seqdata.uspto.gov/?pageRequest=docDetail&DocID=US07953557B2). An electronic copy of the table will also be available from the USPTO upon request and payment of the fee set forth in 37 CFR 1.19(b)(3).
The Sequence Listing, which is a part of the present disclosure, includes a computer readable form and a written sequence listing comprising nucleotide and amino acid sequences of the present invention. The sequence listing information recorded in computer readable form is identical to the written sequence listing. The subject matter of the Sequence Listing is incorporated herein by reference in its entirety.
FIELD
The present invention relates to three dimensional structures and models of cytochrome P450 2A6 complexed with various ligands, and uses thereof.
INTRODUCTION
Human cytochrome P450 2A6, a xenobiotic-metabolizing P450 monooxygenase, is the primary enzyme responsible for nicotine detoxification. Nicotine ( FIG. 1 ) is the primary addictive agent in tobacco products that contributes to the establishment and maintenance of tobacco dependence. Individual variation in cytochrome P450 2A6-mediated nicotine metabolism resulting from allelic differences can alter nicotine bioavailability and affect smoking behavior. Additionally, treatment of volunteers with the cytochrome P450 2A6 inhibitor methoxsalen (8-methoxypsoralen, FIG. 1 ) increases oral availability of nicotine and decreases smoking.
Cytochrome P450 2A6 oxidizes a number of relatively small substrate molecules, including pharmaceutical compounds such as coumarin (1,2-benzopyrone, FIG. 1 ), which is selectively oxidized to a 7-hydroxylated product, umbelliferone; (+)-cis-3,5-dimethyl-2-(3-pyridyl)thiazolidin-4-one hydrochloride (SM-12502); fadrozole; and losigamone. Additionally, cytochrome P450 2A6 catalyzes the conversion of the prodrug Tegafur to the antineoplastic agent, 5-fluorouracil.
Cytochrome P450 2A6 also activates tobacco-specific carcinogens such as (NNN) N′-nitrosonornicotine 4 and 4-(methyinitrosamino)-1-(3pyridyl)-1-butanone (NNK), converting them to mutagenic products. A recent study in the Japanese population demonstrated that individuals having at least one of several alleles encoding cytochrome P450 2A6 with diminished activity exhibited a significantly lower incidence of tobacco-related lung cancer. This effect was most pronounced in individuals who were homozygous for the 2A6*4 deletion allele. Additionally, an in vivo study demonstrated that inhibition of cytochrome P450 2A6 activity using the inhibitor methoxsalen allows nicotine levels to remain elevated while significantly more NNK is metabolized to an inactive NNAL glucuronide conjugate.
Diminished cytochrome P450 2A6 activity appears to correlate with a decrease in tobacco-related lung cancer without causing apparent adverse effects on drug metabolism. However, a detailed view of related conformational changes has remained unsolved. Thus, the development of useful reagents for treatment or diagnosis of disease has been hindered by lack of structural information of cytochrome P450s, and in particular cytochrome-ligand complexes. Therefore, there is a need in the art to elucidate the three dimensional structure and models of cytochrome-ligand complexes, and to use such structures and models in therapeutic strategies, such as drug design.
SUMMARY
Accordingly, the present inventors have developed methods for designing drugs which reduce inactivation rates of pharmaceutically active compounds which are inactivated by a cytochrome P450 such as a cytochrome P450 2A6. Similarly, the present inventors have developed methods for inhibiting activation of at least one procarcinogen. These methods, in various configurations, comprise selecting an inhibitor of cytochrome P450 2A6 by performing a structure based drug design using a three-dimensional structure determined for a crystal comprising cytochrome P450 2A6 complexed with a cytochrome P450 2A6 ligand; and contacting a sample or a subject comprising cytochrome P450 2A6 with the inhibitor. A subject can be, in some configurations, a human subject in need of treatment wherein the treatment involves reduction of inactivation rate of a pharmaceutically active compound, inhibiting activation of at least one procarcinogen, or a combination thereof. Furthermore, in various aspects, the contacting the subject with the inhibitor can comprise administering the inhibitor to the human subject. Some examples of pharmaceutically active compounds for which inactivation can be inhibited include, without limitation, 1,2-benzopyrone, halothane, letrozole, losigamone, (+)-cis-3,5-dimethyl-2-(3-pyridyl) thiazolidin-4-one hydrochloride (SM-12502), valproic acid, disulfiram, and 8-methoxypsoralen. Examples of procarcinogens whose activation can be inhibited include, without limitation, certain tobacco procarcinogens such as N′-nitrosonornicotine (NNN) and 4-(methyinitrosamino)-1-(3-pyridyl)-1-butanone (NNK).
In various configurations of the present teachings, the cytochrome P450 2A6 ligand comprised by a crystal can be a psoralen, such as 8-methoxypsoralen (methoxsalen). In certain alternative configurations, the ligand can be a coumarin, such as 1,2-benzopyrone. In addition, the selecting can comprise a) performing a structure-based drug design using a three-dimensional structure determined for a crystal of the cytochrome P450 2A6 to identify a candidate inhibitor; b) contacting the candidate inhibitor with a cytochrome P450 2A6; and c) detecting inhibition of at least one activity of the cytochrome P450 2A6. In various aspects of the present teachings, a cytochrome P450 2A6 can be a human cytochrome P450 2A6. In addition, in some configurations, a cytochrome P450 2A6 inhibitor can be an antibody directed against cytochrome P450 2A6, such as a monoclonal antibody directed against cytochrome P450 2A6.
In various aspects of the present teachings, the inventors have developed methods for designing a drug which interferes with an activity of a cytochrome P450 2A6. These methods comprise (a) providing on a digital computer a three-dimensional structure of a cytochrome P450 2A6-ligand complex comprising the cytochrome P450 2A6 and a ligand of the cytochrome P450 2A6; and (b) using software comprised by the digital computer to design a chemical compound which is predicted to bind to the cytochrome P450 2A6. These methods can further comprise (c) synthesizing or obtaining the chemical compound; and (d) evaluating the chemical compound for an ability to interfere with an activity of the cytochrome P450 2A6. In some configurations, the methods can further include using software comprised by the digital computer to design a chemical compound which not only is predicted to bind to cytochrome P450 2A6, but is also predicted not to bind to other cytochrome P450 proteins, such as, for example, cytochrome P450 2C8, cytochrome P450 2C9, and/or cytochrome P450 3A4.
In various configurations of these aspects, a cytochrome P450 2A6 can consist of an amino acid sequence as set forth in SEQ ID NO: 2, can consist essentially of an amino acid sequence as set forth in SEQ ID NO: 2, or can comprise an amino acid sequence as set forth in SEQ ID NO: 2. In various alternative configurations of these aspects, a cytochrome P450 2A6 can consist of an amino acid sequence as set forth in SEQ ID NO: 3, can consist essentially of an amino acid sequence as set forth in SEQ ID NO: 3, or can comprise an amino acid sequence as set forth in SEQ ID NO: 3.
In these aspects, a cytochrome P450 2A6 ligand can be a psoralen such as 8-methoxypsoralen, or a coumarin such as 1,2-benzopyrone. In addition, a cytochrome P450 2A6 ligand can be (5-(Pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide (Aldrithiol™). Furthermore, in these aspects, a chemical compound can be designed by computational interaction with reference to a three dimensional site of the structure of the cytochrome P450 2A6-ligand complex, wherein the three dimensional site comprises an amino acid selected from the group consisting of Phe107, Phe111, Phe118, Phe209, Phe480, Val117, Asn297, Ile 300, Gly301, Thr305, Ile366, Leu370 and a combination thereof.
In certain aspects of the present teachings, the present inventors have developed methods for generating a model of a three dimensional structure of a cytochrome P450 2A6-ligand complex. In these aspects, a method can comprise (a) providing an amino acid sequence of a reference cytochrome P450 family 2 polypeptide and an amino acid sequence of a target cytochrome P450 2A6 comprised by the cytochrome P450 2A6-ligand complex; (b) identifying structurally conserved regions shared between the reference cytochrome P450 family 2 amino acid sequence and the target cytochrome P450 2A6 amino acid sequence; and (c) assigning atomic coordinates from the conserved regions to the target cytochrome P450 2A6-ligand complex. The amino acid sequence of a cytochrome P450 2A6 in these aspects can be as described above. In these aspects, a target cytochrome P450 2A6-ligand complex can have a three dimensional structure described by atomic coordinates which substantially conform to atomic coordinates set forth in Table 1 (describing coordinates of a cytochrome P450 2A6 complexed with 8-methoxypsoralen) or in Table 2 (describing coordinates of a cytochrome P450 2A6 complexed with 1,2-benzopyrone). Additionally, a reference cytochrome P450 can be, in some configurations, a cytochrome P450 2C8 having a three dimensional structure described by atomic coordinates that substantially conform to atomic coordinates set forth in Table 3. In addition, a target cytochrome P450 2A6-ligand complex can have a three dimensional structure described by atomic coordinates which substantially conform to atomic coordinates set forth in Table 4 (describing coordinates of a cytochrome P450 2A6 complexed with (5-(Pyridin-3-yl) furan-2-yl) methanamine) or in Table 5 (describing coordinates of a cytochrome P450 2A6 complexed with 4,4′-dipyridyldisulfide).
In certain aspects of the present teachings, the present inventors have developed methods for determining a three dimensional structure of a target cytochrome P450 2A6-ligand complex. In various configurations of these aspects, a method can comprise (a) providing an amino acid sequence of a target cytochrome P450 2A6 (b) predicting the pattern of folding of the amino acid sequence in a three dimensional conformation using a fold recognition algorithm; and (c) comparing the pattern of folding of the target structure amino acid sequence with the three dimensional structure of a known cytochrome P450 family 2 polypeptide-ligand complex. The amino acid sequence of a target cytochrome P450 2A6 in these aspects can be as described above, and a known cytochrome P450 family 2 polypeptide-ligand complex can comprise a three dimensional structure described by atomic coordinates that substantially conform to atomic coordinates of cytochrome P450 2C8 as set forth in Table 3, or can be an amino acid sequence of a polypeptide selected from the group consisting of cytochrome P450 2C8, cytochrome P450 2A7 and cytochrome P450 2A13.
In various aspects of the present teachings, the present inventors disclose a crystal comprising a cytochrome P450 2A6 and a cytochrome P450 2A6 ligand. In certain configurations of these aspects, a cytochrome P450 2A6 ligand can be a psoralen such as 8-methoxypsoralen, and a crystal can comprise a space group P2 1 so as to form a unit cell of dimensions a=70.66 Å, b=159.03 Å, c=103.88 Å, and β=92.00. In an alternative configuration, a cytochrome P450 2A6 ligand can be a coumarin such as 1,2-benzopyrone, and a crystal can comprise a space group P2 1 so as to form a unit cell of dimensions a=70.62 Å, b=157.59 Å, c=103.54 Å, and β=92.25.
In other aspects of the present teachings, the inventors have developed a crystal comprising cytochrome P450 2A6 complexed with a cytochrome P450 2A6 ligand, wherein the crystal is sufficiently pure to determine atomic coordinates of the complex by X-ray diffraction to a resolution of about 2.05 Å. In some configurations of these aspects, the cytochrome P450 2A6 ligand can be 8-methoxypsoralen, 1,2-benzopyrone, (5-(Pyridin-3-yl) furan-2-yl) methanamine), or 4,4′-dipyridyldisulfide. In alternative configurations, the crystal can be sufficiently pure to determine atomic coordinates of the complex by X-ray diffraction to a resolution of about 1.90 Å. In some configurations of these aspects, the cytochrome P450 2A6 ligand can be 8-methoxypsoralen, 1,2-benzopyrone, (5-(Pyridin-3-yl) furan-2-yl) methanamine), or 4,4′-dipyridyidisulfide.
In some aspects of the present disclosure, the invention includes a therapeutic compound which inhibits tobacco carcinogen activation by cytochrome P450 2A6. In these aspects, a compound can be selected by a) performing a structure based drug design using a three-dimensional structure determined for a crystal comprising cytochrome P450 2A6 and a cytochrome P450 2A6 ligand, b) contacting a sample comprising cytochrome P450 2A6 with the compound, and c) detecting inhibition of at least one activity of the cytochrome P450 2A6. In some aspects, the activity of the cytochrome P450 2A6 can be activation of a tobacco carcinogen.
Certain aspects of the present teachings include a three dimensional computer image of the three dimensional structure of a cytochrome P450 2A6-ligand complex. In these aspects, a structure can substantially conform with the three dimensional coordinates listed in Table 1, Table 2, Table 4 or Table 5.
Certain aspects of the present teachings include a computer-readable medium encoded with a set of three dimensional coordinates as set forth in Table 1, Table 2, Table 4 or Table 5. In these aspects, the three dimensional coordinates set forth in Table 1, Table 2, Table 4 or Table 5 can be used in conjunction with a graphical display software program to create an electronic file that can be visualized on a computer capable of representing the electronic file as a three dimensional image.
Certain aspects of the present teachings include a computer-readable medium encoded with a set of three dimensional coordinates of a three dimensional structure which substantially conforms to the three dimensional coordinates represented in Table 1, Table 2, Table 4 or Table 5. In these aspects, using a graphical display software program, the set of three dimensional coordinates can be used to create an electronic file that can be visualized on a computer capable of representing said electronic file as a three dimensional image.
Some aspects of the present teachings disclose methods of forming a crystal comprising a cytochrome P450 2A subfamily member and a ligand of the cytochrome P450 2A subfamily member ligand. In various configurations, these methods can comprise forming a composition comprising the cytochrome P450 2A subfamily member, the ligand, water and a non-ionic detergent; and adding a solution comprising ammonium sulfate and a polyethylene glycol to the composition. In various configurations, the non-ionic detergent can be a polyoxyethylene non-ionic detergent, such as, without limitation, ANAPOE®-X405 non-ionic detergent. In various aspects, the cytochrome P450 2A subfamily member can be a cytochrome P450 2A6 and the cytochrome P450 2A subfamily member ligand can be a cytochrome P450 2A6 ligand. As described above, a ligand in these configurations can be a psoralen such as 8-methoxypsoralen, or a coumarin such as 1,2-benzopyrone.
In various aspects of the present teachings, the inventors have developed methods for promoting cessation of tobacco smoking. Methods of these aspects can comprise selecting an inhibitor of cytochrome P450 2A6 by performing a structure based drug design using a three-dimensional structure determined for a crystal comprising the cytochrome P450 2A6 and a cytochrome P450 2A6 ligand such as those described above, and administering an effective amount of the inhibitor to a human individual in need thereof. In various aspects, a method can further comprise administering nicotine to the individual. The administering nicotine can comprise administering nicotine to the individual orally. In various aspects, a method can further comprise a method for inhibiting activation of at least one tobacco procarcinogen. In these aspects, the administering an effective amount of the inhibitor can comprise administering an amount effective for both promoting cessation of tobacco smoking and inhibiting activation of at least one tobacco procarcinogen. In addition, in some configurations, the tobacco procarcinogen can be a carcinogen which can be activated by cytochrome P450 2A6, such as N′-nitrosonornicotine (NNN), 4-(methyinitrosamino)-1-(3pyridyl)-1-butanone (NNK) or a combination thereof. In certain aspects, the selecting can comprise a) performing a structure-based drug design using a three-dimensional structure determined for a crystal of the cytochrome P450 2A6 to identify a candidate inhibitor, b) contacting the candidate inhibitor with a cytochrome P450 2A6, and c) detecting inhibition of at least one activity of the cytochrome P450 2A6. Furthermore, in these and the other aspects described herein, the cytochrome P450 2A6 can be a human cytochrome P450 2A6.
These and other features, aspects and advantages of the present teachings will become better understood with reference to the following description, examples and appended claims.
DRAWINGS
FIG. 1 . Chemical structures of CYP2A6 ligands 1,2-benzopyrone, 8-methoxypsoralen, nicotine, (5-(Pyridin-3-yl) furan-2-yl) methanamine, and 4,4′-dipyridyldisulfide.
FIG. 2 . Two views of the overall fold of CYP2A6 (left) and cytochrome P450 2C8 (right).
FIG. 3 . Two views of Cα trace overlays of CYP2A6 (left) and cytochrome P450 2C8 (right).
FIG. 4 . Two wall-eyed stereo views of stabilizing interactions between CYP2A6 helix B′ and the helix F′ to helix G region.
FIG. 5 . Two views of the CYP2A6 active site cavity.
FIG. 6 . Wall-eyed stereo view of σA weighted 2|Fo|-|Fc| composite omit electron density map of the heme and coumarin.
FIG. 7 . Two wall-eyed stereo views of σA weighted 2|Fo|-|Fc| composite omit electron density maps of the heme and methoxsalen.
FIG. 8 . Two views showing the superposed structures of the coumarin (a) and methoxsalen (b) complexes of CYP2A6.
FIG. 9 . Two wall-eyed stereo views of the potential hydrogen bonding of Asn297 with coumarin, the polypeptide chain and a conserved water molecule bound in a turn following helix B′.
FIG. 10 . Two wall-eyed stereo views of interactions between cytochrome P450 2A6 and the heme prosthetic group.
FIG. 11 . σA weighted 2|Fo|-|Fc| omit electron density maps contoured at 1σ and rendered within 1.5 Å of the ligand for the complexes of CYP2A6 with (5-(Pyridin-3-yl) furan-2-yl) methanamine (left) and 4,4′-dipyridyidisulfide (ALDRITHIOL™) (right) bound in the active site.
FIG. 12 . 4,4′-dipyridyldisulfide (ALDRITHIOL™ (ALD)) interactions with CYP2A6.
DETAILED DESCRIPTION
The present teachings relate to the discovery of three-dimensional structures of cytochrome P450 2A6 (“CYP2A6”; human sequence having SEQ ID NO: 1) complexed with various ligands (each complex individually referred to as a “cytochrome P450 2A6-ligand complex” or a “Cytochrome-Ligand Complex”), models of such three-dimensional structures, a method of structure-based drug design using such structures, the compounds identified by such methods and the use of such compounds in therapeutic compositions. In particular, the present teachings relate to a novel crystal of CYP2A6 complexed with ligands coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine, and 4,4′-dipyridyldisulfide; methods of production of such crystals; three dimensional coordinates of such CYP2A6-ligand complexes; three dimensional structures of the CYP2A6-ligand complexes; and uses of such structure and models to derive other Cytochrome-Ligand Complex structures and in drug design strategies.
One aspect of the present teachings includes a model of a Cytochrome-Ligand Complex in which the model represents a three dimensional structure of a Cytochrome-Ligand Complex. Another aspect of the present teachings includes the three dimensional structure of a Cytochrome-Ligand Complex, such as the three dimensional structure of a Cytochrome-Ligand Complex which substantially conforms with the atomic coordinates represented in Table 1, Table 2, Table 4 or Table 5, corresponding to a CYP2A6-methoxsalen complex, a CYP2A6-coumarin complex, a CYP2A6-(5-(pyridin-3-yl) furan-2-yl) methanamine) complex, and a CYP2A6-(4,4′-dipyridyldisulfide) complex respectfully. In to the present teachings, the term “substantially conforms” refers to at least a portion of a three dimensional structure of a Cytochrome-Ligand Complex which is sufficiently spatially similar to at least a portion of a specified three dimensional configuration of a particular set of atomic coordinates (e.g., those represented by Table 1, Table 2, Table 4 or Table 5) to allow the three dimensional structure of a Cytochrome-Ligand Complex to be modeled or calculated using the particular set of atomic coordinates as a basis for determining the atomic coordinates defining the three dimensional configuration of a Cytochrome-Ligand Complex.
More particularly, a structure that substantially conforms to a given set of atomic coordinates is a structure wherein at least about 50% of such structure has an average root-mean-square deviation (RMSD) of less than about 1.8 Å for the backbone atoms in secondary structure elements in each domain, and in various aspects, less than about 1.25 Å for the backbone atoms in secondary structure elements in each domain, and, in various aspects less than about 1.0 Å, in other aspects less than about 0.75 Å, less than about 0.5 Å, and, less than about 0.25 Å for the backbone atoms in secondary structure elements in each domain. In one aspect of the present teachings, a structure that substantially conforms to a given set of atomic coordinates is a structure wherein at least about 75% of such structure has the recited average RMSD value, and in some aspects, at least about 90% of such structure has the recited average RMSD value, and in some aspects, about 100% of such structure has the recited average RMSD value. In particular, the above definition of “substantially conforms” can be extended to include atoms of amino acid side chains. As used herein, the phrase “common amino acid side chains” refers to amino acid side chains that are common to both the structure which substantially conforms to a given set of atomic coordinates and the structure that is actually represented by such atomic coordinates.
In another aspect of the present teachings, a three dimensional structure that substantially conforms to a given set of atomic coordinates is a structure wherein at least about 50% of the common amino acid side chains have an average RMSD of less than about 1.8 Å, and in various aspects, less than about 1.25 Å, and, in other aspects, less than about 1.0 Å, less than about 0.75 Å, less than about 0.5 Å, and less than about 0.25 Å. In one aspect of the present teachings, a structure that substantially conforms to a given set of atomic coordinates is a structure wherein at least about 75% of the common amino acid side chains have the recited average RMSD value, and in some aspects, at least about 90% of the common amino acid side chains have the recited average RMSD value, and in some aspects, about 100% of the common amino acid side chains have the recited average RMSD value.
A three dimensional structure of a Cytochrome-Ligand Complex which substantially conforms to a specified set of atomic coordinates can be modeled by a suitable modeling computer program such as MODELER (A. Sali and T. L. Blundell, J. Mol. Biol., vol. 234:779-815, 1993 as implemented in the INSIGHT II® software package (INSIGHT II®, available from ACCELERYS® (San Diego, Calif.)) and those software packages listed in the Examples, using information, for example, derived from the following data: (1) the amino acid sequence of the Cytochrome-Ligand Complex; (2) the amino acid sequence of the related portion(s) of the protein represented by the specified set of atomic coordinates having a three dimensional configuration; and, (3) the atomic coordinates of the specified three dimensional configuration. A three dimensional structure of a Cytochrome-Ligand Complex which substantially conforms to a specified set of atomic coordinates can also be calculated by a method such as molecular replacement, which is described in detail below.
A suitable three dimensional structure of the Cytochrome-Ligand Complex for use in modeling or calculating the three dimensional structure of another Cytochrome-Ligand Complex comprises the set of atomic coordinates represented in Table 1, Table 2, Table 4 or Table 5. The set of three dimensional coordinates set forth in Table 1, Table 2, Table 4 and Table 5 are represented in standard Protein Data Bank format. According to the present teachings, a Cytochrome-Ligand Complex has a three dimensional structure which substantially conforms to the set of atomic coordinates represented by Table 1, Table 2, Table 4 and/or Table 5. As used herein, a three dimensional structure can also be a most probable, or significant, fit with a set of atomic coordinates. According to the present teachings, a most probable or significant fit refers to the fit that a particular Cytochrome-Ligand Complex has with a set of atomic coordinates derived from that particular Cytochrome-Ligand Complex. Such atomic coordinates can be derived, for example, from the crystal structure of the protein such as the coordinates determined for the Cytochrome-Ligand Complex structure provided herein, or from a model of the structure of the protein. For example, the three dimensional structure of a monomeric or multimeric protein, including a naturally occurring or recombinantly produced cytochrome P450 protein, substantially conforms to and is a most probable fit, or significant fit, with the atomic coordinates of Table 1, Table 2, Table 4 and/or Table 5. The three dimensional crystal structure of the Cytochrome-Ligand Complex may comprise the atomic coordinates of Table 1, Table 2, Table 4 or Table 5. Also as an example, the three dimensional structure of another Cytochrome-Ligand Complex would be understood by one of skill in the art to substantially conform to the atomic coordinates of Table 1, Table 2, Table 4 and/or Table 5. This definition can be applied to the other cytochrome P450 proteins in a similar manner.
In various aspects of the present teachings, a structure of a Cytochrome-Ligand Complex substantially conforms to the atomic coordinates represented in Table 1, Table 2, Table 4 and/or Table 5. Such values as listed in Table 1, Table 2, Table 4 and/or Table 5 can be interpreted by one of skill in the art. In other aspects, a three dimensional structure of a Cytochrome-Ligand Complex substantially conforms to the three dimensional coordinates represented in Table 1, Table 2, Table 4 and/or Table 5. In other aspects, a three dimensional structure of a Cytochrome-Ligand Complex is a most probable fit with the three dimensional coordinates represented in Table 1, Table 2, Table 4 and/or Table 5. Methods to determine a substantially conforming and probable fit are within the expertise of skill in the art and are described herein in the Examples section.
A Cytochrome-Ligand Complex that has a three dimensional structure which substantially conforms to the atomic coordinates represented by Table 1, Table 2, Table 4 or Table 5 includes an cytochrome P450 protein having an amino acid sequence that is at least about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%,46%, 47%, 48%,49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% identical to an amino acid sequence of a eukaryotic CYP2A6 protein, in particular an amino acid sequence having SEQ ID NO: 2 or SEQ ID NO: 3, across the full-length of the CYP2A6 protein sequence. A sequence alignment program such as BLAST (available from the National Institutes of Health Internet web site) may be used by one of skill in the art to compare sequences of CYP2A6 protein to other cytochrome P450 proteins.
A three dimensional structure of any Cytochrome-Ligand Complex can be modeled using methods generally known in the art based on information obtained from analysis of a Cytochrome-Ligand Complex crystal, and from other Cytochrome-Ligand Complex structures which are derived from a Cytochrome-Ligand Complex crystal. The Examples section below discloses the production of a Cytochrome-Ligand Complex crystal, in particular CYP2A6 complexed with coumarin, CYP2A6 complexed with methoxsalen, CYP2A6 complexed with (5-(pyridin-3-yl) furan-2-yl) methanamine, CYP2A6 complexed with 4,4′-dipyridyidisulfide, as well as a model of a cytochrome P450 2A-ligand complex, in particular the three dimensional structure of CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide, using information obtained from analysis of a cytochrome P450 2A-ligand complex crystal. An aspect of the present teachings comprises using the three dimensional structure of a crystalline cytochrome P450 2-ligand complex to derive the three dimensional structure of another Cytochrome-Ligand Complex. Therefore, the crystalline CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide and the three dimensional structure of CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide permits one of ordinary skill in the art to now derive the three dimensional structure, and models thereof, of any cytochrome P450-ligand complex. The derivation of the structure of any Cytochrome-Ligand Complex can now be achieved even in the absence of having crystal structure data for such other Cytochrome-Ligand Complexes, and when the crystal structure of another Cytochrome-Ligand Complex is available, the modeling of the three dimensional structure of the new Cytochrome-Ligand Complex can be refined using the knowledge already gained from the Cytochrome-Ligand Complex structure.
In some configurations of the present teachings, the absence of crystal structure data for other Cytochrome-Ligand Complexes, the three dimensional structures of other Cytochrome-Ligand Complex can be modeled, taking into account differences in the amino acid sequence of the other Cytochrome-Ligand Complex. Moreover, the present teachings allow for structure-based drug design of compounds which affect the activity of virtually any cytochrome P450, particularly a CYP2 family member, more particularly a CYP2A subfamily member, and more particularly a CYP2A6 such as a human CYP2A6.
One aspect of the present teachings includes a three dimensional structure of a Cytochrome-Ligand Complex, in which the atomic coordinates of the Cytochrome-Ligand Complex are generated by a method comprising: (a) providing a Cytochrome P450 complexed with a ligand in crystalline form; (b) generating an electron-density map of the crystalline Cytochrome P450 complexed with the ligand; and (c) analyzing the electron-density map to produce the atomic coordinates. For example, the structure of human CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide are provided herein.
In some aspects, crystals of CYP2A6 in complex with coumarin can be prepared by mixing a protein solution comprising CYP 2A6, coumarin, and a non-ionic detergent with a crystallization solution comprising a polyethylene glycol polymer, a buffer, and ammonium sulfate. A high resolution data set can be collected from these crystals. Similarly, crystals of a CYP2A6-methoxsalen complex can be prepared by mixing a protein solution comprising CYP2A6, methoxsalen, and a non-ionic detergent with a crystallization solution comprising a polyethylene glycol polymer, a buffer, and ammonium sulfate. (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyldisulfide crystals can be prepared similarly. Crystals prepared by these methods can be used to generate initial datasets.
In various aspects of the present teachings, X-ray diffraction data for a CYP2A6 in complex with a coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyidisulfide can be collected on an individual crystal using methods well known to skilled artisans. In some configurations, initial data for the coumarin complex can be phased in the P2 1 space group by molecular replacement in AMoRe using a model of CYP2C8 (PDB Accession No.1 PQ2) in which non-equivalent side-chains are replaced with alanine residues. In some configurations, initial data for other complexes can be phased in the P2 1 space group by isomorphous replacement using a model of CYP2A6 (Table 2, Protein DataBank Accession No. 1Z10). For data refinement, four-fold NCS restraints can be applied to each of the monomers in the asymmetric unit. During later stages of refinement, NCS restraints can be released to allow for differences in each of the monomers. For example, the model for the initial coumarin complex can be further refined against data to about 2.65 Å using multiple rounds of torsion angle simulated annealing. In a final stage, isotropic individual B-factor refinement can be used. In some aspects of the invention, a model generated in this manner can be used to phase the data set for the high resolution coumarin complex, which can be further built and Used to phase a methoxsalen data set. In various aspects, models for the coumarin and methoxsalen complexes can be refined against data such as 2.05 Å and 1.90 Å data using multiple rounds of conjugant gradient least-squares minimization, torsion angle simulated annealing and isotropic individual B-factor refinement using a computer program such as CNS (Brunger, A. T. et al. Crystallography & NMR system: A new software suite for macromolecular structure determination. Acta Crystallogr. D. Biol. Crystallogr. 1998, 54 (Pt 5), 905-921). During the final stages of refinement of the coumarin and methoxsalen complexes, ligands, substrates and water molecules can be added. Multiple cycles of editing and adjustment of the model into σ A -weighted 2F o |-|f c |, 1|F o |-|f c | and 2F o |-|f c | composite omit maps can be performed using the graphics program O (Jones, T. A. and Kjeldgaard, M. Electron-Density Map Interpretation. Methods Enzymol. 1997, 277, 173-208). In some configurations, molecular graphics can be generated using a computer program such as PyMOL (available from DeLano Scientific, LLC (South San Francisco, Calif.; pymol.sourceforge.net). Probe accessible cavity volumes can be calculated with the aid of a computer program such as VOIDOO (Tan, Y. Z. et al. Competitive interactions between CYP2A6 and cytochrome P450 2E1 for NADPH-cytochrome P450 oxidoreductase in the microsomal membranes produced by a baculovirus expression system. Arch. Biochem. Biophys. 342, 82-91 (1997)). In these calculations, a probe radius such as 1.4 Å and grid spacing such as 0.33 Å can be used.
According to the present teachings, a three dimensional structure of the CYP2A6 protein complexed with 1,2-benzopyrone, 8-methoxypsoralen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide can be used to derive a model of the three dimensional structure of another Cytochrome-Ligand Complex (i.e., a structure to be modeled). As used herein, a “structure” of a protein refers to the components and the manner of arrangement of the components to constitute the protein. As used herein, the term “model” refers to a representation in a tangible medium of the three dimensional structure of a protein, polypeptide or peptide. For example, a model can be a representation of the three dimensional structure in an electronic file, on a computer screen, on a piece of paper (i.e., on a two dimensional medium), and/or as a ball-and-stick figure. Physical three-dimensional models are tangible and include, but are not limited to, stick models and space-filling models. The phrase “imaging the model on a computer screen” refers to the ability to express (or represent) and manipulate the model on a computer screen using appropriate computer hardware and software technology known to those skilled in the art. Such technology is available from a variety of sources including, for example, ACCELERYS® (San Diego, Calif.). The phrase “providing a picture of the model” refers to the ability to generate a “hard copy” of the model. Hard copies include both motion and still pictures. Computer screen images and pictures of the model can be visualized in a number of formats including space-filling representations, α-carbon traces, ribbon diagrams and electron density maps.
Suitable target Cytochrome-Ligand Complex structures to model using a method of the present teachings include any cytochrome P450 protein, polypeptide or peptide, including monomers and multimers of a cytochrome P450 protein that is substantially structurally related to a CYP2A6 protein complexed with coumarin or methoxsalen, e.g., 1,2-benzopyrone, 8-methoxypsoralen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide. In various aspects, a target Cytochrome-Ligand Complex structure that is substantially structurally related to a different Cytochrome-Ligand Complex can include a target Cytochrome-Ligand Complex structure having an amino acid sequence that is at least about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40%, 41%, 42%, 43%, 44%, 45%,46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% identical to an amino acid sequence of a eukaryotic CYP2A6 protein such as a human CYP2A6 protein, in particular an amino acid sequence comprising, consisting essentially of, or consisting of a sequence set forth herein as SEQ ID NO: 2 or SEQ ID NO: 3. In these configurations, a sequence alignment program such as BLAST (supra) can be used to aid in the analysis. In various aspects of the present teachings, target Cytochrome-Ligand Complex structures to model include proteins comprising amino acid sequences that are at least about 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%,88%, 89%,90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% identical to amino acid sequence SEQ ID NO: 2 or SEQ ID NO: 3 when comparing suitable regions of the sequence, such as the amino acid sequence for a ligand or substrate binding site of any one of the amino acid sequences, when using an alignment program such as BLAST (supra) to align the amino acid sequences.
In various configurations of the present teachings, a structure can be modeled using techniques generally described by, for example, Sali, Current Opinions in Biotechnology, vol. 6, pp. 437-451, 1995, and algorithms can be implemented in program packages such as Insight II, available from ACCELERYS® (San Diego, Calif.). Use of INSIGHT II® HOMOLOGY requires an alignment of an amino acid sequence of a known structure having a known three dimensional structure with an amino acid sequence of a target structure to be modeled. The alignment can be a pairwise alignment or a multiple sequence alignment including other related sequences (for example, using the method generally described by Rost, Meth. Enzymol., vol. 266, pp. 525-539, 1996) to improve accuracy. Structurally conserved regions can be identified by comparing related structural features, or by examining the degree of sequence identity between the known structure and the target structure. Certain coordinates for the target structure are assigned using known structures from the known structure. Coordinates for other regions of the target structure can be generated from fragments obtained from known structures such as those found in a resource such as the Protein Data Bank. Conformation of side chains of the target structure can be assigned with reference to what is sterically allowable and using a library of rotamers and their frequency of occurrence (as generally described in Ponder and Richards, J. Mol. Biol., vol.193, pp. 775-791, 1987). The resulting model of the target structure, can be refined by molecular mechanics to ensure that the model is chemically and conformationally reasonable.
Accordingly, one aspect of the present teachings is a method to derive a model of the three dimensional structure of a target cytochrome P450 2A-ligand complex structure, the method comprising the steps of: (a) providing an amino acid sequence of a Cytochrome-Ligand Complex and an amino acid sequence of a target ligand-complexed cytochrome P450; (b) identifying structurally conserved regions shared between the Cytochrome-Ligand Complex amino acid sequence and the target ligand-complexed cytochrome P450 amino acid sequence; (c) determining atomic coordinates for the target ligand-complexed cytochrome P450 by assigning said structurally conserved regions of the target ligand-complexed cytochrome P450 to a three dimensional structure using a three dimensional structure of a Cytochrome-Ligand Complex based on atomic coordinates that substantially conform to the atomic coordinates represented in Table 1 or Table 2, to derive a model of the three dimensional structure of the target ligand-complexed cytochrome P450 amino acid sequence. In one aspect, a model of the present teachings comprises a computer model. Generation of a computer model can, in some configurations, comprise electronically simulating structural assignments to derive a computer model of a three dimensional structure of a target ligand-complexed cytochrome P450 2A amino acid sequence.
Another aspect of the present teachings is a method to derive a computer model of the three dimensional structure of a target ligand-complexed cytochrome P450 2A structure for which a crystal has been produced (referred to herein as a “crystallized target structure”). A suitable method to produce such a model includes the method comprising molecular replacement. Methods of molecular replacement are generally known by those of skill in the art and are performed in a software program including, for example, X-PLOR available from ACCELERYS® (San Diego, Calif.). In various aspects, a crystallized target ligand-complexed cytochrome P450 structure useful in a method of molecular replacement according to the present teachings has an amino acid sequence that is at least about 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%,40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or 100% identical to the amino acid sequence of the search structure (e.g., CYP2A6), when the two amino acid sequences are compared using an alignment program such as BLAST (supra). A suitable search structure of the present teachings includes an Cytochrome-Ligand Complex having a three dimensional structure that substantially conforms with the atomic coordinates listed in Table 1, Table 2, Table 4 or Table 5.
Another aspect of the present teachings is a method for determining a three dimensional structure of a target Cytochrome-Ligand Complex. Such a method is useful for identifying structures that are related to the three dimensional structure of a Cytochrome-Ligand Complex based only on the three dimensional structure of the target structure. For example, the present method enables identification of structures that do not have high amino acid sequence identity with a CYP2A6 protein but share three dimensional structure similarities of a ligand-complexed CYP2A6. In various aspects of the present teachings, a method to determine a three dimensional structure of a target Cytochrome-Ligand Complex structure can comprise: (a) providing an amino acid sequence of a target structure, wherein the three dimensional structure of the target structure is not known; (b) analyzing the pattern of folding of the amino acid sequence in a three dimensional conformation by fold recognition; and (c) comparing the pattern of folding of the target structure amino acid sequence with the three dimensional structure of a Cytochrome-Ligand Complex to determine the three dimensional structure of the target structure, wherein the three dimensional structure of the Cytochrome-Ligand Complex substantially conforms to the atomic coordinates represented in Table 1, Table 2, Table 4 and/or Table 5. For example, methods of fold recognition can include the methods generally described in Jones, Curr. Opinion Struc. Biol., vol. 7, pp. 377-387, 1997. Such folding can be analyzed based on hydrophobic and/or hydrophilic properties of a target structure.
One aspect of the present teachings includes a three dimensional computer image of the three dimensional structure of a Cytochrome-Ligand Complex. In one aspect, a computer image is created to a structure which substantially conforms with the three dimensional coordinates listed in Table 1, Table 2, Table 4 and/or Table 5. A computer image of the present teachings can be produced using any suitable software program, including, but not limited to, PyMOL (supra). Suitable computer hardware useful for producing an image of the present teachings are known to those of skill in the art.
Another aspect of the present teachings relates to a computer-readable medium encoded with a set of three dimensional coordinates represented in Table 1, Table 2, Table 4 and/or Table 5, wherein, using a graphical display software program, the three dimensional coordinates create an electronic file that can be visualized on a computer capable of representing said electronic file as a three dimensional image. Yet another aspect of the present teachings relates to a computer-readable medium encoded with a set of three dimensional coordinates of a three dimensional structure which substantially conforms to the three dimensional coordinates represented in Table 1, Table 2, Table 4 and/or Table 5 wherein, using a graphical display software program, the set of three dimensional coordinates create an electronic file that can be visualized on a computer capable of representing said electronic file as a three dimensional image.
The present teachings also include a three dimensional model of the three dimensional structure of a target structure, such a three dimensional model being produced by the method comprising: (a) providing an amino acid sequences of an cytochrome P450 comprised by a Cytochrome-Ligand Complex and an amino acid sequence of a target Cytochrome-Ligand Complex structure; (b) identifying structurally conserved regions shared between the cytochrome P450 amino acid sequence and the amino acid sequence comprised by the target Cytochrome-Ligand Complex structure; (c) determining atomic coordinates for the target Cytochrome-Ligand Complex by assigning the structurally conserved regions of the target Cytochrome-Ligand Complex to a three dimensional structure using a three dimensional structure of the cytochrome P450 comprised by a Cytochrome-Ligand Complex based on atomic coordinates that substantially conform to the atomic coordinates represented in Table 1, Table 2, Table 4 and/or Table 5 to derive a model of the three dimensional structure of the target Cytochrome-Ligand Complex. In one aspect, the model comprises a computer model.
Any isolated cytochrome P450 protein can be used with the methods of the present teachings. An isolated cytochrome P450 protein can be isolated from its natural milieu or produced using recombinant DNA technology (e.g., polymerase chain reaction (PCR) amplification, cloning) or chemical synthesis. To produce recombinant cytochrome P450 protein, a nucleic acid molecule encoding cytochrome P450 protein can be inserted into any vector capable of delivering the nucleic acid molecule into a host cell. A nucleic acid molecule of the present teachings can encode any portion of a cytochrome P450 protein, in various aspects a full-length cytochrome P450 protein, and in various aspects a soluble form of cytochrome P450 protein (i.e., a form of cytochrome P450 protein capable of being secreted by a cell that produces such protein). A suitable nucleic acid molecule to include in a recombinant vector, and particularly in a recombinant molecule, includes a nucleic acid molecule encoding a protein having the amino acid sequence represented by SEQ ID NO: 2 or SEQ ID NO: 3.
A recombinant vector can be either RNA or DNA, either prokaryotic or eukaryotic, and typically is a virus or a plasmid. In various aspects, a nucleic acid molecule encoding an cytochrome P450 protein is inserted into a vector comprising an expression vector to form a recombinant molecule. As used herein, an expression vector is a DNA or RNA vector that is capable of transforming a host cell and of affecting expression of a specified nucleic acid molecule. Expression vectors of the present teachings include any vectors that function (i.e., direct gene expression) in recombinant cells of the present teachings, including in bacterial, fungal, endoparasite, insect, other animal, and plant cells.
An expression vector can be transformed into any suitable host cell to form a recombinant cell. A suitable host cell includes any cell capable of expressing a nucleic acid molecule inserted into the expression vector. For example, a prokaryotic expression vector can be transformed into a bacterial host cell. One method to isolate cytochrome P450 protein useful for producing ligand-complexed cytochrome P450 crystals includes recovery of recombinant proteins from cell cultures of recombinant cells expressing such cytochrome P450 protein.
Cytochrome P450 proteins of the present teachings can be purified using a variety of standard protein purification techniques, such as, but not limited to, affinity chromatography, ion exchange chromatography, filtration, electrophoresis, hydrophobic interaction chromatography, gel filtration chromatography, reverse phase chromatography, chromatofocusing and differential solubilization. In various aspects of the present teachings, an cytochrome P450 protein is purified in such a manner that the protein is purified sufficiently for formation of crystals useful for obtaining information related to the three dimensional structure of an Cytochrome-Ligand Complex. In some aspects, a composition of cytochrome P450 protein is about 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, or 99% pure.
Another aspect of the present teachings includes a composition comprising a Cytochrome-Ligand Complex in a crystalline form (i.e., Cytochrome-Ligand Complex crystals). As used herein, the terms “crystalline Cytochrome-Ligand Complex” and “Cytochrome-Ligand Complex crystal” both refer to crystallized a Cytochrome-Ligand Complex and are intended to be used interchangeably. In various aspects of the present teachings, a crystalline Cytochrome-Ligand Complex is produced using the crystal formation method described in the Examples.
In particular, the present teachings include a composition comprising CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide in a crystalline form (i.e., ligand-complexed CYP2A6 crystals). As used herein, the terms “crystalline ligand-complexed CYP2A6” and “ligand-complexed CYP2A6 crystal” both refer to crystallized CYP2A6 complexed with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide. These terms are intended to be used interchangeably. In various aspects of the present teachings, a crystal ligand-complexed CYP2A6 is produced using the crystal formation method described in the Examples. In some aspects, a composition of the present teachings includes ligand-complexed CYP2A6 molecules arranged in a crystalline manner in a space group P2 1 , so as to form a unit cell of dimensions a=70.62 Å, b=157.59 Å, c=103.54 Å, and β=92.25° (CYP2A6-coumarin) or a=70.66 Å, b=159.03 Å, c=103.88 Å, and β=92.00° (CYP2A6-methoxsalen).
A suitable crystal of the present teachings provides X-ray diffraction data for determination of atomic coordinates of the ligand-complexed CYP2A6 to a resolution of about 4.2 Å, and in some aspects about 3.0 Å, and in other aspects to about 1.5 Å.
According to an aspect of the present teachings, a crystalline Cytochrome-Ligand Complex can be used to determine the ability of a compound of the present teachings to bind to a cytochrome P450 in a manner predicted by a structure based drug design method of the present teachings. In various aspects of the present teachings, a Cytochrome-Ligand Complex crystal is soaked in a solution containing a chemical compound of the present teachings. Binding of the chemical compound to the crystal is then determined by methods standard in the art such as those provided in the Examples section herein.
One aspect of the present teachings is a therapeutic composition. A therapeutic composition of the present teachings comprises one or more therapeutic compounds. In one aspect, a therapeutic composition involving a cytochrome P450 is provided which promotes smoking cessation. For example, a therapeutic composition of the present teachings can inhibit (i.e., prevent, block) binding of a cytochrome P450 on a cell having a cytochrome P450 (e.g., eukaryotic cells) to a, e.g., a cytochrome P450 ligand or substrate by interfering with a binding site of a cytochrome P450. As used herein, the term “binding site” refers to the region of a molecule to which another molecule specifically binds. In one aspect of the present teachings, a method is provided for inducing smoking cessation in a subject comprising administering to the subject in need thereof a therapeutically effective amount of a therapeutic composition of the present teachings.
Suitable inhibitory compounds of the present teachings are compounds that interact directly with an cytochrome P450 protein, and in various aspects a CYP2A6 protein, thereby inhibiting the binding of a cytochrome P450 ligand or substrate, e.g., coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide, to a cytochrome P450 by blocking a binding site of a cytochrome P450 (referred to herein as substrate analogs). A cytochrome P450 substrate analog refers to a compound that interacts with (e.g., binds to, associates with, modifies) a binding site of a cytochrome P450. A cytochrome P450 substrate analog can, for example, comprise a chemical compound that mimics 1,2-benzopyrone, 8-methoxypsoralen, (5-(pyridin-3-yl) furan-2-yl) methanamine, 4,4′dipyridyldisulfide, or another ligand or substrate of a binding site of a cytochrome P450.
According to the present teachings, suitable therapeutic compounds of the present teachings include peptides or other organic molecules, and inorganic molecules. Suitable organic molecules include small organic molecules. In various aspects, a therapeutic compound of the present teachings is not harmful (e.g., toxic) to an animal when such compound is administered to an animal. Peptides refer to a class of compounds that is less than about 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 kDa and yields two or more amino acids upon hydrolysis. A polypeptide is comprised of two or more peptides. As used herein, a protein is comprised of one or more polypeptides. Suitable therapeutic compounds to design include peptides composed of “L” and/or “D” amino acids that are configured as normal or retroinverso peptides, peptidomimetic compounds, small organic molecules, or homo- or hetero-polymers thereof, in linear or branched configurations.
Therapeutic compounds of the present teachings can be designed using structure-based drug design. Structure-based drug design refers to the use of computer simulation to predict a conformation of a peptide, polypeptide, protein, or conformational interaction between a peptide or polypeptide, and a therapeutic compound. In the present teachings, knowledge of the three dimensional structure of the coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyldisulfide binding sites of a cytochrome P450 provide one of skill in the art the ability to design a therapeutic compound that 1) specifically binds to cytochrome P450s, or to a selected subset of cytochrome P450s, 2) is stable, and 3) results in inhibition of a biological response such as procarcinogen activation in a cell having a cytochrome P450. For example, knowledge of the three dimensional structure of the coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyldisulfide binding sites of a cytochrome P450 provides to a skilled artisan the ability to design an analog of coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyidisulfide which can function as a substrate or ligand of cytochrome P450s or with high specificity to a selected subset of cytochrome P450s, e.g., CYP2A6, and in particular human CYP2A6.
Suitable structures and models useful for structure-based drug design are disclosed herein. Models of target structures to use in a method of structure-based drug design include models produced by any modeling method disclosed herein, such as, for example, molecular replacement and fold recognition related methods. In some aspects of the present teachings, structure based drug design can be applied to a structure of CYP2A6 in complex with coumarin, methoxsalen, (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyidisulfide, and to a model of a target cytochrome P450 structure.
One aspect of the present teachings is a method for designing a drug which interferes with an activity of a cytochrome P450. In various configurations, the method comprises providing a three-dimensional structure of a Cytochrome-Ligand Complex comprising the cytochrome P450 and at least one ligand of the cytochrome; and designing a chemical compound which is predicted to bind to the cytochrome P450. The designing can comprise using physical models, such as, for example, ball-and-stick representations of atoms and bonds, or on a digital computer equipped with molecular modeling software. In some configurations, these methods can further include synthesizing the chemical compound, and evaluating the chemical compound for ability to interfere with an activity of the cytochrome P450.
Suitable three dimensional structures of a Cytochrome-Ligand Complex and models to use with the present method are disclosed herein. According to the present teachings, designing a compound can include creating a new chemical compound or searching databases of libraries of known compounds (e.g., a compound listed in a computational screening database containing three dimensional structures of known compounds). Designing can also include simulating chemical compounds having substitute moieties at certain structural features. In some configurations, designing can include selecting a chemical compound based on a known function of the compound. In some configurations designing can comprise computational screening of one or more databases of compounds in which three dimensional structures of the compounds are known. In these configurations, a candidate compound can be interacted virtually (e.g., docked, aligned, matched, interfaced) with the three dimensional structure of a Cytochrome-Ligand Complex by computer equipped with software such as, for example, the AutoDock software package, (The Scripps Research Institute, La Jolla, Calif.) or described by Humblet and Dunbar, Animal Reports in Medicinal Chemistry, vol. 28, pp. 275-283, 1993, M Venuti, ed., Academic Press. Methods for synthesizing candidate chemical compounds are known to those of skill in the art.
Various other methods of structure-based drug design are disclosed in references such as Maulik et al., 1997, Molecular Biotechnology: Therapeutic Applications and Strategies, Wiley-Liss, Inc., which is incorporated herein by reference in its entirety. Maulik et al. disclose, for example, methods of directed design, in which the user directs the process of creating novel molecules from a fragment library of appropriately selected fragments; random design, in which the user uses a genetic or other algorithm to randomly mutate fragments and their combinations while simultaneously applying a selection criterion to evaluate the fitness of candidate ligands; and a grid-based approach in which the user calculates the interaction energy between three dimensional structures and small fragment probes, followed by linking together of favorable probe sites.
In one aspect, a chemical compound of the present teachings that binds to an Cytochrome-Ligand Complex can be a chemical compound having chemical and/or stereochemical complementarity with a CYP2A6, e.g., a CYP2A6 ligand, such as, for example, 1,2-benzopyrone, 8-methoxypsoralen, (5-(pyridin-3-yl) furan-2-yl) methanamine or 4,4′-dipyridyldisulfide. In some configurations, a chemical compound that binds to a cytochrome P450 can associate with an affinity of at least about 10 −6 M, at least about 10 −7 M, or at least about 10 −8 M.
Several sites of cytochrome P450s can be targets for structure based drug design. These sites include, in non-limiting example residues which contact a ligand or substrate such as 8-methoxysalen or 1,2-benzopyrone (e.g., Phe107, Phe111, Phe118, Phe209, Phe480, Val117, Asn297, Ile 300, Gly301, Thr305, Ile366, Leu370). Such sites may include several amino acids toward either the N- or C-terminus in addition to the specific listed amino acids.
Drug design strategies as specifically described above with regard to residues and regions of the ligand-complexed CYP2A6 crystal can be similarly applied to the other cytochrome P450 structures, including other cytochrome P450 2 and cytochrome P450 2A structures disclosed herein. One of ordinary skill in the art, using the art recognized modeling programs and drug design methods, many of which are described herein, can modify the cytochrome P450 design strategy according to differences in amino acid sequence. For example, this strategy can be used to design compounds which regulate smoking cessation or procarcinogen activation in other cytochrome P450s. In addition, one of skill in the art can use lead compound structures derived from one cytochrome P450, such as CYP2A6, and take into account differences in amino acid residues in other cytochrome P450s, such as, for example, CYP2C8.
In the present method of structure-based drug design, it is not necessary to align a candidate chemical compound (i.e., a chemical compound being analyzed in, for example, a computational screening method of the present teachings) to each residue in a target site. Suitable candidate chemical compounds can align to a subset of residues described for a target site. In some configurations of the present teachings, a candidate chemical compound can comprise a conformation that promotes the formation of covalent or noncovalent cross-linking between the target site and the candidate chemical compound. In certain aspects, a candidate chemical compound can bind to a surface adjacent to a target site to provide an additional site of interaction in a complex. For example, when designing an antagonist (i.e., a chemical compound that inhibits the binding of a ligand to a cytochrome P450 by blocking a binding site or interface), the antagonist can be designed to bind with sufficient affinity to the binding site or to substantially prohibit a ligand (i.e., a molecule that specifically binds to the target site) from binding to a target area. It will be appreciated by one of skill in the art that it is not necessary that the complementarity between a candidate chemical compound and a target site extend over all residues specified here.
In various aspects, the design of a chemical compound possessing stereochemical complementarity can be accomplished by means of techniques that optimize, chemically or geometrically, the “fit” between a chemical compound and a target site. Such techniques are disclosed by, for example, Sheridan and Venkataraghavan, Acc. Chem Res., vol. 20, p. 322, 1987: Goodford, J. Med. Chem., vol. 27, p. 557, 1984; Beddell, Chem. Soc. Reviews, vol. 279, 1985; Hol, Angew. Chem., vol. 25, p. 767, 1986; and Verlinde and Hol, Structure, vol. 2, p. 577, 1994, each of which are incorporated by this reference herein in their entirety.
Some aspects of the present teachings for structure-based drug design comprise methods of identifying a chemical compound that complements the shape of a cytochrome P450 or a structure that is related to a cytochrome P450. Such method is referred to herein as a “geometric approach”. In a geometric approach of the present teachings, the number of internal degrees of freedom (and the corresponding local minima in the molecular conformation space) can be reduced by considering only the geometric (hard-sphere) interactions of two rigid bodies, where one body (the active site) contains “pockets” or “grooves” that form binding sites for the second body (the complementing molecule, such as a ligand).
The geometric approach is described by Kuntz et al., J. Mol. Biol., vol. 161, p. 269, 1982, which is incorporated by this reference herein in its entirety. The algorithm for chemical compound design can be implemented using a software program such as AutoDock, available from the The Scripps Research Institute (La Jolla, Calif.). One or more extant databases of crystallographic data (e.g., the Cambridge Structural Database System maintained by University Chemical Laboratory, Cambridge University, Lensfield Road, Cambridge CB2 IEW, U.K. or the Protein Data Bank maintained by Rutgers University) can then be searched for chemical compounds that approximate the shape thus defined. Chemical compounds identified by the geometric approach can be modified to satisfy criteria associated with chemical complementarity, such as hydrogen bonding, ionic interactions or Van der Waals interactions.
In some aspects, a therapeutic composition of the present teachings can comprise one or more therapeutic compounds. A therapeutic composition can further comprise other compounds capable of inducing smoking cessation or inhibiting procarcinogen activation. A therapeutic composition of the present teachings can be used to treat disease in an animal such as, for example, a human in need of treatment by administering such composition to an animal. Non-limiting examples of animals to treat include mammals, marsupials, reptiles and birds, humans, companion animals, food animals, zoo animals and other economically relevant animals (e.g., race horses and animals valued for their coats, such as chinchillas and minks). Additional animals to treat include dogs, cats, horses, cattle, sheep, swine, chickens, turkeys. Accordingly, in some aspects, animals to treat include humans, dogs and cats.
A therapeutic composition of the present teachings can also include an excipient, an adjuvant and/or carrier. Suitable excipients include compounds that the animal to be treated can tolerate. Examples of such excipients include water, saline, Ringer's solution, dextrose solution, Hank's solution, and other aqueous physiologically balanced salt solutions. Nonaqueous vehicles, such as fixed oils, sesame oil, ethyl oleate, or triglycerides may also be used. Other useful formulations include suspensions containing viscosity enhancing agents, such as sodium carboxymethylcellulose, sorbitol, or dextran. Excipients can also contain minor amounts of additives, such as substances that enhance isotonicity and chemical stability. Examples of buffers include phosphate buffer, bicarbonate buffer and Tris buffer, while examples of preservatives include thimerosal, o-cresol, formalin and benzyl alcohol. Standard formulations can either be liquid injectables or solids which can be taken up in a suitable liquid as a suspension or solution for injection. Thus, in a non-liquid formulation, the excipient can comprise dextrose, human serum albumin, preservatives, etc., to which sterile water or saline can be added prior to administration.
In one aspect of the present teachings, a therapeutic composition can include a carrier. Carriers include compounds that increase the half-life of a therapeutic composition in the treated animal. Suitable carriers include, but are not limited to, polymeric controlled release vehicles, biodegradable implants, liposomes, bacteria, viruses, other cells, oils, esters, and glycols.
Acceptable protocols to administer therapeutic compositions of the present teachings in an effective manner include individual dose size, number of doses, frequency of dose administration, and mode of administration. Determination of such protocols can be accomplished by those skilled in the art. Modes of administration can include, but are not limited to, inhalation, subcutaneous, intradernal, intravenous, intranasal, oral, transdermal, intraocular and intramuscular routes.
TABLE 6
Data collection and refinement statistics for CYP2A6dH
Cytochrome P450
2A6dH
2A6dH
Construct
Complex
methoxsalen
coumarin
P2 1 Unit Cell (a, b, c, β)
70.66, 159.03, 103.88,
70.62, 157.59, 103.54,
92.00°
92.25°
Data Collection
Beam line
SSRL BL9-2
SSRL BL 11-1
Wavelength (Å)
1.03 and 0.98
0.98
Resolution Range (Å)
50-2.05
50-1.9
Unique Reflections >
134, 956
164, 494
0.0σ|F|
Redundancy [1]
2.2 (2.4)
3.4 (3.2)
Completeness (%) [1]
94.3 (90.5)
98.6 (96.6)
<i/σI> [1]
30.0 (2.6)
22.4 (2.1)
Rsymm(I) [1]
0.054 (0.243)
0.108 (0.464)
Refinement
Rwork
0.219
0.194
Rfree
0.261
0.230
RMS deviation bonds
0.011
0.019
(Å)
RMS deviation angles
1.44
1.79
(deg) [2]
Model
Residues/No. of atoms/Ave. B-factor (Å 2 )
Protein [3]
15039 53.9
15037 42.2
Heme
172 39.5
172 31.6
Substrate
64 84.6
44 60.4
Water Molecules
504 52.0
816 46.2
[1] Values for the highest resolution shell in parentheses. Values for Rsym are averaged between two resolution passes. Value for redundancy is averaged.
[2] Ramachandran plot for methoxsalen complex: 89.2 % of the residues in the most favored regions, 10.2 % in allowed regions, 0.3 % in generously allowed regions, 0.2 % in disfavored regions. Ramachandran plot for the coumarin complex: 90.5 % of the residues in the most favored regions, 9.1% in allowed regions, 0.2% in generously allowed regions, 0.2% in disfavored regions.
[3] Residues 30 to 496, 32 to 495, 31 to 494, 31 to 494 molecules A-D respectively for the methoxsalen complex. Residues 30 to 494, 32 to 496, 31 to 494, 31 to 494 molecules A-D respectively for the coumarin complex. Residue L370 found in alternate conformations in coumarin complex.
TABLE 7
Data Collection and Refinement Statistics.
Ligand
Aldrithiol ™
(5-(pyridin-3-yl)furan-2-yl)
methanamine
PDB Identifier
2FDY
2FDW
Resolution Range (Å)
50.0-1.95
50.0-2.05
Unique Reflections
160, 717
131, 309
Average Redundancy a
3.4 (2.6)
3.6 (3.6)
Completeness (%) a
98.7 (91.3)
93.9 (99.9)
(I/σaverage I) a
7.6 (2.0)
16.4 (2.1)
Rsymm (I) a
0.089 (0.451)
0.09 (0.669)
R (R free ) a
0.212 (0.250)
0.205 (0.22)
RMSD bonds (Å)
0.006
0.006
RMSD angles (°)
1.26
1.23
a Values are for the highest resolution shell. All data presented in the table was collected at the Stanford Synchrotron Radiation Laboratory on beamline 9-1.
EXAMPLES
The methods and compositions described herein utilize laboratory techniques which are well known to skilled artisans and which can be found in laboratory manuals such as Sambrook, J., Fritsch, E. F. and Maniatis, T. (1989) Molecular Cloning: A Laboratory Manual, 2nd ed. Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y.
Example 1
This Example Illustrates CYP2A6dH Construct Generation
The CYP2A6dH construct was designed to produce a conditionally soluble enzyme that retains wild-type activity. To accomplish this goal, DNA encoding the N-terminal transmembrane signal anchor region composed of the first 28 residues was replaced with DNA encoding the sequence MAKKTS (SEQ ID NO: 4), which had been optimized for the expression and crystallization of rabbit P450 2C5 (Johnson, E. F. The 2002 Bernard B. Brodie Award lecture: deciphering substrate recognition by drug-metabolizing cytochromes P450. Drug Metab Dispos. 31, 1532-1540 (2003). In addition to the N-terminal mutations, DNA encoding a four residue histidine tag was added to the C-terminus to aid in purification. This construct is referred to as the CYP2A6dH construct. This strategy produced a truncated protein which crystallized in the P2 1 space group and demonstrated a K m of 0.23±0.03 μM and V max of 10.83±1.38 nmols/min/nmol P450 for coumarin 7-hydroxylation when reconstituted with P450 reductase. Dissociation constants for the binding of purified CYP2A6dH were determined for coumarin and 8-methoxypsoralen by monitoring substrate dependent conversion of the enzyme to a high spin ferric heme protein and are 0.27 μM and 1.85 μM, respectively. Similar values of coumarin hydroxylation (mean values of Km are 0.40 μM and V max are 6.34 nmols/min/nmol P450) and methoxsalen inhibition (K i =1.9 μM) were reported by Koenigs et al. (Mechanism-based inactivation of human liver cytochrome CYP2A6 by 8-methoxypsoralen. Drug Metab. Dispos. 25, 1407-1415 (1997)) for full length wild-type CYP2A6 in microsomal preparations from a panel of 12 human liver microsomes. These results suggest that the modification to the N-and C-termini did not significantly alter the substrate binding or catalytic activity of the enzyme.
In this example, a vector was designed for expression of a cytochrome CYP2A6 comprising a truncated the N-terminal transmembrane signal anchor domain while expressing residues 29-494 of the catalytic domain without internal modifications that may alter catalytic activity. SEQ ID NO: 2. In this example, DNA encoding residues 1-28 was replaced with DNA encoding the amino acid sequence MAKKTS using a polymerase chain reaction. Additionally, DNA encoding a four residue histidine tag was added to the C-terminus. This DNA construct was expressed in Escherichia coli and is referred to as CYP2A6dH. CYP2A6dH was expressed and purified as previously described for P450 2C5 with minor modifications (Johnson, E. F. The 2002 Bernard B. Brodie Award lecture: deciphering substrate recognition by drug-metabolizing cytochromes P450. Drug Metab Dispos. 31, 1532-1540 (2003). The sequence of the polypeptide encoded by this construct is disclosed herein as SEQ ID NO: 3.
Example 2
This Example Illustrates Enzyme Activity of the CYP2A6dH Polypeptide
In this example, to determine catalytic properties for the purified protein, CYP2A6dH was reconstituted with E. coli -expressed purified human reductase in the absence of L-α-dilauroyl-L-α-lecithin with slight modifications to the protocol described by Tan et al. (Competitive interactions between CYP2A6 and cytochrome P450 2E1 for NADPH-cytochrome P450 oxidoreductase in the microsomal membranes produced by a baculovirus expression system. Arch. Biochem. Biophys. 342, 82-91 (1997)). 10 pmol CYP2A6dH was incubated on ice for 10 min. with 0.06 U human reductase at a ratio of 1:6, CYP2A6dH to reductase in a final volume of 10 μl. 1,2 benzopyrone at concentrations ranging from 25 μM to 2.5 mM were then added in 10 μl aliquots, along with 430 μL of 50 mM Tris pH 7.4. The reaction mixture was allowed to equilibrate at 37° C. for 3 min. To start the reaction, 50 μl of an NADPH regeneration system (50 mM isocitrate, 50 mM MgCl 2 , 5 U/ml isocitrate dehydrogenase and 10 mM NADPH) was added. The reaction was allowed to proceed for 5 min., and stopped by addition of 100 μl of cold 20% trichloroacetic acid. The components were centrifuged at 13,000 rpm. 10 μl of the supernatant was removed and added to 190 μl 100 mM Tris buffer, pH 9.0. the coumarin content was quantified fluorometrically (excitation at 368 nm and emission at 453 nm).
Example 3
This Example Illustrates Crystallization
In this example, the initial dataset was collected using a crystal prepared by mixing equal volumes of a protein solution containing 380 μM CYP2A6dH in XB, 1 mM coumarin, and 0.17% ANAPOE®-X-405 with crystallization well solution containing 30% Polyethylene glycol 4000, 100 mM Tris pH 8.5, 200 mM ammonium sulfate. The high resolution data set was collected from a crystal prepared by mixing equal volumes of a protein solution containing 540 μM CYP2A6dH in XB, 8.89 mM coumarin, and 0.2% ANAPOE®-X-405 with crystallization well solution containing 30% Polyethylene glycol 3350, 100 mM Tris pH 8.5, and 200 mM ammonium sulfate. Crystals of the methoxsalen complex were prepared by first diluting 540 μM CYP2A6dH 100 times in XB containing 100 μM methoxsalen and then concentrating the solution to the original volume. Equal volumes of protein solution containing ˜540 μM CYP2A6dH methoxsalen complex in XB and 0.2% ANAPOE®-X-405 were combined with crystallization well solution containing 30% Polyethylene glycol3350, 100 mM Tris pH 8.5, and 200 mM ammonium sulfate, 100 μM Methoxsalen. All substrates and detergents were purchased from SIGMA® (St. Louis, Mo.) and ANATRACE® (Maumee, Ohio), respectively. All crystals were grown by sitting drop vapor diffusion in 2.5 μl drops.
To reduce radiation damage induced by the X-ray beam, the crystals were frozen in liquid N 2 . Crystals were flash cooled to 100 K in a stream of liquid N 2 using a cryoprotectant solution containing 700 μl of a 1:1 mixture of XB and crystallization well solution and 300 μl of 100% ethylene glycol.
Example 4
This Example Illustrates Collection of Diffraction Data
In this example, data for the coumarin and methoxsalen complex were collected on a single crystal cooled to 100 K at the Stanford Synchrotron Radiation Laboratory (SSRL, Palo Alto, Calif.) on beamline 11-1 for the coumarin complex and on beamline 9-2 for the methoxsalen complex. All data were processed in HKL2000®, and Scalepack was used to scale and reduce the data (Fukami, T. et al. A novel polymorphism of human CYP2A6 gene CYP2A6*17 has an amino acid substitution (V365M) that decreases enzymatic activity in vitro and in vivo. Clin. Pharmacol. Ther. 76, 519-527 (2004)). The initial data for the coumarin complex were phased in the P2 1 space group by molecular replacement in AMoRe using a model of CYP2C8 (PDB Accession No. 1PQ2) in which non-equivalent side-chains were replace by alanine residues (Kitagawa, K., Kunugita, N., Kitagawa, M., & Kawamoto, T. CYP2A6*6, a novel polymorphism in cytochrome p450 2A6, has a single amino acid substitution (R128Q) that inactivates enzymatic activity. J. Biol. Chem. 276, 17830-17835 (2001)). The Mathews coefficient suggested that there were four molecules in the asymmetric unit, and four were found. During early stages of refinement, four-fold NCS restraints were applied to each of the monomers in the asymmetric unit. During later stages of refinement, NCS restraints were released to allow for differences in each of the monomers. The model for initial coumarin complex was refined against data to 2.65 Å using multiple rounds of torsion angle simulated annealing. In the final stage, one round of isotropic individual B-factor refinement was done. This model was used to phase the data set for the high resolution coumarin complex, which was further built and used to phase the methoxsalen data set. The models for the coumarin and methoxsalen complexes were refined against 2.05 Å and 1.90 Å data using multiple rounds of conjugant gradient least-squares minimization, torsion angle simulated annealing and isotropic individual B-factor refinement using the program CNS. During the final stages of refinement of the coumarin and methoxsalen complexes, substrates and water molecules were added. Data collection and structure refinement statistics for the coumarin and methoxsalen complexes can be found in Tables 1 and 2. Multiple cycles of editing and adjustment of the model into σ A -weighted 2|F o |-|f c |, 1|F o |-|f c | and 2|F o -|f c | composite omit maps was performed using the graphics program O (Denton, T. T., Zhang, X., & Cashman, J. R. 5-Substituted, 6-Substituted, and Unsubstituted 3-Heteroaromatic Pyridine Analogues of Nicotine as Selective Inhibitors of Cytochrome P-450 2A6. J. Med. Chem. 48, 224-239 (2005)). Unless otherwise indicated, molecular graphics were generated in PyMOL (supra). All probe accessible cavity volumes were calculated with the program VOIDOO with a probe radius of 1.4 Å and grid spacing of 0.33 Å.
Example 5
This Example Illustrates Determination of Three Dimensional Structure
Data from a single crystal of a CYP2A6dH coumarin complex that diffracted to a limiting resolution of 2.65 Å was phased by molecular replacements using a model of cytochrome P450 2C8 (Protein Data Bank accession code 1PQ2) in which non-equivalent side chains were replaced by alanine residues. As higher resolution data sets became available the current model was used to phase the new data set. Manual building of the peptide backbone and side-chains into electron density maps was continued. The final model was generated by subsequent fitting and refinement using data collected from a single crystal of the coumarin complex that diffracted to a limiting resolution of 1.9 Å. The resultant structure exhibited an R value of 0.194 and an R free value of 0.230 with four molecules in the asymmetric unit (Table 6). Residues 30-496, 32-495, 31-494, and 31-494 of chains A-D respectively, 816 water molecules, 4 molecules of coumarin and one glycerol molecule were defined by 2|Fo|-|Fc| σ A weighted electron density maps. Fitting and refinement of the methoxsalen complex utilized data collected for a single crystal of the complex that diffracted to a limiting resolution of 2.05 Å. The structure exhibits an R value of 0.219 and an R free value of 0.261 (Table 6). Residues 30-494, 32-495, 31-494, and 31-494 of chains A-D respectively, 4 molecules of methoxsalen, one molecule of glycerol and 521 water molecules were modeled into 2|Fo|-|Fc| σ A -weighted electron density maps.
Example 6
This Example Illustrates Determination of Binding Constants by Visible Difference Spectroscopy
In this example, the conversion of CYP2A6dH from a low spin to a high spin state in the presence of coumarin or methoxsalen was monitored by observing spectral changes from 260 nm to 700 nm at ambient temperature on a CARY 1 E UV-visible spectrophotometer. Purified CYP2A6dH was diluted to ˜3 μM in 50 mM KPi pH 7.4, 500 mM NaCl, 20% glycerol, 1 mM EDTA (refered to as XB) in a 1-cm path length microcuvette. Freshly prepared aliquots of coumarin or methoxsalen dissolved in 50% methanol were added to the diluted protein, and the measurements were taken. The total concentration of methanol remained under 1%. Binding was monitored as the absorbance difference, ΔA, between the peak (˜385 nm) and trough (˜417 nm) of the difference spectrum. The apparent binding constant, Ks, and the extrapolated maximum spectral change, ΔAmax, were estimated from nonlinear least-squares regression fitting using the following equation:
Δ A = Δ A max 2 P [ P + S + Ks - ( P + S + Ks ) ^ 2 - 4 PS ]
where S is the total concentration of ligand and P is the total concentration of P450.
Example 7
This Example Illustrates Substrate and Inhibitor Binding
In this example, the locations of the coumarin and methoxysalen molecules in the active site of CYP2A6 are defined by σA-weighted 2|Fo|-|Fc| omit electron density ( FIGS. 4 and 5 ). The tertiary structures of the coumarin and methoxsalen complexes are very similar, with a RMSD of 0.27 Å for all equivalent Cα positions. Additionally, the RMSD for regions associated with the active site (101-120, 196-256, 288-318, 364-371 and 476-484) is 0.15 Å, demonstrating that there are essentially no structural changes in the backbone upon binding the larger methoxsalen molecule. Furthermore, differences in the positions of the side chains contacting the substrate molecules are also minimal ( FIG. 8 ). In FIG. 8 , two views (a) and (b) showing the superposed structures of the coumarin (arrow 120 ) and methoxsalen (arrow 121 ) complexes of CYP2A6 are provided. Oxygen atoms are indicated by arrow 113 , nitrogen atoms are indicated by arrow 114 , carbon atoms are indicated by arrow 120 (coumarin complex) or arrow 121 (methoxsalen complex). Side chains within 5 Å of the ligands are displayed as a stick representation. The heme group is displayed as a stick figure. The pyran rings of each substrate are oriented so that the hydrogens interact with the π-electron system of Phe107. Moreover, the positions of the substrates and side-chains are highly similar in each of the molecules that constitute the asymmetric unit. However, Leu370 is found in two alternative positions in the A molecule of the coumarin complex indicating that it is not confined by substrate binding in the complex.
The electron density suggests that ketal oxygen of each molecule is oriented with the potential to form 3.3±0.13 and 2.9±0.02 Å hydrogen bonds with the side chain nitrogen of Asn297 for coumarin and methoxsalen, respectively ( FIGS. 4 and 5 ). In FIG. 4 , The active site cavity, located above the heme group, is rendered as a mesh and is indicated by arrow 108 , the heme is indicated by arrow 109 , side chains forming stabilizing interactions are indicated by arrow 110 , and the peptide backbone is displayed as a ribbon and is indicated by arrow 111 . Glu221 forms hydrogen bond interactions with the peptide backbone and electrostatic interactions with the helix dipole, stabilizing the N-terminus of helix B′ and helix F′, Trp109 forms π-π interactions with Phe238, stabilizing the packing of helix B′ with helix G. In FIG. 5 , two views of the active site cavity, which are rendered as a thin mesh (indicated by arrow 112 ) are shown. The side chains that contact the active site cavity are displayed as sticks. Atoms are represented according to element; O is indicated by arrow 113 ; N is indicated by arrow 114 , and C is indicated by arrow 115 with the exception of the heme group which is indicated by arrow 116 .
Although the electron density alone is unable to distinguish the orientation of the Asn side chain heteroatoms, additional hydrogen bonding interactions suggest that it is oriented as shown in FIG. 6 , which depicts a wall-eyed stereo view of σA weighted 2|Fo|-|Fc| composite omit electron density maps contoured at 1σ and rendered within 1 Å of the heme and substrate for the coumarin. The substrate was omitted from the model used for the generation of the map. coumarin and methoxsalen are stabilized by hydrogen bonding with Asn297, which places the oxidized carbon 3.2±0.13 Å (coumarin) or 3.8±0.09 Å (methoxsalen) from the heme iron. The distances are shown as a dotted line and the values quoted for distances are the mean and standard deviation for the four molecules in the asymmetric unit. The peptide backbone is represented as a thin coil indicated by arrow 117 , side chains are rendered as stick figures with the following representations for atoms; Carbons are indicated by arrow 118 for the protein or arrow 119 for substrates, oxygens are indicated by arrow 113 , and nitrogens are indicated by arrow 114 . The heme group is represented by arrow 107 . In this conformation, the nitrogen from the Asn 297 side chain is able to donate a hydrogen bond to the ketal oxygen of the coumarin molecule, whereas the oxygen atom of the Asn 297 side chain is positioned to potentially accept two hydrogen bonds from the backbone nitrogen atom of residue 117 and a conserved water molecule normally found stabilizing the turn after the helix B′. The water molecule can accept a hydrogen bond from the peptide nitrogen of F 118 and donate a hydrogen bond to the carbonyl of Y 114 ( FIG. 6 ). If the Asn297 side chain were rotated 180°, the nitrogen atoms from the Asn 297 side chain would clash with the backbone hydrogen atoms of residues 116 and 117 .
Coumarin is positioned so that the 7′ carbon, which is oxidized by the iron-oxo intermediate, resides 3.24±0.13 Å from the heme iron. Spectral titration studies with the purified CYP2A6 enzyme indicated that coumarin causes a type I spectral change which is consistent with displacement of water from its position as the sixth, axial ligand for the heme. The position of coumarin in the active site of CYP2A6 is consistent with the UV-visible spectroscopy, however the close distance between the coumarin molecule and the heme iron indicates that coumarin will have to move for the oxygen to bind and catalysis to occur. Typically, the distance of the heme iron atom to the atom that is oxidized is 4-5 Å based on a survey of P450-substrate complexes.
In addition to hydrogen bonding, there is a favorable interaction from the aromatic hydrogen of the coumarin molecule pointing directly into the ring system of Phe 107 depicted in FIG. 7 . FIG. 7 is a depiction of a wall-eyed stereo view of σA weighted 2|Fo|-|Fc| composite omit electron density maps contoured at 1σ and rendered within 1 Å of the heme and substrate for the methoxsalen. The substrate was omitted from the model used for the generation of the map. Coumarin and methoxsalen are stabilized by hydrogen bonding with Asn 297 , which places the oxidized carbon 3.2±0.13 Å (coumarin) or 3.8±0.09 Å (methoxsalen) from the heme iron. The distances are shown as a dotted line and the values quoted for distances are the mean and standard deviation for the four molecules in the asymmetric unit. The peptide backbone is represented as a thin coil indicated by arrow 117 , side chains are rendered as stick figures with the following representations for atoms; Carbons are indicated by arrow 118 for the protein or arrow 119 for substrates, oxygens are indicated by arrow 113 , and nitrogens are indicated by arrow 114 . The heme group is represented by arrow 107 . Non-bonded potential energy calculations estimated the free energy gained from the aromatic interaction to be on the order of −1 to −2 kilocalories per mole, while the hydrogen bond between Asn 297 and coumarin is likely to contribute about −0.5 to −1.8 Kcal mol. Thus, the two interactions are likely to contribute to orienting the substrate for selective 7′-hydroxylation.
Methoxsalen is a mechanism based inhibitor of CYP2A6. Without being bound by a particular theory, the proposed mechanism for inactivation is indicated to be oxidation of the 5′ carbon of methoxsalen to form a furanoepoxide followed by inactivation of CYP2A6. The location of the methoxsalen molecule is defined by the electron density in the active site as shown in FIG. 5 . Although larger in size than coumarin, the ketal oxygen of methoxsalen also forms a hydrogen bond with the nitrogen atom of the Asn 297 side chain and aromatic hydrogens interact with the p-electron system of Phe 107 . Although the 5′carbon is positioned 3.83±0.09 Å from the heme iron, the closest atom to the heme iron is the 1′ oxygen, which resides only 3.33±0.08 Å from the heme iron. The slightly closer position of the oxygen molecule could limit the oxidation of the 5′ position of methoxsalen, leading to uncoupling and generation of reactive oxygen species. Thus, this would support a model in which methoxsalen binding leads to significant uncoupling and subsequent inactivation of CYP2A6 by reactive oxygen species as proposed by Koenigs et al. (supra). No water molecules are evident in the active site, and as seen for coumarin, the binding of methoxsalen to the enzyme yields a type I spectral change.
In FIG. 9 , a wall-eyed stereo view of the potential hydrogen bonding of Asn297 with coumarin (arrow 122 ), the polypeptide chain and a conserved water molecule bound in a turn following helix B′ is depicted. The water molecule (arrow 123 ) is stabilized by accepting a hydrogen bond from the peptide nitrogen of F118 and donating hydrogen bonds to the carbonyl of Y114 and the side chain oxygen atom of N297. N297 is also stabilized by interactions with the hydrogen from the peptide nitrogen of V117. Hydrogen atoms are indicated by arrow 124 , carbons are indicated by arrow 120 (coumarin) or arrow 118 (protein), oxygens are indicated by arrows 113 and nitrogens are indicated by arrow 114 . The water molecule is displayed as a sphere (arrow 123 ), the side chains and heme group are rendered as stick figures.
In FIG. 10 , a Wall-eyed stereo view of interactions between CYP2A6 and the heme prosthetic group. CYP2A6 differs from other cytochrome P450s by lacking the highly conserved WXXXR (SEQ ID NO: 5) motif, in which the W and R side chains hydrogen bond to the heme proprionate. CYP2A6 has an alanine (not shown) substitution for the tryptophan. The tryptophan side-chain of P450 2B4 at the equivalent position is shown for reference, A124W. Side chains donating hydrogen bonds to the heme proprionates are displayed as stick figures. The conserved cysteine residue (C439) that coordinates to the axial position of the heme iron is also shown. Carbons are indicated by arrow 125 (CYP2A6) or arrow 126 (cytochrome P450 2B4), nitrogens are indicated by arrow 114 , oxygens are indicated by arrow 113 , sulfur is indicated by arrow 127 , and iron is indicated by arrow 128 .
Example 8
This Example Illustrates Overall Fold and Comparison of CYP2A6 with Cytochrome P450 2C8
In this example, analysis of the structure of CYP2A6 based upon the data collected as described herein led us to conclude that CYP2A6 adopts an overall fold that is characteristic of other mammalian membrane associated P450s ( FIG. 2 ), containing 16 α-helices, labeled A-L and 4 β-sheets, labeled numerically β1-β4. It differs from soluble prokaryotic cytochrome P450s by the addition of two helices, F′ and G′, located between helix F and G which are hydrophobic and thought to form part of the membrane interaction domain. In FIG. 2 , helices are represented by arrow 100 , and β-strands are represented by arrow 101 . The cavity surface is rendered as a mesh and is indicated by arrow 102 . The heme group is represented as a stick figure and is indicated by arrow 103 .
The largest difference between the CYP2A6 structure and other experimentally determined structures of human drug metabolizing cytochrome P450s is the compact, hydrophobic nature of the active site cavity, which is bounded by the mesh surface shown in FIG. 2 a . Substrate or solvent access channels are not evident. The active site volume is ˜250 Å, which is significantly smaller than other human drug metabolizing P450s 2C8, 2C9 or 3A4 that exhibit volumes that are 4-6 fold larger. This reflects in part differences in the conformation of the peptide backbone that forms the outer surfaces of the active site cavity as shown in FIG. 2 a , which compares Cα traces for CYP2A6 and cytochrome P450 2C8. These regions typically vary between family 2 drug metabolizing P450s and contribute to differences in the size and shape of the active site cavities. In contrast, the structural cores of the enzymes are highly similar as seen for CYP2A6 and cytochrome P450 2C8 ( FIG. 2 b ). The comparison in FIG. 2 indicates that the pitch of the F and G helices that extend over the top of active site cavity above the heme is lower in CYP2A6 than in cytochrome P450 2C8. Additionally, the compact structure exhibits tight packing interactions between flexible portions of the cytochrome P450 structure, helix B to C and helix F to G with each other and the rest of the structure.
Hydrogen bonding and electrostatic interactions between Glu221 on helix F′ and the backbone nitrogens of residues 105 and 106 in the first turn of helix B′ and with the helix dipole of helix B′ stabilize this packing ( FIG. 3 a ). In FIG. 3 , regions that differ in position are depicted by arrow 104 for CYP2A6 and arrow 105 for cytochrome P450 2C8. Regions in which Ca positions overlay well are depicted by arrows 106 . The heme group is represented as a stick figure and indicated by arrow 107 with the iron shown as a sphere. Thr 106 from helix B′ and the backbone carbonyl of Gly 217 also interact through a bridging water molecule. A π-π stacking interaction between Trp 109 from helix B′ and Phe 238 from helix G ( FIG. 3 a ) also stabilizes the “active site” in a “closed” conformation. Additionally, there are significant aromatic interactions between the bulky side-chains of 5 phenylalanine residues (Phe 107 , Phe 111 , Phe 118 , Phe 209 and Phe 480 ) that line the surface of the active site cavity above the heme, FIG. 3 b . These residues contribute to the largely hydrophobic nature and small size of the CYP2A6 active site and are likely to stabilize the compact fold of the enzyme. The phenylalanine cluster lines the roof of the active site and may play an important role in stabilizing the binding of aromatic substrates within the active site. There are only two polar residues Asn 297 and Thr 305 ( FIG. 3 b ). Thr305 is highly conserved in P450 active sites where it is thought to stabilize the interactions of reduced oxygen intermediates with a chain of water molecules that facilitate protonation of the reduced oxygen molecule to produce a compound I like oxo-heme intermediate.
Example 9
Crystallization of CYP2A6/(5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyidisulfide Complexes
Crystallization of CYP2A6 was performed as described above. Data were collected from single crystals at Stanford Synchrotron Radiation Laboratory on beamline 9-1. All data were reduced and scaled in either HKL2000®/Scalepack (Otwinowski, Z. and Minor, W. Processing of X-ray diffraction data collected in oscillation mode. Methods Enzymol. 1997, 276, 307-326.) or Mosflm/Scala (CCP The CCP4 suite: programs for protein crystallography. Acta Cryst. 1994, D50, 760-763). The data were phased initially by isomorphous replacement using the previously determined structure of CYP2A6dH, PDB:1Z10. The protein and inhibitor structures were fit to electron density maps using the computer program O (supra) and refined using CNS (supra). Data reduction and structure refinement statistics are presented in Table 7.
Example 10
Characterization of (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyidisulfide CYP2A6 Inhibition
(5-(pyridin-3-yl) furan-2-yl) methanamine, a known inhibitor of CYP2A6, and Aldrithiol-4™ (4,4′-dipyridyldisulfide), a potent inhibitor of CYP2A6, were compared. The activity of (5-(pyridin-3-yl) furan-2-yl) methanamine is described in Denton et al. 5-Substituted, 6-Substituted, and Unsubstituted 3-Heteroaromatic Pyridine Analogues of Nicotine as Selective Inhibitors of Cytochrome P-450 2A6. J. Med. Chem. 2005, 48, 224-239, incorporated herein by reference in its entirety.
The enzyme inhibitor complexes were crystallized using conditions similar to those employed previously for CYP2A6dH complexed with the substrate coumarin bound in the active site (supra). The data used for structure determination were collected from single crystals that diffracted to limiting resolutions of 2.05 Å and 1.65 Å in the P2 1 spacegroup for each of the (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyldisulfide complexes (Table 7). Isomorphous replacement using the structure of CYP2A6dH (Table 2, Protein Data Bank Accession No. 1Z10) was used for initial phasing of the data followed by rounds of fitting and refinement. The position and orientation of each inhibitor in the active site was defined in sigma A weighted electron density maps. The results indicated that the (5-(pyridin-3-yl) furan-2-yl) methanamine and 4,4′-dipyridyldisulfide coordinated to the heme iron through the nitrogen atom of the primary amino group, respectively ( FIG. 11 ). In FIG. 11 , σA weighted 2|Fo|-|Fc| omit electron density maps contoured at 1σ and rendered within 1.5 Å of the ligand for the complexes of CYP2A6 with (5-(Pyridin-3-yl) furan-2-yl) methanamine (left) and 4,4′-dipyridyldisulfide (right) bound in the active site are depicted. In each case, the substrate was omitted from the model used for the generation of the map. The dotted red lines indicate the potential for hydrogen bonding interactions with Asp297 or distance from the coordinating nitrogen to the heme iron.
The nitrogen of the amino group was located directly above the heme iron in the axial ligation position at distances of 2.27±0.02 Å for the primary amine. The structure of the CYP2A6 protein complexed with the primary amine was highly similar to that of the coumarin complex indicating that little reorganization of the enzyme was required for binding of (5-(pyridin-3-yl) furan-2-yl) methanamine. A comparison with the the CYP2A6 complexes of coumarin and methoxsalen shows that (5-(pyridin-3-yl) furan-2-yl) methanamine, the identities of CYP2A6 residues that contact the substrates are the same. Additionally, most of the changes in contact residue positions are restricted to slight rearrangements of the phenylalanine residues to maximize orthogonal aromatic interactions with the inhibitors. The active site volume of the complexes also remains similar to that of the coumarin complex at ˜240-275 Å.
This is in contrast to the complex of 4,4′-dipyridyidisulfide ( FIG. 12 ). In FIG. 12 , 4,4′-dipyridyldisulfide (Aldrithiol™ (ALD)) interactions with CYP2A6. The offset (shaded regions depicted behind the amino acids) in each of the amino acids depicted indicates the spatial differences as compared to the coumarin complex (coumarin is not depicted in the figure). In order to accommodate 4,4′-dipyridyidisulfide, the side chain of F 209 moves away from the active site by ˜3 Å relative to the coumarin complex to make room for the sulfur atoms of 4,4′-dipyridyldisulfide. This increases the active site volume to ˜325 Å. The change in the active site provides clues as to how the protein can adapt to fit other, larger molecules in the active site. The pyridyl nitrogen of one ring is positioned 2.30±0.01 Å from the heme iron, and the bulky pryidyl ring also causes a repositioning of Thr 301 and an opening of helix I with a concomitant occupancy of the cleft by two water molecules. The other pyridyl nitrogen of 4,4′-dipyridyldisulfide is positioned 2.93±0.13 Å from the side-chain nitrogen of Asn297 and is in a position to accept a hydrogen bond as seen for the 3-pyridyl ring of (5-(pyridin-3-yl) furan-2-yl) methanamine. Thus, the changes in the active site maintain strong nitrogen coordination to the heme iron, a hydrogen bonding interaction with Asn 297 , and orthogonal aromatic-aromatic interactions between the inhibitor and protein side-chains for all of these potent inhibitors. Without being bound by a particular theory, the high binding affinity for these relatively small molecules also likely stems from significant contributions of the hydrophobic effect arising from the displacement of water from the closed, hydrophobic active site cavity that exhibits extensive van der Waals interactions between the protein and inhibitor.
The results indicate that it is the side chain amino group of (5-(pyridin-3-yl) furan-2-yl) methanamine, that coordinates to the heme iron. This could reflect the importance of the hydrogen bonding and aromatic-aromatic interactions with the aromatic nitrogen of the pyridine ring relative to any inherent difference in the affinity of the amino versus the pyridine nitrogen for coordination to the heme iron.
Example 11
Graphics
Unless otherwise indicated, molecular graphics were generated in PyMOL (supra). All probe accessible cavity volumes were calculated with the program VOIDOO with a probe radius of 1.4 Å and grid spacing of 0.33 Å.
Other Aspects
The detailed description set-forth above is provided to aid those skilled in the art in practicing the present teachings. However, the teachings described and claimed herein is not to be limited in scope by the specific aspects herein disclosed because these aspects are intended as illustration of several aspects of the teachings. Any equivalent aspects are intended to be within the scope of this teachings. Indeed, various modifications of the teachings in addition to those shown and described herein will become apparent to those skilled in the art from the foregoing description which do not depart from the spirit or scope of the present inventive discovery. Such modifications are also intended to fall within the scope of the appended claims.
References Cited
All publications, patents, patent applications and other references cited in this application are incorporated herein by reference in their entirety for all purposes to the same extent as if each individual publication, patent, patent application or other reference was specifically and individually indicated to be incorporated by reference in its entirety for all purposes. Citation of a reference herein shall not be construed as an admission that such is prior art to the present teachings. In particular, incorporated herein by reference in its entirety is: Yano J K, Hsu M H, Griffin K J, Stout C D, Johnson E F. Structures of human microsomal cytochrome P450 2A6 complexed with coumarin and methoxsalen. Nat. Struct. Mol. Biol. 2005 September; 12(9):822-3. | The teachings relates to the three-dimensional structure of a crystal of a cytochrome protein complexed with a ligand. The three-dimensional structure of four cytochrome P450 2A6-ligand complexes are disclosed. Cytochrome P450 2A6-ligand crystal structures, wherein the ligand is an inhibitor molecule, are useful for providing structural information that may be integrated into drug screening and drug design processes. Thus, the teachings also relate to methods for utilizing a crystal structure of a cytochrome P450 2A6-ligand complex for identifying, designing, selecting, or testing inhibitors of the cytochrome protein. Such inhibitors are useful as therapeutics for the treatment or modulation of i) diseases; ii) disease symptoms; or iii) the effect of other physiological events mediated by the cytochrome. | 8 |
FIELD OF THE INVENTION
The present invention relates to the field of integrated circuits and, in particular, to a method and process of forming a terraced film stack in an integrated circuit, such as dynamic random access memories (DRAMs).
BACKGROUND OF THE INVENTION
As integrated circuits continue to scale to still smaller feature sizes, shrinking device geometry and differing material properties pose challenges for feature processing at 90 nm and below. One problem is that of etch undercut that occurs when etching a film stack consisting of several different materials. FIG. 22A illustrates a stack of materials to be etched using a photoresist 400 . In this example, the stack consists of a metal layer 402 , such as titanium, an insulating layer 404 , such as tetraethylorthosilicate (TEOS) or other oxide, and other film layers, such as a polysilicon layer 406 . The photoresist layer 400 is patterned on top, and all of the layers below are etched. Etch selectivity, which describes the etching rate of one material relative to the etching rate of another material, is poor between the Ti metal layer and the TEOS insulating layer. Accordingly, while polysilicon layer 406 is being cleaned, the TEOS insulating layer 404 is unintentionally etched as well, as illustrated in FIG. 22B . That is, as the polysilicon in polysilicon layer 406 underneath the TEOS insulating layer 404 is being etched vertically, the TEOS insulating layer 404 is etched laterally. Additional undercutting may further result from a subsequent cleaning prior to a deposition as depicted by FIG. 22C , resulting in an undercut trench 408 . Such an undercut trench becomes difficult to reliably fill using conventional techniques without creating voids in the fill. These voids can be fatal to device performance.
SUMMARY OF THE INVENTION
It is against the above background that the present invention provides a method and apparatus directed to forming a terraced film stack in a semiconductor device, for example, a DRAM device, which provides a number of advancements and advantages over the prior art.
In one embodiment, a method of forming a memory device is disclosed. The method comprises providing a substrate assembly having underlying material layers, and providing an insulating layer over the underlying material layers. The method further includes providing a first metal layer on the insulating layer, providing a photoresist with a first pattern, and etching the insulating layer and the first metal layer through the first pattern to expose at least one of the underlying material layers, the etching defining in the insulating layer a first cavity having a first width. The method also includes etching the photoresist to provide a second pattern, etching the first metal layer through the second pattern to define a second cavity over the first cavity, the second cavity having a second width larger than the first width, removing the photoresist, and depositing a second metal layer over the substrate to fill the first and second cavities.
In another embodiment, a memory device having a terraced film stack is disclosed, which comprises a substrate assembly having underlying material layers. An insulating layer is provided over the underlying material layers. The insulating layer has a first cavity having a first width. A metal layer is provided on the insulating layer. The metal layer has a second cavity over the first cavity. The second cavity has a second width larger than the first width, and a material layer is provided over the substrate to fill the first and second cavities.
These and other features and advantages of the invention will be more fully understood from the following description of various embodiments of the invention taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1 is a cross-sectional view of the early stages of fabrication of a semiconductor device in accordance with an exemplary embodiment of the present invention.
FIG. 2 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 1 .
FIG. 3 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 2 .
FIG. 4 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 3 .
FIG. 5 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 4 .
FIG. 6 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 5 .
FIG. 7 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 6 .
FIG. 8 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 7 .
FIG. 9 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 8 .
FIG. 10 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 9 .
FIG. 11 shows the semiconductor device of FIG. 1 at a processing step according to an alternate embodiment of the present invention.
FIG. 12 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 11 according to an alternate embodiment of the present invention.
FIG. 13 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 12 according to an alternate embodiment of the present invention.
FIG. 14 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 13 according to an alternate embodiment of the present invention.
FIG. 15 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 14 according to an alternate embodiment of the present invention.
FIG. 16 shows the semiconductor device of FIG. 1 at a processing step subsequent to that shown in FIG. 15 according to an alternate embodiment of the present invention.
FIG. 17 shows another embodiment of a semiconductor device at a processing step according to another alternative embodiment of the present invention.
FIG. 18 shows the semiconductor device of FIG. 17 at a processing step subsequent to that shown in FIG. 17 according to an alternate embodiment of the present invention.
FIG. 19 shows the semiconductor device of FIG. 17 at a processing step subsequent to that shown in FIG. 18 according to an alternate embodiment of the present invention.
FIG. 20 shows the semiconductor device of FIG. 17 at a processing step subsequent to that shown in FIG. 19 according to an alternate embodiment of the present invention.
FIG. 21 shows the semiconductor device of FIG. 17 at a processing step subsequent to that shown in FIG. 20 according to an alternate embodiment of the present invention.
FIGS. 22A , 22 B, and 22 C depict a conventional etching process resulting in an undercut trench.
DETAILED DESCRIPTION
In the following detailed description, reference is made to various specific embodiments in which the invention may be practiced. These embodiments are described with sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be employed, and that various structural, logical, and electrical changes may be made without departing from the spirit or scope of the invention. Additionally, well-known structures, processes, and materials associated with microelectronic device fabrication have not been shown in detail in order to avoid unnecessarily obscuring the description of the embodiments of the invention.
Furthermore, skilled artisans appreciate that elements in the figure are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of the various embodiments of the present invention.
The term “substrate” used in the following description may include any semiconductor-based structure that has an exposed substrate surface. Structure should be understood to include silicon-on-insulator (SOI), silicon-on-sapphire (SOS), doped and undoped semiconductors, epitaxial layers of silicon supported by a base semiconductor foundation, and other semiconductor structures. When reference is made to a substrate or wafer in the following description, previous process steps may have been utilized to form regions or junctions in or over the base semiconductor or foundation.
The present invention relates to forming, during a buried bit line connection process flow, low resistance contacts to a substrate in the peripheral circuit logic area and to poly plugs in the memory cell array area formed as part of a memory device, such as a DRAM memory device. The present invention will be described as set forth in an exemplary embodiment illustrated below. Other embodiments may be used and structural or logical changes may be made without departing from the spirit or the scope of the present invention.
In accordance with the present invention, a method is provided for forming low resistance contacts for both N and P doped active regions in a peripheral logic circuitry area, which is typically formed outside of and around a memory cell array area. Referring now to the drawings, where like elements are designated by like reference numerals, FIGS. 1 through 16 illustrate exemplary embodiments of the fabrication steps and resulting structures in accordance with the present invention.
Referring to FIG. 1 , a first embodiment of a semiconductor device is illustrated wherein on a substrate 100 , a memory cell array indicated generally by reference numeral 102 and a peripheral circuitry area, indicated generally by reference numeral 104 are shown during an early stage of fabrication. The peripheral circuitry area 104 is typically either an N-channel transistor area or a P-channel transistor area. The memory cell array 102 includes gate stacks 106 , 108 , 110 , 112 , where in one embodiment, gate stacks 108 and 110 in the memory cell array comprise electrically isolated word lines 114 , 116 . Active areas are provided about the gate stacks 106 , 108 , 110 , 112 , such as the doped active areas 120 , 122 , 124 that form Field Effect Transistors (FETs) provided between field isolation areas 118 , 126 .
Each of the gate stacks 106 , 108 , 110 , 112 includes a layer of oxide 128 , such as silicon dioxide in contact with the substrate, a layer of polysilicon 129 provided on the oxide, a conductive gate layer 130 provided on the poly, an insulating cap layer 132 , and insulating sidewalls 134 . Provided between the gate stacks 106 , 108 , 110 , 112 are polysilicon (poly) plugs 136 , 138 , 140 . The polysilicon (poly) plugs 136 , 140 shown in FIG. 1 will connect with subsequently formed memory cell capacitors and poly plug 138 will connect with a subsequently formed bit line. Accordingly, gate stacks 108 , 110 are part of access transistors 142 , 144 for respective memory cells. Additionally, gate stacks 106 , 112 formed part of other memory cells in a different cross-sectional plane from that illustrated, which are used for self-aligned fabrication processes, and field oxide regions 118 , 126 are used to isolating the memory cells in the memory cell array 102 .
A doped well 146 may be provided in the substrate 100 and associated with a respective memory cell array 102 and peripheral circuitry area 104 . For the N-channel transistors, the doped well 146 is a p-well, while for the P-channel transistors the doped well is a n-well, as is well known in the art.
As further shown in FIG. 1 , planarized first insulating layer 148 , formed of, for example, borophosphosilicate glass (BPSG) or silicon dioxide has been formed over the gate stacks and active areas. The first insulating layer 148 is then planarized by chemical mechanical polishing (CMP) or other suitable means. A second insulating layer 150 , formed of, for example, tetraethylorthosilicate (TEOS) or other oxide, is formed over the first insulating layer 148 . The second insulating layer 150 is deposited with a thickness, for low resistance contacts of current integration size and levels, in a range of about 5 Angstroms to about 10,000 Angstroms. Of course, one skilled in the art will be able to easily vary the relevant dimensions to fit the particular application. If desired, the second insulating layer 150 may also by planarized by chemical mechanical polishing (CMP) or other suitable means; however, this step may be skipped as the first insulating layer 148 is planar. The substrate assembly shown by FIG. 1 serves as the starting foundation for the invention which is discussed hereafter.
The process of the present invention begins by applying a photoresist mask 152 to the second insulating layer 150 . Opening 154 in the mask defines an etch location of a peripheral contact to other wordlines and actives areas. As shown in FIG. 2 , a first portion of the first and second insulating layers is removed by etching to expose, for example, an active area 156 which is N+ doped for N-channel transistors, and P+ doped for P-channel transistors. It is also possible to dope the active area 156 after the etching operation instead of doping such areas prior to etching. The contact opening 158 is thus provided, as shown in FIG. 2 .
As shown by the structure illustrated in FIG. 3 , after contact opening 158 is formed, such as by reactive ion etching (RIE), the photoresist mask 152 is removed and a low resistance metal film layer 160 is deposited by CVD over the second insulating layer 150 . The metal film layer 160 is titanium which will cover the contact opening 158 , and form titanium silicide (TiSi x ) in the peripheral circuitry area 104 in a subsequent heating cycle when the layers are annealed at temperatures above 650° C. The metal film layer 160 is deposited with a thickness in a range of about 1 Angstrom to about 5,000 Angstroms. As the second insulating layer 150 is intact over the memory cell array area 102 , no CVD Ti comes into contact with poly plug 138 , which will connect with a subsequently formed bit connection.
In another embodiment, TiSi x can be provided in the contact opening 158 by reacting chemically vapor deposited Ti with Si from the substrate 100 or with Si simultaneously added from the vapor phase. For example, the titanium silicide areas in the contact opening 158 may be formed by depositing Ti from the precursor TiCl 4 , with the Si coming from the substrate 100 or from added gas-phase SiH 4 or SiH 2 Cl 2 .
After Ti deposition, a second photoresist mask 162 is provided over the Ti film layer 160 to a thickness standard in the art, and patterned to provide an opening 164 located over the memory cell array area 102 , and in particular poly plug 138 as illustrated by FIG. 4 . As shown by the structure illustrated in FIG. 5 , bit connection opening 166 is formed by anisotropically etching through the first and second insulating layers 150 , 160 , thereby opening the bit connections in the memory cell array area 102 . It is to be appreciated that the etching process to form the bit connection openings in the memory cell array area 102 can be one or more process steps (in-situ or ex-situ).
In the first part of the bit connection opening formation process, the Ti metal film layer 160 is anisotropically etched using a reactive halogen containing plasma etch process, such as chlorine, fluorine, and the like, which is very selective and stops at the first insulating layer 150 . In the second part of the bit connection opening formation process, the first insulating layer 150 is then anisotropically etched using a reactive halogen containing plasma etch process to remove the portion of the first insulating layer 150 over the bit connections, thereby exposing the bit connection poly plugs, such as for example, poly plug 138 .
At this point in the bit connection opening formation process, the steps illustrated by FIGS. 6 and 7 and explained hereafter, are performed in order to provided a terrace film stack. In order to address metal undercut during a pre-clean process, such as with an aqueous or non-aqueous mixture of HF and/or NH 4 F, to a subsequent metal deposition step, a second etch is conducted to the bit connection opening 166 . To conduct the second etch, the second photoresist mask provides a second pattern having an opening 168 that is wider than the bit connection opening 166 as illustrated by FIG. 6 . In one embodiment, the photoresist layer 162 is isotropically etched using an oxygen containing plasma etch process to expose precise portions of the Ti film layer 160 around the connection opening 166 . Lastly, the exposed portions of the Ti film layer 160 are then anisotropically etched by a reactive halogen containing plasma etch process as is illustrated by FIG. 7 .
As shown by FIG. 8 , the second photoresist mask 162 is stripped and then the metal deposition pre-clean step is performed. It is to be appreciated that the pre-clean process further widens the connection opening 166 , as indicated by the dotted lines, but not as wide as opening 168 . In the pre-clean process, the TEOS insulating layer 150 etches faster than the CVD Ti film layer 160 , and without the widening process providing opening 168 , the Ti film layer 160 would most likely get undercut. The trimming of the photoresist layer 152 and subsequent additional Ti etch will result in a terraced film stack as illustrated in the subsequent process flow which prevents void formation in the bit connection.
Referring now to FIG. 9 , after the formation and cleaning of the contact opening, a low-resistivity metal mode titanium/tungsten nitride/tungsten (MMTI/WN/W) terraced film stack is provided. First, a metal mode (metallic) titanium film layer 170 is deposited, using a physical vapor deposition (PVD) process, over the memory cell array and peripheral circuitry areas 102 and 104 , respectively, which fills into the openings 154 , 166 , 168 ( FIG. 8 ). It is to be appreciated that the metal mode titanium film layer 170 does not form suicides or ultra thin silicides, thus providing good contact to the poly plug 138 without voiding. The metal mode titanium film layer 170 is deposited with a thickness in a range of about 1 Angstrom to about 5000 Angstroms.
Next the WN/W layer 172 is deposited using either a PVD or CVD process, which completely fills the peripheral contact opening 154 . The WN/W film layer 172 is deposited with a thickness in a range of about 5 Angstroms to about 5000 Angstroms. Finally, a nitride capping layer 174 is deposited and planarized to have a thickness in a range of about 100 Angstroms to about 10,000 Angstroms.
As shown in FIG. 10 , a directional etching process or other suitable process is used to etch through a photoresist mask (not shown) to remove portions of layers 160 , 170 , 172 , 174 in areas not desired and in order to form low resistance contacts 176 , 178 . The contacts 176 , 178 may be of any suitable size and shape so as to provide a low resistance vertical path to the active areas 122 , 146 . The contacts, such as contact 176 , in the peripheral circuitry area 104 are preferably of a smaller area than the contacts, such as contact 178 , in the memory cell array area 102 .
An alternate embodiment is described with reference to FIGS. 11–16 . Like numerals from the first described embodiment are utilized where appropriate, with differences being indicated by 200 series numerals or with different numerals. FIG. 11 , shows a processing step conducted similar to the processing steps shown in FIG. 1 , except that the first photoresist mask 152 is patterned to provide the contact opening 164 in the memory cell array area 102 , and not the peripheral circuitry area 104 as in FIG. 1 . A directional etching process or other suitable process occurs to etch through the first insulating layer 150 as indicated by the dotted lines in FIG. 11 , thus exposing poly plug 138 .
Referring to FIG. 12 , the photoresist mask layer 152 is then removed after the etching process, and the metal mode titanium layer 170 is deposited over the memory cell array and the peripheral circuitry areas 102 and 104 , respectively. The metal mode deposition is then followed by a deposition of a tungsten nitride layer 200 . Accordingly, the metal mode titanium layer 170 is formed over the exposed outer surfaces of poly plug 138 . Alternatively, layer 170 may comprise titanium, titanium nitride, tungsten, cobalt, molybdenum or tantalum, but any suitable metal may be used. Additionally, each layer 170 , 200 may be planarized by, for example, by CMP after deposition.
As shown in FIG. 13 , the second photoresist layer 162 has been deposited over the substrate to fill opening 164 above the poly plug 138 . The photoresist layer 162 is then patterned to form the etching opening 154 for the subsequently formed peripheral contact.
As shown in FIG. 14 , a directional etching or other suitable etch process is performed to etch through layers 148 , 150 , 170 , and 200 to form the contact opening 154 so as to expose a contact area in the substrate 100 . It is to be appreciated that the metal mode titanium layer 170 and tungsten nitride layer 200 are used as a hard mask if needed, such that only the first and second insulating layers 148 , 150 are etched after etching portions of layers 170 , 200 with the directional etching process. The contact opening 154 in one embodiment is of a smaller diameter than the opening 164 above the poly plug 138 .
After formation of the peripheral contact opening 154 , the process steps for forming the terraced film stack as explained previously above in reference to FIGS. 6 and 7 is conducted. As explained above, the second photoresist layer 162 is used again to provide an opening that is wider than the contact opening 154 . In one embodiment, the second photoresist layer 162 is isotropically etched using an oxygen containing plasma etch process to expose precise portions of the tungsten nitride layer 200 around the connection opening 154 . Lastly, the exposed portions of the tungsten nitride layer 200 and the underling metal mode titanium layer 170 are then anisotropically etched by a reactive halogen containing plasma etch process to widen opening 154 to the dashed line 155 .
Next, the second photoresist layer 162 is striped away, and the titanium layer 160 is deposited by CVD as shown by FIG. 15 . As mentioned previously above, the CVD Ti layer 160 provides a low resistance periphery contact, which due to the process flow illustrated in FIGS. 11–14 , does not coming into contact with the poly plug 138 in the memory cell array area 102 , thus preventing voiding. An adhesion/barrier layer 202 formed from a suitable material such as titanium nitride is then deposited by CVD or other suitable deposition process. This deposition is then followed by a conductive layer 204 formed from a suitable conductive material such as tungsten or other metal to fill the contact opening 154 as illustrated by FIG. 16 . The nitride capping layer 174 is then deposited and layers 174 , 204 , 202 , 160 , 200 , 170 are etched and patterned so as to form contacts 206 , 208 having a top portion situated on the second insulating layer 150 as also shown by FIG. 16 . The contacts 206 , 208 may be of any suitable size and shape so as to provide a low resistance vertical path to the active areas of the memory cell array and peripheral circuitry areas 102 and 104 , respectively.
In accordance with the present invention the contacts are formed after the formation of the capacitors. In particular, the process of forming the contacts begins after the completion of all high temperature processing steps utilized in wafer fabrication and after any other temperature changes that affect the metal layers provided in the contact formation process. In one embodiment, the process begins after the heat cycles used for cell poly activation and capacitor formation. The contacts may be formed prior to forming upper cell plate contacts to the capacitor of the memory device but subsequent to high temperature processing treatment for the capacitor. Furthermore, the present invention is not limited to the illustrated layers. Any suitable number and/or arrangement of conductive and insulating layers may be used without departing from the spirit of the invention.
For example, referring to FIG. 17 , a second embodiment of a semiconductor device is illustrated, wherein like numerals from the first described embodiment are utilized where appropriate, with differences being indicated by 300 series numerals or with different numerals. On a substrate 100 , a memory cell array indicated generally by reference numeral 102 is shown during an early stage of fabrication. The memory cell array 102 includes gate stacks 106 , 108 , 110 . Active areas are provided about the gate stacks 106 , 108 , 110 , such as the doped active areas 120 , 122 , that form Field Effect Transistors (FETs) provided between field isolation areas 118 , 126 .
Each of the gate stacks 106 , 108 , 110 , includes a layer of oxide 128 , such as silicon dioxide in contact with the substrate, a layer of polysilicon 129 provided on the oxide, a conductive gate layer 130 provided on the poly, an insulating cap layer 132 , and insulating sidewalls 134 . Provided between the gate stacks 106 , 108 , 110 , are polysilicon (poly) plugs 136 , 138 . Additionally, a trench capacitor, generally indicated by symbol 300 , is provide below the gate stacks, and in particular, centrally below gate stack 108 .
As further shown in FIG. 17 , a first insulating layer 148 , formed of, for example, borophosphosilicate glass (BPSG) or silicon dioxide surrounds the gate stacks 106 , 108 , 110 and remaining active areas. The first insulating layer 148 and insulating cap layer 132 is planarized, such as by chemical mechanical polishing (CMP) or other suitable means.
A second insulating layer 150 , formed of, for example, tetraethylorthosilicate (TEOS) or other oxide, is formed over the first insulating layer 148 and insulating cap layer 132 . The second insulating layer 150 is deposited with a thickness, for low resistance contacts of current integration size and levels, in a range of about 5 Angstroms to about 10,000 Angstroms. Of course, one skilled in the art will be able to easily vary the relevant dimensions to fit the particular application. If desired, the second insulating layer 150 may also by planarized by chemical mechanical polishing (CMP) or other suitable means; however, this step may be skipped as the first insulating layer 148 is planar. A low resistance metal film layer 160 is deposited by CVD over the second insulating layer 150 . In one embodiment, the metal film layer 160 is titanium or other suitable metal or metal based film. The metal film layer 160 is deposited with a thickness in a range of about 1 Angstrom to about 5,000 Angstroms.
Next, the process of the present invention begins by applying a photoresist mask 152 to the metal film layer 160 . The openings in the mask defines etch locations, and as shown in FIG. 18 , portions of the second insulating layer 150 and metal film layer 160 are removed by etching to expose, for example, portions of the insulating cap layer 132 and the first insulating layer 148 .
A second etch is then conducted to the metal film layer 160 . To conduct the second etch, the photoresist mask 152 provides a second pattern having openings wider than the previous pattern openings illustrated by FIG. 17 . In one embodiment, the photoresist layer 152 is isotropically etched using an oxygen containing plasma etch process to expose precise portions of the metal film layer 160 . Lastly, the exposed portions of the metal film layer 160 are then anisotropically etched by a reactive halogen containing plasma etch process as is illustrated by the dotted lines in FIG. 19 .
As shown by FIG. 20 , the photoresist mask 152 is stripped and then a metal deposition pre-clean step is performed. In one embodiment, it is to be appreciated that the pre-clean process further etches the insulating layer 150 , as indicated by the dotted lines. In this embodiment, a TEOS insulating layer 150 etches faster than the CVD Ti film layer 160 , and without the trimming process discussed above, the Ti film layer 160 is often undercut, which in a subsequent material deposition step, would result in void formation. The subsequent material deposition of a material 302 is illustrated by FIG. 21 . The material 302 in one embodiment is a metal or material containing metal. It is to be appreciated that the trimming of the photoresist layer 152 and subsequent additional metal film layer etch results in a terraced film stack which prevents void formation.
The above description and drawings are only to be considered illustrative of exemplary embodiments, which achieve the features and advantages of the present invention. Modification and substitutions to specific process conditions and structures can be made without departing from the spirit and scope of the present invention. Accordingly, the 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. | A process and apparatus directed to forming a terraced film stack of a semiconductor device, for example, a DRAM memory device, is disclosed. The present invention addresses etch undercut resulting from materials of different etch selectivity used in the film stack, which if not addressed can cause device failure. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to wireless communications and particularly to radio frequency components for use in mobile communication terminals such as mobile phones and wireless communication terminals such as wireless LAN, which feature increased function, high integration, reduced size and low price.
[0003] 2. Description of the Related Art
[0004] With the growing tendency towards more compact wireless communication terminals, there is demand for radio frequency components for wireless communication terminals that fit into a smaller packaging area. Conventionally, circuit of radio frequency parts have been divided into several blocks by function and the blocks have been manufactured separately as modules while efforts have been made to improve reliability, reduce size and increase integrtaion for each module. For example, methods of heat dissipation in power amplifier (hereinafter referred to as PA) modules including power amplifiers as heater elements are disclosed in JP-A No. 27570/1997 and JP-A No. 147349/1995.
[0005] In recent years, JP-A No. 8584/1997 and JP-A No. 266546/1999 disclose techniques which produce more compact radio frequency components with higher integration in function by combining modules which would be separately manufactured in the former methods.
[0006] PA requires a heat dissipation structure because it consumes much electric power and generates heat. For this reason, various PA module structures for effective heat dissipation are disclosed: one example is a multilayer substrate which has, on its surface layer, an electrically isolated metallized layer or a metallized layer connected to a grounding layer (JP-A No. 147349/1995) and another example concerns a structure of a substrate in which the almost whole surface of the ceramic substrate is covered with a metal layer and through holes for heat dissipation are uniformly distributed almost all over the substrate (JP-A No. 27570/1997).
[0007] However, these conventional techniques have the following drawback: in a module which integrates a power amplifier and a device whose operating characteristics vary with rise in temperature, namely a device having sensitive temperature dependence of characteristics, on a substrate, the influence of the heat generated by the PA on the device having sensitive temperature dependence of characteristics is not taken into consideration, or though it is taken into consideration to mount a PA and a deveice having sensitive temperature dependence of characteristics together in a module, attention is not paid to the fact that part of the heat is conducted in the module substrate and then to the above-said device having sensitive temperature dependence of characteristics.
[0008] Therefore, in the conventional techniques, when a device having sensitive temperature dependence of characteristics is mounted together with a power amplifier on a substrate, the fair distance between both the devices was needed to avoid the influence of the heat generated by the power amplifier. Furthermore, a deterioration in electrical characteristics which is caused by change in characteristics with temperature rise has been unavoidable. For this reason, it has been impossible to produce a compact, high performance radio frequency module in the form of both a power amplifier, which generates heat, and a device having sensitive temperature dependence of characteristics are mounted together.
SUMMARY OF THE INVENTION
[0009] The present invention introduces a new concept of suppressing temperature rise in the part of a substrate where the above-mentioned device having sensitive temperature dependence of characteristics is placed for a radio frequency module where a power amplifier and the device having sensitive temperature dependence of characteristics are integrated, thereby solving the above problem and realizing a compact, high-performance radio frequency module.
[0010] The present invention focuses the structure of a radio frequency module which solves the above problem and particularly the arrangement of conductor layers.
[0011] According to one aspect of the present invention, a radio frequency module comprises at least: a first chip forming a heater element; a second chip forming a device whose operating characteristics vary with temperature change or whose maximum operating temperature is lower than the maximum operating temperature of the first chip; and a multilayer substrate which is comprised of a plurality of dielectric layers and a plurality of conductor layers and mechanically supports the first chip and the second chip with some of the conductor layers electrically connected with these chips, wherein the first chip is located on a conductor layer provided on the top face of the multilayer substrate or on a first conductor pattern made on a conductor layer inside a cavity made in the multilayer substrate; the second chip is located on a conductor layer provided on the top face of the multilayer substrate or on a second conductor pattern made on a conductor layer inside a cavity made in the multilayer substrate; and when the multilayer substrate is fixed on another substrate, it is fixed with its bottom face in contact with the other substrate, and the module has at least one of the following means: means for conducting the heat generated by the first chip throughout the module; means for guiding the heat generated by the first chip from the module's top face to its bottom face; and means for interrupting heat conduction from the first conductor pattern to the second conductor pattern.
[0012] According to another aspect of the invention, a radio frequency module comprises at least: a first chip forming a heater element; a second chip forming a device whose operating characteristics vary with temperature change or whose maximum operating temperature is lower than the maximum operating temperature of the first chip; and a multilayer substrate which is comprised of a plurality of dielectric layers and a plurality of conductor layers and mechanically supports the first chip and the second chip with some of the conductor layers electrically connected with these chips, wherein the first chip is located on a conductor layer provided on the top face of the multilayer substrate or on a first conductor pattern made on a conductor layer inside a cavity made in the multilayer substrate; the second chip is located on a conductor layer provided on the top face of the multilayer substrate or on a second conductor pattern made on a conductor layer inside a cavity made in the multilayer substrate; and when the multilayer substrate is fixed on another substrate, it is fixed with its bottom face in contact with the other substrate and the first conductor pattern and another conductor pattern electrically connected with the first conductor pattern are isolated from the second conductor pattern and another conductor pattern electrically connected with the second conductor pattern at the conductor layer in which the second conductor pattern is formed and conductor layers closer to the top face of the multilayer substrate than the conductor layer in which the second conductor pattern is formed.
[0013] According to a further aspect of the invention, the first conductor pattern and another conductor pattern electrically connected with the first conductor pattern are isolated from the second conductor pattern and another conductor pattern electrically connected with the second conductor pattern at the conductor layer in which the second conductor pattern is formed and conductor layers closer to the top face of the multilayer substrate than the conductor layer in which the second conductor pattern is formed and the former conductor patterns are connected with the latter ones at least at one of the conductor layers located closer to the bottom face of the multilayer substrate than the conductor layer in which the second conductor pattern is formed.
[0014] According to a further aspect of the invention, a radio frequency module comprises a first chip; a second chip whose heat value per unit time may be smaller than that of the first chip; and a multilayer substrate comprised of a plurality of conductor layers and a plurality of dielectric layers, wherein the first chip and the second chip are electrically connected with any of the conductor layers, and there are a first structure for conducting the heat generated by the first chip horizontally in the module and a second structure for conducting the heat vertically in the module.
[0015] A conductor layer may be used for the first structure. The conductor layer can conduct the heat generated by the first chip horizontally. When the conductor layer extends to the substrate's outer edge area, it realize easier heat conduction in a substrate. One approach to controlling the heat conductivity of the conductor layer is to cut off patterns in the conductor layer. To this end, part of the conductor layer may be removed or a groove may be made.
[0016] The first chip, for example a power amplifier, does not always generate heat but turns on and off periodically in some cases. The primary object of the invention is to prevent the second chip from being affected by the heat generated by the first chip which is operating.
[0017] According to a further aspect of the invention, as a method for preventing heat conduction from the first chip to the second chip, a heat isolation zone which crosses the line connecting the first chip and the second chip is specified on the main surface of the multilayer substrate and the conductor layer area corresponding to the projection from the heat isolation zone is removed or a groove is made in the area corresponding to the projection from the heat isolation zone. The conductor layer area corresponding to the projection from the heat isolation zone may be removed in all the conductor layers or in a single conductor layer. Also, the whole area corresponding to the projection or part of the area may be removed.
[0018] One example of the second structure is a via hole.
[0019] To put the first chip and the second chip at the different conductor layer each other is effective to reduce the thermal effect to the second chip, because the distance between the first chip and the second chip becomes longer than that in case of mounting them on the same layer.
[0020] According to the present invention, even when a first device which has a power amplifying function and a second device which has sensitive temperature dependence of characteristics such as a surface acoustic wave device (hereinafter referred to as a “SAW” device) are integrated on a substrate, the temperature rise of the area in which the second device is placed can be suppressed and its thermal interference with the first device can be reduced so that it is possible to provide a compact radio frequency module with higher integration in function which allows the first device and the second device to operate normally and stably.
[0021] The use of a radio frequency module according to the present invention enables to realize of a more compact wireless communication terminal or if the size of a wireless communication terminal is fixed, it offers more space for new additional functions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be more particularly described with reference to the accompanying drawings, in which:
[0023] FIG. 1 is a sectional view showing a first embodiment of the present invention;
[0024] FIG. 2 is a sectional view showing a second embodiment of the present invention;
[0025] FIG. 3A is a top view showing a conductor pattern on a conductor layer 5 a according to the second embodiment of the present invention and FIG. 3B is a top view showing a conductor pattern on a conductor layer 5 b according to the second embodiment of the present invention;
[0026] FIG. 4C is a top view showing a conductor pattern on a conductor layer 5 c according to the second embodiment of the present invention and FIG. 4D is a top view showing a conductor pattern on a conductor layer 5 d according to the second embodiment of the present invention;
[0027] FIG. 5E is a top view showing a conductor pattern on a conductor layer 5 e according to the second embodiment of the present invention and FIG. 5F is a top view showing a conductor pattern on a conductor layer 5 f according to the second embodiment of the present invention;
[0028] FIG. 6 is a sectional view showing a third embodiment of the present invention;
[0029] FIG. 7 is a sectional view showing a fourth embodiment of the present invention;
[0030] FIG. 8 is a sectional view showing a fifth embodiment of the present invention;
[0031] FIG. 9 is a top view showing a conductor layer pattern according to the fifth embodiment of the present invention;
[0032] FIG. 10 is a sectional view showing a sixth embodiment of the present invention;
[0033] FIG. 11 is a sectional view showing a variation of the sixth embodiment of the present invention;
[0034] FIG. 12 is a perspective view showing a seventh embodiment of the present invention;
[0035] FIG. 13 is a perspective view showing an eighth embodiment of the present invention;
[0036] FIG. 14 is a sectional view showing a ninth embodiment of the present invention;
[0037] FIG. 15 is a perspective view showing a tenth embodiment of the present invention;
[0038] FIG. 16 is a sectional view showing the tenth embodiment of the present invention; and
[0039] FIG. 17 is another sectional view showing the tenth embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] Next, preferred embodiments of the present invention will be described in detail referring to the accompanying drawings. In the figures which illustrate the embodiments, components which have the same functions are designated by the same reference numerals and components which are once explained will not be explained again.
[0041] FIG. 1 is a sectional view showing a radio frequency module according to a first embodiment of the present invention. The first embodiment is a radio frequency module in which a power amplifier 1 and a SAW device 2 ( ) are mounted on a ceramic multilayer substrate 3 . The SAW device 2 in this embodiment has a function as a transmitting filter. The multilayer substrate 3 is composed of six dielectric layers 4 a , 4 b , 4 c , 4 d , 4 e , 4 f and seven conductor layers 5 a , 5 b , 5 c , 5 d , 5 e , 5 f , 5 g . According to the first embodiment, the power amplifier 1 is mounted by silver paste or solder on a conductor pattern 10 formed on the conductor layer 5 a . The SAW device 2 is mountd by silver paste or solder on a conductor pattern 13 formed on the conductor layer 5 e inside a cavity 6 made by partially removing the dielectric layers 4 a to 4 d . The conductor pattern on the surface of each device and the relevant conductor layer of the multilayer substrate are connected by bonding wires 7 . The cavity, in which the SAW device 2 is located, is hermetically sealed by a cover 40 . With a passive device 8 and the like on the top face of the multilayer substrate, the substrate top is covered by a lid 50 .
[0042] In this embodiment, the multilayer substrate 3 has two areas: a first area 100 and a second area 200 . The first area 100 includes the power amplifier 1 , the passive device 8 for its operation, a wiring pattern 101 which connects them, and a conductor pattern 102 which serves as the ground for the power amplifier 1 ; the second area 200 includes the SAW device 2 and a passive device 80 for its operation, a wiring pattern 201 which connects them and a conductor pattern 202 which serves as the ground for the SAW device 2 .
[0043] The heat generated by the power amplifier 1 is conducted partially from the module surface and partially through the conductor pattern 10 holding the power amplifier 1 , then through conductor layers and dielectric layers or via holes 11 down to the bottom face 12 of the module while being cconducted horizontally and vertically. From the bottom face 12 , the heat goes, for example, through a motherboard (not shown) on which the module is mounted, before being forced out of the module (for example, dissipated into the air).
[0044] In the present invention, the SAW device 2 , which has sensitive temperature dependence of characteristics, and the power amplifier 2 are integrated on the same multilayer substrate 3 so it is necessary to minimize temperature rise of the conductor pattern 13 holding the SAW device 2 in order to prevent or reduce the possibility of deterioration in the SAW device 2 .
[0045] For this purpose, preferably the module should have either of the following structures or a combination of them: one structure is such that the heat is conducted throughout the module to reduce rise in the overall temperature of the module; another structure is such that the heat can easily emanate from the conductor pattern 10 holding the power amplifier 1 or from the conductor pattern 13 holding the SAW device; and a further structure is such that the heat from the power amplifier 1 is hardly transfered to the conductor pattern holding the SAW device 2 .
[0046] In the first embodiment of the present invention, in order to facilitate heat conduction inside the module, as many conductors as possible are provided in each of the first area 100 and the second area 200 . In the first embodiment there is an area 300 where conductors are not connected between the area 100 and the area 200 at the following conductor layers; conductor layers between the conducter layer in which the conductor pattern 13 is formed and the conductor layer in which the conductor pattern 10 is formed, namely conductor layer 5 a , 5 b , 5 c , 5 d and 5 e . Therefore, as the heat conducted from the conductor pattern 10 passes mainly through conductors or via holes 11 and enters the first area 100 , the heat conductivity becomes low in the area 300 and the heat is hardly conducted into the second area 200 . As a result, the amount of heat which is conducted into the second area 200 decreases. Also in the second area 200 , as many conductors as possible are provided in order to conduct the incoming heat throughout the second area 200 . Therefore, the amount of heat which is conducted to the conductor pattern 13 holding the SAW device 2 decreases so that the temperature rise of the conductor pattern 13 can be suppressed, resulting in a reduction in the temperature rise of the SAW device 2 .
[0047] Consequently, even when the power amplifier 1 and SAW device 2 are ingtegrated into one module, the SAW device 2 can operate with stability.
[0048] Next, a second embodiment of the present invention is described referring to FIG. 2 . FIG. 2 is a sectional view showing a radio frequency module according to the second embodiment. The structure of the second embodiment is the same as that of the first embodiment except that the multilayer substrate 3 is composed of five dielectric layers and six conductor layers and a cavity in which the SAW device 2 is located extends from the dielectric layer 4 b to the dielectric layer 4 e.
[0049] In this embodiment, a conductor pattern electrically connected with the conductor pattern 10 holding the power amplifier 1 is connected with another conductor pattern electrically connected with the conductor pattern 13 holding the SAW device 2 at the conductor layers 5 e and 5 f which are located below the conductor pattern 13 . Between the conductor layers 5 a to 5 d , there is an area 300 in which the conductor pattern 10 holding the power amplifier 1 and the other conductor pattern electrically connected with the conductor pattern 10 are not connected with the conductor pattern 13 holding the SAW device 2 and the other conductor pattern electrically connected with the conductor pattern 13 .
[0050] FIGS. 3A to 5 F respectively show the respective conductor patterns on the conductor layers 5 a to 5 f . The power amplifier 1 is mounted on the conductor pattern 10 as shown in FIG. 3A and the heat generated by the power amplifier 1 is conducted through conductor patterns (shown in FIG. 3A to FIG. 5F ) horizontally or mainly through the via holes 11 vertically. In this embodiment, the power amplifier is held by the conductor pattern 10 (as shown in FIG. 3A ) while the SAW device 2 is held by the conductor pattern 13 (as shown in FIG. 3B ). The module is designed so that the conductor pattern 14 ( FIG. 3B ), conductor pattern 15 ( FIG. 4C ) and conductor pattern 16 ( FIG. 4D ), which are electrically connected through the via holes 11 to the conductor pattern 10 , are not connected with the conductor pattern 31 ( FIG. 4C ) and conductor pattern 32 ( FIG. 4D ) which are electrically connected through via holes 30 to the conductor pattern 13 holding the SAW device, at the same layer level. On the other hand, as shown in FIGS. 5E and 5F , the conductor pattern electrically connected with the conductor pattern 10 and the conductor pattern electrically connected with the conductor pattern 13 are connected with each other at the conductor layers 5 e and 5 f , by a conductor pattern 17 and a conductor pattern 18 , respectively.
[0051] As a consequence, the heat generated by the power amplifier 1 is hardly conducted to the conductor layer 5 b holding the SAW device 2 and the conductor layers located adjacent to it, 5 a , 5 c and 5 d , which curbs the temperature rise of the conductor pattern 13 and enables the SAW device 2 to operate with stability.
[0052] The wiring which carries signals from the power amplifier 1 to the SAW device 2 crosses the boundary zone between the first area 100 to the second area 200 through a wiring pattern 60 provided on the conductor layer 5 d as shown in FIG. 4D . The area of wiring which carries signals from the power amplifier 1 to the SAW device 2 is smaller than that of the conductor patterns 10 and 14 and thus the amount of heat which is conducted from the first area 100 to the second area 200 is smaller. Accordingly, the influence of the heat conducted through the wiring pattern 60 on the SAW device 2 is not considerable so the wiring pattern 60 need not always be provided on the conductor layer 5 d ; instead it may be provided on a layer above or below the conductor layer 5 d.
[0053] Therefore, even when the power amplifier 1 and SAW device 2 are mounted on the same multilayer substrate 3 , the adoption of the structure as defined by the present invention reduces the influence of the heat generated by the power amplifier 1 on the SAW device 2 , so it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability even when both the devices are densely integrated in the substrate.
[0054] Next, a third embodiment of the present invention is described, referring to FIG. 6 . FIG. 6 is a sectional view showing the third embodiment. The structure of the radio frequency module in the third embodiment is the same as that in the second embodiment except that via holes 70 are provided between the conductor pattern 10 holding the power amplifier 1 and the conductor pattern 13 holding the SAW device 2 , in addition to the via holes 11 located beneath the power amplifier 1 . These via holes 70 further encourage the heat to be conducted vertically, thereby decreasing the amount of heat to be conducted towards the conductor pattern 13 holding the SAW device 2 . As a consequence, the influence of the heat generated by the power amplifier 1 on the SAW device 2 is reduced so it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability even when both the devices are densely integrated in the substrate.
[0055] Next, a fourth embodiment of the present invention is described, referring to FIG. 7 . FIG. 7 is a sectional view showing the fourth embodiment. The structure of the radio frequency module in the fourth embodiment is the same as that in the second embodiment except that there is a groove 80 between the conductor pattern 10 holding the power amplifier 1 and the conductor pattern 13 holding the SAW device 2 . The groove 80 decreases the amount of heat to be conducted horizontally. As a consequence, the influence of the heat generated by the power amplifier 1 on the SAW device 2 is reduced so it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability even when both the devices are densely integrated in the substarate.
[0056] Next, a fifth embodiment of the present invention is described, referring to FIG. 8 . FIG. 8 is a sectional view showing the fifth embodiment. The structure of the radio frequency module in the fifth embodiment is the same as that in the second embodiment except that a conductor pattern 17 electrically connected with the conductor pattern 10 holding the power amplifier 1 is electrically connected with a metal lid 40 for the cavity 6 in which the SAW device 2 is located. The difference between the conductor layer 5 e in the second embodiment and that in the fifth embodiment is explained below referring to FIG. 5E and FIG. 9 .
[0057] FIG. 9 illustrates the conductor pattern on the conductor layer 5 e in the radio frequency module according to the fifth embodiment while FIG. 5E illustrates the conductor pattern on the conductor layer 5 e according to the second embodiment. In the second embodiment, an area 41 which is in contact with the metal lid 40 for the cavity 6 is not electrically connected with the conductor pattern 17 surrounding it. On the other hand, in the fifth embodiment, as shown in FIG. 9 , the conductor pattern 17 is in contact with the area 41 which is in contact with the metal lid 40 . As a result, since the heat from the power amplifier 1 is conducted to the metal lid 40 , the heat is easier to disperse inside the radio frequency module than in the second embodiment and thus the overall temperature of the module is decreased, which leads to a decrease in the temperature of the area in which the SAW device 2 is located. Accordingly, the module structure according to this embodiment makes the temperature rise of the conductor pattern 13 holding the SAW device smaller than the module structure according to the second embodiment. As a consequence, the adoption of the same module structure as defined by this embodiment reduces the influence of the heat generated by the power amplifier 1 on the SAW device 2 so it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability even when both the devices are densely integrated in the substrate.
[0058] Next, a sixth embodiment of the present invention is described, referring to FIG. 10 . FIG. 10 is a sectional view showing the sixth embodiment. The structure of the module in this embodiment is the same as that in the first embodiment except that the conductor pattern in the first area 100 and that in the second area 200 are not connected with each other at the conductor layers 5 f and 5 g . Thus, the conductor patterns which serve as the grounds in the first area 100 and the second area 200 are not connected at any layer, so horizontal heat conduction is smaller than in the first embodiment. This means that, although the module temperature in the first area 199 may rise a little, the amount of heat which is conducted from the power amplifier 1 to the conductor pattern 13 holding the SAW device 2 can be reduced. Consequently it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability.
[0059] FIG. 11 shows a variation of the embodiment shown in FIG. 10 . As can be seen from FIG. 11 , in a situation that the radio frequency module according to the sixth embodiment of the present invention is mounted on a motherboard 350 , a conductor-free zone 352 which fits the conductor free area between the first area 100 and the second area 200 of the radio frequency module is made in a conductor pattern 351 on the motherboard 350 so that the heat which is conducted from the first area 100 through the conductor on the motherboard 350 to the second area 200 can be reduced. Hence, it is possible to provide a radio frequency module which allows the SAW device 2 to operate with stability even when the power amplifier 1 and the SAW device 2 are densely integrated in the substrate.
[0060] FIG. 12 shows a seventh embodiment of the present invention.
[0061] FIG. 13 shows an eighth embodiment of the present invention.
[0062] FIGS. 12 and 13 only show the shape of the multilayer substrate 3 and the positional relationship between the power amplifier 1 and the SAW device 2 where the conductor patterns of the radio frequency module are omitted. Here, the conductor patterns on the respective layers are much the same as those in the embodiments mentioned earlier. In these embodiments, the power amplifier 1 is located on the top face of the multilayer substrate 3 and the SAW device 2 is located inside the cavity 6 made through the bottom of the substrate 3 . The multilayer substrate 3 is mounted on the motherboard 350 .
[0063] In these embodiments, top view of the substrate of the radio frequency module is not rectangular but L-shaped or U-shaped and the power amplifier 1 and the SAW device 2 are located in the peripheral area of the module as illustrated in FIGS. 12 and 13 . The module structures according to these embodiments make it possible to increase the distance between the power amplifier 1 and the SAW device 2 and thereby reduce heat conduction, resulting in a decrease in the temperature of the area in which the SAW device 2 is located. Part of the heat conducted to the motherboard 350 is conducted through the motherboard 350 by the conductor pattern 351 . Therefore, as illustrated in FIG. 13 , the conductor pattern 351 on the motherboard 350 may have a conductor-free area 352 between the SAW device 2 and the power amplifier 1 .
[0064] Referring to FIG. 14 , a ninth embodiment of the present invention is explained next. The ninth embodiment is the same as the embodiments mentioned so far except that the power amplifier 1 is located inside a cavity 90 made in the multilayer substrate 3 . Like the embodiment shown in FIG. 6 , this embodiment has via holes 70 between the power amplifier 1 and the SAW device 2 in addition to the via holes beneath the power amplifier 1 in order to help the heat conduct towards the motherboard.
[0065] Referring to FIG. 15 , a tenth embodiment of the present invention is explained next. FIG. 15 shows a radio frequency module which combines not only the power amplifier 1 and the SAW device but also an RF-IC 400 . In FIG. 15 , the SAW device is located in a cavity (not shown). This embodiment has different areas with different functions: a first area 100 which includes the power amplifier 1 and components of a matching circuit for the power amplifier; a second area 200 which includes filter components such as a SAW device, switch, capacitance and inductor; and a third area 500 which includes an RF-IC 400 and components related to RF-IC operation.
[0066] In this case, although the conductors which serve as the grounds for the respective areas may be connected not within the multilayer substrate 3 but on the motherboard 350 as in the embodiment shown in FIG. 10 , from the viewpoint of suppressing the module temperature rise caused by the heat generated by the power amplifier 1 it is desirable to use a structure that conducts the heat throughout the module by connecting conductor patterns as far as possible while at the same time preventing the heat from being conducted to the conductor pattern (not shown) holding the SAW device.
[0067] FIG. 16 is a sectional view taken along the dotted line A-B of FIG. 15 . In the embodiment shown in FIG. 16 , at the conductor layer holding the SAW device 2 and the conductor layers located above it, the conductors which serve as the grounds for the first area 100 and third area 500 are continuous with each other. In addition, via holes 71 and 72 are provided under the RF-IC chip 400 and the SAW device respectively so that the heat conducted to the third area 500 and the second area 200 is guided to the motherboard (not shown). As a consequence, the temperature rise of the conductor pattern 13 holding the SAW device 2 is suppressed and thus it is possible to provide a radio frequency module which enables the SAW device 2 to operate with stability.
[0068] FIG. 17 shows another example of a radio frequency module structure. Needless to say, the radio frequency module structure is not limited to that shown in FIG. 16 ; it is acceptable to employ the radio frequency structure as shown in FIG. 17 in which, while the conductor patterns which serve as the grounds for the second area 200 and the third area 500 are continuous with each other, the conductor patterns in the first area 100 are not connected at the conductor layer on which the conductor pattern 13 where the SAW device 2 is mounted and the conductor layers located above that layer.
[0069] This approach, in which the power amplifier and SAW device are integrated in a module as described above, combined with a integration of a switch and an RF-IC in the module, makes it easier to design radio frequency curcuit parts, requires a smaller number of man-hours for assembling, provides more handling ease and thus enables production of terminals at lower cost than the conventional method in which components are individually assembled into a terminal.
[0070] As discussed so far, the adoption of a module structure according to the present invention makes it possible to provide a more compact radio frequency module which assures more stable operation of a SAW device with no deterioration in the SAW device performance than existing radio frequency modules.
[0071] It is apparent that the present invention is not limited to a combination of a power amplifier and a SAW device and may be applied to a combination of another type of heater element and another type of device having sensitive temperature dependence of characteristics.
[0072] Furthermore, the invention may be embodied in any forms other than the above-mentioned embodiments without departing from the spirit and scope of the invention. | In a compact radio frequency module, a first chip forms a heater element and a second chip forms a device whose operating characteristics vary with temperature change or whose maximum operating temperature is lower than the maximum operating temperature of the first chip. A multilayer substrate has a plurality of dielectric layers and a plurality of conductor layers and mechanically supports the first chip and the second chip with some of the conductor layers electrically connected with these chips. The module can conduct the heat generated by the first chip throughout the module; guide the heat generated by the first chip from the module's top face side to its bottom face side; and interrupt the heat conduction from the first conductor pattern on which the first chip is placed to the second conductor pattern on which the second chip is placed. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 14/046,924, which was filed on Oct. 5, 2013, and entitled “Prosthesis for Partial and Total Joint Replacement.
TECHNICAL FIELD
[0002] The present invention relates to prosthetic joints. More specifically, a prosthetic joint having an improved connection to the medullary canals is provided. Additionally, a prosthetic joint that may be used for either partial or total joint replacement is provided.
BACKGROUND INFORMATION
[0003] There are three bones in the elbow: the humerus, the ulna, and the radius. These three bones articulate in the ulnohumeral, radiohumeral and radioulnar joints. Each of the joint surfaces is covered with articular cartilage and motion occurs at these articulations with distinct motion profiles. The cartilage allows the bones to slide easily against one another as the joint moves through its range of motion. The ulnohumeral joint is most essential for transmitting forces through the elbow.
[0004] Degenerative joint diseases such as Osteoarthritis as well as inflammatory arthritides such as Rheumatoid arthritis commonly affect the elbow joints and causes articular degeneration and marginal bone formation. In post-traumatic settings, where surgical efforts have failed to restore adequate alignment, post-traumatic arthritis may set in and become symptomatic with patients experiencing pain and a loss of range of motion. Whether idiopathic, inflammatory or post-traumatic, elbow arthritis is often painful and may interfere with function of the entire arm.
[0005] Initial non-operative intervention often includes splinting and steroid injections. Elbow joint synovectomy and debridement of arthritic spurs are surgical options when the cartilage damage is limited. Arthodesis (i.e., joint fusion) is an option for very damaged joints and is rarely used as elbow range of motion is sacrificed. Functional requirements of the patient often necessitate a durable solution that maintains range of motion. Accordingly, numerous prior efforts have been undertaken to replace this joint.
[0006] Whereas degenerative joint diseases usually affect patients after the fifth decade of life, traumatic conditions may cause elbow joint impairment in younger age groups. Elbow fractures such as of the distal humerus or olecranon often exhibit intra-articular involvement, which can lead to permanent cartilage damage despite the best surgical reconstruction efforts. This is particularly true when anatomic reconstruction of the joint surfaces is not successful or if osteochondral portions are missing as may occur in open injuries. In these settings, consideration for a primary joint replacement as an option may be given. Often, only a portion of the elbow joint is injured such as the distal humerus and it may benefit from reconstruction. High energy injuries such as Motorcycle accidents may damage the distal humerus of younger patients and leave the ulna and radius relatively uninjured. Thus, the ability to replace either the distal humerus only (hemiarthroplasty) or the entire elbow (total arthroplasty) is quite helpful.
[0007] Initial joint replacement efforts were done as early as 1947, when surgeons employed custom made hinges to replace elbow joints. However, the results of these early efforts were characterized by implant loosening, instability and poor clinical results. Hurri L, Pulkki T, Vainio K. Arthroplasty of the Elbow in Rheumatoid Arthritis , ACTA CHIR SCAND 964; 127:459-465; Dee R. Total Replacement Arthroplasty of the Elbow for Rheumatoid Arthritis , J BONE JOINT SURG BR 1972; 54 (1):88-95; Cross M B, Sherman S L, Kepler C K et al. The Evolution of Elbow Arthroplasty: Innovative Solutions to Complex Clinical Problems , J BONE JOINT SURG AM 2011; 92 Suppl 2:98-104. In the 1970s, the first simple hinged elbow prostheses were implanted using cementing techniques. Cross M B, Sherman S L, Kepler C K et al. The Evolution of Elbow Arthroplasty: Innovative Solutions to Complex Clinical Problems , J BONE JOINT SURG AM 2011; 92 Suppl 2:98-104. This improved the stability of the construct, but still resulted in rates of loosening of up to 50%. Garrett J C, Ewald F C, Thomas W H et al. Loosening Associated with G.S.B. Hinge Total Elbow Replacement in Patients with Rheumatoid Arthritis , CLIN ORTHOP RELAT RES 1977; (127):170-174. As a result of these observations, different design concepts have emerged: linked, unlinked, convertible and modular elbow prostheses.
[0008] Linked, or “semi-constrained,” prostheses are commonly used implants and employ a “sloppy hinge” mechanism that allows for some varus, valgus, and rotational movement. The linked design offers superior stability and dislocations of these joints are rare, however, the constrained design transfers forces through the bone-cement or bone-implant interface which then results in significant loosening rates.
[0009] Unlinked or “unconstrained” prosthesis designs work without a mechanical linkage between the components. These prostheses can be implanted while maintaining good bone stock and offer decreased polyethylene wear when compared to their linked counterparts. Since there is no mechanical linkage between the components, the stability of the construct relies greatly on the soft tissues around the elbow. It is believed that a well-balanced soft tissue envelope reduces stress at the bone-cement and bone-implant interfaces which results in lower loosening rates compared to linked designs. Understandably, this reliance on soft tissues to maintain stability results in higher rates of instability and joint dislocation compared to linked designs. These characteristics prevent the use of an unlinked prosthesis in situations where soft tissue integrity is poor or extensive bone loss has occurred.
[0010] Total elbow arthroplasty systems have been developed that allow intra-operative decision making with regards to what type of implant may be best suited. “Convertible” systems have been developed that allow the placement of either a semi-constrained or an unconstrained construct based on the soft tissue integrity of the patient. These designs allow intraoperative conversion between unlinked and linked inplants as dictated by the integrity of the soft tissues and bone.
[0011] Modular arthroplasty relates to replacement of a portion of the elbow joint. Total elbow arthroplasty may not be an ideal solution for younger patients. This group may benefit from replacement of only those regions that are damaged while preserving unaffected joint surfaces. On occasion, the distal humerus is severely injured with relative sparing of the proximal ulna or radius. In some instances, such as high energy motor vehicle accidents, the distal humerus is not salvageable. Thus, the ability to replace either the distal humerus only (hemiarthroplasty) or the entire elbow (total arthroplasty) is quite helpful. A modular system would then also allow the surgeon to add implants at a later time as subsequent wear and tear of the remaining native joint surfaces may occur.
[0012] A currently available modular elbow arthroplasty system is the UNI-Elbow Radio Capitellum System (Small Bone Innovations) that allows for replacement of the radio-humeral joint in isolation. It is a Uni-compartmental arthroplasty of the elbow where the lateral side of the elbow is replaced in isolation. Additionally, the Latitude Total Elbow prosthesis (Tornier, USA) is a total elbow replacement system whose distal humerus component matches native anatomy closely and can be used in isolation (hemiarthroplasty) in instances where the ulna is in good condition.
[0013] In a case series on hemiarthroplasty for distal humerus fractures in elderly patients using the Latitude System mainly good to excellent short-term results based on a Mayo score and good functional results were achieved. None of the complications required implant removal and only in one case did progressive osteoarthritis of the proximal ulna and radius occur. These results only represented a mean follow-up of 12.1 months, however, and therefore must be interpreted cautiously. Burkhart K J, Nijs S, Mattyasovszky S G et al. Distal Humerus Hemiarthroplasty of the Elbow for Comminuted Distal Humeral Fractures in the Elderly Patient , J TRAUMA 2011; 71 (3):635-642. The use of the Kudo prosthesis for hemiarthroplasty purposes has been described in a small case series with reasonable functional outcome after a mean of 4 years status after implantation. However, radiographic signs of attrition indicate that this implant may not be ideally suited for this role. Adolfsson L, Nestorson J. The Kudo Humeral Component as Primary Hemiarthroplasty in Distal Humeral Fractures , J SHOULDER ELBOW SURG 2012; 21 (4):451-455.
[0014] At this time, all commercially available implants whether linked, unlinked, convertible or modular are cemented in place. Even though this offers a quick, reliable, and relatively durable bone-to-implant fixation, there are significant limitations. The most noteworthy is that the implant and cement mantle is difficult to remove if this is required such as in the face of an infection or peri-prosthetic fracture. If the implant is merely loose and improved fixation is required, then the cement can be removed where it is loose and left in place where it is often quite inaccessible. It is when eradicating an infection, however, when the entire cement mantle needs to be accounted for and eliminated, that the surgical effort to accomplish this becomes quite involved. Damage to the soft tissues as well as neurovascular structures can occur and, even in the best of circumstances, significant bone stock is removed along with the cement. To address the subsequent bone loss, Zimmer (Warsaw, Ind., USA) markets a method whereby new bone is introduced through impaction grafting around a repeat cement mantle when a second implant is placed in a revision arthroplasty setting. With patients living longer and more active lives, it is of paramount importance to offer an implant that can be rigidly placed but then also removed without undue trauma to the bones and the soft tissue envelope into which they gain fixation.
[0015] The use of cement has the potential added drawback of causing thermal osteonecrosis. The cement is inserted at room temperature into the intramedullary canal to secure an implant and employs an exothermic reaction to become hard. This high temperature may damage the surrounding bone and potentially compromise its ability to heal after implant installation. It may also hinder new bone growth advantageous to helping secure the implant after installation.
[0016] Elbow arthroplasty carries serious potential complications. The most dire complication is the development acute, subacute, or chronic infections. The soft tissue envelope that surrounds the elbow is thin, thereby making this location vulnerable to this complication. The incidence of deep infections after Total Elbow Arthroplasty lies between 3 and 8%. Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339; Tachihara A, Nakamura H, Yoshioka T et al., Postoperative Results and Complications of Total Elbow Arthroplasty in Patients with Rheumatoid Arthritis: Three Types of Nonconstrained Arthroplasty , MOD RHEUMATOL 2008; 18 (5):465-471; Gschwend N, Simmen B R, Matejovsky Z. Late Complications in Elbow Arthroplasty , J SHOULDER ELBOW SURG 1996; 5 (2 Pt 1):86-96. The causative organism is usually Staph. Aureus or Epidermidis. Staph. Epidermidis is considered more virulent due to its ability to form biofilms. In most patients the time span between index arthroplasty and revision is more than three weeks and spontaneous drainage after ten days may be indicative of deep bacterial colonization. Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339.
[0017] Infections after Total Elbow Arthroplasty should be managed aggressively and resection arthroplasty may be warranted. Resistant infections are managed by hardware removal and debridement of all affected structures including bone, soft tissues and bone cement. Because of the significant recurrence rate, re-implantation should only be performed cautiously given that prosthesis survival is significantly diminished in those cases (77% 3-year, 48% 8-year survival). Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339. Given that the cement must be removed in addition to the implant in order to eradicate the infection, the likelihood of having reasonable bone stock remaining after the implant and bone cement has been removed is low. Realizing the low survival rate of the second implant, the decision to re-implant a new arthroplasty is often met with significant resistance. Most patients do not want to undergo a re-implantation effort. Having an implant system that contains no cement and can be removed much more easily when compared to its cemented brethren would minimize the bone loss associated with implant removal and increase the likelihood of subsequent re-implantation.
[0018] Peri-prosthetic loosening may occur after implantation and often requires revision surgical efforts. Bennett J B, Mehlhoff T L. Total Elbow Arthroplasty: Surgical Technique , J HAND SuRG AM 2009; 34 (5):933-939. To ensure longevity, patients must be willing to accept a lifelong 5-lb lifting restriction to that extremity. Bennett J B, Mehlhoff T L. Total Elbow Arthroplasty: Surgical Technique , J HAND SURG AM 2009; 34 (5):933-939. In general, the ulnar components are at the highest risk for aseptic loosening and this risk is associated with the quality of fixation. An estimated 7 to 17% of all total elbow arthroplasties show clinical loosening, whereas the rate of radiographic loosening is even higher. Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339. Tachihara A, Nakamura H, Yoshioka T et al. Postoperative Results and Complications of Total Elbow Arthroplasty in Patients with Rheumatoid Arthritis: Three Types of Nonconstrained Arthroplasty , MOD RHEUMATOL 2008; 18 (5):465-471; Gschwend N, Simmen B R, Matejovsky Z. Late Complications in Elbow Arthroplasty , J SHOULDER ELBOW SURG 1996; 5 (2 Pt 1):86-96. The design of a semi-constrained elbow prosthesis, allowing for an element of varus-valgus laxity, is thought to reduce the incidence of aseptic loosening. Ensuring both accurate implant positioning as well as excellent cement fixation are crucial to minimize stress on the implant as well as the development of aseptic loosening. Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339. Revision arthroplasty should be considered in the setting of instability and pain. When this happens, both the prosthesis and cement should be removed using adequate instruments. Sometimes an osteotomy or the creation of bone windows is needed. Cementless implantation is rarely employed. Uncemented elbow arthroplasty in rheumatoid arthritis patients was described utilizing the Kudo prosthesis which demonstrated a high rate of aseptic loosening (7 of 49) within the ulnar component ultimately leading to an inability to recommend this implant without the use of cement fixation. Brinkman J M, de Vos M J, Eygendaal D. Failure Mechanisms in Uncemented Kudo Type 5 Elbow Prosthesis in Patients with Rheumatoid Arthritis: 7 of 49 Ulnar Components Revised Because of Loosening After 2-10 years , ACTA ORTHOP 2007; 78 (2):263-270.
[0019] Periprosthetic fracture after primary total elbow arthroplasty occurs with an incidence of 5 to 29% with underlying causes including direct trauma, osteoarthritis, or aseptic loosening. Kim J M, Mudgal C S, Konopka J F et al. Complications of Total Elbow Arthroplasty , J AM ACAD ORTHOP SURG 2011; 19 (6):328-339. Tachihara A, Nakamura H, Yoshioka T et al. Postoperative Results and Complications of Total Elbow Arthroplasty in Patients with Rheumatoid Arthritis: Three Types of Nonconstrained Arthroplasty , MOD RHEUMATOL 2008; 18 (5):465-471; Hildebrand K A, Patterson S D, Regan W D et al. Functional Outcome of Semiconstrained Total Elbow Arthroplasty , J BONE JOINT SURG AM 2000; 82-A (10):1379-1386; O'Driscoll S W, Morrey B F. Periprosthetic Fractures about the Elbow , ORTHOP CLIN NORTH AM 1999; 30 (2):319-325. Periprosthetic elbow fracture treatment has been characterized in the literature. O'Driscoll S W, Morrey B F. Periprosthetic Fractures about the Elbow , ORTHOP CLIN NORTH AM 1999; 30 (2):319-325; Foruria A M, Sanchez-Sotelo J, Oh L S et al. The Surgical Treatment of Periprosthetic Elbow Fractures Around the Ulnar Stem Following Semiconstrained Total Elbow Arthroplasty , J BONE JOINT SURG AM 2011; 93 (15):1399-1407; Sanchez-Sotelo J, O'Driscoll S, Morrey B F. Periprosthetic Humeral Fractures After Total Elbow Arthroplasty: Treatment with Implant Revision and Strut Allograft Augmentation , J BONE JOINT SURG AM 2002; 84-A (9):1642-1650.
[0020] Not all fractures require surgical treatment and immobilization may be sufficient in some cases. With significant displacement, open reduction and internal fixation should be performed. In these cases the bone stock at the fracture site dictates the technique used such as cerclage wiring or plate fixation. A significant hardship when treating periprosthetic fractures involves the cement mantle that surrounds the implant. As it lies within the fractured bone and exhibits no healing capability, the cement often has to be removed and then the void filled with bone graft. Not all periprostetic fractures are associated with implant loosening yet frequently these two occur in combination mandating a revision-arthroplasty effort in addition to the fracture open reduction and internal fixation. Sanchez-Sotelo J, O'Driscoll S, Morrey B F. Periprosthetic Humeral Fractures After Total Elbow Arthroplasty: Treatment with Implant Revision and Strut Allograft Augmentation , J BONE JOINT SURG AM 2002; 84-A (9):1642-1650. Some cases even require two-staged treatment where fracture union is achieved first and revision arthroplasty is done in a second step. Tokunaga D, Hojo T, Ohashi S et al. Periprosthetic Ulnar Fracture After Loosening of Total Elbow Arthroplasty Treated by Two - Stage Implant Revision: A Case Report , J SHOULDER ELBOW SURG 2006; 15 (6):e23-26. If significant loss of bone stock is present within the distal humerus or proximal ulna, successful surgical revision may not be possible leading to salvage options such as an arthrodesis or leaving the elbow flail or even consideration of an amputation.
[0021] Other complications may occur that are unrelated to the method of component fixation. For example, ulnar nerve irritation is a concern with any extensive surgery around the elbow and triceps insufficiency may occur either in the acute or later stages.
[0022] Bone cement implantation syndrome (BCIS) is a unique problem associated with cement fixation of an implant. It occurs primarily in association with cemented Total Hip arthroplasty. It is characterized by hypoxia, hypotension or both and/or unexpected loss of consciousness occurring around the time of cementation, prosthesis insertion, reduction of the joint or, occasionally, limb tourniquet deflation in a patient undergoing cemented bone surgery. Bone cement implantation syndrome (BCIS) is poorly understood and yet is an important cause of intraoperative mortality and morbidity in patients undergoing cemented hip arthroplasty and may also be seen in the postoperative period in a milder form causing hypoxia and confusion. Currently, when preparing for cementation, the anesthesiologist is informed that the cementation process is being started so as to closely monitor any adverse intra-operative effect. Our design does not include cement fixation at all and, thereby, eliminates this risk. A. J. Donaldson, H. E. Thomson, N. J. Harper and N. W. Kenny. Bone cement implantation syndrome , BR J ANAESTH 2009; 102: 12-22.
[0023] Different devices for the prosthetic treatment of the elbow joint have been developed. Commercially available systems for elbow arthroplasty at the present time include:
1. Solar® total elbow system, sold by Stryker Orthopaedics, which is a linked hinge design that employs cement fixation. 2. GBS III Elbow System, sold by Sulzer Orthopedics, which is an unlinked, cemented total elbow system. 3. Coonrad/Morrey Total Elbow, sold by Zimmer Inc., which is a linked hinge system that employs cement fixation. 4. Discovery elbow system, sold by Biomet, which is a linked, cemented total elbow system. 5. IBP Elbow System, sold by Biomet, which is a linked, cemented total elbow system. 6. Biomet Huene BiAxial Elbow System, sold by Biomet, which is a linked, cemented total elbow system. 7. DePuy Pritchard ERS (DePuy, USA)—not currently marketed 8. Latitude Total Elbow, which is a modular, convertible, cemented total elbow system. 9. Stryker Howmedica Souter-Strathclyde, which is sold by Stryker, and which is not currently marketed. 10. Stryker Howmedica Kudo type 5 elbow prosthesis, sold by Stryker, and which is not currently marketed. 11. Stryker Osteonics elbow prosthesis, sold by Styker, which is a linked, cemented total elbow system. This system is not currently marketed. 12. Volz AHSC elbow prosthesis, which is not presently marketed. 13. Wright Sorbie-Questor Total Elbow Systems, sold by Wright, which is an unlinked, cemented total elbow system. This system is not currently marketed. 14. Acclaim Total Elbow System, sold by DePuy, which is a convertible, cemented total elbow system. This system is not currently marketed. 15. Biopro Total Elbow System, which is sold by Biopro Inc., USA. This system is not currently marketed.
[0039] All of the above elbow prostheses are secured to the respective bones with bone cement and, therefore, carry all of the disadvantages inherent in bone cement.
[0040] Numerous other elbow prostheses have been proposed. For example, U.S. Pat. No. 2,696,817 discloses a prosthetic elbow joint comprising two threaded shafts that are separately inserted into the medullary canals. The threads of each shaft cut mating threads or grooves in the walls of the bone cavity to prevent axial displacement and rotational displacement. After installation into the respective bones, these shafts are connected with a low friction bearing.
[0041] U.S. Pat. No. 3,547,115 discloses a prosthetic replacement of the articular surface of the distal humerus that is attached by trimming the bone to match the inner surface of the prosthesis and is locked in place by a keyhole-type mechanism. An intramedullary stem fixation method is not intended. This patent only replaces the distal humerus.
[0042] U.S. Pat. No. 3,708,805 discloses a prosthetic elbow joint. The humeral member and ulnar member are connected to form a hinge. The male portion of the hinge corresponds to the surface of the female portion of the hinge to avoid tissue being trapped therein. The stems used to cement each component to the bone are non-round to prevent rotation, and tapered to facilitate removal. The ulnar stem is curved eight inches, and the humerus stem is curved three inches. The elbow joint itself is angled to correspond to a natural elbow. This joint is designed for assembly prior to insertion. The hinge appears to prohibit any varus and valgus laxity.
[0043] U.S. Pat. No. 3,772,709 discloses an elbow prosthesis having a humeral component made of steel, and an ulnar component made of silicone. The components are held together using a metal pin, and are secured to the respective bones using cement.
[0044] U.S. Pat. No. 3,816,854 discloses a prosthesis for total arthroplasty of the elbow joint. The humeral and ulnar components are cemented to the bones with stems having a square cross-section. The ulnar component includes a cylindrical polyethylene bearing that articulates with a mating concave cylindrical surface defined by the humeral component.
[0045] U.S. Pat. No. 3,852,831 discloses an endoprosthetic elbow joint. The elbow joint includes a humeral component including a cylindrical bearing surface that is widest at its ends, tapering to a narrow center. This component articulates with an ulnar component that is saddle shaped. The wear surface of the ulnar component can be releasably connected with a dovetail connection. The humeral and ulnar components are retained together by the patient's joint capsule, making this an unconstrained joint.
[0046] U.S. Pat. No. 3,868,730 discloses a knee or elbow prosthesis. This prosthesis incorporates a coupled ball and socket connection. Although the title indicates that either an elbow or knee could be replaced, this reference is directed primarily towards knee replacement. A ball on a connecting rod extending upwardly from the tibial component is enclosed by a high density polyethylene socket insert retained within the bottom of the femoral component. The joint is designed to permit a slight degree of twisting or wobbling.
[0047] U.S. Pat. No. 3,919,725 discloses a hingeless endoprosthetic device for the elbow joint that comprises humeral and ulnar components. The cylindrical humeral surface is intramedullary fixed. The complementary ulnar component is made from silicone and sits within the ulna. The absence of long stems going into the bone is described as an advantage by this reference, providing for ease of installation and less removal of bone. The hingeless design is called advantageous due to the ease of installation and reduced chances of loosening. This unconstrained device requires that the patient's natural soft tissues are functional.
[0048] U.S. Pat. No. 3,939,496 discloses an endoprosthetic joint. The joint includes a humeral component having a pair of spherical bearing members. The ulnar component has a bearing block. Each component is secured on the bone by a long, grooved stem that is anchored by acrylic cement. The grooves key the stem to the acrylic. When installed, a pin passes through the bearings and bearing block to form a hinge. Once the joint capsule heals, the pin is removed to reduce distraction stresses. This joint is, therefore, convertible between a constrained and unconstrained design.
[0049] U.S. Pat. No. 3,990,117 discloses an implantable elbow prosthetic joint with cemented stems that articulate in a simple hinged mechanism. Varus and valgus forces are accounted for by allowing “wobble” to avoid damaging the pin assembly, and to place these forces between the shoulders of the implant.
[0050] U.S. Pat. No. 3,991,425 discloses a prosthetic joint. The prosthetic joint includes ceramic components having mating concave and convex condylar surfaces. Intersecting lands are provided for stopping motion at the joint's extended and contracted positions. Each of the mating components also includes a stem for implantation in the appropriate medullary canals.
[0051] U.S. Pat. No. 4,008,495 discloses a prosthetic bone joint. This joint is designed for minimal bone removal. The humeral component is a pair of frustoconical shapes joined at their narrow ends, which is installed by wedging the component into the intracondylar notch. The ulnar component is made from polymer, and includes a convex bearing surface. The ulnar component is held in place by a bone screw as well as acrylic cement.
[0052] U.S. Pat. No. 4,057,858 discloses an elbow prosthesis. This prosthesis includes a humeral component defining a groove in the shape of the helix for mating with a concave surface of the ulnar component. The obliquity of the groove within the trochlea allows the ulnar implant to move into valgus during elbow extension and varus in flexion. A second groove may mate with a radial component. This prosthesis is therefore unconstrained. All components include stems that are secured to the bone by cement.
[0053] U.S. Pat. No. 4,079,469 discloses an elbow joint endoprosthesis. The humeral component defines a T-shaped channel for receiving an I shaped portion of the ulnar component. The humeral component includes short longitudinal and transverse keys for securing to the bone. The humeral component also includes a surface for bearing against a radial component. The humeral component is made from polymer, and the ulnar component is made from chrome cobalt. The joint allows minimal varus and valgus yet allows for flexion and extension motion.
[0054] U.S. Pat. No. 4,129,902 discloses an elbow prosthesis. The humeral component is connected to an ulnar component by a shaft on the humeral implant and a sleeve on the ulnar implant, providing for hinged articulation between these components. Both implants include tapered stems that are cemented into the bone. A radial implant includes a metal shaft that rotates within a polymer sleeve, and is connected to the humeral component by a chain.
[0055] U.S. Pat. No. 4,131,956 discloses an elbow prosthesis. The humeral component includes a U-shaped section holding a non-rotatable polyethylene head. The ulnar component includes a corresponding curved surface for forming an unconstrained joint. Both components include spikes that are cemented into the bone.
[0056] U.S. Pat. No. 4,224,695 discloses an endoprosthetic elbow joint. The joint provides a hinged connection between the humeral component, ulnar component, and radial component. The radial component permits rotation around the axis of the radius as well as around the hinge joint. No varus and valgus laxity is allowed between the humerus and ulna.
[0057] U.S. Pat. No. 4,242,758 discloses an elbow prosthesis. The humeral components are a tube shaped metal piece with three generally spherical surfaces. A very accurate reproduction of the distal humerus articular surface is provided. It can be used either with an ulnar or a radial replacement or in isolation in which it acts as a hemi-arthroplasty. The ulnar component includes a concave plastic bearing surface with a metal support. The radial component includes a metal pin with a plastic, concave bearing surface. The joint appears unconstrained.
[0058] U.S. Pat. No. 4,280,231 discloses an elbow prosthesis. The humeral component includes a pair of sides connected by a cylindrical cross member. The ulnar component has a hook for engaging the cylindrical cross member. Both components include stems for securing to the bones with acrylic cement. The humeral member also includes a surface for engaging the radius.
[0059] U.S. Pat. No. 4,293,963 discloses an unconstrained elbow prosthesis. The prosthesis includes a humeral component having an elongated stem and a substantially cylindrical, convex articulating surface. The ulnar component includes a metal retainer with a polyethylene bearing. The metal retainer includes an elongated stem depending from a metal base, and which is slightly curved. The bearing includes a concave cylindrical cavity for receiving the cylinder of the humeral component. A limited amount of medial-lateral motion in addition to flexion and extension is allowed.
[0060] U.S. Pat. No. 4,383,337 discloses an elbow prosthesis. The humeral member has a stem and a flange on either side for retaining a bushing as well as a spherical surface for engaging a radial member or a radius. The ulnar member has a stem, a concave surface, and a central projection ending in a cylinder. The projection fits within the bearing. The radial member includes a concave surface. This implant is intended to be a semi constrained joint. The patent claims that the joint is capable of handling up to 50 kg of force.
[0061] U.S. Pat. No. 4,538,306 discloses an elbow prosthesis having a humeral component consisting of a sleeve with a circumferential slot. A cylindrical sliding member fits inside the sleeve, abutted by the sides of a slot cut into the humerus. The shaft is inserted through the slot in the sleeve, and secured to the sliding member. The shaft is secured within a hole in the ulna. The shaft and sliding member can, therefore, pivot with respect to the sleeve, forming a hinge. The shaft includes ridges for better retention within the ulna.
[0062] U.S. Pat. No. 4,681,590 discloses a femoral stem prosthesis. The prosthesis includes an elongated stem portion, and a ball shaped head. The stem portion includes one or more elongated resilient spring strips which are acted upon by an adjustable screw to cause the spring strips to bow outwardly into engagement with the canal walls.
[0063] U.S. Pat. No. 4,840,633 discloses a cementless endoprosthesis. The prosthesis includes a stem that is tapered towards its distal end. A pair of windows are defined the proximal area of the stem. The endoprosthesis further includes a screw spindle having a broad flanged thread in the form of a helix. The thread projects from the windows on either side of the endoprosthesis. Turning the screw spindle causes the helical broad flanged thread to cut into the adjacent bone structure, thereby securing the implant in place. This endoprosthetic stem provides for a load transmission exclusively into the proximal portion of the bone, while the distal portion is free of axial loads.
[0064] U.S. Pat. No. 5,167,666 discloses an endoprosthesis for a femur. The endoprosthesis includes a stem that is hollow, slotted, flexible and intended to avoid placing pressure on the bone at this point. A collar and clamping cone are located at the upper end of the endoprosthesis. A tension anchor includes a screw that passes through the femur and is fastened to the prosthesis collar.
[0065] U.S. Pat. No. 5,314,484 discloses a biaxial elbow joint replacement. The joint replacement includes a hinge block having an ulnar pivot as well is a humerus pivot. Each pivot permits movement through about 90°. A spike is attached to each pivot for cementing within the respective bone. The design is intended to minimize the transfer of stresses from one component to the other.
[0066] U.S. Pat. No. 5,376,121 discloses a dual constraint elbow prosthesis. The prosthesis includes humeral and ulnar members consisting of a spike for insertion into the bone, and the yoke for connecting to a connecting link. The spikes are intended to be secured with cement. The pivot dimensions for the ulnar member are intended to permit a slight sideways rocking, while the humeral member is more constrained. The prosthesis permits 16° of varus and valgus laxity as well as 10° of rotational laxity between the humeral and ulnar components with the hope that this would decrease polyethylene wear. Pivotal rotation that decreases torque is described. By using two axes of rotation, this design reproduces the anterior translocation of the ulna during motion.
[0067] U.S. Pat. No. 5,458,654 discloses a screw fixed femoral component for a hip joint prosthesis. The prosthesis includes an intramedullary stem as well as a portion for receiving a ball head. The stem has lateral screw holes defined therein. The stem is secured to the bone by drilling holes into the bone corresponding to the screw holes in the stem, and then driving screws into these holes.
[0068] U.S. Pat. No. 5,667,510 discloses a system for fusing the middle and distal phalanx bones in the finger.
[0069] U.S. Pat. No. 5,723,015 discloses an elbow prosthesis. The prosthesis includes an ulnar component having a head for receiving the spindle of the humeral components. A ring-like clip retains the spindle within the head. Both components have stems that are cemented into the intramedullary canal. Some play is permitted between the spindle and the clip.
[0070] U.S. Pat. No. 5,782,923 discloses an endoprosthesis for an elbow joint. The endoprosthesis includes hingedly connected humeral and ulnar components, each of which having a shaft for engagement in the bone canal. The ulnar component includes a lateral flange having a socket for guiding a sliding member. A radial component has a head portion that is swingingly mounted in the sliding member, thereby providing ball and socket articulation. The radial portion is, therefore, both swingable and displaceable with respect to the ulnar portion. The stems for the humeral, ulnar and radial components are cemented.
[0071] U.S. Pat. No. 5,879,395 discloses a total elbow prosthesis. The prosthesis includes cooperating humeral and ulnar elements. A radial element is provided with a ball that fits within a concave surface defined within the humeral element.
[0072] U.S. Pat. No. 6,027,534 discloses a modular elbow. The elbow includes humeral and ulnar components having stems for implantation in the intramedullary canals of the respective bones, and body portions that are each designed to receive bearings. The humeral member includes a pair of arms with a pivot extending therebetween, upon which one of the bearings may be placed. The ulnar member includes a slot for receiving a bearing member. The elbow may be used in an unconstrained manner by placing a generally cylindrical bearing on the humeral portion and a bearing having a concave surface on the ulnar portion. Alternatively, the implant may be used in a constrained manner by using a single bearing connected to both the humeral and ulnar components. A similar device is disclosed in U.S. Pat. No. 6,290,725 and U.S. Pat. No. 6,699,290.
[0073] U.S. Pat. No. 6,126,691 discloses a bone prosthesis fixation device. The mechanism includes a main body for implantation within the canal of a bone. The main body includes an internal passageway, as well as a plurality of openings extending between the passageway and the exterior of the main body. A plurality of bone engaging members are reciprocally positioned within each opening. When a plunger is passed into the internal passageway, the bone engaging members are pushed outward, thereby engaging the bone and securing the prosthesis into the bone. A second embodiment also provides a prosthetic device implantable into skeletal bone and has an elaborate gear system that rotates screws that gain fixation into the intramedullary canal.
[0074] U.S. Pat. No. 6,162,253 discloses a total elbow arthroplasty system that is intended for use in dogs, but for which the patent also recites possible use in humans. The device includes a combined radio-ulnar component having stems for installation into the canals of both the radius and the ulna. A concave surface on this component mates with a convex surface on the humeral components.
[0075] U.S. Pat. No. 6,306,171 discloses a total elbow arthroplasty system that is intended primarily for use in dogs, but for which the patent also recites possible use in humans. The implant includes a radial component having an isometric ball component that fits within a corresponding humeral component to form an unconstrained joint.
[0076] U.S. Pat. No. 6,379,387 discloses an elbow prosthesis. The elbow prosthesis includes a humeral component having a substantially cylindrical articulating surface that is concave, with its narrowest portion near the center of the part that interacts with the ulnar component. An ulnar component includes a second articulating surface having a concave portion structured to articulate with the humeral component, and having a convex surface to correspond to the surface of the cylindrical articulating surface. Varus and valgus movement is, therefore, permitted while retaining contact between the humeral and ulnar articulating surfaces. The ulnar component further includes a locking element forming an additional articulating surface, so that the total articulating surface of the ulnar component can extend over more than 180° of the humeral articulating surface. The locking element may be omitted if the surgeon realizes that the tendons and ligaments of the joint are in good condition. A portion of the humeral component's articulating surface extends beyond the retaining arms and interfaces with a radial component. A similar elbow prosthesis is disclosed in U.S. Pat. No. 6,760,368.
[0077] U.S. Pat. No. 6,475,242 discloses a plastic joint assembly. The joint assembly includes a flexible U-shaped connector that is secured to adjacent bones by threaded connectors.
[0078] U.S. Pat. No. 6,514,288 discloses a prosthetic femoral stem with a strengthening rib.
[0079] U.S. Pat. No. 6,517,541 discloses an axial intramedullary screw for the ostia synthesis of long bones. The screw is used for connecting pieces of fractured bones. The screw includes two tips at opposing ends for interfacing with a screwdriver, and threads across the remainder of its length for cutting into the cortical bone of the medullary canal. The screw can be threaded into one portion of a bone fragment and then, after connecting another bone fragment at the fracture site, screwed in the opposite direction into the second fragment.
[0080] U.S. Pat. No. 6,716,248 discloses a prosthetic joint that may be utilized to form either a single axis joint or a double axis joint, permitting the surgeon to decide which type to construct from the kit once the elbow has been exposed during surgery. A similar device is disclosed in U.S. Pat. No. 6,997,957.
[0081] U.S. Pat. No. 6,890,357 discloses an elbow prosthesis similar to that of U.S. Pat. No. 6,379,387. The elbow prosthesis includes a humeral component having a substantially cylindrical articulating surface that is concave, with its narrowest portion near the center of the part that interacts with the ulnar component. An ulnar component includes a second articulating surface having a concave portion structured to articulate with the humeral component, and having a convex surface to correspond to the surface of the cylindrical articulating surface. Varus and valgus movement is, therefore, permitted while retaining contact between humeral and ulnar articulating surfaces. The ulnar component further includes a locking element forming an interconnection with an additional articulating surface, so that the total articulating surface of the ulnar component can extend 360°. The locking element may be omitted if the surgeon realizes that the tendons and ligaments of the joint are in good condition. A portion of the humeral component's articulating surface extends beyond the retaining arms, and interfaces with a radial component or native radial head.
[0082] U.S. Pat. No. 7,247,170 discloses an elbow prosthesis. The ulnar component includes a pair of concave spherical bearing surfaces that interface with a pair of convex spherical bearing surfaces on the humeral components. An axis passing through the ulnar component connects the two bearing surfaces of the humeral components. The spherically shaped bearing surfaces are intended to transmit load over a relatively large area rather than at a point or over a line of contact. The surgeon may employ a modular flange for compressing a bone graft, a tissue fastener for securing soft tissue to a portion of the prosthetic joint, a cam for limiting the amount by which the prosthetic joint articulates or a bearing insert for tailoring the degree of varus/valgus constraint.
[0083] U.S. Pat. No. 7,850,737 discloses a prosthetic elbow replacement. The elbow replacement includes a humeral component having a stem dimension to fit within a medullary canal of a humorous, as well as a J shaped flange for providing additional support of the implant with respect to the humerus. Both the stem and the J shaped flange include porous surface sections into which bone tissue can grow and/or bone cement can infiltrate. The humeral component also includes a yoke terminating in a pair of arms having a pivot connected therebetween. The pivot includes a through hole for use in attaching an ulnar component. The ulnar component also includes an ulnar stem having a porous surface portion. Varus and valgus motion is provided by movement of the ulnar component with respect to the through hole of the pivot.
[0084] US 2005/0049710 discloses a prosthesis for partial replacement of an articulating surface on bone. The surfaces that are to be replaced are for the coronoid and the radial head. The fixation of these partial prostheses is done with headless and regular screws.
[0085] US 2007/0185584 discloses a method and apparatus for digit joint arthroplasty. The method includes drilling and tapping the intramedullary canal, and then utilizing a threaded rod to secure the implants in place. The implant is intended to replace the articular surface of the bone with a similarly shaped metal surface, thereby avoiding the use of a hinge joint with a constant center of rotation, and maintaining the mechanical advantage of the flexor and extensor tendons in the same manner as the natural joint structure. Additionally, reproducing normal physiologic motion has the added benefit of limiting the stresses transmitted through the prosthesis to the stem-bone interface.
[0086] US 2010/0179661 discloses an elbow prosthesis. The ulnar component includes a pair of concave spherical bearing surfaces that interface with a pair of convex spherical bearing surfaces on the humeral components. An axis passing through the ulnar component connects the two bearing surfaces of the humeral component. The spherically shaped bearing surfaces are intended to transmit load over a relatively large area rather than at a point or over a line of contact. The prosthesis is provided in the form of a joint kit having a plurality of interchangeable bearing inserts which permit the surgeon to tailor the degree of varus/valgus constraint. Some examples can be linked together without fasteners or other hardware.
[0087] US 2012/0109322 discloses a prosthesis to replace at least a portion of a comminuted bone fracture. The prosthesis reproduces the articular surface of a comminuted distal humerus fracture in order to restore joint viability and articulation.
[0088] From the above description, it is clear that the vast majority of elbow prostheses are secured utilizing bone cement and, therefore, carry all of the inherent disadvantages of bone cement. Of the minority that are secured by screws, the hinge components of many of these implants must be turned along with the threaded shaft, preventing the hinge portion of the implant from being pulled precisely into the correct position and orientation within the bone. Furthermore, threaded attachments are subject to loosening if not further secured by some additional means. Accordingly, there is a need for a mechanical fastener that pivots with respect to the hinge component of the implant, thereby positioning the hinge portion in the correct position at whatever point the mechanical fastener reaches its maximum depth. There is a further need for a threaded or other mechanical attachment for securing implant components to bone that includes both a major loadbearing portion, and a secondary securing portion to ensure the stability of the major loadbearing portion.
[0089] Although it is often difficult for a surgeon to know whether a hemiarthroplasty or total arthroplasty will be required prior to commencing surgery, very few of the implants described above may be used for either type of surgery. Accordingly, there is a need for a prosthetic elbow that may be interchangeably used for hemiarthroplasty and total arthroplasty, permitting the surgeon to decide between the two operations mid-surgery.
[0090] Numerous methods have been proposed for permitting varus/valgus movements, thereby reducing stresses on the elbow prosthesis as well as the bones to which the prosthesis is attached. However, none of these methods has included any type of ligament reconstruction that would essentially reproduce that which was present in the elbow prior to injury or deterioration. Accordingly, there is a need for an elbow prosthesis that is installed in a manner that includes ligament reconstruction.
[0091] All mechanical devices are subject to wear. It is, therefore, helpful to have specific, easily replaceable components that are subject to wear in preference to other, more critical, and more difficult to replace components. Structures which are designed to wear in preference to other structures, and which are easily replaced during simple follow-up surgeries, are therefore needed.
SUMMARY
[0092] The above needs are met by a prosthetic joint. One example of the prosthetic joint has a first component having a first intramedullary stem and a first connection portion. The first intramedullary stem is externally threaded and being pivotally secured to the first connection portion. The prosthetic joint further includes a second component having a second intramedullary stem and a second connection portion. The second intramedullary stem being externally threaded and being pivotally secured to the second connection portion. The second connection portion is structured to be movably secured to the first connection portion.
[0093] Another example of the prosthetic joint includes a first component having a first intramedullary bone securing portion and a first connection portion. The first connection portion is structured so that it can mate with a natural second bone end or a reconstructed second bone end without modification to the first connection portion.
[0094] Yet another example of the prosthetic joint includes a first joint component that is structured for attachment to a first bone. The first joint component being structured to secure a portion of a ligament reconstruction member. The prosthetic joint further includes a second joint component that is structured for attachment to a second bone. The second joint component is structured to secure a portion of a ligament reconstruction member.
[0095] A method of installing a prosthetic joint is also provided. One example of the method is carried out by first providing a prosthetic joint having first and second assemblies. The first assembly has a first threaded intramedullary securing member rotatably secured to a first connection portion. The second assembly has a second threaded intramedullary securing member rotatably secured to a second connection portion. The intramedullary canal of the first bone is broached, drilled, and tapped. The first threaded intramedullary securing member is installed into the intramedullary canal of the first bone. The first threaded intramedullary securing member is used to draw the first connection portion into the intramedullary canal of the first bone. The intramedullary canal of the second bone is broached, drilled, and tapped. The second threaded intramedullary securing member is installed into the intramedullary canal of the second bone. The second threaded intramedullary securing member is used to draw the second connection portion into the intramedullary canal of the second bone.
[0096] Another example of the method of installing a prosthetic joint between a first bone and a second bone begins by attaching a first joint component to the first bone. A second joint component is attached to the second bone. At least one tendon is removed. A portion of the tendon is secured to the first joint component. Another portion of the tendon is secured to the second joint component.
[0097] These and other aspects of the invention will become more apparent through the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0098] FIG. 1 is an isometric view of a prosthetic joint.
[0099] FIG. 2 is an isometric view of the hinge portion of a prosthetic joint.
[0100] FIG. 3 is a side view of the prosthetic joint.
[0101] FIG. 4 is a partially cutaway isometric view of a second prosthetic joint component, showing the second prosthetic joint component engaging a spool attached to a first prosthetic joint component.
[0102] FIG. 5 is an isometric view of a base for a connection portion of a second joint components for a prosthetic joint.
[0103] FIG. 6 is an isometric view of a bearing retaining bracket.
[0104] FIG. 7 is a cross-sectional side view of a broaching process for installation of a prosthetic joint component.
[0105] FIG. 8 is a cross-sectional side view of a drilling process for installation of a prosthetic joint component.
[0106] FIG. 9 is a cross-sectional side view of a tapping process for installation of a prosthetic joint component.
[0107] FIG. 10 is a cross-sectional side view of a prosthetic joint component being installed within a bone.
[0108] FIG. 11 is a cross-sectional side view of a spool for a prosthetic joint component being installed.
[0109] FIG. 12 is a cross-sectional front view of a broaching process for installation of a prosthetic joint component.
[0110] FIG. 13 is a cross-sectional front view of a drilling process for installation of a prosthetic joint component.
[0111] FIG. 14 is a cross-sectional front view of a tapping process for installation of a prosthetic joint component.
[0112] FIG. 15 is a cross-sectional front view of a prosthetic joint component being installed within a bone, showing the prosthetic joint component partially installed.
[0113] FIG. 16 is a cross-sectional front view of a prosthetic joint component being installed within a bone, showing the final position of the prosthetic joint component.
[0114] FIG. 17 is a cross-sectional side view showing the insertion of ligament reconstruction members through the first prosthetic joint component.
[0115] FIG. 18 is a cross-sectional side view showing the attachment of ligament reconstruction members to the second prosthetic joint component, as well as the installation of cross locking members.
[0116] FIG. 19 is a cross-sectional side view of a ligament reconstruction for a prosthetic joint.
[0117] FIG. 20 is a cross-sectional front view of a prosthetic joint after installation for a hemiarthroplasty.
[0118] FIG. 21 is a cross-sectional front view of a prosthetic joint after installation for a total arthroplasty.
[0119] FIG. 22 is an isometric view of a connection portion for a humeral component of a prosthetic joint.
[0120] FIG. 23 is an isometric view of a bearing for a prosthetic joint.
[0121] FIG. 24 is a side elevational view of the bearing of FIG. 23 .
[0122] Like reference characters denote like elements throughout the drawings.
DETAILED DESCRIPTION
[0123] Referring to the drawings, an example of a prosthetic joint 10 is illustrated. As shown in FIG. 1 , the illustrated example of the prosthetic joint 10 is a hinge joint, with the specific example illustrated being an elbow joint. The prosthetic joint 10 includes a first component 12 , which in the illustrated example is a humeral component utilized for reconstruction of the distal end of a humerus. The prosthetic joint 10 further includes a second component 14 , which in the illustrated example is an ulnar components for use in reconstructing the proximal end of an ulna.
[0124] The humeral component 12 includes an intramedullary stem 16 that is rotatably and removably secured to a connection portion 18 . The intramedullary stem 16 is structured for uncemented, mechanical securing within the intramedullary canal of the humorous. The illustrated example of the intramedullary stem 16 includes a threaded portion 20 disposed at one end, that is structured to engage a portion of the intramedullary canal that has been tapped with corresponding threads as described in greater detail below. The opposite end of the intramedullary stem 16 includes a head 22 , which in the illustrated example has a slightly larger diameter than the immediately adjacent portion of the intramedullary stem 16 . The tip 24 of the head 22 includes actuator engaging structures 26 that are structured to engage a rotatable actuation school. For example, the actuator engaging structures 26 could be a slot for a slotted screwdriver, a cross shaped slot for a Phillips head screwdriver, a hexagon shaped hole for an Allen wrench, a star shaped hole for a Torx screwdriver, or any other conventional actuator engaging structure.
[0125] Referring to FIGS. 1-4 and 22 , the connection portion 18 of the humeral component 12 in the illustrated example includes a yoke 28 having first and second legs 30 , 32 , respectively, extending therefrom. The yoke's base 34 defines a channel 36 therein. As shown in FIG. 3 , the channel 36 includes a narrow portion 38 that is a suitable diameter to receive the majority of the intramedullary stem 16 , but is too narrow to receive the head 22 . The channel 36 further includes a wider portion 40 having a sufficient diameter to receive the head 22 . The intramedullary stem 16 may therefore be placed within the channel 36 , where it is free to rotate, but where the head 22 is prevented from passing into the narrow portion 38 of the channel 36 . A hole 35 is defined within the connection portion 18 for securing a cross locking member 33 , as described in more detail below.
[0126] The distal ends 42 , 44 of the legs 30 , 32 , respectively are structured to removably secure a spool 46 therebetween. In the illustrated example, openings 48 , 50 are defined within the distal ends 42 , 44 of the legs 30 , 32 . The holes 48 , 50 are each structured to receive a fastener such as the illustrated screws 52 ( FIG. 7 ) passing therethrough and into corresponding threaded holes 53 defined within the spool 46 . The spool 46 is generally cylindrical, and has a generally concave bearing surface 54 extending between its ends. The end 56 of the spool 46 corresponding to the leg 32 is generally flat, and the end 58 of the spool 46 corresponding to the leg 30 is partially spherical. The spool 46 therefore has a shape that generally corresponds to the shape of the distal end of an undamaged humerus. A central bore 53 passes through the spool 46 , with corresponding holes 55 , 57 being defined within the distal ends 42 , 44 of the legs 30 , 32 , respectively.
[0127] Referring to FIGS. 20 and 22 , the humeral portion 12 includes a cross locking member 33 . In the illustrated example, the cross locking member 33 is a screw passing through a corresponding opening 35 defined within the connection portion 12 . The screw 33 is secured at the opposite and of the hole 35 by a nut 37 .
[0128] Referring to FIGS. 1-6 , the ulnar component 14 includes in intramedullary stem 60 and a connection portion 62 . The intramedullary stem 60 is structured for mechanical, cementless installation into the intramedullary canal of an ulna. In the illustrated example, the distal end 64 of the intramedullary stem 60 is threaded, so that it may engage corresponding threads that have been tapped into the ulna intramedullary canal. The proximal end of the intramedullary stem 60 includes a head 66 , having a larger diameter than adjacent portions of the intramedullary stem 60 . The tip 68 of the head 66 includes actuator engaging structures 70 that are structured to engage a rotatable actuation school. For example, the actuator engaging structures 70 could be a slot for a slotted screwdriver, a cross shaped slot for a Phillips head screwdriver, a hexagon shaped hole for an Allen wrench, a star shaped hole for a Torx screwdriver, or any other conventional actuator engaging structure.
[0129] The connection portion 62 includes a base 72 . The base 72 defines a channel 74 therein. The channel 74 includes a narrow portion 76 that is structured to receive the intramedullary stem 60 , but not the head 66 . A wider portion 78 of the channel 74 is structured to receive the head 66 . The intramedullary stem 60 may therefore be placed within the channel 74 , and rotatably secured therein, in a manner that prevents the head from passing into the narrow portion 76 . The illustrated example includes a threaded hole 80 which, in the illustrated example, is coaxial with the channel 74 , and whose purpose will be explained below.
[0130] The connection portion 72 further includes a bearing retention structure 82 . The bearing retention structure 82 includes a concave, generally circular interior surface 84 . A bearing retaining flange 86 is disposed at one and of the interior surface 84 . The other end of the interior surface 84 terminates adjacent to the threaded hole 80 . Referring specifically to FIGS. 5-6 , a pair of locating flanges 88 , 90 are disposed on either side of the threaded hole 80 . A bearing retaining bracket 92 , which is best illustrated in FIG. 5 , defines a generally circular surface 94 that is structured to form a continuation of the surface 84 , and terminating in a bearing retaining flange 96 . The opposite end of the bracket 92 defines a hole 98 therethrough, corresponding to the threaded hole 80 . A pair of slots 100 , 102 on either side of the hole 98 correspond to the locating flanges 88 , 90 , respectively, facilitating precise placement of the bracket 92 in the desired location. With the bracket in this position, a bearing 104 may be retained by the connection portion 14 . A screw 106 passing through the hole 98 and engaging the threaded hole 80 secures the bearing retaining bracket 92 to the base 72 .
[0131] Referring to FIGS. 1-4 and 23-24 , the bearing 104 is generally half doughnut shaped, defining an interior, generally semicircular surface 108 , and an exterior, generally semicircular surface 110 . The bearing 104 preferably extends around at least about half of the spool 46 , but defines a sufficient opening to allow for easy installation of the bearing 104 on the spool 46 , for example, within a range of about 180° to about 270°. The bearing 104 in the illustrated example extends around about 236°. The interior surface 108 is generally convex, having a shape corresponding to the shape of the spool 46 . The exterior surface 110 defines a channel 111 therein for receiving the bearing retention structure 82 as well as the bracket 92 . The channel 111 is angled with respect to the circumference of the bearing 104 to accommodate the angle made by the bearing 104 with respect to the ulnar component 14 , which in the illustrated example is about 7°. The retaining flanges 86 , 96 are wider than the channel 111 so that the bearing 104 is properly retained. The bearing 104 is preferably made from a material having a wear resistance that is less than the wear resistance of the components with which it interfaces, so that the bearing 104 will experience wear in preference to other portions of the prosthetic joint. In the illustrated example, the bearing 104 is preferably made from polyethylene.
[0132] Referring to FIGS. 17-20 , a cross locking assembly 114 for the ulnar component 14 is illustrated. The cross locking assembly 114 includes a plurality of cross locking members 116 , which in the illustrated example are screws. The cross locking screws 116 pass through corresponding holes 118 ( FIG. 4 ) defined it within the base 72 , and are retained by corresponding nuts 120 disposed on the opposite sides of the holes 118 . The screws 116 and nuts 120 also retain the bars 122 , 124 in place against the base 72 , for a purpose that will be described in greater detail below.
[0133] A method of installing the first joint component within the first bone (installing the humeral portion within the distal end of the humerus 126 in the illustrated example) is illustrated in FIGS. 7-11 . This method remains the same regardless of whether a hemiarthroplasty or total arthroplasty is being performed. Initially, the damaged distal end of the humerus is cut with a saw. Next, as illustrated in FIG. 7 , the intramedullary canal 128 is broached to remove marrow, as well as to provide adequate room for a drilling jig, as well as ultimately for the humeral implant 12 . In some examples, three different sizes of brooches 130 may be utilized.
[0134] As shown in FIG. 8 , a jig 132 is inserted into the intramedullary canal 128 , and is used to guide a drill 134 in further clearing the marrow from the intramedullary canal 128 . Successively larger drill bits are used until proprioceptive and or audible indications of drilling solid bone are heard. Once solid bone has been reached, the intramedullary canal 128 is tapped using a handheld tap 136 , as shown in FIG. 9 , thereby providing threads corresponding to the threads 20 of the intramedullary stem 16 .
[0135] Referring to FIG. 10 , an appropriately sized intramedullary stem 16 and connection portion 18 are selected. It is anticipated that different sizes of intramedullary stem 16 and connection portion 18 may be provided, thereby accommodating patients of different sizes. Because the intramedullary stem 16 is removably secured to the connection portion 18 , the appropriate combination of parts may be selected. The intramedullary stems 16 is placed within the channel 36 , and is then threaded until secured within the intramedullary canal utilizing an appropriate screwdriver 138 or other suitable hand tool. Because the intramedullary stem 16 is rotatable with respect to the connection portion 18 , the connection portion 18 remains in the appropriate position for proper seating within the distal humerus 126 well-being drawn tightly into place by turning the intramedullary stem 16 . During this operation, the spool 46 is detached from the connection portion 18 in order to facilitate access by the tool 138 .
[0136] Once the connection portion 18 is firmly seated in place, as shown in FIG. 11 , a hole corresponding to the hole 35 is drilled into the humerus 126 , and the cross locking screw 33 is inserted into the hole 35 . The nut 37 is added to complete the humeral cross locking structure. Next, the spool 46 is positioned between the legs 30 , 32 , and secured in place using the screws 52 . At this point, the end is surface of the distal humerus 126 has been restored, and may be utilized for either a hemiarthroplasty utilizing an undamaged proximal ulna, or a total arthroplasty by installing an ulnar component as described below.
[0137] Referring to FIGS. 12-16 , a method of installing the ulnar joint portion 14 is illustrated. Initially, the proximal end of the ulna 140 is broached utilizing a hand-held broach 142 to remove marrow from the intramedullary canal 144 , as shown in FIG. 12 . Next, a jig 146 is positioned within the proximal end of the intramedullary canal 144 to guide a drill 148 into the intramedullary canal 144 as shown in FIG. 13 . Successively larger drill bits 148 are utilized until the marrow has been removed from a portion of the intramedullary canal to be tapped, and proprioceptive or audible indications that solid bone has been engaged are felt or heard. At this point, the intramedullary canal is tapped as shown in FIG. 14 by a handheld tap 150 to produce threads corresponding to the threads and 64 of the intramedullary stem 60 . At this point, the ulna 140 is prepared for installation of the prosthetic joint portion 14 .
[0138] An appropriately sized intramedullary stem 60 is paired with an appropriately sized base 72 , as shown in FIG. 15 . Different sized, interchangeable intramedullary stems 16 and bases 72 may be selected depending on the characteristics of the patient. The intramedullary stem 60 is placed within the channel 74 , and the threads 64 are brought into engagement with the threads that were tapped into the intramedullary canal 144 . An appropriate tool, which in the illustrated example is the screwdriver 152 , is inserted into the threaded hole 80 and brought into engagement with the actuator engaging structures 70 within the head 66 of the intramedullary stem 60 . The screwdriver 152 is turned to pull the prosthetic joint portion 114 into the ulna 140 . Because the intramedullary stem 60 is rotatable with respect to the base 72 , the base 72 may remain in a proper orientation as the intramedullary stem 60 is turned, thereby permitting the turning of the intramedullary stem 60 to draw the base 72 tightly into position within the ulna, as shown in FIG. 16 .
[0139] Once the prosthetic joint component 14 has been installed within the ulna, a bearing 104 is placed against the interior surface 84 of the base 72 ( FIGS. 4-6 ). The bearing retaining bracket 92 is positioned against the base 72 . The screw 106 is then secured within the threaded hole 80 , thereby securing the bracket 92 and bearing 104 in position within the prosthetic joint component 14 . At this point, the prosthetic joint components 12 , 14 are ready to be joined together. Also, at this time, holes are drilled in the ulna 140 to correspond to the holes 118 in the base 72 .
[0140] Regardless of whether hemiarthroplasty or total arthroplasty is being performed, the illustrated example substantially mimics the movement and stability of a natural joint through a system of ligament reconstruction. Joint stability is defined as the resistance to subluxation under physiologic stress and is the result of the mechanical interaction of the articular contours, the dynamic support of the investing musclotendinous units, and the static viscoelastic constraint of the capsuloligatmentous structures. In order to be useful to the patient, the design of the prosthetic joint 10 must preserve this stability. Given that this design aims to replicate the native elbow bony anatomy and does not utilize a mechanical hinge to resist varus and valgus forces, the stability requirements are placed on the soft tissues.
[0141] Collateral ligaments are complex structures whose individual fascicles are under differential tension and whose properties depend on joint position and load. The collateral ligaments of the elbow, by virtue of their medial and lateral locations, have a mechanical advantage in resisting medially and laterally directed forces that would cause joint subluxation. In an effort to gain joint visualization during arthroplasty surgery, these ligaments are detached and then re-inserted once the implants have been placed. Reattachment is difficult to do particularly when the ligament integrity is compromised such as in the joints of elderly patients. Patients suffering from post-traumatic arthritis often sustained soft tissue as well as bony trauma making a subsequent collateral ligament repair more tenuous. Therefore, tendons taken from the patient or allograft tendons are utilized as ligament reconstruction members, as described below.
[0142] Initially, tendons are selected from the patient for use in reconstructing the ligaments. The specific tendon or tendon portion selected are chosen because its loss will have minimal or no impact on the patient. Tendons that may be advantageously utilized include a longitudinal strip of triceps tendon or the Palmaris Longus tendon. Alternatively, toe extensors or the Plantaris tendon or even half of the Flexor Carpi Radialis tendon can be used. Allograft tendon material may also be utilized.
[0143] With the appropriate ligament reconstruction members 154 obtained, the humeral joint portion 12 and ulna (in the case of hemiarthroplasty) or ulnar joint portion 14 (in the case of total arthroplasty) are placed against each other as shown in FIG. 17 . The ulnar articulating surface will be native cartilage if a hemiarthroplasty is being performed, or the bearing 104 if total elbow arthroplasty is being performed. The ligament reconstruction members 154 are utilized to connect the humeral joint portion 12 and ulnar joint portion 14 by securing a portion of the ligament reconstruction members 154 to the humeral portion 12 , and another portion of the ligament reconstruction members 154 to the ulnar portion 14 . In the illustrated example, a central portion 156 of the ligament reconstruction members 154 is passed through the central bore 53 of the spool 46 , as well as the holes 55 , 57 defined within the distal ends 42 , 44 of the legs 30 , 32 of the yoke 28 . The end portions 158 of the ligament reconstruction members 154 are then tensioned in order to remove their viscous properties, and secured to either the ulna (in the case of a hemiarthroplasty) or to the base 72 of the ulnar joint component 14 (in the case of a total arthroplasty) by securing the ends of the ligament reconstruction members 154 underneath the plates 122 , 124 . The plates 122 , 124 in the illustrated example are held in place by the cross locking screws 116 and nuts 120 , so cross locking of the ulnar component is also accomplished during this step. The tendon to bone fixation is, thereby, accomplished through the creation of compressive force exerted between the ulna and the plate. This method will maintain the appropriate tension within the tendons while bone to tendon healing occurs, and thereby ensures the stability of the reconstructed joint. This design also maintains the dynamic support of the extensor and flexor tendon insertions, which is accomplished by leaving the lateral and medial epicondyles intact.
[0144] The prosthetic joint described above provides numerous advantages over the prior art. The present design does not include cement fixation at all, and thereby eliminates the risk of bone cement implantation syndrome, as well as the other disadvantages of using bone cement. It is anticipated that, as the bones heal, they will grow into and/or around the various components of the prosthetic joint, thereby enhancing the security with which the prosthetic joint components are attached to the respective bones. Avoiding bone cement removes the exothermic curing process that may damage bone secondary to thermal osteonecrosis. In the event of infection, removal and replacement of prosthetic joint components is greatly simplified.
[0145] The attachment of the prosthetic joint components to the respective bones is particularly secure, and is anticipated to be able to withstand forces imparted to the biomechanical construct in excess of those which could be withstood by prior prosthetic joints. The use of relatively long intramedullary stems increases the surface area against which forces are applied, thereby reducing the pressure applied for an equivalent force. A screw that gains purchase in the threaded intra-medullary canal can pull the implant into the bone and create a very stable intra-medullary fixation based construct by distributing the forces over a sizeable number of threads. By leveraging the length of the humerus and ulna as well as the high cortical to cancellous bone ratio within the middle thirds of the humerus and ulna, the proposed method of fixation will make secure un-cemented implant fixation possible in a safe and reproducible manner. By distributing the forces over multiple threads, fixation through the intra-medullary screw is possible and reproducible even in bone that is fragile as is seen in osteoporotic patients. The use of interchangeable intramedullary stems and connection portions makes it possible to provide different length threaded rods that would not over-penetrate the far cortex beyond where it is achieving fixation. The use of cross locking members resists any tendency of the intramedullary stems to loosen over time.
[0146] The prior art method of constraining a total elbow arthroplasty resides in either using a hinge device in the implant (constrained) or repairing the ligaments after elbow replacement (unconstrained). No commercially available or previously marketed design attempts to provide stability through reconstruction of the elbow ligaments. Conversely, in the present design, the elbow is stabilized in a manner that most closely approximates how it functions in vivo. Secure ligament reconstruction is particularly advantageous as the patient populations that frequently receives this type of surgery often suffer from inflammatory arthritis and may not have a soft tissue envelope that can be relied on to provide stability when reattached after implantation. The use of autograft or allograft ligament reconstruction members provides a means of accommodating varus/valgus movement by transferring forces to the medial and lateral ligaments of the elbow similar to what is experienced in vivo.
[0147] The prosthetic joint described above further provides for simplified surgery. The surgeon need not decide between hemi arthroplasty and total arthroplasty prior to performing the surgery, and can instead make this intraoperative decision. An easily replaced bearing is designed to wear in preference to components that are more difficult to replace. When the bearing wears out, which is anticipated to be a period of years, a relatively simple surgery may be used to replace the bearing.
[0148] A variety of modifications to the above-described embodiments will be apparent to those skilled in the art from this disclosure. For example, other methods of attaching ligament reconstruction methods between the respective joint components could be utilized without departing from the scope of the invention. Additionally, other hinge joints, such as knees, fingers, etc., may be repaired using a prosthetic joint described herein. Additionally, a ball and socket joint such as a shoulder or hip would equally benefit from the cementless attachment methods taught herein, as well as variations of ligament reconstruction utilizing tendons from the patient to secure the mating joint components. Thus, the invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The particular embodiments disclosed are meant to be illustrative only and not limiting as to the scope of the invention. The appended claims, rather than to the foregoing specification, should be referenced to indicate the scope of the invention. | A prosthetic joint is secured to the bones forming the original joint by utilizing strictly mechanical fasteners, for example, a threaded rod engaging a tapped intramedullary canal. Cross locking members may be provided. The need for bone cement is avoided. The prosthetic joint may be used to replace one end of one bone forming the joint, utilizing the naturally occurring end of the other bone. Alternatively, both bone ends may be replaced with prosthetic joint portions. The decision to replace one or both bone ends may be made mid-surgery. The prosthetic joint portions are secured together utilizing ligament reconstruction members made from portions of the patient's tendons or allograft tendons. A bearing forming the interface between the two joint portions is designed to wear in order to protect the remaining components from wear, and to be easily replaced in relatively simple future surgeries. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to an illumination device, more particularly an illumination device for a projection or display apparatus and especially an illumination device of an optical valve such as a liquid-crystal screen.
DESCRIPTION OF THE PRIOR ART
A projection apparatus essentially comprises an illumination device making it possible to project at least one image such as that produced by means of an optical valve, more particularly by means of a liquid-crystal screen. In this case, the image generated is projected onto a screen by a projection optic. In the case of a display device, the image is displayed directly on the liquid-crystal screen. A known illumination device used for this type of apparatus includes, as shown in FIG. 1, a lamp 1 , which may be an arc lamp, a halogen lamp, a neon lamp or a filament lamp, and a reflector 2 , preferably a parabolic reflector, in order to reflect the light and focus the light rays onto a surface such as a liquid-crystal screen 3 . This type of illumination device has a number of drawbacks. This is because the shape of the beam reflected by the parabolic reflector is different from that of the optical valve onto which it is directed. However, an optical valve requires a uniform and a strong illumination. With a parabolic reflector, there may therefore be considerable light losses which may be at least 45% for the illumination of a valve of rectangular shape, especially a valve of the 16/9 type. Moreover, when the optical valve is a liquid-crystal screen, this must be provided with a polarizer and with a polarization analyser since the source is unpolarized. This leads to an additional loss which may be as much as 60 to 70%. Consequently, with an illumination device of this type and as shown in FIG. 2, a low illumination uniformity and a light efficiency of approximately 30% are observed. The average illumination aperture is approximately ±5° and the solid angle is not optimized. This means that the light distribution is not uniform within the solid angle.
SUMMARY OF THE INVENTION
The object of the present invention is to remedy these drawbacks by providing a novel illumination device making it possible to obtain an illumination shape which corresponds to the format of the surface to be illuminated and gives a high illumination uniformity.
The subject of the present invention is a device for illuminating at least one surface, which includes a light source and a reflector in order to focus the light rays emitted by the source, characterized in that the focal plane of the reflector lies between the light source and the said surface and in that it includes, positioned close to the focal plane of the reflector, a means forming a second light source.
According to one particular embodiment, the reflector has an ellipsoidal shape and the surface receiving the illumination consists of an optical valve such as a liquid-crystal screen, the optical valve being associated, preferably on the entrance side, with a field lens which collimates the beam emanating from the second light source.
According to a first embodiment, the means forming a second light source consists of a microlens array optionally followed by a thick lens.
According to a second embodiment, the means forming a second light source consists of a diffuser optionally followed by a thick lens.
Other features and advantages of the present invention will appear on reading the detailed description of several embodiments, this description being given with reference to the drawings appended hereto, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 already described is a diagrammatic view of an illumination system according to the prior art;
FIG. 2 is a curve associated with an optical ray-tracing simulation giving the light distribution in the plane of the liquid-crystal screen of the illumination device of FIG. 1;
FIG. 3 is a diagrammatic cross-sectional view of an illumination device according to the present invention;
FIG. 4 shows a curve associated with an optical ray-tracing simulation giving the light distribution in the plane of the liquid-crystal screen of the device of FIG. 3;
FIG. 5 is a diagrammatic view of a second means forming a second source; and
FIGS. 6 a and 6 b are diagrammatic views showing respectively a monochrome projection device and a trichrome projection device using an illumination device according to the embodiment of FIG. 3 .
DESCRIPTION OF PREFERRED EMBODIMENTS
To simplify the description, identical elements in the figures bear the same references.
FIG. 3 shows an illumination device provided with a first embodiment of a means forming a second light source. In FIG. 3, the reference 10 indicates a lamp which, in the embodiment shown, is a lamp of the metal-halide type. The reference 11 indicates a reflector, more particularly an elliptical reflector, which sends the rays r back to a focal point lying in a focal plane P.
In accordance with the present invention, a microlens array 12 is positioned close to this focal plane. Throughout the document, microlens array should be understood to mean a structure consisting of small lenses which may be arranged in a regular or non-regular array, the shape of the microlenses and their numerical aperture being fitted to certain parameters such as the format of the surface to be illuminated, especially the format of the liquid-crystal screen, the characteristics of the light source 10 and the illumination uniformity. The dimensions of the microlenses are between 2 mm and less than 50 μm. The microlens array 12 is associated with a thick lens 13 whose function will be explained below. This combination acts as a secondary light source and the rays r′ emitted by this source illuminate a surface which, in the embodiment shown, consists of an optical valve 14 , more particularly a liquid-crystal screen. In the embodiment of FIG. 3, a field lens 15 is positioned in front of the liquid-crystal screen 14 , the function of this field lens being to collimate the light emanating from the microlens array 12 /lens 13 combination onto the liquid-crystal screen 14 . When the liquid-crystal screen is used in a television-type projection system, it has a rectangular shape. Consequently, the microlens array preferably consists of rectangular microlenses.
The principle of operation of the system shown in FIG. 3 will be explained in a little more detail.
Thus, when a rectangular microlens array is positioned close to the focal plane of an elliptical reflector, such as the reflector 11 , followed by a thick lens 13 , it is possible to illuminate the liquid-crystal screen 14 with the correct format and with good uniformity. This is because the rectangular format, preferably slightly greater than that of the liquid-crystal screen of the microlens array, acts as a light-shaping element. The image of each microlens is amplified over a large area of the liquid-crystal screen. The contributions of each microlens are thus superposed and/or juxtaposed in order to give a uniform illumination with a format corresponding to that of the liquid-crystal screen. Moreover, in order to avoid light losses and according to another feature of the present invention, the f-number of the microlens array is chosen to be of the same order as the f-number of the field lens 15 , provided in front of the liquid-crystal screen 14 and which collimates the light coming from the new point source. In addition, the cone angle of the illumination falling on the microlenses may also be adjusted so as to obtain the best compromise between as small as possible a decrease in the image of the arc lamp and a decrease in the illumination cone angle in order to avoid the light losses within the f-number of the microlens array. These two conditions may be slightly modified depending on the shape of the image of the light source and also depending on the uniformity and efficiency which it is desired to obtain.
By way of example, for a 16/9 format liquid-crystal screen having dimensions of 90 mm×50 mm, a spherical-curvature microlens array is used, the microlenses being rectangular and having dimensions of 210×80 μm and a focal length of approximately 300 μm in air. The microlens array is followed by a thick lens, namely a lens having a thickness of approximately 10 mm and a focal length of 50 mm. The field lens is an aspheric lens and has a focal length of approximately 160 mm.
The simulations of the above system have given the curves shown in FIG. 4 . This figure shows the light distribution in the plane of the liquid-crystal screen. An efficiency of approximately 40% is obtained. In this case, the light distribution within the solid angle is optimized, which means that the solid angle is completely filled by the light beam and has no dead area.
According to a second embodiment of the present invention, instead of a microlens array in order to produce the means forming a second light source, a diffuser 20 as shown in FIG. 5 may be used. This diffuser may be of the holographic type. In this case, the hologram may be a volume hologram or a surface hologram. For cost reasons, it is preferred to use a surface hologram. Moreover, the diffuser may also be produced by means of a random arrangement of microlenses or of microstructures having a known macroscopic scattering lobe. In this case, the scattering lobe must have a numerical aperture close to that of the incident beam so as not to degrade the extent of the beam, but the diffuser must not have a lobe which is axisymmetric so as not to alter the illumination format. Preferably, the scattering lobe is elliptical and the scattering angle is approximately ±20° in the horizontal and ±10° in the vertical in order to obtain an illumination format in the plane of the liquid-crystal screen pretty much similar to 16/9.
The illumination devices described above have many advantages; in particular, they are composed of few elements, which means that the Fresnel losses are small. In addition, the uniformity obtained is approximately 95%, this uniformity depending on the distribution of the light source, on the number of microlenses and on the f-number of the microlenses. The colour uniformity obtained over the entire screen is also high. Furthermore, the illumination aperture can be controlled by shutting off the image of the light source.
As shown in FIGS. 6 a and 6 b, this illumination device can be used with projection systems using a single liquid-crystal screen (monovalve), as shown in FIG. 6 a. In this case, the device of FIG. 3 indicated by 200 is associated with a focusing lens 21 which directs the light beam onto a projection lens 22 and then onto a projection screen 23 .
According to the present invention, the illumination device can also be used in projection systems having several liquid-crystal screens (tri-valve), as shown in FIG. 6 b. In this case, three screens 14 a, 14 b, 14 c are associated with mirrors 16 , arranged in a manner known by those skilled in the art, on the exit side of the field lens 15 and direct the light beams onto a projection lens 22 , as in the embodiment above.
The present invention may be modified without departing from the scope of the claims below. The means forming a second source, consisting either of a microlens array or a diffuser, may be used without a field lens. | The present invention relates to a device for illuminating at least one surface, which includes a light source and a reflector in order to focus the light rays emitted by the source. In said device, the focal plane of the reflector lies between the light source and the said surface and it includes, positioned close to the focal plane of the reflector, a means forming a second light source. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/265,279, filed Nov. 30, 2009, which is hereby incorporated by reference herein in its entirety, including but not limited to those portions that specifically appear hereinafter, the incorporation by reference being made with the following exception: In the event that any portion of the above-referenced provisional application is inconsistent with this application, this application supercedes said above-referenced provisional application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
[0003] The disclosure relates generally to vehicle engines and more specifically, but not necessarily entirely, to engines that may be operated at high specific output, such as turbo charged or supercharged diesel and gasoline engines.
SUMMARY OF THE DISCLOSURE
[0004] An electronically controlled fuel blending system that injects compressed natural gas into the air intake of a diesel engine resulting in lower emissions, increased fuel economy, and air fuel ration is disclosed. Air fuel ratios may be monitored and adjusted by a CPU (Central Processing Unit) and may be monitored by a user on a visual display, which outputs the monitored vital engine functions such as: fuel usage, fuel ratio, actual mileage in real time, fuel levels, fuel flow rates, altitude adjustments, GPS position and comparison of fuel consumption. The CPU may also monitor the current cost of fuel per mile per gallon at current speeds and conditions, allowing drivers to adjust driving habits to reduce fuel consumption and emission levels.
[0005] The system may use standard 3600 PSI natural gas and is capable of using up to 5000 PSI natural gas levels. These pressure levels may be controlled by a high pressure reducer, which takes the natural gas pressure levels from a high level of 3600-5000 PSI to less than 100 PSI, thereby allowing air to efficiently mix with the natural gas and provide optimal fuel hybrid mixtures.
[0006] The system may comprise a pressure reducer with an integrated heating element (12V) to eliminate: (1) icing and freezing problems; (2) formation of condensation; and (3) formation of methane from the reduction in pressure of natural gas.
[0007] The system may also comprise an electronically controlled valve, which may comprise a stepper motor actuated valve that has electronically controlled variable valve opening sizes.
[0008] The system may also comprise a natural gas nozzle assembly, which may be built as a one piece unit that replaces a short section of an air flexible air intake or may be placed in line with an air intake of an engine.
[0009] The system may also comprise a mass air flow sensor that monitors air flow and volume on the fly during use. This sensor may produce a 0-5 analog signal, which is sent to the CPU to adjust the air to gas mixture levels produced by the injection nozzle on the fly during use.
[0010] The system may also comprise an air temperature sensor that may work in conjunction with the mass air flow sensor to enable the CPU to accurately measure actual air volume entering the engine and to adjust temperature on the fly to keep efficiency levels as high as possible.
[0011] The system may also comprise a pressure sensor that may be installed on the air intake, downstream from a turbo charger. This sensor may be used to help the CPU calculate the optimum air fuel ratio.
[0012] The system may also comprise a diesel fuel flow meter that may be used to determine the diesel consumption in real time. The diesel fuel flow meter may send the CPU data that allows the display screen to display the diesel consumption that assists in the cost per mile calculation and the miles per gallon (or kilometers per liter) cost calculation displayed on the screen. That data and information may be transmitted to a computer system allowing fleet management to assist drivers in adjusting driving habits. Such data may be networked wherein a control base and fleet members form a network wherein data is exchanged in order to maximize certain parameters.
[0013] The natural gas/diesel injection system, bi-fuel, hybrid, mixing system, fuel enhancement, emission control device, may enhance combustion and fumigation. The system may incorporate a fuel metering system and fuel blending system that improves efficiency and reduces diesel fuel consumption.
[0014] The system may also comprise the components of an electronic control unit with a display screen, a regulator, a natural gas injection nozzle assembly, and multiple sensors for monitoring conditions and operation during use of the system.
[0015] The system may be microprocessor controlled, wherein current conditions may be displayed to a user on the fly during use such as natural gas and diesel fuel levels, natural gas/diesel ratio being used, current mileage MPG (separate and combined), fuel consumption maybe monitored and adjusted constantly and automatically within the bounds of the system components. The system may optimize natural gas usage, which reduces diesel consumption for the same relative and proportional power output, resulting in lower fuel costs, lower emissions, and increased power.
[0016] The system may use multiple sensors to gather input on vital engine conditions such as a mass airflow sensor allowing the system to precisely adjust for optimum air to natural gas ratio, which results in a dramatic reduction in diesel consumption. Exhaust gas temperature, temperature, pressure, natural gas flow meter, diesel flow meter, natural gas pressure sensor, are also used for the optimization method.
[0017] The system may be integrated with a vehicle's on-board computer system and may automatically adjust according to current conditions experienced by the vehicle. The driver of the vehicle may also be able to manually override certain system functions if needed.
[0018] The natural gas system maybe designed to operate within a range of 3600 PSI to 5000 PSI or higher in order to accommodate the amount of fuel desired, and to provide the vehicle with the fuel needed to travel reasonable distances between fill-ups.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The features and advantages of the disclosure will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
[0020] FIG. 1 is a schematic view of an embodiment of the disclosure;
[0021] FIG. 2 is a schematic view of an embodiment of the disclosure;
[0022] FIG. 3 is an illustrative embodiment of a natural gas injection system in accordance with the principles of the disclosure;
[0023] FIG. 4 is a system and network for monitoring resource usage in accordance with the principles of the disclosure;
[0024] FIG. 5 is a schematic view of an embodiment of the disclosure in accordance with the principles of the disclosure;
[0025] FIG. 6 is a schematic view of an embodiment of the disclosure illustrating a single natural gas injector in accordance with the principles of the disclosure;
[0026] FIG. 7 is a schematic view of an embodiment of the disclosure illustrating a plurality of natural gas injectors in accordance with the principles of the disclosure;
[0027] FIG. 8 is a schematic view of an embodiment of the disclosure illustrating a single controller in accordance with the principles of the disclosure;
[0028] FIG. 9 illustrates a graphical representation of natural gas injection in accordance with the principles of the disclosure;
[0029] FIG. 10 illustrates a graphical representation of natural gas injection in accordance with the principles of the disclosure;
[0030] FIG. 11 illustrates a graphical representation of natural gas injection in accordance with the principles of the disclosure;
[0031] FIG. 12 illustrates a method of natural gas injection in accordance with the principles of the disclosure; and
[0032] FIG. 13 illustrates a hardware schematic of natural gas injection in accordance with the principles of the disclosure.
DETAILED DESCRIPTION
[0033] For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure.
[0034] Before the digital closed loop natural gas and diesel hybrid fuel blending systems and methods are disclosed and described, it is to be understood that this disclosure is not limited to the particular configurations, process steps, and materials disclosed herein as such configurations, process steps, and materials may vary somewhat. It is also to be understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the disclosure will be limited only by the patent claims and equivalents thereof.
[0035] It must be noted that, as used in this specification and appended claims, if any, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0036] In describing and claiming the subject matter of the disclosure, the following terminology will be used in accordance with the definitions set out below.
[0037] As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps.
[0038] As used herein, the phrase “consisting of” and grammatical equivalents thereof exclude any element, step, or ingredient not specified in the claim.
[0039] As used herein, the phrase “consisting essentially of” and grammatical equivalents thereof limit the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic or characteristics of the claimed disclosure.
[0040] With reference primarily to FIG. 1 , a system 100 for fueling an engine with a fuel comprising diesel and natural gas will be discussed. The system 100 may comprise an engine 102 as a primary component. The engine 102 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 104 for suppling the engine 102 with improved combustibles. An air intake 106 may be incorporated to provide air into the system 100 and may have an air filter 108 attached thereto. The air intake 106 may also comprise an air temperature sensor 107 for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 106 may comprise a mass air flow sensor 109 for sensing the mass of the air flowing into the system 100 . The air take intake 106 may comprise a mass air flow sensor 111 located between a natural gas injector assembly 144 and the turbo charger 104 to provide additional data to a computer 110 . The system 100 may further comprise the computer 110 for processing data from said sensors. The system 100 may comprise a battery 112 for suppling electrical power to components of the system 100 that rely on electrical power in order to operate within the system 100 . The system 100 may comprise a fuel tank 114 for holding fuel for powering the engine 102 . The fuel tank 114 may comprise a fuel level sensor 115 for sensing the level of the fuel in the fuel tank 114 and may be configured for communicating fuel data to the computer 110 . The system 100 may further comprise a diesel fuel flow sensor 116 that senses the flow volume of diesel fuel into the engine 102 . Engine 102 may use an injection process to inject diesel fuel into the engine 102 by way of a diesel fuel injection pump 117 .
[0041] The turbo charger 104 may interface with the engine 102 through an inlet channel 118 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 102 . The inlet channel 118 may comprise a temperature sensor 119 for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 110 . The inlet channel 118 may comprise a pressure sensor 120 for sensing the pressure of the fluid mixture in the inlet channel 118 . The inlet channel 118 may comprise a pressure switch 122 configured to control the pressure of the fluids in the inlet channel 118 so as to allow control of the fluids in the inlet channel 118 as it enters the engine 102 .
[0042] After the engine 102 has consumed the chemical energy of the fuel air mixture entering the engine 102 by way of the inlet channel 118 , exhaust gasses enter an outlet channel 124 . The outlet channel 124 may comprise an exhaust temperature sensor 126 . The outlet channel 124 channels the exhaust fluids into the turbo charger 104 to actuate the working elements of a turbo charger as is well known in the art.
[0043] The system 100 may further comprise natural gas fuel tanks 130 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 130 may be pressurized in a range from about 2500 psi to about 7000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 130 within the system 100 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 130 to the system 100 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0044] A natural gas fuel line 132 may be used to move the natural gas from the tanks 130 into the system 100 and more particularly into a pressure reducer 138 . The natural gas fuel line 132 may comprise a natural gas pressure sensor 134 configured to sense the pressure of the natural gas and send data to the computer 110 . The natural gas fuel line 132 may further comprise a fuel shut-off valve 136 configured to open and close thereby stopping the flow of natural gas into the pressure reducer 138 .
[0045] The pressure reducer 138 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 138 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element 139 may be employed to control the temperature of the pressure reducer 138 . By controlling the temperature of the pressure reducer 138 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range.
[0046] A natural gas flow sensor 140 may be employed in the system 100 to sense the flow of natural gas in to the system 100 . A natural gas flow controller 142 may be implemented to control the flow of natural gas in the system and may be controlled by the computer 110 or another control apparatus. The natural gas flow controller 142 may operate by opening and closing a valve that physically restricts the flow of the natural gas.
[0047] A natural gas injection assembly 144 may be employed in the system 100 and may comprise a natural gas nozzle 146 that is configured to inject natural gas into the air intake 106 such that the natural gas is mixed with the incoming air thereby creating a more energy rich combustible fluid. The nozzle 146 may be configured to disperse the natural gas in a homogeneous mixture and may produce a venturi effect in order to cause greater mixing of the incoming air and the natural gas.
[0048] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 148 . The control unit 148 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 148 may also be configured with a visual display for visually displaying the data generated within the system 100 . The control unit 148 may further comprise audio alerts. The control unit 148 may be configured to cause the system 100 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 148 may be fully engaged in the system 100 there by controlling all aspects of the operation of the system 100 . In an embodiment the control unit 148 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device 150 , such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 148 .
[0049] Referring now to FIG. 2 , an embodiment of a system 200 for fueling an engine with a fuel comprising diesel and natural gas will be discussed. The system 200 may comprise an engine 202 as a primary component. The engine 202 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 204 for suppling the engine 202 with improved combustibles. An air intake 206 may be incorporated to provide air into the system 200 and may have an air filter 208 attached thereto. The air intake 206 may also comprise an air temperature sensor 207 for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 206 may comprise a mass air flow sensor 209 for sensing the mass of the air flowing into the system 200 . The air take intake 206 may comprise a mass air flow sensor 211 located between a natural gas injector assembly 244 and the turbo charger 204 to provide additional data to a computer 210 . The system 200 may further comprise a computer 210 for processing data from said sensors. The system 200 may comprise a battery 212 for suppling electrical power to components of the system 200 that rely on electrical power in order to operate within the system 200 . The system 200 may comprise a fuel tank 214 for holding fuel for powering the engine 202 . The fuel tank 214 may comprise a fuel level sensor 215 for sensing the level of the fuel in the fuel tank 214 and may be configured for communicating fuel data to the computer 210 . The system 200 may further comprise a diesel fuel flow sensor 216 that senses the flow volume of diesel fuel into the engine 202 . Engine 202 may use an injection process to inject diesel fuel into the engine 202 by way of a diesel fuel injection pump 217 .
[0050] The turbo charger 204 may interface with the engine 202 through an inlet channel 218 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 202 . The inlet channel 218 may comprise a temperature sensor 219 for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 210 . The inlet channel 218 may comprise a pressure sensor 220 for sensing the pressure of the fluid mixture in the inlet channel 218 . The inlet channel 218 may comprise a pressure switch 222 configured to control the pressure of the fluids in the inlet channel 218 so as to allow control of the fluids in the inlet channel 218 as it enters the engine 202 .
[0051] After the engine 202 has consumed the chemical energy of the fuel air mixture entering the engine 202 by way of the inlet channel 218 , exhaust gasses enter an outlet channel 224 . The outlet channel 224 may comprise an exhaust temperature sensor 226 . The outlet channel 224 channels the exhaust fluids into the turbo charger 204 to actuate the working elements of a turbo charger as is well known in the art.
[0052] The system 200 may further comprise natural gas fuel tanks 230 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 230 may be pressurized in a range from about 2500 psi to about 7000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 230 within the system 200 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 230 to the system 200 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0053] A natural gas fuel line 232 may be used to move the natural gas from the tanks 230 into the system 200 and more particularly into a pressure reducer 238 . The natural gas fuel line 232 may comprise a natural gas pressure sensor 234 configured to sense the pressure of the natural gas and send data to the computer 210 . The natural gas fuel line 232 may further comprise a fuel shut-off valve 236 configured to open and close thereby stopping the flow of natural gas into the pressure reducer 238 .
[0054] The pressure reducer 238 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 238 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element 239 may be employed to control the temperature of the pressure reducer 238 . By controlling the temperature of the pressure reducer 238 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range.
[0055] A motorized control valve 241 may be employed to control the flow of natural gas after it has been depressurized. A natural gas flow sensor 240 may be used inline after the motorized control valve 241 in order to monitor the operation of the control valve 241 . A diaphragm metering valve 243 may be incorporated to react to changes in the negative pressure created in the air intake 206 as a result of the turbo charger 204 . The diaphragm metering valve 243 may be passive and made of a material with a predetermined bias or elasticity to properly control the flow of the natural gas in direct response to the changes in the system 200 . For example, the material may be made from silicon or from multiple layers of silicon. In an embodiment, multiple diaphragms may be used in place of a single diaphragm. A natural gas injection assembly 244 may be included to disperse the natural gas into the air flow in the air intake 206 .
[0056] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 248 . The control unit 248 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 248 may also be configured with a visual display for visually displaying the data generated within the system 200 . The control unit 248 may further comprise audio alerts. The control unit 248 may be configured to cause the system 200 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 248 may be fully engaged in the system 200 thereby controlling all aspects of the operation of the system 200 . In an embodiment the control unit 248 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device 250 , such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 248 .
[0057] With reference to FIG. 3 , the design of a natural gas injection assembly will be discussed in greater detail. 304 illustrates a portion on an air intake on an engine having a natural gas injection assembly interacting therewith. As can be seen in the illustration air is mixed with natural gas by the injection assembly. 308 represents a top down view of an injection means having open ports the may be adjusted relative to the direction of air flow in an air intake thereby dispersing the natural gas in a predetermined manner. 306 illustrates a side view of the natural gas injection assembly, showing the simplicity that the physical form may take. The ratio range at which natural gas and diesel can be mixed within the scope of the system may be from a ratio of 1:1 to 1:10. Other ratios are contemplated to be within the scope of this disclosure.
[0058] With reference to FIG. 4 , a network employing the system 100 will be discussed wherein a plurality of trucks and a base unit are used to form the network. In order to maximize the efficiency of the system, a database can be developed and maintained on a server 404 . The server 404 comprises the components typical of computer server. In particular the server 404 comprises a storage whereon the data collected from other network members can be stored for later access. The network members may comprise trucks, trains, ships and other means of transport and travel. A truck 408 has been fitted with system 100 and is therefor capable of operating on a mixture of natural gas and diesel. The system 100 monitors the operating characteristics of truck 408 such as location, route, fuel consumption, load, incline of road, speed and acceleration. Many other characteristics may be monitored and reported by a truck to the server for analysis and storage. With each member of the network reporting the operating conditions, a database can be developed that can be used to guide the members of the network on the most efficient use of system 100 . For example, truck 410 may be followed on the same route with similar loads by trucks 412 and 414 . The system 100 on truck 410 may report over the network the operating conditions it is experiencing. Trucks 412 and 414 may receive the data from truck 410 over the network and can make adjustments on the fly as to the way they operate over the same portion of the route. Truck 412 may provide a further refinement of the operational data from which latter truck 414 may further benefit. Truck 416 may make the trip later in time and may receive refined data stored on the server 404 for trucks 410 , 412 , and 414 . A terminal 406 may allow access to the network for users such that they can monitor the operational data from the truck members of the network and input data onto the network that will be received by the truck members. A user at a terminal 406 may further use the network to compare two trucks in route such as trucks 408 and 418 . Control parameters may be transmitted over the network, such that members may be parameters from which to operate for a period of time.
[0059] With reference primarily to FIG. 5 , a system 500 for fueling an engine with a fuel comprising diesel and natural gas will be discussed. The system 500 may comprise an engine 502 as a primary component. The engine 502 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 504 for suppling the engine 502 with improved combustibles. An air intake 506 may be incorporated to provide air into the system 500 and may have an air filter 508 attached thereto. The air intake 506 may also comprise an air temperature sensor for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 506 may comprise a mass air flow sensor for sensing the mass of the air flowing into the system 500 . The air take intake 506 may comprise a mass air flow sensor located between a natural gas injector assembly 544 and the turbo charger 504 to provide additional data to a computer 510 . The system 500 may further comprise the computer 510 for processing data from said sensors. The computer 510 may be a secondary or second computer the may or may not be electronically connected to a primary or first computer 511 leaving the primary or first computer 511 to responsively function to the introduction of natural gas. The secondary or second computer 510 and the primary or first computer 511 may be linked or connected electronically so as to communicate with one another for greater flexibility in the system 500 . The secondary or second computer 510 may have a one way communication with the primary or first computer 511 , so as to receive information and data from the primary or first computer 511 , but not transmit data to the primary or first computer 511 . Such data may include engine load, engine speed, fuel input, various mass flows from throughout the system 500 , and various temperatures at locations throughout the system 500 . The system 500 may comprise a battery for suppling electrical power to components of the system 500 that rely on electrical power in order to operate within the system 500 . The system 500 may comprise a fuel tank for holding fuel for powering the engine 502 . The fuel tank may comprise a fuel level sensor for sensing the level of the fuel in the fuel tank and may be configured for communicating fuel data to the computers 510 and/or 511 . The system 500 may further comprise a diesel fuel flow sensor that senses the flow volume of diesel fuel into the engine. Engine 502 may use an injection process to inject diesel fuel into the engine 502 by way of a diesel fuel injection pump.
[0060] The turbo charger 504 may interface with the engine 502 through an inlet channel 518 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 502 . The inlet channel 518 may comprise a temperature sensor for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 510 . The inlet channel 518 may comprise a pressure sensor for sensing the pressure of the fluid mixture in the inlet channel 518 . The inlet channel 518 may comprise a pressure switch configured to control the pressure of the fluids in the inlet channel 518 so as to allow control of the fluids in the inlet channel 518 as it enters the engine 502 .
[0061] After the engine 502 has consumed the chemical energy of the fuel air mixture entering the engine 502 by way of the inlet channel 518 , exhaust gasses enter an outlet channel 524 . The outlet channel 524 may comprise an exhaust temperature sensor 526 . The outlet channel 524 channels the exhaust fluids into the turbo charger 504 to actuate the working elements of a turbo charger as is well known in the art.
[0062] The system 500 may further comprise natural gas fuel tanks 530 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 530 may be pressurized in a range from about 2500 psi to about 7000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 530 within the system 500 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 530 to the system 500 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0063] A natural gas fuel line 532 may be used to move the natural gas from the tanks 530 into the system 500 and more particularly into a pressure reducer 538 . The natural gas fuel line 532 may comprise a natural gas pressure sensor 534 configured to sense the pressure of the natural gas and send data to the computer 510 . The natural gas fuel line 532 may further comprise a fuel shut-off valve configured to open and close thereby stopping the flow of natural gas into the pressure reducer 538 .
[0064] The pressure reducer 538 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 538 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element may be employed to control the temperature of the pressure reducer 538 . By controlling the temperature of the pressure reducer 538 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range. Heat may be applied to other elements of the system 500 to control freezing and other operating conditions of the components. For example, the tanks and the natural gas lines within the system 500 may benefit from thermal control.
[0065] A natural gas flow sensor may be employed in the system 500 to sense the flow of natural gas in to the system 500 . A natural gas flow controller may be implemented to control the flow of natural gas in the system and may be controlled by the computer 510 or another control apparatus. The natural gas flow controller may operate by opening and closing a valve that physically restricts the flow of the natural gas.
[0066] A natural gas injection assembly or array 544 maybe employed in the system 500 and may comprise a natural gas injector 546 or a plurality of natural gas injectors, that are configured to inject natural gas into the air intake 506 such that the natural gas is mixed with the incoming air thereby creating a more energy rich combustible fluid. The injector 546 may be configured to disperse the natural gas in a homogeneous mixture and may produce a venturi effect in order to cause greater mixing of the incoming air and the natural gas. The array 544 of injectors 546 may cause the injectors 546 to operate independently from one another or in concert, as discussed in greater detail below. The introduction of natural gas may be made prior to the turbo charger 504 or after the turbo charger 504 .
[0067] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 548 . The control unit 548 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 548 may also be configured with a visual display for visually displaying the data generated within the system 500 and may communicate with the computers 510 and 511 . The control unit 548 may further comprise audio alerts. The control unit 548 may be configured to cause the system 500 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 548 may be fully engaged in the system 500 there by controlling all aspects of the operation of the system 500 . In an embodiment the control unit 548 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device, such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 548 . The system 500 may further include exhaust sensors 555 in order to comply with regulatory systems and requirements.
[0068] With reference primarily to FIG. 6 , a system 600 for fueling an engine with a fuel comprising diesel and natural gas will be discussed having a single natural gas injector. The system 600 may comprise an engine 602 as a primary component. The engine 602 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 604 for suppling the engine 602 with improved combustibles. An air intake 606 may be incorporated to provide air into the system 600 and may have an air filter 608 attached thereto. The air intake 606 may also comprise an air temperature sensor for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 606 may comprise a mass air flow sensor for sensing the mass of the air flowing into the system 600 . The air take intake 606 may comprise a mass air flow sensor located between a natural gas injector assembly 644 and the turbo charger 604 to provide additional data to a computer 610 . The system 600 may further comprise the computer 610 for processing data from said sensors. The computer 610 may be a secondary computer the may or may not be electronically connected to a primary or first computer 611 leaving the primary or first computer 611 to responsively function to the introduction of natural gas. The secondary or second computer 610 and the primary or first computer 611 may be linked or connected electronically so as to communicate with one another for greater flexibility in the system 600 . The secondary or second computer 610 may have a one way communication with the primary or first computer 611 , so as to receive information and data from the primary or first computer 611 but not transmit data to the primary or first computer 611 . Such data may include engine load, engine speed, fuel input, various mass flows from throughout the system 600 , and various temperatures at locations throughout the system 600 . The system 600 may comprise a battery for suppling electrical power to components of the system 600 that rely on electrical power in order to operate within the system 600 . The system 600 may comprise a fuel tank for holding fuel for powering the engine 602 . The fuel tank may comprise a fuel level sensor for sensing the level of the fuel in the fuel tank and may be configured for communicating fuel data to the computers 610 and/or 611 . The system 600 may further comprise a diesel fuel flow sensor that senses the flow volume of diesel fuel into the engine. Engine 602 may use an injection process to inject diesel fuel into the engine 602 by way of a diesel fuel injection pump.
[0069] The turbo charger 604 may interface with the engine 602 through an inlet channel 618 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 602 . The inlet channel 618 may comprise a temperature sensor for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 610 . The inlet channel 618 may comprise a pressure sensor for sensing the pressure of the fluid mixture in the inlet channel 618 . The inlet channel 618 may comprise a pressure switch configured to control the pressure of the fluids in the inlet channel 618 so as to allow control of the fluids in the inlet channel 618 as it enters the engine 602 .
[0070] After the engine 602 has consumed the chemical energy of the fuel air mixture entering the engine 602 by way of the inlet channel 618 , exhaust gasses enter an outlet channel 624 . The outlet channel 624 may comprise an exhaust temperature sensor 626 . The outlet channel 624 channels the exhaust fluids into the turbo charger 604 to actuate the working elements of a turbo charger as is well known in the art.
[0071] The system 600 may further comprise natural gas fuel tanks 630 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 630 may be pressurized in a range from about 2500 psi to about 7000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 630 within the system 600 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 630 to the system 600 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0072] A natural gas fuel line 632 may be used to move the natural gas from the tanks 630 into the system 600 and more particularly into a pressure reducer 638 . The natural gas fuel line 632 may comprise a natural gas pressure sensor 634 configured to sense the pressure of the natural gas and send data to the computer 610 . The natural gas fuel line 632 may further comprise a fuel shut-off valve configured to open and close thereby stopping the flow of natural gas into the pressure reducer 638 .
[0073] The pressure reducer 638 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 638 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element may be employed to control the temperature of the pressure reducer 638 . By controlling the temperature of the pressure reducer 638 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range. Heat may be applied to other elements of the system 600 to control freezing and other operating conditions of the components. For example the tanks and the natural gas lines within the system 600 may benefit from thermal control.
[0074] A natural gas flow sensor may be employed in the system 600 to sense the flow of natural gas in to the system 600 . A natural gas flow controller may be implemented to control the flow of natural gas in the system and may be controlled by the computer 610 or another control apparatus. The natural gas flow controller may operate by opening and closing a valve that physically restricts the flow of the natural gas.
[0075] As seen in the FIG. 6 a single natural gas injector is used in an embodiment. A natural gas injection assembly or array 644 may be employed in the system 600 and may comprise a natural gas injector 646 or a plurality of natural gas injectors, that are configured to inject natural gas into the air intake 606 such that the natural gas is mixed with the incoming air thereby creating a more energy rich combustible fluid. The injector 646 may be configured to disperse the natural gas in a homogeneous mixture and may produce a venturi effect in order to cause greater mixing of the incoming air and the natural gas. The array 644 of injectors 646 may cause the injectors 646 to operate independently from one another or in concert, as discussed in greater detail below. The introduction of natural gas may be made prior to the turbo charger 604 or after the turbo charger 604 .
[0076] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 648 . The control unit 648 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 648 may also be configured with a visual display for visually displaying the data generated within the system 600 and may communicate with the computers 610 and 611 . The control unit 648 may further comprise audio alerts. The control unit 648 may be configured to cause the system 600 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 648 may be fully engaged in the system 600 there by controlling all aspects of the operation of the system 600 . In an embodiment the control unit 648 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device, such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 648 . The system 600 may further include exhaust sensors 655 in order to comply with regulatory systems and requirements.
[0077] With reference primarily to FIG. 7 , a system 700 for fueling an engine with a fuel comprising diesel and natural gas will be discussed having a plurality of natural gas injectors. The system 700 may comprise an engine 702 as a primary component. The engine 702 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 704 for suppling the engine 702 with improved combustibles. An air intake 706 may be incorporated to provide air into the system 700 and may have an air filter 708 attached thereto. The air intake 706 may also comprise an air temperature sensor for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 706 may comprise a mass air flow sensor for sensing the mass of the air flowing into the system 700 . The air take intake 706 may comprise a mass air flow sensor located between a natural gas injector assembly 744 and the turbo charger 704 to provide additional data to a computer 710 . The system 700 may further comprise the computer 710 for processing data from said sensors. The computer 710 may be a secondary computer the may or may not be electronically connected to a primary or first computer 711 leaving the primary or first computer 711 to responsively function to the introduction of natural gas. The secondary computer 710 and the primary or first computer 711 may be linked or connected electronically so as to communicate with one another for greater flexibility in the system 700 . The secondary computer 710 may have a one way communication with the primary or first computer 711 , so as to receive information and data from the primary or first computer 711 but not transmit data to the primary or first computer 711 . Such data may include engine load, engine speed, fuel input, various mass flows from throughout the system 700 , and various temperatures at locations throughout the system 700 . The system 700 may comprise a battery for suppling electrical power to components of the system 700 that rely on electrical power in order to operate within the system 700 . The system 700 may comprise a fuel tank for holding fuel for powering the engine 702 . The fuel tank may comprise a fuel level sensor for sensing the level of the fuel in the fuel tank and may be configured for communicating fuel data to the computers 710 and/or 711 . The system 700 may further comprise a diesel fuel flow sensor that senses the flow volume of diesel fuel into the engine. Engine 702 may use an injection process to inject diesel fuel into the engine 702 by way of a diesel fuel injection pump. The first or primary controller may aid in a map table or a plurality of map tables. The second or secondary controller may retrieve and execute instructions derived from the map tables.
[0078] The turbo charger 704 may interface with the engine 702 through an inlet channel 718 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 702 . The inlet channel 718 may comprise a temperature sensor for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 710 . The inlet channel 718 may comprise a pressure sensor for sensing the pressure of the fluid mixture in the inlet channel 718 . The inlet channel 718 may comprise a pressure switch configured to control the pressure of the fluids in the inlet channel 718 so as to allow control of the fluids in the inlet channel 718 as it enters the engine 702 .
[0079] After the engine 702 has consumed the chemical energy of the fuel air mixture entering the engine 702 by way of the inlet channel 718 , exhaust gasses enter an outlet channel 724 . The outlet channel 724 may comprise an exhaust temperature sensor 726 . The outlet channel 724 channels the exhaust fluids into the turbo charger 704 to actuate the working elements of a turbo charger as is well known in the art.
[0080] The system 700 may further comprise natural gas fuel tanks 730 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 730 may be pressurized in a range from about 2500 psi to about 7000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 730 within the system 700 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 730 to the system 700 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0081] A natural gas fuel line 732 may be used to move the natural gas from the tanks 730 into the system 700 and more particularly into a pressure reducer 738 . The natural gas fuel line 732 may comprise a natural gas pressure sensor 734 configured to sense the pressure of the natural gas and send data to the computer 710 . The natural gas fuel line 732 may further comprise a fuel shut-off valve configured to open and close thereby stopping the flow of natural gas into the pressure reducer 738 .
[0082] The pressure reducer 738 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 738 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element may be employed to control the temperature of the pressure reducer 738 . By controlling the temperature of the pressure reducer 738 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range. Heat may be applied to other elements of the system 700 to control freezing and other operating conditions of the components. For example the tanks and the natural gas lines within the system 700 may benefit from thermal control.
[0083] A natural gas flow sensor may be employed in the system 700 to sense the flow of natural gas in to the system 700 . A natural gas flow controller may be implemented to control the flow of natural gas in the system and may be controlled by the computer 710 or another control apparatus. The natural gas flow controller may operate by opening and closing a valve that physically restricts the flow of the natural gas.
[0084] A natural gas injection assembly or array 744 maybe employed in the system 700 and may comprise a natural gas injector 746 or a plurality of natural gas injectors, that are configured to inject natural gas into the air intake 706 such that the natural gas is mixed with the incoming air thereby creating a more energy rich combustible fluid. The injector 746 may be configured to disperse the natural gas in a homogeneous mixture and may produce a venturi effect in order to cause greater mixing of the incoming air and the natural gas. Shown in the corresponding figure is an array of four injectors. It is within the scope of the disclosure to anticipate any number of injectors and apply those injectors in concert. The array of injectors may be independently controlled so as to overlap one another in duration or may have multiple injectors open and close simultaneously. The array 744 of injectors 746 may cause the injectors 746 to operate independently from one another or in concert, as discussed in greater detail below. The introduction of natural gas may be made prior to the turbo charger 704 or after the turbo charger 704 .
[0085] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 748 . The control unit 748 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 748 may also be configured with a visual display for visually displaying the data generated within the system 700 and may communicate with the computers 710 and 711 . The control unit 748 may further comprise audio alerts. The control unit 748 may be configured to cause the system 700 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 748 may be fully engaged in the system 700 there by controlling all aspects of the operation of the system 700 . In an embodiment the control unit 748 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device, such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 748 . The system 700 may further include exhaust sensors 755 in order to comply with regulatory systems and requirements.
[0086] With reference primarily to FIG. 8 , a system 800 for fueling an engine with a fuel comprising diesel and natural gas will be discussed having a having a single controller or a first controller. The system 800 may comprise an engine 802 as a primary component. The engine 802 may be of diesel configuration as is well known in the art and may further comprise a turbo charger 804 for suppling the engine 802 with improved combustibles. An air intake 806 may be incorporated to provide air into the system 800 and may have an air filter 808 attached thereto. The air intake 806 may also comprise an air temperature sensor for sensing the temperature of the air going into the system thereby assisting the system in determine the density of the air. The air intake 806 may comprise a mass air flow sensor for sensing the mass of the air flowing into the system 800 . The air take intake 806 may comprise a mass air flow sensor located between a natural gas injector assembly 844 and the turbo charger 804 to provide additional data to a computer 810 . The system 800 may further comprise the single computer or controller 810 for processing data from said sensors. The system 800 may comprise a battery for suppling electrical power to components of the system 800 that rely on electrical power in order to operate within the system 800 . The system 800 may comprise a fuel tank for holding fuel for powering the engine 802 . The fuel tank may comprise a fuel level sensor for sensing the level of the fuel in the fuel tank and may be configured for communicating fuel data to the computer 810 . The system 800 may further comprise a diesel fuel flow sensor that senses the flow volume of diesel fuel into the engine. Engine 802 may use an injection process to inject diesel fuel into the engine 802 by way of a diesel fuel injection pump.
[0087] The turbo charger 804 may interface with the engine 802 through an inlet channel 818 that has been configured to facilitate the movement of fluids (gas or liquid) into the engine 802 . The inlet channel 818 may comprise a temperature sensor for sensing the temperature of the air in the inlet channel and reporting the resultant data to the computer 810 . The inlet channel 818 may comprise a pressure sensor for sensing the pressure of the fluid mixture in the inlet channel 818 . The inlet channel 818 may comprise a pressure switch configured to control the pressure of the fluids in the inlet channel 818 so as to allow control of the fluids in the inlet channel 818 as it enters the engine 802 .
[0088] After the engine 802 has consumed the chemical energy of the fuel air mixture entering the engine 802 by way of the inlet channel 818 , exhaust gasses enter an outlet channel 824 . The outlet channel 824 may comprise an exhaust temperature sensor 826 . The outlet channel 824 channels the exhaust fluids into the turbo charger 804 to actuate the working elements of a turbo charger as is well known in the art.
[0089] The system 800 may further comprise natural gas fuel tanks 830 . A single natural gas fuel tank may be used or a bank or array of fuel tanks may be used. The tanks 830 may be pressurized in a range from about 2500 psi to about 8000 psi. It will be appreciated that tanks containing pressures outside that range may also be used by the disclosure and it is within the scope of this disclosure to contemplate tanks pressurized to far higher pressures or far lower pressures than provided in the above range. The pressures of the tanks 830 within the system 800 are generally pressurized such that the pressure differential between the operating pressure of the system and the pressure in the tank or tanks causes natural gas to flow from the tanks 830 to the system 800 . Accordingly any pressure or means for facilitating flow from tanks into an engine system is within the scope of this disclosure.
[0090] A natural gas fuel line 832 may be used to move the natural gas from the tanks 830 into the system 800 and more particularly into a pressure reducer 838 . The natural gas fuel line 832 may comprise a natural gas pressure sensor 834 configured to sense the pressure of the natural gas and send data to the computer 810 . The natural gas fuel line 832 may further comprise a fuel shut-off valve configured to open and close thereby stopping the flow of natural gas into the pressure reducer 838 .
[0091] The pressure reducer 838 may be configured to reduce the pressure of the natural gas fluid. The pressure reducer 838 may reduce the pressure of natural gas by providing volume of space for which the natural gas may freely expand thereby reducing its pressure. As heat is transferred or absorbed into the depressurizing fluid of natural gas, a heating element may be employed to control the temperature of the pressure reducer 838 . By controlling the temperature of the pressure reducer 838 freezing, condensation of water, and the formation of methane can be controlled. It may be noted that the natural gas may be inserted into the air flow system at a pressure in the range from about 10 psi to about 200 psi, or over a larger or smaller range. Heat may be applied to other elements of the system 800 to control freezing and other operating conditions of the components. For example the tanks and the natural gas lines within the system 800 may benefit from thermal control.
[0092] A natural gas flow sensor may be employed in the system 800 to sense the flow of natural gas in to the system 800 . A natural gas flow controller may be implemented to control the flow of natural gas in the system and may be controlled by the computer 810 or another control apparatus. The natural gas flow controller may operate by opening and closing a valve that physically restricts the flow of the natural gas.
[0093] A natural gas injection assembly or array 844 maybe employed in the system 800 and may comprise a natural gas injector 846 or a plurality of natural gas injectors, that are configured to inject natural gas into the air intake 806 such that the natural gas is mixed with the incoming air thereby creating a more energy rich combustible fluid. The injector 846 may be configured to disperse the natural gas in a homogeneous mixture and may produce a venturi effect in order to cause greater mixing of the incoming air and the natural gas. Shown in the corresponding figure is an array of four injectors. It is within the scope of the disclosure to anticipate any number of injectors and apply those injectors in concert. The array of injectors may be independently controlled so as to overlap one another in duration or may have multiple injectors open and close simultaneously. The array 844 of injectors 846 may cause the injectors 846 to operate independently from one another or in concert, as discussed in greater detail below. The introduction of natural gas may be made prior to the turbo charger 804 or after the turbo charger 804 . Instructions may be derived or executed from map tables representing different operating states or conditions of use. One map table may represent data for use during a no load or light load operating state or condition. Another map table may represent data for heavy or high load operating state or condition, such as a truck that is pulling a full pay load.
[0094] The sensors as discussed above and the various control mechanisms may be electronically connected to a control unit 848 . The control unit 848 may comprise components typical of control units such as a processor for processing data, memory for rapid data storage and data reading, storage for storing data, and circuitry supporting the components. The control unit 848 may also be configured with a visual display for visually displaying the data generated within the system 800 and may communicate with the computer 810 . The control unit 848 may further comprise audio alerts. The control unit 848 may be configured to cause the system 800 to operate within a certain set of parameters by causing various control means to control their respective subjects. The control unit 848 may be fully engaged in the system 800 there by controlling all aspects of the operation of the system 800 . In an embodiment the control unit 848 may be capable of partial control thereby leaving a portion of the system control to native control elements. The control unit may further comprise a communication device, such as a wireless transmitter that is configured to communicate with other systems or a control base thereby forming a network. Any data transmitted to the computer can be transmitted to the control unit 848 . The system 800 may further include exhaust sensors 855 in order to comply with regulatory systems and requirements.
[0095] FIG. 9 illustrates a graphical representation of the operation of two natural gas injectors operating simultaneously as instructed by a map table. In the figure it can be seen that a solid line 910 may represent a first natural gas injector. In the figure it can be seen that a second dashed line 920 may represent a second natural gas injector. The figure illustrates a condition wherein the map table provides instructions causing the injectors to fire simultaneously. In contrast FIG. 10 illustrates a graphical representation wherein the injectors are instructed to fire at different times. In other words, where the first injector is open, the second is closed. This condition would also be derived from map tables. FIG. 11 illustrates a condition wherein the injectors are instructed to fire with an over lap. In other words before a first injector closes a second injector is opened. The advantage of over lapping operation of the injectors maybe to provide a more homogeneous mixtures of natural gas into a system.
[0096] FIG. 12 illustrates a method of use for an apparatus that injects natural gas as an additional fuel. During use at 1202 the apparatus senses and records to computer readable memory a collection operational data from said engine. At 1204 a computer processor processes said operational data to create operational map tables for said engine and writing said tables to computer readable memory. At 1206 the apparatus is instructing a secondary controller in communication with said engine to retrieve from memory said tables and controlling said engine operation from said values of said tables during use. At 1208 the apparatus is retrieving from a first map table during a portion of use. At 1210 the apparatus is retrieving from a second map table during a portion of use. At 1212 the apparatus is Controlling a main fuel injector capable of directly injecting a second gaseous fuel into a combustion chamber and controlling a pilot fuel injector capable of injecting a pilot fuel into said combustion chamber. At 1214 the apparatus is directing said natural gas fuel into said combustion chamber by controlling an array having a natural gas injector configured to inject natural gas in to said intake conduit wherein the natural gas is introduced into said combustion chamber of said engine with a primary fuel and air.
[0097] FIG. 13 illustrates an embodiment of an apparatus for controlling the injection of natural gas in schematic form illustrating the various components. An apparatus may have a processor 1306 for processing data within the system. A processor 1306 may be included in a primary or first controller 1312 and a secondary controller 1314 . An apparatus may have a user interface for displaying operational information of the system to a user, and may be used for receiving instruction from a user as discussed above. The apparatus may include memory 1308 or storage for storing map tables and data thereon. The memory 1308 may be accessed by the processor 1306 , the first controller 1312 , and/or the secondary controller 1314 . The above components may be used in concert to control the hardware 1318 of the apparatus as discussed above. The components of the apparatus may be connected electronically and may be part of a network as is commonly known in the art.
[0098] It is within the scope of the disclosure to offer the components of the system in a kit form that can be fitted to a variety of vehicles.
[0099] An embodiment may comprise a plurality of sensors for collecting operational data from the engine, wherein said operational data comprises engine speed, engine load, and mass flow into said engine, and a first controller that processes said operational data to create operational map tables for said engine. The embodiment may further comprise a second controller that instructs said engine to follow said map tables during use of said engine. The embodiment may further comprise a first map table representing a first operating mode and a second map table representing a second operating mode or condition. Additionally the embodiment may have a main fuel injector capable of directly injecting a second gaseous fuel into said combustion chamber, and a pilot fuel injector capable of injecting a pilot fuel into said combustion chamber. The embodiment may further comprise an intake conduit for directing said natural gas fuel into said combustion chamber and an array having a natural gas injector configured to inject natural gas into said intake conduit, wherein the natural gas is introduced into said combustion chamber of said engine with a primary fuel and air.
[0100] An embodiment of a system for using natural gas in combination with diesel fuel for combustion in an engine may comprise:
[0101] an engine;
[0102] a tank of natural gas;
[0103] a tank of diesel fuel;
[0104] a depressurization chamber; and
[0105] an injection assembly for injecting metered natural gas into an air take of the engine.
[0106] An embodiment of a method for using natural gas in combination with diesel fuel for combustion in an engine may comprise:
[0107] depressurizing natural gas from a pressurized state;
[0108] mixing said natural gas with air in an air in take to an engine;
[0109] supplying diesel fuel to said engine; and
[0110] supplying natural gas to said engine, such that said natural gas and said diesel fuel are mixed in a predetermined ratio thereby optimizing efficiency.
[0111] An embodiment of a network for maximizing efficiency of the operation of network members may comprise:
[0112] a first data set relating to operational conditions of network members;
[0113] a second data set identifying network members;
[0114] a third data set comprising optimizational information and parameters;
[0115] wherein the first data set, the second data set and the third data set are stored on a server connected to the network.
[0116] An embodiment of a method of use may perform the step of sensing and recording operational data from said engine to computer readable memory, wherein said operational data comprises engine speed, engine load, mass flow into said engine. The embodiment may further perform the step of processing with a first computer processor said operational data to create operational map tables for said engine and writing said operational map tables to computer readable memory. Additionally, an embodiment may perform the step of instructing a second computer processor that is in communication with said engine to retrieve from memory said operational map tables for controlling engine operation with the second computer processor based on values retrieved from said operational map tables during use. The embodiment may further include the steps of generating a first instruction from a first map table during a portion of use, and generating a second instruction from a second map table during a portion of use. The method may further include controlling a main fuel injector capable of directly injecting a second gaseous fuel into a combustion chamber and controlling a pilot fuel injector capable of injecting a pilot fuel into said combustion chamber, such that directing said natural gas fuel into said combustion chamber by controlling an array having a natural gas injector configured to inject natural gas in to said intake conduit, wherein the natural gas is introduced into said combustion chamber of said engine with a primary fuel and air.
[0117] In the foregoing Detailed Description, various features of the disclosure are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, inventive aspects lie in less than all features of a single foregoing disclosed embodiment.
[0118] It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the disclosure. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the disclosure and the appended claims are intended to cover such modifications and arrangements. Thus, while the disclosure has been shown in the drawings and described above with particularity and detail, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein. | An electronically controlled fuel blending system that injects compressed natural gas into the air intake of a diesel engine resulting in lower emissions, increased fuel economy is disclosed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
BACKGROUND OF THE INVENTION
The present invention relates to a connecting system for structural panels. More particularly, it relates to a connecting device for assembling skylight and vertical glazing panels composed of a polycarbonate material.
Polycarbonate plastic has become the material of choice in constructing building structures where the admission of light is desirable. While polycarbonate has many desirable properties such as transparency and resiliency, it also has a high coefficient of expansion and contraction.
A connecting or glazing bar system for assembling polycarbonate panels is disclosed in U.S. Pat. No. 5,163,257. While this system allows for expansion of the polycarbonate panels 32,34 it does not afford a locking type connection between the panels and the glazing bars 48, 50. A somewhat similar glazing system is disclosed in U.S. Pat. No. 4,850,167.
A skylight assembly is illustrated in U.S. Pat. No. 4,117,638. A somewhat floating connection is stated to be afforded between the skylight panel 11 and the two suspension panels. An interlocking glazing construction is depicted in U.S. Pat. Nos. 5,216,855 and 4,573,300.
The prior art does not provide a glazing system which affords a movable connection between panels and a structural retaining member without the need of additional connecting means such as bolts, screws, etc. Neither does the prior art provide a one-piece movable connecting device for a structural glazing system which also includes a sealing feature.
Thus, the need exists for a simplified connection in a glazing system for constructing a skylight and vertical glazing.
SUMMARY OF THE INVENTION
In one aspect, the invention provides a connecting device for locking a panel to a structural retaining member, the structural retaining member having a channel therein. A body member is adapted to be attached to a panel, and an arm member extends from the body member.
A head member extends from the leg member opposite from the body member. The head member is constructed and arranged to fit within a channel of the structural retaining member and to be movable therein.
In a preferred embodiment the body member, arm member and head member are of a one-piece construction and the head member is umbrella shaped.
In another aspect, the invention provides a structural glazing system for mounting at least one panel in the structure. A first structural retaining member has a channel therein and a second structural retaining member has a locking channel therein. First and second connecting devices have a body member and an arm member extending from the body member. A head member extends from the leg member opposite from the body member. The body of the first connecting device is connected to one end of a panel with the head member constructed and arranged to fit within the channel of the first structural retaining member and to be movable therein. The body of the second connecting device is connected to an opposing end of the panel with the head member constructed and arranged to fit within the locking channel.
In still another aspect, the invention provides a structural glazing system for mounting four panels in the structure. A structural retaining member has first and second channels at one end and third and fourth channels at an opposing end. Four connecting devices have a body member, an arm member extending from the body member, and a head member extending from arm member opposite the body member. The body member of the connecting devices is separately connected to four panels. The head members of each connecting device is positioned in the channels of the structural retaining member.
The objects of the invention therefore include:
(a) providing a locking type yet movable connection in a glazing system for panel members;
(b) providing a locking type connection of the above type which is particularly suited for skylight and vertical glazing fabrication;
(c) providing a locking type connection of the above type wherein a connecting device is of a one-piece construction;
(d) providing a locking type connection of the above type wherein the connecting device includes a one-piece seal feature; and
(e) providing a locking type connection of the above type which is particularly suited for polycarbonate panels.
These and still other objects and advantages of the invention will be apparent from the description which follows. In the detailed description below preferred embodiments of the invention will be described with reference to the accompanying drawings. These embodiments do not represent the full scope of the invention. Rather the invention may be employed in other embodiments. Reference should therefore be made to the claims herein for interpreting the full breadth of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a skylight structure a preferred embodiment with the connection system of this invention.
FIG. 2 a sectional view taken along line 2--2 of FIG. 1.
FIG. 2A is a sectional view taken along line 2A--2A of FIG. 2.
FIG. 2B is a view similar to FIG. 2A illustrating movement of a locking panel.
FIG. 3 is a side view taken along line 3--3 of FIG. 2 illustrating one method of connecting panel members of a skylight structure to a building.
FIG. 4 is a view in side elevation illustrating another version of t panel connection system.
FIG. 5 is a view in elevation illustrating an alternative connection system cross-section.
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5.
FIG. 7 a view similar to FIG. 5 showing another version of the alternative connection system.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 3, there is shown a panel connection system, generally 10, for interconnecting glazing panels 12. The panels are supported by curb 14 which in turn pivotally connected to a curb base 16 by means of a ball and socket connection 15. The curb 14 is in turn supported by a building support 18. The panels 12 are supported by across bar members 22 which are connected to structural retaining members 20 such by the screws 17. This is best seen in FIG. 2.
As also seen in FIG. 2, the structural retaining members 20 include rafter support members 24 and 26 which are interconnected by a retainer 28. Grooves 30 and 31 are provided in the rafter support members 24 and 26 for receiving a portion of the retainer 28. There are connecting devices 33 and 35 which are composed of polycarbonate and secured to the ends of the polycarbonate panels 12 such as by ultrasonic welding. These connecting devices 33 and 35 have respective body members 37 and 38, as well as arm members 39 and 45 terminating in heads 40 and 46.
The head members 40 and 46 ride in channels 42 of the rafter support members 24 and 26. A cap 48 is joined to the retainer 28 by the interfitting flanged connection 50. Connecting devices 33 have foot members 43 extending from arm members 39 for sealing engagement with the cap 48. Closures 49 are also provided at the bottom of the support members 24 and 26.
Referring to FIG. 3, there is shown one means of attaching the skylight panels 12 to a support wall 56. Support bracket 58 extends from the wall 56 and is connected to a curb 14 upon which rests against the panel 12. A suitable flashing 54 is afforded between the wall 56 and the cap 48, extending over the top panel 51 of curb 14. There is also the flashing indicated at 53 extending between the building support 18 and the curb 14. It will be seen in FIG. 3 that the rafter support members 26 are secured to the curb such as by the screws 17. An intermediate panel retainer is also shown at 64.
FIGS. 2A and 2B illustrate the movement of the connecting devices such as 33 in the channels 42 of the retainer 28. This is best seen by the broken line showing of connecting device 33 in FIG. 2B and illustrates the allowance for expansion and contraction of the panels 12.
Referring to FIG. 4, there is shown another means of placing the panels 12 with the connecting devices 33 and 35 in the rafter support member 26 and with respect to the wall support 56. The flashing 54 extends from the wall 56 and is engaged in a sealing manner with the foot member 43 of the connecting device 33.
FIGS. 5-7 show an alternative panel connection system 10A. Similar components are designated with the same numbers except with the suffix "A". The major difference between the two embodiments 10 and 10A is that the connecting device 33A has a head 40A which is locked into a grove 61A. This grove is provided in the cap 48A which is interconnected with a base member 60A of the retaining member 20A. In this particular version and by the connection of the connecting devices 33A with the panel 12A, one end of the panel is locked into the structural retaining member 20A while the opposite end is free to move such as with the head 40A in the channel 42A of the cap 48A.
FIGS. 6 and 7 illustrate different means of positioning the panels 12A in conjunction with the panel connection system 10A with respect to support walls 56A. As seen in FIG. 6, opposing curbs 14A are connected to building supports 18A with suitable flashing 54A and 53A provided between the curb 14A and the wall 56A in one instance and between the cap 48A and the wall 56A. As seen in this figure, the base member 60A of the structural retaining member 20A is connected to the curbs 14A. As also seen in this figure, there is an intermediate panel retainer 64A for supporting the panel 12A.
Referring to FIG. 7, this represents still another means of attachment of the panel connection system 10A with respect to the wall 56A. As shown, the flashing 54A is connected to the panel 12A and extends over the end of the wall 56A.
An important feature of the panel connection systems 10 and 10A described herein is the fact they can provide lateral and expansive movement of the polycarbonate panels 12 and 12A in a skylight arrangement. This is afforded by the movement of the heads of the connecting members such as 40 and 40A in the channels 42 and 42A of the respective structural retaining members 20 and 20A. Not only is expansive movement afforded but also a locking arrangement.
Another important feature is the elimination of additional attachment devices such as screws, at the point of connection of the connecting devices 33 and 33A to the retaining members 20 and 20A. Yet another important feature is the sealing engagement between the connecting device 33 and the cap 48.
Preferred embodiments have been described herein for the panel connection system. It is obvious that other alternative embodiments can be employed. For example, while the connecting devices 33, 33A and 35 and panels 12 are specifically described as being composed of polycarbonate other plastic materials could be employed such as acrylic, polyester or PVC or combinations thereof. If desired, glass could also be employed for the panels for use with the connecting devices and in the connection system. In addition, the structural retaining members 20 and 20A are preferably fabricated from aluminum. However, other materials could be employed such as polycarbonate, fiberglass or steel.
The foregoing invention can now be practiced by those skilled in the art. Such skilled persons will know that the invention is not necessarily restricted to the particular embodiments therein. The scope of the invention is to be defined by terms of the following claims as given meaning by the preceding description. | A panel connection system provides lateral expansion of panel members in a skylight and vertical glazing arrangement while at the same time affording a secure connection. In a preferred embodiment, the connecting members provide a slidable seal arrangement so as to substantially reduce entry by the elements. The connecting system is readily adapted to be used in conjunction with various types of support systems for the skylight and vertical glazing arrangements. | 4 |
This is a divisional of co-pending application Ser. No. 07/140,026 filed on Dec. 31, 1987 now U.S. Pat. No. 4,880,414.
This invention relates to a catheter. It relates more particularly to improved means for connecting a flexible infusion catheter to a source of infusate.
BACKGROUND OF THE INVENTION
The treatment of certain diseases of the human body often requires the short-term or long-term infusion of drugs, blood products or nutritional or other fluids into the patient's venous or arterial system or peritoneal or epidural space. While such fluids can be administered extracorporeally by transcutaneous injection, in some cases, as when a particular patient's regime requires repeated access for drug infusion, or where infection is of acute concern, it is desirable to provide the patient with a totally implanted infusion system.
Such a system includes an injection portal which is an infusate chamber implanted subcutaneously and placed on the chest wall or other convenient body location. The portal is fitted with a needle-penetrable septum which is located directly under the skin by which drugs or other fluids may be introduced into the portal by transcutaneous injection through the septum. The portal has a fluid outlet tube or stem which is connected to one end of a flexible catheter which leads to the infusion site which is usually a blood vessel or particular body cavity, e.g., the peritoneal cavity. Since the system is completely implanted, it reduces the risk of infectious complications and allows drug infusion which is targeted to the specific patient malady. Even though the delivery system may be implanted for a long period, the patient remains ambulatory and can be treated on an out-patient basis and the system does not interfere with the normal daily activities of the patient.
A similar prosthesis can be used to draw blood from an artery or vein for blood sampling purposes.
Since an implantable device of this type may remain in the patient's body for many months, it is essential that the connection or attachment of the catheter to the portal remain secure and fluid-tight during the entire period of implantation. If the connection should fail or if there should be an infusate leak at that location, the infusate dose required to treat the patient which is injected into the portal will not be conducted to the targeted infusion site in the patient's body. Rather, some or all of the infusate will be dispensed at the site of the portal and could cause complications at that body location. In this connection, it should be appreciated that after a drug delivery system is implanted, the catheter is subjected to various stresses and strains due to movements of the patient's body, weight changes, etc. These are reflected in tensile and twisting forces at the connection of the catheter to the portal outlet which tend to upset the integrity of that union.
In an attempt to avoid this leakage problem and the attendant complications, various steps have been taken to strengthen the connection between the catheter and the portal. These include the providing of raised circular rings or ribs on the portal outlet stem over which the catheter wall is stretched. These lines of localized resilient engagement resist sliding movements of the catheter from the portal stem. In some systems, the connection is made somewhat more secure by providing a locking ring or bushing which encircles the catheter and is releasably captured on the catheter segment engaged on the portal stem by the raised ribs thereon.
We have found, however, that these prior catheter connections are not entirely satisfactory. Sometimes the tensile forces exerted on the catheter due to movements of the patient still suffice to separate the catheter from the portal or to tear the catheter at that point of connection because of a poor distribution of stresses on the catheter wall. Certain prior systems are disadvantaged in that it is quite difficult to connect the catheter to the portal outlet stem. This is because that stem is often very small (e.g. 1 mm OD), and to make the connection, the stem must be threaded into the end of the catheter lumen which is itself equally small. Furthermore, when inserting the portal stem into the catheter, if one is not quite careful, the catheter will be punctured by the end of the stem which, being so small, constitutes a sharp point. Certain prior systems are disadvantaged in that they have loose parts that are hard to handle and can be lost. This is because the system requires a separate lock that must be put on the catheter before the connection to the stem is made. These lock parts are small and easy to drop or lose.
In addition, it should be kept in mind that it may be necessary to disconnect the catheter from an already implanted injection portal in the event that the catheter has to be replaced for one reason or another. For example, it sometimes happens that the catheter lumen becomes clogged by clots or other debris. Therefore, it is desirable that any connection between the catheter and the portal be separable from the portal with a minimum amount of effort and finger manipulation by the surgeon who must make that repair subcutaneously. The prior catheter connection or attachment systems of which applicant is aware, do not facilitate such ready connection and disconnection of the catheter to and from the portal.
SUMMARY OF THE INVENTION
Accordingly, the present invention aims to provide an improved catheter attachment system.
Another object of the invention is to provide a catheter attachment system which is very strong, yet which can be released quite easily if the need should arise.
Another object of this invention is to provide a catheter connection system which has no loose part that can be lost.
Another object of the invention is to provide a catheter connection which is specially adapted for use in an implantable infusion system for joining the catheter to an injection portal.
Yet another object of the invention is to provide an attachment system of this type which minimizes localized stresses on the catheter in the region of the attachment.
Other objects will, in part, be obvious and will, in part, appear hereinafter.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts which will be exemplified in the following detailed description, and the scope of the invention will be indicated in the claims.
The catheter attachment or connection system of interest here may be used in any application where it is necessary to releasably connect the end of a flexible resilient catheter or other tube to a stem, tube or rod by inserting the stem, tube or rod into the end of the catheter. Since the invention has particular application to the connection of a catheter to the outlet stem of an implantable injection portal, we will describe the invention in this context. It should be understood, however, that the invention may be applied to other applications where similar flexible tube-to-rigid tube connections are required.
Briefly, the present attachment system involves the coaction and cooperation of a flexible resilient catheter, a relatively rigid stem o tube onto which the catheter is slid to effect the connection and a specially designed, locking retainer which encircles the stem and catheter on the stem. The system provides strain relief to the catheter and minimizes localized stresses on the catheter due to tensile and other forces exerted on the catheter in use.
The stem component of the system is formed with an axially symmetric radial enlargement. This enlargement takes the form of a three-dimensional bulb located adjacent to the distal end of the stem. The distal end segment of the stem beyond the enlargement has a diameter which is approximately the same as the diameter of the lumen in the catheter being connected to the stem with the enlargement being appreciably larger than that lumen.
When the catheter, which is the second component of the system, is slid onto the stem, the elastic wall of the catheter stretches outward as required to accommodate the larger diameter stem enlargement. Thus, when the end segment of the catheter has received the full extent of the stem, the catheter resiliently engages the outer surface of the stem and conforms closely to the enlargement thereof.
The third component of my connection system, namely the retainer, is a sleeve or ring which loosely encircles the proximal end segment of the portal stem. The sleeve is free to move back and forth along the stem, but it cannot come off the stem due to its engagement with a flange adjacent to the proximal end of the stem. When the catheter is slid onto the stem over the stem enlargement it is guided into the sleeve until the end of the catheter butts against the stem flange. When that sleeve is slid outward along the stem, the sleeve captures the catheter against the stem enlargement.
As will be described shortly in greater detail, when the retainer component of my connection system is seated on the portal stem so that it captures the catheter thereon, there results a very secure connection of the catheter to the stem. Even very strong pulling, twisting and bending forces exerted on the catheter are unable to disconnect the catheter from the stem or to break the fluid-tight integrity of that connection. Actually, as we will see, such forces enhance that connection.
The catheter connection system described here is also quite easy and inexpensive to manufacture, being composed of simple metal parts which can be fabricated in quantity at minimum cost. Also, the connection is easy to make and to release, even if that needs to be done in the case of an injection portal already implanted in the body. In other words, the present apparatus facilitates sliding a catheter onto the end of a portal outlet stem and into the locking sleeve to secure the catheter to the stem with no loose parts. Also, simple finger movements suffice to manipulate the connector's locking ring to release the catheter from the stem. Consequently, the present attachment system could be used conveniently wherever it is necessary to releasably connect a flexible catheter or other tube to a relatively rigid rod or stem.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing, in which:
FIG. 1 is an isometric view of an implantable injection portal incorporating a catheter attachment system made in accordance with this invention;
FIG. 2 is an exploded side elevational view on a much larger scale and with parts broken away showing the catheter attachment system in its unlocked position; and
FIG. 3 is a side elevational view showing the connection system in its locked position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawing, my catheter attachment system, indicated generally at 10, is shown connecting the proximal end of a catheter 12 to the tubular outlet stem 14 of an implantable injection portal 16. The portal is made of a material such as titanium and in use it is implanted at a convenient location in the body, such as on the chest wall. This portal might be used, for example, to conduct infusate to a vein leading to the heart. Usually, small eyes 16a are provided around the base of the portal through which sutures may be passed to anchor the portal to the chest wall. The portal also includes a septem 16b composed of a suitable resilient, needle-penetrable material, such as silicone rubber.
When the portal is implanted, the septum is situated directly under the patient's skin so that infusate can be introduced into the portal by transcutaneous injection through the septum. The infusate thereupon flows through the portal outlet stem 14 to the catheter 12 whose distal end is placed at a selected infusion site in the body, such as a blood vessel or a body cavity such as the peritoneal cavity. Catheter 12 is made of a flexible, resilient biocompatible material, such as silicone rubber. The inside diameter of the catheter, which corresponds more or less to the nominal outside diameter of portal stem 14, may vary depending upon the particular application, from, say 0.5 to 3.0 mm. Likewise, the volume of the portal 16 may vary from, say, 0.4 ml to 1.0 ml.
Referring now to FIGS I and 2 of the drawing, connection system 10 is composed of three distinct parts or components. These include the proximal end segment 12a of the catheter 12, the portal outlet stem 14 and a special locking retainer shown generally at 18. The tubular stem 14 is formed with a radial enlargement 22 along its length. In the system embodiment depicted herein, the enlargement 22 is located adjacent to the outer or distal blunt end segment 14a of the stem 14 and it has the general form of a barrel with two back-to-back frustoconical segments 22a and 22b. The enlargement has a relatively large, rounded shoulder 22c midway along its length, i.e. between segments 22a and 22b whose diameter is appreciably larger than the inside diameter of catheter 12. The enlargement 22 tapers from that shoulder to stem end segment 14a and to a longer stem segment 14b closer to the portal 16 housing. The inner end of stem segment 14b leads to a much larger proximal stem segment 14c projecting from the wall of the portal housing. For reasons to be described later, a radial flange 24 is provided at the boundary of stem segments 14b and 14c. The flange 24 has a radial outer or distal surface 24a and a beveled inner or proximal surface 24b. The diameter of stem segment 14a may be somewhat smaller than the inside diameter of the catheter to aid in initiating catheter engagement, i.e. in aligning the proximal end segment 12a of the catheter with the stem end segment 14a. The diameter of stem segment 14b is somewhat larger than the diameter of the catheter 12 so that a fluid tight seal is produced between that segment and the catheter.
The shape of the enlargement 22 is such that the stem end segment 14a and the frustoconical segment 22b of the enlargement 22 can be introduced into the end of the catheter segment 12a for a distance corresponding to about half the enlargement diameter without extending or stretching the catheter wall. Further penetration of the stem 14 into the catheter segment 12a results in the catheter wall stretching or deforming to accommodate enlargement 22, particularly shoulder 22c. That is, the catheter 12, which is typically silicone rubber, is very resilient. Thus, when catheter segment 12a is engaged fully on stem 14 as shown in FIG. 3, i.e. with the end of the catheter engaging flange 24, due to the resiliency of the catheter material, the catheter segment assumes the exact shape of outlet stem 14, including its enlargement 22 and stem segments 14a and 14b.
As best seen in FIGS. 2 and 3, the locking retainer 18 is a generally cylindrical sleeve-like member which is slidably engaged on the stem 14. Retainer 18 is an easily fabricated, metal (e.g. titanium) or molded plastic part. The inside diameter of the retainer is slightly larger than that of stem flange 24 and its length is comparable to the combined lengths of stem segments 14b and 14c. The inner or proximal end of the retainer is necked down to form an inwardly extending circular flange or rib 18a which overhangs stem flange 24 and is oriented at more or less the same angle as the bevelled surface 24b of that flange.
The outer or distal end of retainer 18 has a reduced inner diameter that creates a circular inner rib, flange or ledge 18b on the retainer. Also, that end of the retainer is bevelled to provide a flared or bevelled surface 18c which extends from the inner edge of ledge 18b toward the outer wall of the retainer. As best seen in FIG. 2, the ledge 18b and bevelled surface 18c together produce a structure at the distal end of the retainer which, in crosssection, has the general shape of an annular barb whose blunted nose 18d projects toward stem 14. When the retainer and stem are coaxial, the flare angle of surface 18c, as measured from the stem 14 longitudinal axis or centerline, is appreciably greater than that of enlargement segment 22a so that when catheter 12 is tensioned, nose 18d will bite into the catheter wall creating strong retention forces. For example, the former angle may be 45° and the latter angle 20°.
Retainer 18 is slidable along stem 14, with the stem flange 24 providing a bearing surface, between an unlocking position shown in FIG. 2 established by the engagement of the retainer flange 18a against the portal housing, wherein the retainer surface 18c and nose 18d are spaced appreciably from enlargement segment 22a and a locking position shown in FIG. 3 wherein the surface 18c and nose 18d are situated close to segment 22a, with the nose lying about halfway along the length of that segment. The stem flange 24, in addition to functioning as a stop for catheter 12 and as a bearing surface for the retainer as described above, also prevents the retainer 18 from sliding off the stem 14 by engaging the retainer flange 18a. A pair of diametrically opposite holes 26 are provided in the wall of retainer 18 to make it easier for the surgeon to see that the catheter is completely in place and abutting flange 24 inside the locking retainer.
The connection of catheter 12 to stem 14 can be made quite easily with one hand, even when the surgeon has no clear view of the connection site. To effect the connection, the surgeon grasps the end of the catheter and, feeling with his fingers, slides the catheter onto the end segment 14a of portal stem 14. He then pushes the end of the catheter over the stem enlargement 22 and into sleeve 18 until the catheter end is stopped by the stem flange 24. He can verify that the catheter is seated properly by observation through the retainer holes 26. The surgeon then pulls back gently on locking retainer 18 until the retainer nose 18d engages against and compresses the outer surface of catheter segment 12a as shown in FIG. 3. Most desirably, the inner diameter of retainer ledge or flange 18b, or more particularly of its nose 18d should be less than the diameter of enlargement shoulder 22c in which event, retainer flange 18a could be dispensed with. However, this creates manufacturing difficulties. To avoid these difficulties, the diameter of retainer nose 18 d is dimensioned to be smaller than the diameter of stem enlargement 22 plus twice the wall thickness of the catheter segment stretched over that segment 14b.
When the connection is made and locked as shown in FIG. 3, it is practically impossible to pull catheter 12 from the portal stem 14. Any pulling or twisting forces applied to the catheter only serve to tighten the connection between the catheter and the stem. That is, when catheter 12 is pulled away from portal 16, it pulls retainer 18 along with it to a locking position against enlargement segment 22a at a circular area of contact C (FIG. 3). Increased tensile forces only serve to pull the retainer more tightly against segment 22a at contact surface C. Resultantly, the retainer surface 18c and nose 18d are moved closer to the frustoconical segment 22a of enlargement 22 so that nose 18d clamps or bites even more firmly into the stretched catheter wall thereby further increasing the retention forces on the catheter. Accordingly, a frustoconical catheter segment is sandwiched or compressed ever more tightly between enlargement segment 22a and the retainer surface at contact surface C, as clearly seen in FIG. 3.
That engaged and compressed segment of the catheter has a relatively large area so that the stresses on the catheter due to such pulling and twisting forces are distributed uniformly over that segment, thus avoiding localized strains in the catheter wall that might tend to promote tears or punctures in that wall. Consequently, there is very little likelihood of the catheter pulling away from the portal outlet stem 14 or tearing due to movements of the patient in which the prosthesis is implanted. Indeed, the integrity of the connection system 10 should be maintained for the entire period of implantation.
However, if it should become necessary to replace the catheter 12 for some reason, the present system 10 facilitates that as well. To remove the catheter, the surgeon simply holds the retainer 18 back or urges it toward the portal housing while pulling the catheter from stem 14. Since the retainer cannot move outward, it cannot clamp the catheter segment 12a to enlargement 22, so the catheter will pull off readily, leaving the stem 14 ready for a new catheter. Indeed, the same locking retainer and portal stem can be assembled and disassembled many times if need be.
It will be seen from the foregoing, then, that my catheter connection system establishes a reliable, releasable, fluid-tight and easily made joint or connection between the end of a catheter or other flexible tube and a rigid tube, stem or other fluid pathway. The system's locking retainer is easy to manipulate when connecting and disconnecting the catheter from the tube or stem even if the surgeon's view is obstructed. Yet the components of the system are relatively easy and inexpensive to make so that the providing of this secure connection does not materially increase the overall cost of the injection portal or other prosthesis incorporating the invention. | This connection system has particular application to releasably securing a flexible elastic catheter to a rigid portal outlet stem received in the catheter lumen. The system includes a radial enlargement on the outlet stem and a retainer sleeve that slidably encircles the stem. The sleeve is slidable along the stem between a clamping position where it tightly engages around the stem enlargement and the segment of catheter encircling same at a circular contact surface and a release position wherein it is spaced from the catheter segment. The system assures a secure, fluid-tight connection of the catheter to the stem and provides strain relief for the catheter. | 8 |
[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 62/203,158 filed on Aug. 10, 2015 the content of which is relied upon and incorporated herein by reference in its entirety.
BACKGROUND
[0002] Laser line and broadband beamsplitters are in wide use in optical systems, with cube beamsplitters being more common. Cube beamsplitters are generally made from pairs of triangular glass prisms that have been bonded together. Bonding may be carried out using several different methods: optical adhesive bonding, optical direct bonding, and diffusion bonding.
[0003] With optical adhesive bonding, the thickness of the adhesive can be adjusted to reflect half the light of a given wavelength incident on one face of the cube and transmit the other half; however, this technique is not without drawbacks. Optical adhesive bonding bonds two polished mirror surfaces with optical adhesive such as, for example, polyester, epoxy, or urethane-based adhesive. Optical adhesive bonding is simple and can be used to bond different materials together; however, the presence of adhesive may lead to flaws or discolorations of the surface. Additionally, it is difficult to match the refractive index of the adhesive material to that of the optical components. Light from adhesive bonded devices loses flux through Fresnel reflection. Finally, the adhesive can be deformed, softened, or degraded when used in a laser system.
[0004] Optical direct bonding occurs when two ultrasmooth surfaces are held in close contact without any adhesive. It is thought that smooth surfaces in close enough contact will be electromagnetically attracted to one another. Under the right conditions, this type of bonding can be stronger than optical adhesive bonding. However, optical direct bonding is generally only suited to bonding between two prisms of the same material, since inconsistent expansion will occur due to differences in thermal expansion coefficients when the optical devices are heated (such as, for example, upon exposure to a laser). Inconsistent expansion can lead to separation of components and is particularly common in high-powered laser systems.
[0005] Meanwhile, high-temperature diffuse bonding is similar to optical direct bonding except that contact is followed by high-temperature heat treatment so that diffusion of atoms from one interface to the other can occur. However, as with optical direct bonding, high-temperature diffuse bonding is best suited to bonding crystal materials of the same type.
[0006] Cube beamsplitters currently on the market can split wavelengths of light down to about 250 nm. Challenges in the shorter wavelength regions include the lack of existence of absorption-free adhesives as well as the porous nature of fluoride coatings currently in use, especially for the ArF laser beam line at 193 nm. Chemical substances used as adhesives or during the bonding process can be absorbed by porous layers, leading to high absorption at short wavelengths. Due to these challenges, hybrid optical devices constructed from fused silicas such as HPFS® (Corning, Inc.) and CaF 2 are not currently available. However, such optical devices would be useful as ArF laser cube beamsplitters, as well as in other applications.
[0007] In the short wavelength region, standard optical bonding processes such as epoxy bonding, frit bonding, diffusion bonding, and optical contacting thus cannot be used due to absorption. One state-of-the-art bonding technology, chemically activated direct bonding (CADB), provides an epoxy-free solution assisted optical-contacting process. However, this process requires chemical soaking and thermal annealing, eliminating its applications for thermally sensitive crystal materials such as CaF 2 .
[0008] Typically, excimer lasers of low wavelengths must be operated at power levels lower than their maximum or, alternatively, users of these lasers had to accept shorter device lifetimes while operating at lower power levels, due to degradation of beamsplitters. Uncoated CaF 2 surfaces, for example, degrade after only a few million pulses when subjected to pulse energies above 40 mJ/cm 2 using 193 nm excimer radiation. Although ArF excimer lasers typically operate at lower pulse energies, local non-uniformities in the beam may be higher than the average value and thus exceed the damage threshold.
[0009] What is needed is an absorption free bonding method for constructing optical devices such as beamsplitters. Ideally, this method could be used to construct optical devices exhibiting no scatter loss or absorption loss such as commonly seen with optical adhesive bonding and could be used with thermally sensitive materials and porous coatings. Further, devices constructed by this method would be more durable than currently available technology. The present invention addresses these needs.
SUMMARY
[0010] Described herein are methods for constructing optical device without the need of chemical adhesives. The methods involve performing the following steps: obtaining a first optical substrate comprising a first surface and a second optical substrate comprising a second surface; applying water to the first surface of the first optical substrate, to the second surface of the second optical substrate, or both; securing the first optical substrate to the second optical substrate, wherein the first surface of the first optical substrate is adjacent to the second surface of the second optical substrate; and applying deep ultraviolet radiation to the first optical substrate and the second optical substrate to form a bond without the use of adhesive. Also provided are optical devices constructed by the methods described herein.
[0011] Additional features and advantages will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
[0012] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description serve to explain principles and operation of the various embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 shows a schematic illustration of the process described herein.
[0014] FIG. 2 shows a schematic illustration of chemical bonding at a SiO 2 —SiO 2 interface.
[0015] FIG. 3 shows a schematic illustration of chemical bonding at a CaF 2 —CaF 2 interface.
[0016] FIG. 4 shows a schematic illustration of chemical bonding at a SiO 2 —CaF 2 interface.
[0017] FIG. 5 shows a scanning electron micrograph (SEM) of a cross section of an F—SiO 2 sealed coating stack (GdF 3 /AlF 3 ) on a CaF 2 surface.
[0018] FIG. 6 shows a photograph demonstrating the chemical bonding of two SiO 2 substrates using the process described herein.
[0019] FIG. 7 shows a photograph demonstrating the chemical bonding of two CaF 2 substrates using the process described herein.
[0020] FIG. 8 shows VUV and DUV spectral transmittances of commercial fused silicas HPFS® 8655, 8650, and 7980 (Corning, Inc.) with thicknesses of 3.3 mm, 3.1 mm, and 3.3 mm, respectively.
[0021] FIGS. 9A and 9B show, respectively, transmittance and reflectance spectra of CaF 2 and SiO 2 based on a 50%:50% unpolarized cube beamsplitter at 193 nm.
DETAILED DESCRIPTION
[0022] Before the present methods and devices are disclosed and described, it is to be understood that the aspects described below are not limited to specific devices or methods, or uses as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[0023] It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a coating includes two or more such coatings, and the like.
[0024] “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not. For example, the phrase “optionally includes an antireflective coating” means that an antireflective coating can or cannot be included.
[0025] As used herein, the term “about” provides flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint without affecting the desired result. Ranges may be expressed herein from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.
[0026] Disclosed are materials and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed compositions and methods. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combination and permutation of these compounds may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a material for making an optical device is disclosed and a discussed and a number of different compatible coatings are discussed, each and every combination and permutation of material for making an optical device and coating that is possible is specifically contemplated unless specifically indicated to the contrary. For example, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F, and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited, each is individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these is also specifically contemplated and disclosed. Thus, for example, the subgroup of A-E, B-F, and C-E is specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, steps in methods of making and using the disclosed compositions. Thus, if a variety of additional steps can be performed, it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination is specifically contemplated and should be considered disclosed.
[0027] Described herein are methods for producing optical devices by bonding a first optical substrate having a first surface and a second optical substrate having a second surface to one another in the absence of a chemical adhesive. In one aspect, both the first optical substrate and the second optical substrate are made of the same material. In another aspect, the first optical substrate and second optical substrate are made of different materials. In one aspect, the first and/or second optical substrate is made of a material suitable for optical lithography. For example, a material suitable for optical lithography is a fused silica such as HPFS® (Corning, Inc.) or a metal fluoride. In a still further aspect, the first and/or second optical substrate can be constructed from an alkaline earth metal fluoride or a mixture of alkaline earth metal fluorides. In one aspect, the alkaline earth metal fluoride or mixture of alkaline earth metal fluorides can be MgF 2 , CaF 2 , BaF 2 , SrF 2 , CaSrF 2 , or any combination thereof.
[0028] In one aspect, both the first optical substrate and second optical substrate are composed of SiO 2 . In another aspect, both the first optical substrate and second optical substrate comprise CaF 2 . In still another aspect, the first optical substrate comprises SiO 2 and the second optical substrate comprises CaF 2 .
[0029] In another aspect, the first optical substrate and the second optical substrate are each triangular prisms used to produce a cube beamsplitter. Further in this aspect, the first surface and the second surface are the hypotenuse faces of the first optical substrate and the second optical substrate, respectively.
[0030] After the first and second optical substrates have been selected, water is applied to at least one surface of the first or second optical substrate. In one aspect, water is applied to the first surface of the first optical substrate. In another aspect, water is applied to both the first surface of the first optical substrate and the second surface of the second optical substrate. In one aspect, the water is deionized water.
[0031] The amount of water that is applied to the surface of the first and/or second optical substrate can vary depending upon the dimensions of the substrate surface and the desired thickness of the water layer between the two substrates. In one aspect, one or more drops of deionized water are applied to either the first surface or the second surface. A thin water layer forms when the two surfaces of the first and second optical substrate come into contact with one another.
[0032] In one aspect, following the application of water to the surface of the first and/or second optical substrate, the first optical substrate can be secured to the second optical substrate in such a manner that a layer of water is evenly dispersed between the first and second optical substrate. FIG. 1 depicts one aspect of this embodiment. Referring to FIG. 1 , a layer of water 100 is disposed between first optical substrate 110 and second optical substrate 120 , where the water layer is in contact with the first surface 115 of the first optical substrate 110 and the second surface 125 of the second optical substrate 125 . Securing devices 130 and 140 hold the first and second optical substrates 110 and 120 in place. The number of securing devices and the amount of pressure exerted by the device can vary. In one aspect, the securing device can be an adjustable clamp. In another aspect the securing device can be magnetic bars. The selection of the securing device should be such that the device does not scratch or damage the resulting optical device.
[0033] The first and/or second surfaces 115 and 125 of the first and second optical substrates 110 and 120 can be contacted with water for a time of from about 5 seconds to about 10 minutes at a temperature of from 20° to 30° C. In one aspect, the first and/or second surfaces can be contacted with water for about 5 seconds, about 10 seconds, about 30 seconds, about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, or about 10 minutes. In another aspect, the first and/or second surfaces are contacted with water at about 20°, about 21°, about 22°, about 23°, about 24°, about 25°, about 26°, about 27°, about 28°, about 29°, or about 30° C. In still another aspect, the first and/or second surfaces are contacted with water at room temperature, where no external heat from a heat source (e.g., an oven) is applied.
[0034] After the water layer 100 has been formed between first optical substrate 110 and second optical substrate 120 to produce the pre-optical device 150 ( FIG. 1 ), the pre-optical device is exposed to deep ultraviolet (DUV) radiation as depicted as 160 in FIG. 1 . In one aspect, the DUV radiation has energy of about 400 kJ/mol to about 800 kJ/mol. In aspect, the DUV radiation can have energy of about 400, about 450, about 475, about 500, about 550, about 600, about 650, about 700, about 750, or about 800 kJ/mol, where any value can form a lower or upper end-point of an energy range. In another aspect, the energy can be 647 kJ/mol or can be 472 kJ/mol.
[0035] In a further aspect, the DUV radiation source is a low-pressure mercury-vapor lamp. In this aspect, the lamp may emit radiation with two primary spectral lines at, for example, 184 nm and 253 nm. In an alternative aspect, the lamp can be constructed to emit radiation at only 184 nm or only 253 nm. In another aspect, the DUV radiation source is not a low-pressure mercury-vapor lamp but can be any other light source that emits a wavelength to which the optical substrates are transparent and that has photon energy high enough to dissociate the water molecules at the contacted interface.
[0036] The DUV radiation is applied to the pre-optical device 150 for a period of time from about 1 minute to about 30 minutes. Further in this aspect, the DUV radiation is applied to the first and second optical substrates for about 1, about 2, about 5, about 10, about 15, about 20, about 25, or about 30 minutes, where any value can form a lower or upper end-point of a time range. In another aspect, the time of DUV radiation exposure is dependent upon the amount of energy applied to the substrates. In one aspect, higher energy radiation requires a shorter DUV exposure time and lower energy radiation requires a longer DUV exposure time.
[0037] Not wishing to be bound by theory, it is believed that the DUV radiation can dissociate water present in the water layer 100 to generate hydroxyl radicals, which can subsequently react with the first and second optical surfaces 115 and 125 to produce new covalent bonds between the first and second surfaces of the first and second optical substrates. Additionally, it is believed that the hydroxyl radicals can be further dissociated by the DUV radiation to form oxygen bridges at the interface of the first and second optical substrates. In one aspect, the energy output of the mercury vapor lamp is able to dissociate bonds such as those found in common optical substrates and coatings. Table 1 shows the bond energies of SiO 2 , CaF 2 , and H 2 O related bonds.
[0000]
TABLE 1
Bond Energies
Bond
Bond Energy (kJ/mol)
O—O
139
O═O
498
O—H
428
Si—H
299
Si—O
780
Si—Si
327
Ca—F
527
Ca—Ca
46
F—H
563
Ca—O
402
F—O
222
[0038] FIGS. 2-4 shows the covalent bonding of SiO 2 —SiO 2 optical substrates ( FIG. 2 ), CaF 2 —CaF 2 optical substrates ( FIG. 3 ), and SiO 2 —CaF 2 optical substrates ( FIG. 4 ). Referring to FIG. 2 , the SiO 2 —SiO 2 optical substrates 210 and 220 are covalently bonded to one another via —Si—O—Si— bonds. In the case of CaF 2 —CaF 2 optical substrates 310 and 320 in FIG. 3 , the optical substrates are covalently bonded to one another via —Ca—O—Ca— bonds. Finally, the SiO 2 —CaF 2 optical substrates 410 and 420 are bonded to one another via —Si—O—Ca— bonds ( FIG. 4 ).
[0039] In still another aspect, the optical device constructed by any of the above methods is not annealed or heated subsequent to the application of DUV radiation. Thus, the methods described herein are useful in adhering optical substrates composed of different material (e.g., first substrate is SiO 2 and the second substrate CaF 2 ). In one aspect, the first substrate is uncoated fused silica such as HPFS® (Corning, Inc.) and the second substrate is CaF 2 . Moreover, the methods described herein do not require the use of chemical adhesives, which has several disadvantages as discussed above.
[0040] In a further aspect, one or more surfaces of the optical device produced by the methods described herein can be coated with one or more coatings known in the art. In one aspect, the coating can be a beamsplitter coating, an anti-reflective coating, a mirror coating, a partial mirror coating, a polarization control coating, or a combination thereof. In one aspect, the coating is a metal fluoride material. In a further aspect, the metal fluoride material can be AlF 3 , NaF, MgF 2 , LaF 3 , GdF 3 , NdF 3 , or a combination thereof. In yet another aspect, multiple metal fluoride coatings are layered on top of one another. In this aspect, 2 layers, 3 layers, 4 layers, 5 layers, 6 layers, 7 layers, 8 layers, 9 layers, or 10 layers of metal fluoride coatings are applied to the devices. In another aspect, the layers may be made from different metal fluorides, the same metal fluorides, or alternating metal fluorides. In one aspect, there are seven metal fluoride coating layers consisting of alternating films of GdF 3 and AlF 3 . FIG. 5 provides an example of this where a surface of an optical device produced herein composed of CaF 2 has alternating layers of AlF 3 and GdF 3 .
[0041] In yet another aspect, after the application of DUV radiation, at least one exposed surface of the optical device can be hermetically sealed. The methods disclosed in U.S. Pat. Nos. 7,242,843 and 8,399,110 can be used herein to hermetically seal the optical devices produced herein. In some aspects, hermetic sealing of the optical device prevents degradation of the optical device from deionized water in immersed lithographic applications. The hermetic seal may be physically or chemically (i.e., covalently) bonded to the underlying surface. In one aspect, the hermetic sealing material is selected from an oxide or fluorinated oxide film. For example, the device can be hermetically sealed with Al 2 O 3 , F:Al 2 O 3 , SiO 2 , SiON, HfO 2 , Si 3 N 4 , ZrO 2 , TiO 2 , SiO 2 /ZrO 2 , F:SiO 2 /ZrO 2 , F:SiO 2 , or any combination thereof.
[0042] In one aspect, the hermetic sealing layer is placed atop and around a coating layer present on the optical device. For example, an anti-reflective coating can be applied to the surface of the optical device followed by hermetically sealing the anti-reflective coating. In one aspect, one or more coating layers can be hermetically sealed on the optical device. An example of this is provided in FIG. 5 , where a plurality of coatings composed of metal fluorides is hermetically sealed by F:SiO 2 .
[0043] In another aspect, when no coating is applied to the surface of the optical device, the device or a surface thereof can be hermetically sealed directly.
[0044] In one aspect, the methods described herein are useful in producing beamsplitters. A “beamsplitter” is an optical device that splits a beam of light in two. In one aspect, cube and laser line beamsplitters can be produced herein. In another aspect, the beamsplitters can be film polarizing beamsplitters, non-polarizing beamsplitters, long and short wavelength cut-off filters, or bandpass filters.
[0045] In one aspect, the optical devices described herein possess numerous advantages over current optical devices. For example, the optical devices produced herein are used in excimer lasers that operate at wavelengths 248 nm, 193 nm, or 157 nm for optical lithography, medical, or industrial applications. In another aspect, the optical devices require fewer materials to construct because they do not require adhesive but instead only require a small amount of deionized water. In another aspect, the optical devices involve a lower production cost because they can be constructed with existing coating and cleaning equipment and because they do not require high temperature annealing or thermal curing for the bonding process. In a still further aspect, the optical devices described herein are durable and degradation is not expected for the photo-activated, water-initiated chemical bonds since they are absorption free.
Examples
[0046] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, and methods described and claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the scope of what the inventors regard as their invention. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.) but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in ° C. or is at ambient temperature, and pressure is at or near atmospheric. There are numerous variations and combinations of reaction conditions, e.g., component concentrations, desired solvents, solvent mixtures, temperatures, pressures and other reaction ranges and conditions that can be used to optimize the product purity and yield obtained from the described process. Only reasonable and routine experimentation will be required to optimize such process conditions.
Procedure for Constructing Optical Devices
[0047] Two optical surfaces were cleaned and put into optical contact with a thin layer of deionized water at the interface between them. The optical surface flatness was lower than 0.2 fringes at 635 nm and the surface roughness was less than 0.2 nm for bare substrates. DUV light from a low-pressure mercury vapor lamp was used to ionize and volatilize the interfacial water, activating chemical bonding of the surfaces. The two surfaces were held together for 10 min at room temperature, for experimental purposes, using a pair of magnetic bars during which time they were irradiated. However, a mechanical holder can also be used. The mercury vapor lamp used in these experiments emitted two main spectral lines at 184 nm and 253 nm, corresponding to 647 kJ/mol and 472 kJ/mol, respectively. This procedure can also be carried out in vacuum.
[0048] Following construction of the optical device, a porous fluoride coating was sealed and smoothed by a dense and smooth F:SiO 2 capping layer using modified plasma ion-assisted deposition in order to provide hermetic sealing and enable direct chemical bonding between the F:SiO 2 layer and coated or uncoated CaF 2 or SiO 2 surfaces. Example devices constructed from (1) two SiO 2 substrates ( FIG. 6 ), (2) two CaF 2 substrates ( FIG. 7 ), and (3) one SiO 2 substrate bonded to a CaF 2 substrate were constructed.
[0049] A finished CaF 2 device was coated with alternating layers of GdF 3 (four layers) and AlF 3 (three layers) and hermetically sealed with F:SiO 2 . A SEM cross-sectional image of this optical device is shown in FIG. 5 .
Performance of Optical Devices
[0050] FIG. 8 shows VUV and DUV spectral transmittance of HPFS® (Corning, Inc.) 8655, 8650, and 7980 glasses with thicknesses of 3.3 mm, 3.1 mm, and 3.3 mm, respectively. All samples of HPFS tested were transparent to the mercury vapor lamp emission. This demonstrated that two HPFS surfaces contacting one another with an intermediate water layer could be chemically bonded using DUV irradiation at 184 nm and 253 nm.
[0051] FIGS. 9A and 9B show, respectively, transmittance and reflectance spectra of a CaF 2 and SiO 2 based unpolarized cube beam splitter at 193 nm.
[0052] Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the methods and articles described herein.
[0053] Various modifications and variations can be made to the materials, methods, and articles described herein. Other aspects of the materials, methods, and articles described herein will be apparent from consideration of the specification and practice of the materials, methods, and articles disclosed herein. It is intended that the specification and examples be considered as exemplary. | Described herein are methods for constructing optical device without the need of chemical adhesives. The methods involve performing the following steps: obtaining a first optical substrate comprising a first surface and a second optical substrate comprising a second surface; applying water to the first surface of the first optical substrate, to the second surface of the second optical substrate, or both; securing the first optical substrate to the second optical substrate, wherein the first surface of the first optical substrate is adjacent to the second surface of the second optical substrate; and applying deep ultraviolet radiation to the first optical substrate and the second optical substrate to form a bond without the use of adhesive. Also provided are optical devices constructed by the methods described herein. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of copending U.S. Provisional Application Ser. No. 61/346,516 filed May 20, 2010, the entire disclosure of which is incorporated herein by reference.
REFERENCE TO GOVERNMENT GRANT
[0002] The invention described herein was supported in part by the Government grant number RO1 GM076471 awarded by the National Institutes of Health (NIH). The Federal Government may have certain rights in the invention.
FIELD OF INVENTION
[0003] The invention relates to a method of preparing silane dipeptide analogs useful as protease inhibitors.
BACKGROUND OF THE INVENTION
[0004] Protease inhibitors inhibit proteases, which are proteins responsible for hydrolyzing peptides or proteins into their carboxylic acid and amine components. Protease inhibitors have been used to prevent or treat viral infections, including HIV and Hepatitis C, both of which require protease activity for the infection process. In the case of HIV, protease inhibitors prevent replication by inhibiting the activity of HIV-1 protease, a viral enzyme that cleaves nascent proteins for final assembly of new virions.
[0005] Protease inhibitors have been developed or are presently undergoing testing for treating various viral infections, such as HIV infections. Examples of anti-HIV protease inhibitors are saquinavir (Fortovase™, Invirase™, Hoffman-La Roche), ritonavir (Norvir™, Abbott), indinavir (Crixivan™, Merck), nelfinavir (Viracept™, Agouron), amprenavir (Agenerase™, GlaxoSmithKline), lopinavir (Kaletra™, Abbott), atazanavir (Reyataz™, Bristol-Myers Squibb), fosamprenavir (Lexiva™, Telzir™, GlaxoSmithKline), tipranavir (Aptivus™, Boehringer-Ingelheim) and darunavir (Prezista™, Tibotec). Examples of protease inhibitors experimentally used for hepatitis C treatment are BILN 2061 (Bohringer Ingleheim), VX 950 (Telaprevir™, Vertex and Johnson & Johnson), and SCH 503034 (Schering-Plough).
[0006] Researchers are further investigating the use of anti-HIV protease inhibitors as anti-protozoals for use against malaria and gastrointestinal protozoal infections. A combination of ritonavir and lopinavir was found to have some effectiveness against Giardia infection (Dunn et al., 2007, Int. J. Antimicrob. Agents 29(1): 98-102). The drugs saquinavir, ritonavir, and lopinavir have been found to have anti-malarial properties (Andrews et al., 2006, Antimicrob. Agents Chemother. 50(2):639-48). A cysteine protease inhibitor drug was found to cure Chagas's disease in mice (Doyle et al., 207, Antimicrob. Agents Chemother. 51(11):3932).
[0007] Protease inhibitors have been further evaluated in the treatment of cancer. For example, nelfinavir and atazanavir are able to kill tumor cells in culture (Gills et al., 2007, Clin. Cancer Res. 13(17):5183-94; Pyrko et al., Cancer Res. 67(22):10920-28). Proteasome inhibitors, such as Velcade™, are now front-line drugs for the treatment of various cancers, notably multiple myeloma.
[0008] Due to the great interest in protease inhibitors, effort has been devoted to the design and synthesis of novel scaffolds that combine protease inhibition capability and good developability properties. One such novel class of compounds is the silanediol-based dipeptide analogs, such as (1). The structure of (1) mimics the structure of the hydrated carbonyl compound (2), which is an intermediate of the hydrolysis reaction of a peptide to the carboxylic acid fragment (3) and amine fragment (4). As a structural mimic of (2), compound (1) binds to the protease active site and inhibits its activity.
[0000]
[0009] Compounds such as (1) have been prepared by a process involving approximately 15 steps, which is far too long a synthetic route to be practical. The final step of the synthesis is treatment of diphenylsilane (5) with acid, whereby a silanediol (1) is formed. Compound (5) could in principle be prepared by a condensation reaction analogous to the addition of a silyl anion (8) to a sulfinimine (7) (Nielsen & Skrydstrup, 2008, J. Am. Chem. Soc. 130:13145-51). Silyl anion (8) may be formed by treating a chlorosilane (9) with lithium metal or a lithium salt. Chlorosilanes are cheap and readily available but are extremely moisture sensitive and fume when exposed to air. Less commonly, a proteosilane (10) is used as a precursor to (8). Proteosilane (10) is easier to manipulate but is generally prepared from a moisture-sensitive chlorosilane.
[0000]
[0010] Due to the strength of the Si-O bond in a siloxy compound, its conversion to a silyl metal derivative is largely unexplored in the chemical literature. An early report described the conversion of triphenylsiloxyethane to triphenylsilyl sodium using sodium-potassium alloy in 40% yield (Benkeser et al., 1952, J. Am. Chem. Soc. 74:648-50). This report did not use substrates containing fewer than three phenyl groups attached to the silicon atom. A more recent report described the conversion of 1-dimethylphenylsiloxydecane to 1-decanol via treatment with lithium naphthalide, followed by acidic hydrolysis (Alonso et al., 1997, Tetrahedron 53:14355-68). This report did not describe the fate of the silicon group, and the synthetic protocol was rather cumbersome and difficult to scale up (Behloul et al., 2005, Tetrahedron 61:6908-15).
[0011] There is thus a need for the development of a novel synthetic methodology that allows for the efficient and convenient synthesis of a silanediol-based dipeptide analog such as (1). The synthetic methodology should allow for the synthesis of targeted compounds from commercially available and inexpensive compounds that are easy to handle. The present invention addresses and meets these needs.
SUMMARY OF THE INVENTION
[0012] The present invention relates to the unexpected discovery that a substituted 1,2-oxasilolane may be efficiently converted to the dilithium salt of a substituted 3-hydroxypropylsilanol using lithium metal, which reductively cleaves the Si-O bond in high yields. The substituted 1,2-oxasilolane starting material is easy to prepare and purify and does not present the same handling problems as chlorosilanes, which have been previously utilized in the synthesis of silyl lithium compounds. The dilithium salt of the 3-hydroxypropylsilanol may be reacted with various nucleophiles. The chemistry disclosed herein may be used to synthesize a silanediol-based dipeptide analog of formula (1) in high yield and in fewer synthetic steps than previously reported.
[0013] The invention includes a process for preparing a compound of formula (15):
[0000]
[0000] wherein:
R 1 , R 2 and R 3 are independently selected from the group consisting of H, C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, and heteroaryl-carbonyl; and, R 4 and R 5 are independently selected from the group consisting of aryl, substituted aryl, heteroaryl and substituted heteroaryl,
the process comprising the step of reacting lithium metal with a compound of formula (11):
[0000]
[0000] to form the compound of formula (15).
[0016] In one embodiment, the reaction is conducted in a solvent comprising tetrahydrofuran, diethyl ether or 1,4-dioxane. In another embodiment, the reaction is run at about 0° C. In yet another embodiment, R 2 and R 3 are H. In yet another embodiment, R 1 is methyl. In yet another embodiment, R 4 and R 5 are phenyl. In yet another embodiment, the compound of formula (11) is (S)-4-methyl-2,2-diphenyl-1,2-oxasilolane.
[0017] The invention further includes a process for preparing a compound of formula (17):
[0000]
[0000] wherein:
R 1 , R 2 and R 3 are independently selected from the group consisting of H, C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, and heteroaryl-carbonyl; R 4 and R 5 are independently selected from the group consisting of aryl, substituted aryl, heteroaryl and substituted heteroaryl, R 7 is —S(O)R 8 , —S(O) 2 R 8 , —S(O) 2 NR 9 R 10 , —C(O)R 9 , —C(O)NR 9 R 10 , a protected carboxyl-linked amino acid or a protected carboxyl-linked peptide; R 6 , R 9 and R 10 are independently selected from the group consisting of H, C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, and substituted aryl-(C 1-3 )alkyl; and, R 8 is C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, or substituted aryl-(C 1-3 )alkyl;
the process comprising the steps of:
(a) reacting lithium metal with a compound of formula (11):
[0000]
[0000] to form a compound of formula (15):
[0000]
(b) reacting the compound of formula (15) with a compound of formula (16):
[0000]
[0000] to form a reaction mixture; and,
(c) neutralizing the reaction mixture to form the compound of formula (17).
[0026] In one embodiment, the reaction in step (a) is conducted in a solvent comprising tetrahydrofuran, diethyl ether or 1,4-dioxane. In another embodiment, R 2 and R 3 are H. In yet another embodiment, R 1 is methyl. In yet another embodiment, R 4 and R 5 are phenyl. In yet another embodiment, the compound of formula (11) is (S)-4-methyl-2,2-diphenyl-1,2-oxasilolane. In yet another embodiment, R 7 is p-methylphenyl-sulfinyl.
[0027] The invention further includes a process for preparing a compound of formula (19):
[0000]
[0000] wherein:
R 11 is C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, or heteroaryl-carbonyl; and, R 4 and R 5 are independently selected from the group consisting of aryl, substituted aryl, heteroaryl and substituted heteroaryl;
the process comprising the step of reacting lithium metal with a compound of formula (18):
[0000]
[0000] wherein:
R 8 is C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, or heteroaryl-carbonyl;
to form a solution of the compound of formula (19).
[0031] In one embodiment, the reaction is conducted in a solvent comprising tetrahydrofuran, diethyl ether or 1,4-dioxane. In another embodiment, the reaction is run at about 0° C. In yet another embodiment, R 11 is methyl. In yet another embodiment, R 4 and R 5 are phenyl. In yet another embodiment, the compound of formula (18) is methoxy(methyl)diphenylsilane.
[0032] As envisioned in the present invention with respect to the disclosed compositions of matter and methods, in one aspect the embodiments of the invention comprise the components and/or steps disclosed therein. In another aspect, the embodiments of the invention consist essentially of the components and/or steps disclosed therein. In yet another aspect, the embodiments of the invention consist of the components and/or steps disclosed therein.
DESCRIPTION OF FIGURES
[0033] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures.
[0034] FIG. 1 shows the 1 H NMR spectra obtained at different time points for the reaction mixture of Example 1. The spectra reproduced were acquired, from top to bottom, at 1.0 h, 1.5 h, 2.5 h and 3.5 h reaction times.
[0035] FIG. 2 shows the 1 H NMR spectrum of compound (25).
DEFINITIONS
[0036] The definitions used in this application are for illustrative purposes and do not limit the scope used in the practice of the invention.
[0037] In the following paragraphs some of the definitions include examples. The examples are intended to be illustrative, and not limiting.
[0038] Unless defined otherwise, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Generally, the nomenclature used herein and the laboratory procedures in analytical, organic and protein chemistries are those well known and commonly employed in the art.
[0039] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
[0040] The term “about” will be understood by persons of ordinary skill in the art and will vary to some extent on the context in which it is used.
[0041] As used herein, the terms “peptide,” “polypeptide,” or “protein” are used interchangeably, and refer to a compound comprised of amino acid residues covalently linked by peptide bonds. A protein or peptide must contain at least two amino acids, and no limitation is placed on the maximum number of amino acids that may comprise the sequence of a protein or peptide. Polypeptides include any peptide or protein comprising two or more amino acids joined to each other by peptide bonds. As used herein, the term refers to both short chains, which also commonly are referred to in the art as peptides, oligopeptides and oligomers, for example, and to longer chains, which generally are referred to in the art as proteins, of which there are many types. “Polypeptides” include, for example, biologically active fragments, substantially homologous polypeptides, oligopeptides, homodimers, heterodimers, variants of polypeptides, modified polypeptides, derivatives, analogs and fusion proteins, among others. The polypeptides include natural peptides, recombinant peptides, synthetic peptides or a combination thereof. A peptide that is not cyclic has an N-terminus and a C-terminus. The N-terminus will have an amino group, which may be free (i.e., as a NH 2 group) or appropriately protected (for example, with a BOC or a Fmoc group). The C-terminus will have a carboxylic group, which may be free (i.e., as a COOH group) or appropriately protected (for example, as a benzyl or a methyl ester). A cyclic peptide does not necessarily have free N- or C-termini, since they are covalently bonded through an amide bond to form the cyclic structure. The term “peptide bond” means a covalent amide linkage formed by loss of a molecule of water between the carboxyl group of one amino acid and the amino group of a second amino acid.
[0042] The structure of amino acids and their abbreviations can be found in the chemical literature, such as in Stryer, 1988, “Biochemistry”, 3rd Ed., W. H. Freeman & Co., NY, N.Y. The natural α-amino acids are alanine, arginine, asparagine, aspartic acid, cysteine, cystine, glutamic acid, glutamine, glycine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine and valine.
[0043] As used herein, the term “carboxyl-linked amino acid” as used to describe a substituent in a molecule refers to an amino acid that is covalently bound to the molecule through the carboxyl group of the amino acid. Therefore, a “carboxyl-linked amino acid” substituent attached to an amino group indicates that the amino acid is linked through a peptide bond to the amino group. In order to facilitate the synthetic manipulation of the molecules useful within the invention, the side-chains of the carboxyl-linked amino acid may be protected with protective groups commonly used in peptide chemistry, such as Fmoc (fluorenylmethyloxycarbonyl) or tBoc (N-tert-butoxycarbonyl) for amine groups and t-butyl, methyl or benzyl esters for carboxylic groups. These groups may be deprotected according to the methods known to those skilled in the art.
[0044] Likewise, the term “carboxyl-linked peptide” as used to describe a substituent in a molecule refers to a peptide that is covalently bound to the molecule through the C-terminus carboxyl group or a side chain carboxyl group of the peptide. Therefore, a “carboxyl-linked peptide acid” substituent attached to an amino group indicates that the C-terminus carboxyl group or a side chain carboxyl group of the peptide is linked through a peptide bond to the amino group. In order to facilitate the synthetic manipulation of the molecules useful within the invention, the side-chains of the carboxyl-linked peptide may be protected with protective groups commonly used in peptide chemistry, such as Fmoc (fluorenylmethyloxycarbonyl) or tBoc (N-tert-butoxycarbonyl) for amine groups and methyl, benzyl or t-butyl esters for carboxylic groups. These groups may be deprotected according to the methods known to those skilled in the art.
[0045] As used herein, the term “alkyl”, by itself or as part of another substituent means, unless otherwise stated, a straight, branched or cyclic chain hydrocarbon having the number of carbon atoms designated (i.e. C 1 -C 10 means one to ten carbon atoms) and includes straight, branched chain or cyclic groups. Examples include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl, pentyl, neopentyl, hexyl, cyclohexyl and cyclopropylmethyl. Most preferred is (C 1 -C 3 )alkyl, particularly ethyl, methyl and isopropyl.
[0046] As used herein, the term “alkenyl,” employed alone or in combination with other terms, means, unless otherwise stated, a stable mono-unsaturated or di-unsaturated straight chain, branched chain or cyclic hydrocarbon group having the stated number of carbon atoms. Examples include vinyl, propenyl (allyl), crotyl, isopentenyl, butadienyl, 1,3-pentadienyl, 1,4-pentadienyl, cyclopentenyl, cyclopentadienyl and the higher homologs and isomers. A functional group representing an alkene is exemplified by —CH═CH—CH 2 13 .
[0047] As used herein, the term “substituted alkyl” or “substituted alkenyl” means alkyl or alkenyl, as defined above, substituted by one, two or three substituents selected from the group consisting of halogen, —OH, alkoxy, —NH 2 , —N(CH 3 ) 2 , —C(═O)OH, trifluoromethyl, —C(═O)O(C 1 -C 4 )alkyl, —C(═O)NH 2 , —SO 2 NH 2 , —C(═NH)NH 2 , —C≡N and —NO 2 , preferably containing one or two substituents selected from halogen, —OH, alkoxy, —NH 2 , trifluoromethyl, —N(CH 3 ) 2 , and —C(═O)OH, more preferably selected from halogen, alkoxy and —OH. Examples of substituted alkyls include, but are not limited to, 2,2-difluoropropyl, 2-carboxycyclopentyl and 3-chloropropyl.
[0048] As used herein, the term “alkoxy” employed alone or in combination with other terms means, unless otherwise stated, an alkyl group having the designated number of carbon atoms, as defined above, connected to the rest of the molecule via an oxygen atom, such as, for example, methoxy, ethoxy, 1 -propoxy, 2-propoxy (isopropoxy) and the higher homologs and isomers. Preferred are (C 1 -C 3 )alkoxy, particularly ethoxy and methoxy.
[0049] As used herein, the term “halo” or “halogen” by themselves or as part of another substituent mean, unless otherwise stated, a fluorine, chlorine, bromine, or iodine atom, preferably, fluorine, chlorine, or bromine, more preferably, fluorine or chlorine.
[0050] As used herein, the term “heteroalkyl” by itself or in combination with another term means, unless otherwise stated, a stable straight or branched chain alkyl group consisting of the stated number of carbon atoms and one or two heteroatoms selected from the group consisting of O, N, and S, and wherein the nitrogen and sulfur atoms may be optionally oxidized and the nitrogen heteroatom may be optionally quaternized. The heteroatom(s) may be placed at any position of the heteroalkyl group, including between the rest of the heteroalkyl group and the fragment to which it is attached, as well as attached to the most distal carbon atom in the heteroalkyl group. Examples include: —O—CH 2 —CH 2 —CH 3 , —CH 2 —CH 2 CH 2 —OH, —CH 2 —CH 2 —NH—CH 3 , —CH 2 —S—CH 2 —CH 3 , and —CH 2 CH 2 —S(═O)—CH 3 . Up to two heteroatoms may be consecutive, such as, for example, —CH 2 —NH—OCH 3 , or —CH 2 —CH 2 —S—S—CH 3
[0051] As used herein, the term “heteroalkenyl” by itself or in combination with another term means, unless otherwise stated, a stable straight or branched chain monounsaturated or di-unsaturated hydrocarbon group consisting of the stated number of carbon atoms and one or two heteroatoms selected from the group consisting of O, N, and S, and wherein the nitrogen and sulfur atoms may optionally be oxidized and the nitrogen heteroatom may optionally be quaternized. Up to two heteroatoms may be placed consecutively. Examples include —CH═CH—O—CH 3 , —CH═CH—CH 2 —OH, —CH 2 —CH═N—OCH 3 , —CH═CH—N(CH 3 )—CH 3 , and —CH 2 —CH═CH—CH 2 —SH.
[0052] As used herein, the term “aromatic” refers to a carbocycle or heterocycle having one or more polyunsaturated rings having aromatic character (i.e. having (4n+2) delocalized π (pi) electrons where n is an integer).
[0053] As used herein, the term “aryl,” employed alone or in combination with other terms, means, unless otherwise stated, a carbocyclic aromatic system containing one or more rings (typically one, two or three rings) wherein such rings may be attached together in a pendent manner, such as a biphenyl, or may be fused, such as naphthalene. Examples include phenyl, anthracyl, and naphthyl. Preferred are phenyl and naphthyl, most preferred is phenyl.
[0054] As used herein, the term “aryl-(C 1 -C 3 )alkyl” means a functional group wherein a one to three carbon alkylene chain is attached to an aryl group, e.g., —CH 2 CH 2 -phenyl. Preferred is aryl(CH 2 )— and aryl(CH(CH 3 ))—. The term “substituted aryl-(C 1 -C 3 )alkyl” means an aryl-(C 1 -C 3 )alkyl functional group in which the aryl group is substituted. Preferred is substituted aryl(CH 2 ) 13 . Similarly, the term “heteroaryl-(C 1 -C 3 )alkyl” means a functional group wherein a one to three carbon alkylene chain is attached to a heteroaryl group, e.g., —CH 2 CH 2 -pyridyl. Preferred is heteroaryl(CH 2 ) 13 . The term “substituted heteroaryl-(C 1 -C 3 )alkyl” means a heteroaryl-(C 1 -C 3 )alkyl functional group in which the heteroaryl group is substituted. Preferred is substituted heteroaryl(CH 2 ) 13 .
[0055] As used herein, the term “heterocycle” or “heterocyclyl” or “heterocyclic” by itself or as part of another substituent means, unless otherwise stated, an unsubstituted or substituted, stable, mono- or multi-cyclic heterocyclic ring system which consists of carbon atoms and at least one heteroatom selected from the group consisting of N, O, and S, and wherein the nitrogen and sulfur heteroatoms may be optionally oxidized, and the nitrogen atom may be optionally quaternized. The heterocyclic system may be attached, unless otherwise stated, at any heteroatom or carbon atom that affords a stable structure. A heterocycle may be aromatic or non-aromatic in nature. In one embodiment, the heterocycle is a heteroaryl.
[0056] As used herein, the term “heteroaryl” or “heteroaromatic” refers to a heterocycle having aromatic character. A polycyclic heteroaryl may include one or more rings that are partially saturated. Examples include tetrahydroquinoline and 2,3-dihydrobenzofuryl.
[0057] Examples of non-aromatic heterocycles include monocyclic groups such as aziridine, oxirane, thiirane, azetidine, oxetane, thietane, pyrrolidine, pyrroline, imidazoline, pyrazolidine, dioxolane, sulfolane, 2,3-dihydrofuran, 2,5-dihydrofuran, tetrahydrofuran, thiophane, piperidine, 1,2,3,6-tetrahydropyridine, 1,4-dihydropyridine, piperazine, morpholine, thiomorpholine, pyran, 2,3-dihydropyran, tetrahydropyran, 1,4-dioxane, 1,3-dioxane, homopiperazine, homopiperidine, 1,3-dioxepane, 4,7-dihydro-1,3-dioxepin and hexamethyleneoxide.
[0058] Examples of heteroaryl groups include pyridyl, pyrazinyl, pyrimidinyl, particularly 2- and 4-pyrimidinyl, pyridazinyl, thienyl, furyl, pyrrolyl, particularly 2-pyrrolyl, imidazolyl, thiazolyl, oxazolyl, pyrazolyl, particularly 3- and 5-pyrazolyl, isothiazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1,3,4-triazolyl, tetrazolyl, 1,2,3-thiadiazolyl, 1,2,3-oxadiazolyl, 1,3,4-thiadiazolyl and 1,3,4-oxadiazolyl.
[0059] Examples of polycyclic heterocycles include indolyl, particularly 3-, 4-, 5-, 6- and 7-indolyl, indolinyl, quinolyl, tetrahydroquinolyl, isoquinolyl, particularly 1- and 5-isoquinolyl, 1,2,3,4-tetrahydroisoquinolyl, cinnolinyl, quinoxalinyl, particularly 2- and 5-quinoxalinyl, quinazolinyl, phthalazinyl, 1,8-naphthyridinyl, 1,4-benzodioxanyl, coumarin, dihydrocoumarin, benzofuryl, particularly 3-, 4-, 1,5-naphthyridinyl, 5-, 6- and 7-benzofuryl, 2,3-dihydrobenzofuryl, 1,2-benzisoxazolyl, benzothienyl, particularly 3-, 4-, 5-, 6-, and 7-benzothienyl, benzoxazolyl, benzthiazolyl, particularly 2-benzothiazolyl and 5-benzothiazolyl, purinyl, benzimidazolyl, particularly 2-benzimidazolyl, benztriazolyl, thioxanthinyl, carbazolyl, carbolinyl, acridinyl, pyrrolizidinyl, and quinolizidinyl.
[0060] The aforementioned listing of heterocyclyl and heteroaryl moieties is intended to be representative and not limiting.
[0061] As used herein, the term “hydrocarbyl” refers to any moiety comprising only hydrogen and carbon atoms. Preferred hydrocarbyl groups are (C 1 -C 12 )hydrocarbyl, more preferred are (C 1 -C 7 )hydrocarbyl, and most preferred are benzyl and (C1-C6) alkyl.
[0062] As used herein, the term “substituted” means that an atom or group of atoms has replaced hydrogen as the substituent attached to another group.
[0063] For aryl, aryl-(C 1 -C 3 )alkyl and heterocyclyl groups, the term “substituted” as applied to the rings of these groups refers to any level of substitution, namely mono-, di-, tri-, tetra-, or penta-substitution, where such substitution is permitted. The substituents are independently selected, and substitution may be at any chemically accessible position. In one embodiment, the substituents vary in number between one and four. In another embodiment, the substituents vary in number between one and three. In yet another embodiment, the substituents vary in number between one and two. In yet another embodiment, the substituents are independently selected from the group consisting of C 1-6 alkyl, —OH, C 1-6 alkoxy, halo, amino, acetamido and nitro. In yet another embodiment, the substituents are independently selected from the group consisting of C 1-6 alkyl, C 1-6 alkoxy, halo, acetamido, and nitro. As used herein, where a substituent is an alkyl or alkoxy group, the carbon chain may be branched, straight or cyclic, with straight being preferred.
DETAILED DESCRIPTION OF THE INVENTION
[0064] The present invention relates to the unexpected discovery that a substituted 1,2-oxasilolane may be efficiently converted to the dilithium salt of a substituted 3-hydroxypropylsilanol using lithium metal, which reductively cleaves the Si-O bond in high yields. The dilithium salt of the 3-hydroxypropylsilanol may be reacted with various nucleophiles to form silicon-containing products.
[0065] The present invention further relates to the unexpected discovery that a substituted silyloxy compound may be efficiently converted to a silyl lithium compound using lithium metal, which reductively cleaves the Si-O bond in high yields. The silyl lithium compound may be reacted with various nucleophiles to form silicon-containing products.
METHODS OF THE INVENTION
[0066] The compounds useful within the methods of the invention may be prepared by synthetic methods known to those skilled in the art of peptide and organic synthesis.
[0067] In one aspect, the 1,2-oxasilolane (11) is useful within the methods of the invention:
[0000]
[0000] wherein:
R 1 , R 2 and R 3 are independently selected from the group consisting of H, C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, and heteroaryl-carbonyl; and R 4 and R 5 are independently selected from the group consisting of aryl, substituted aryl, heteroaryl and substituted heteroaryl.
[0070] Compound (11) may be prepared by methods known to those skilled in organic chemistry. In a non-limiting example, (11) may be prepared in a two-step procedure as illustrated below. The substituted allylic alcohol (12) may be reacted with the substituted chlorosilane (13) in the presence of a base, such as, but not limited to, triethylamine, diisopropylethylamine or pyridine, in an inert solvent, such as dichloromethane or tetrahydrofuran. The substituted silyloxy compound (14) may be cyclized to the corresponding substituted 1,2-oxasilolane, using in a non-limiting example a catalytic amount of rhodium (I) complexed with commercially available (S,S)-Et-ferrotane, also known as (−)-1,1′-bis[(2S,4S)-2,4-diethylphosphotano]ferrocene, as the ligand. Depending on the general substitution of (14) and the identity of the cyclization reagents the substituted 1,2-oxasilolane (11) may be obtained in high enantioselectivity.
[0000]
[0071] The Si-O bond in (11) may be reductively cleaved by treatment with lithium metal in an inert solvent, such as but not limited to tetrahydrofuran, diethyl ether or 1,4-dioxane. The reaction should be run under an inert atmosphere, such as argon or nitrogen gas, and under anhydrous conditions. The reaction may be run at temperatures ranging from −78° C. to room temperature. More preferably the reaction may be run at about 0° C. Ring opening in (11) yields the dilithium intermediate (15), which may be used as such in the next synthetic step.
[0000]
[0072] Compound (15) may be reacted with a nucleophile such as substituted enamine (16):
[0000]
[0000] wherein:
R 7 is —S(O)R 8 , —S(O) 2 R 8 , -—S(O) 2 NR 9 R 10 , —C(O)R 9 , —C(O)NR 9 R 10 , a protected carboxyl-linked amino acid or a protected carboxyl-linked peptide; R 6 , R 9 and R 10 are independently selected from the group consisting of H, C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, and substituted aryl-(C 1-3 )alkyl; and R 8 is C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, or substituted aryl-(C 1-3 )alkyl;
whereby compound (17) is formed.
[0076] The reaction of compound (15) with a nucleophile should be run in an inert solvent, such as but not limited to tetrahydrofuran, diethyl ether or 1,4-dioxane. The reaction should be run under an inert atmosphere, such as argon or nitrogen gas, and under anhydrous conditions. The reaction may be run at temperatures ranging from −78° C. to 0° C. In one embodiment of the invention, the solution of (15) is added dropwise to the chilled solution of (16). In another embodiment of the invention, the solution of (16) is added dropwise to the chilled solution of (15). The reaction may be monitored by methods that are known to those skilled in the art, such as 1 H NMR, 13 C NMR, thin-layer chromatography, analytical HPLC or mass spectrometry. After the reaction is ruled to be sufficiently complete, the reaction mixture may be quenched with a mildly acidic aqueous solution, such as an ammonium chloride solution or an ammonium bisulfate solution. The desired product (17) may be isolated by methods such as silica gel chromatography, preparative chromatography, fractional crystallography or precipitation.
[0000]
[0077] Compound (17) may be further derivatized using methods known to those skilled in the art.
[0078] In a non-limiting example contemplated within the invention, the primary alcohol in (17) may be oxidized to the corresponding carboxylic acid, using reagents such as but not limited to potassium permanganate or potassium dichromate, and coupled to amine via a peptide bond.
[0079] In another non-limiting example contemplated within the invention, the group R 7 may be removed using a method that preserves the integrity of the rest of the molecule. In a non-limiting example, when R 7 is —S(O)R 8 , sulfinamide (17) may be hydrolyzed to the corresponding primary amine. In a non-limiting example, sulfinamines may be hydrolyzed to the corresponding amine by stirring with 4 equivalents of trifluoroacetic acid in methanol (0.25 M in methanol) at 0° C., warming to room temperature for 4 hours (Fanelli et al., “Organic Syntheses,” Collected Vol. 10, pp 47-53). The resulting amine may then be coupled to a carboxylic acid via a peptide bond.
[0080] In yet another non-limiting example contemplated within the invention, groups R 4 and R 5 may be hydrolyzed to yield the corresponding silanediol. Hydrolysis of such compound may be achieved by treatment with trifluoromethanesulfonic (triflic) acid in dichloromethane at low temperature, such as 0° C.
[0081] In another aspect, the silyloxy compound (18),
[0000]
[0000] wherein:
R 8 and R 11 are independently selected from the group consisting of C 1-10 alkyl, substituted C 1-10 alkyl, C 1-10 alkenyl, substituted C 1-10 alkenyl, heteroalkyl, heteroalkenyl, heterocyclyl, substituted heterocyclyl, aryl, substituted aryl, aryl-(C 1-3 )alkyl, substituted aryl-(C 1-3 )alkyl, formyl, alkyl-carbonyl, aryl-carbonyl, and heteroaryl-carbonyl; and, R 4 and R 5 are independently selected from the group consisting of aryl, substituted aryl, heteroaryl and substituted heteroaryl;
may be converted to the corresponding silyl lithium compound (19) by treatment with lithium metal in an inert solvent, such as but not limited to tetrahydrofuran, diethyl ether or 1,4-dioxane. The reaction should be run under an inert atmosphere, such as argon or nitrogen gas, and under anhydrous conditions. The reaction may be run at temperatures ranging from −78° C. to room temperature. More preferably the reaction may be run at about 0° C. Compound (19) may be further reacted with nucleophiles, as appropriate.
[0000]
[0084] In the cases where R 7 in compound (16) is a protected carboxyl-linked peptide, the corresponding peptide may be synthesized de novo using peptide synthesis methods. In such methods, the peptide chain is prepared by a series of coupling reactions in which the constituent amino acids are added to the growing peptide chain in the desired sequence. The use of various N-protecting groups, e.g., the carbobenzoxy (CBZ) group or the t-butoxycarbonyl (tBoc) group; various coupling reagents e.g., dicyclohexylcarbodiimide (DCC) or carbonyldiimidazole (CDI); various active esters, e.g., esters of N-hydroxyphthalimide or N-hydroxy-succinimide; and the various cleavage reagents, e.g., trifluoroacetic acid (TFA), HCl in dioxane, boron tris(trifluoroacetate) and cyanogen bromide; and reaction in solution with isolation and purification of intermediates are methods well-known to those of ordinary skill in the art. The reaction may be carried out with the peptide either in solution or attached to a solid-phase support. In the solid phase method, the peptide is released from the solid-phase support following completion of the synthesis.
[0085] In an embodiment, peptide synthesis method may follow Merrifield solid-phase procedures. See Merrifield, 1963, J. Am. Chem. Soc. 85: 2149-54 and Merrifield, 1965, Science 50: 178-85. Additional information about the solid-phase synthetic procedure can be obtained from the treatises: Atherton & Sheppard, 1989, “Solid Phase Peptide Synthesis: A Practical Approach”, Oxford. University Press, NY, N.Y; Stewart & Young, 1984, “Solid phase peptide synthesis”, 2nd edition, Pierce Chemical Company, Rockford, Ill.; and the review chapters by R. Merrifield, 1969, Adv. Enzymol. 32: 221-296, and by B. W. Erickson and R. Merrifield, 1976, in “The Proteins”, Vol. 2, pp. 255 et seq., edited by Neurath and Hill, Academic Press, NYC, N.Y. Peptide synthesis may follow synthetic techniques such as those set forth in Fields et al., 2008, “Introduction to Peptide Synthesis”, in “Current Protocols in Molecular Biology”, Chapter 11, Unit 11.15, John Wiley and Sons, Hoboken, N.J., and Amblard et al., 2006, Molecular Biotechnology 33: 239-254.
[0086] The synthesis of peptides by solution methods is described in “The Proteins”, 3rd Edition, Vol. 11, Neurath et al., Eds., Academic Press, St. Louis, Mo., 1976. Other general references to the synthesis of peptides include: “Peptide Synthesis Protocols”, 1994, edited by M. W. Pennington and Ben M. Dunn, Humana Press, Totowa, N.J.; Bodanszky, 1993, “Principles of Peptide Synthesis”, 2nd edition, Springer-Verlag, NYC,N.Y.; Lloyd-Williams et al., 1997, “Chemical Approaches to the Synthesis of Peptides and Proteins”, CRC Press, Boca Raton, Fla.; and “Synthetic Peptides: A User's Guide”, G. Grant, Ed., Oxford University Press, NY, N.Y., 2002.
[0087] In accordance with the present invention, as described above or as discussed in the Examples below, there may be employed conventional chemical and biochemical techniques that are known to those of skill in the art. Such techniques are explained fully in the literature.
[0088] The invention should not be construed to be limited solely to the assays and methods described herein, but should be construed to include other methods and assays as well. One of skill in the art will know that other assays and methods are available to perform the procedures described herein.
[0089] Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the following illustrative examples, make and utilize the compounds of the present invention and practice the claimed methods. The following working examples therefore, specifically point out the preferred embodiments of the present invention, and are not to be construed as limiting in any way the remainder of the disclosure.
EXAMPLES
[0090] The invention is described hereafter with reference to the following examples. The examples are provided for the purpose of illustration only and the invention should in no way be construed as being limited to these examples, but rather should be construed to encompass any and all variations that become evident as a result of the teaching provided herein.
Materials & Methods
[0091] NMR spectra were obtained using a Bruker WM-400 (400 MHz 1 H, 125 MHz 13 C) spectrometer.
[0092] HPLC-MS was acquired using a Hewlett-Packard Series 1200 instrument with a Waters Xterra MS C 18 column (3 μm packing, 4.6×150 mm) with a solvent system of H 2 O/acetonitrile with 0.1% formic acid at a flow rate of 0.8 mL/min.
Example 1
Generation of Lithium Methyldiphenylsilane (21)
[0093]
[0094] To an excess of lithium shot in THF (4 mL) under argon at 0° C. was added chlorotrimethylsilane (0.1 mL) and the mixture was stirred for 40 minutes. The solution was removed by syringe and replaced with fresh THF (5 mL).
[0095] Methoxy(methyl)diphenylsilane (20) (0.34 g, 1.49 mmol) was added and the mixture stirred at 0° C. Aliquots of the mixture were removed after 1.0 hour, 1.5 hours, 2.5 hours and 3.5 hours of reaction time, and added to a flask containing a large excess of chlorotrimethylsilane. The resulting mixture was stirred for 10 minutes, evaporated, and analyzed by 1 H NMR spectroscopy to monitor the disappearance of (20) and the formation of (22). Based on these spectra, the silyl ether (20) was completely converted to the silyllithium reagent (21) after 3.5 hours.
[0096] 1 H NMR spectrum of (22): (CDCl 3 ) δ 0.16 (s, 9H), 0.61 (s, 3H), 7.34-7.50 (m, 10H).
Example 2
1 , 1 , 1 -Trimethyl-2-(2-methyl-3-((trimethylsilyl)oxy)propyl)-2,2-diphenyldisilane (25)
[0097]
[0098] To an excess of lithium shot in THF (4 mL) under argon was added chlorotrimethylsilane (0.1 mL) and the mixture was stirred for 40 minutes. The solution was removed via syringe and replaced by fresh THF (4 mL), followed by racemic silyl ether (23) (0.15 g, 0.58 mM) to give a 0.15 M solution of silane. Aliquots of the solution were removed periodically and quenched with chlorotrimethylsilane, concentrated and examined by 1 H NMR. After 6 h at room temperature the reaction was complete, showing only product (25).
[0099] 1 H NMR spectrum of (25): (CDCl 3 ) δ 0.06 (s, 9H), 0.17 (s, 9H), 0.78 (d, 3H, J=6.5 Hz), 0.94 (dd, 1H, J=9, 15 Hz), 1.39 (dd, 1H, J=4.5, 15 Hz), 1.82-1.84 (m, 1H), 3.28 (dd, 1H, J=7.3, 9.8 Hz), 3.34 (dd, 1H, J=6, 10 Hz), 7.32-7.51 (m, 10H).
[0100] 13 C NMR spectrum of (25): (CDCl 3 ) δ 135.6, 135.5, 128.8, 127.9, 70.4, 32.8, 20.0, 16.9, −0.35, −1.05.
Example 3
N-((R)-1-(((S)-3-Hydroxy-2-methylpropyl)diphenylsilyl)-3-methlbutyl-2-methylpropane-2-sulfinamide (27) and
N-((R)-1-(((R)-3-Hydroxy-2-methylpropyl)diphenylsilyl)-3-methylbutyl)-2-methylpropane-2-sulfinamide (28)
[0101]
[0102] A solution of racemic dianion (24) (0.35 mmol in THF), prepared as described above, was added dropwise to a −78° C. solution of (26) (30 mg, 0.18 mmol) in THF (2.2 mL) and the resulting mixture stirred for 2 h. After addition of saturated ammonium chloride solution the aqueous phase was extracted with ethyl acetate. The combined organics were dried over sodium sulfate, filtered and concentrated. Flash chromatography gave the diastereomeric mixture of (27) and (28) (70%). Rf=0.44 (1:1 ethyl acetate/hexanes).
[0103] 1 H NMR spectrum of the mixture: (CDCl 3 ) δ 0.79-0.82 (m, 3H), 0.87-0.90(m, 3H), 0.95-0.99(m, 3H), 1.036 (s, 4.5H), 1.042 (s, 4.5H), 1.30-1.38(m, 1H), 1.38-1.44(m, 2H), 1.55-1.65(br, 1H), 1.65-1.73(m, 1H), 2.06-2.14(m, 1H), 2.57-2.69(m, 1H), 3.32-3.34(m, 2H), 3.47-3.52(m, 1H), 7.39-7.63(m, 10H).
[0104] 13 C NMR spectrum of the mixture: (CDCl 3 ) δ 16.55, 16.70, 20.06, 20.12, 21.44, 21.48, 23.16, 24.18, 25.14, 30.05, 32.33, 32.37, 42.83, 42.94, 44.31, 56.95, 70.52, 70.59, 128.30, 128.36, 128.43, 130.16, 130.22, 133.34, 133.47, 133.65, 133.75, 135.94, 135.99, 136.04.
[0105] LC-MS, retention time=25.09 min. [M+H] + calculated for this product=446.3; found=446.2.
[0106] The disclosures of each and every patent, patent application, and publication cited herein are hereby incorporated herein by reference in their entirety. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. While the invention has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations of this invention may be devised by others skilled in the art without departing from the true spirit and scope used in the practice of the invention. The appended claims are intended to be construed to include all such embodiments and equivalent variations. | The invention provides a method of preparing silane dipeptide analogs, comprising the steps of treating a solution of a substituted 1,2-oxasilolane with lithium metal to form a solution of the dilithium salt of a substituted 3-hydroxypropylsilanol, and reacting the solution of the dilithium salt of the substituted 3-hydroxypropylsilanol with a substituted enamine. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a sewing machine of a type in which the base is enabled by manupulation to remain in a mode adapted to provide a wide flat plane on which is supported an ordinary flat fabric or to be placed in another mode adapted to provide a narrower or smaller plane around which a tubular form fabric is positioned.
2. Description of the Prior Art
In some of the prior art sewing machines of this type, an extra or supplemental base was provided separately detachable from the sewing machine head. This arrangement was found to be inconvenient for the operator when either altering the sewing operation from a flat to a tubular fabric or storing the machine in its portable case. In addition, the supplemental base when separated from the main base necessitated a larger space in storage with the added possibility of its being lost.
SUMMARY OF THE INVENTION
A principle object of the present invention therefore is to provide a sewing machine which avoids the drawbacks of the prior art sewing machine briefly outlined above by pivotally mounting the supplemental base on the base of a head with the convenient capability of changing the mode of operation from flat to tubular fabric sewing and with the added capability of using an unused area for storing ordinary tools for maintenance of the sewing machine.
Accordingly, the embodiment of the invention includes a main base, a head extending from the base thereover, a needle plate associated with the base for supporting fabric in position to be stitched, and a supplemental base connected to the main base through means of link mechanisms so as to be placed in a position in which the supplemental base is substantially in a plane including the main base and is immediately contiguous to the main base or in another position in which the supplemental base is separated from the main base a distance sufficient to allow a tubular work fabric to be supported around the main base.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is a perspective view of a sewing machine head according to the invention;
FIG. 2 is a similar view to that of FIG. 1 showing a different mode of operation from that shown in FIG. 1;
FIG. 3 is a similar view to that of FIG. 2 showing an internal space of a part of the sewing machine head; and
FIG. 4 is a cross sectional view taken along the line IV--IV in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The sewing machine of the present invention may include a main base 12 having the usual hollow upright bracket 14 extending upwardly therfrom, the hollow arm 16 extending, in a substantially conventional manner over base 12 to present the usual front bearing upright 18 immediately over needle plate 20 provided in base 12. Upright 18 may provide bores or other suitable guides in which may slide presser foot bar 22 and needle bar 24. A shaft (not shown) may be positioned in arm 16 from which, by suitable mechanisms, reciprocating motion is imparted to needle bar 24. Reference numeral 26 represents a conventional presser foot to resiliently press fabric (not shown) which may have been positioned upon the needle plate 20.
A flat bottom plate 28 is fastened by means of, for example, bolts (not shown) to the main base 12 and extends under the base 12 to define a clearance 60 between the base 12 and the bottom plate 28. As shown in FIG. 3, a pair of link members 30 and 32 are pivotally mounted at their lower end sections on pins 30a and 32a, respectively. Links 30 and 32 are of identical length and the pins 30a and 32a are in alignment with each other. As will be seen in FIG. 4, link 30 has the foot thereof to cooperate with a groove or slit 30b the bottom of which is inclined to define an angle through which the link 30 is permitted to swing. The other link 32 also cooperates with a corresponding slit (not shown) similar to that of link 30.
Both links 30 and 32 in turn are pivoted at their other ends to a receptacle like second link member 34 on pins 30c and 32c, respectively. The axes of the pins 30c and 32c are in alignment with each other. As will be understood from FIG. 3, link member 30 cooperates with a slit 30d in the wall of member 34 at the upper end of the member 30 while the other link member 32 is pivoted at the upper end thereof to a side face of member 34. As will be seen in FIG. 4, the slit 30d has an inclined wall 36 to which abuts the link 30 so that member 34 is held in the position shown. In this position, the member 34 in turn has an edge 38 thereof in abutment with a wall 40 of base 12 so that the position shown of the link 30 and member 34 is ensured under influence of gravity. A supplemental base 42 is pivoted to member 34 at the other edge thereof on pins 44 and 46 (FIG. 3) the axes of which are in alignment with each other. The supplemental base 42 is of a generally L-shaped contour to accomodate a part of periphery of the main base 12 when the sewing machine 10 is in an ordinary mode of operation adapted to ordinary flat fabric. Such mode of operation may hereinafter be termed an "ordinary mode".
The supplemental base 42 is provided with a rib 48 in the back face thereof as shown in FIG. 4. The rib 48 abuts the edge 38 of the member 34 in the position shown for strictly holding the supplemental base 42 in a horizontal plane in which lies the main base 12. The supplemental base 42 is further provided with means for locking therof in the position shown in FIG. 4 in solid lines. The locking means may be of an ordinary male-and-female resilient locking type. One half of the locking means shown at 50 in FIG. 4 is in the rib of the supplemental base 42 and the other half shown at 52 in FIG. 2 is in a side face of the base 12. The locking means serves to prevent the supplemental base from being unintentionally opened during the ordinary mode.
The ordinary mode is shown in FIG. 4 in full lines. Another mode of operation, shown in double dot-and-dash lines, may hereinafter be referred to as "tube sewing mode" is provided by swinging the links 30 and 32 until the links abut the inclined bottoms of the slits 30b and 32b respectively. In the tube sewing mode, the supplemental base 42 may be swung as shown in single dot-and-dash lines to thereby open the receptacle 34 for ingress and egress of the tools and the like. As shown in FIG. 2, the machine 10 in tube sewing mode is in condition for readily sewing the fabric into tubular form such as, for example, trousers.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | This invention concerns a sewing machine of the kind in which a main base and a supplemental base are provided. The supplemental base is connected to the main base through link mechanisms so as to be either contiguously positioned with respect to the main base or spaced therefrom so as to present a narrower support surface conducive to supporting a tubular fabric. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved reference value transmitter for a drive regulation apparatus or system, wherein the reference value transmitter is provided with a control store, in which at least permissible jerk or jolt values and threshold values of acceleration are stored and which is connected with a reference value clock pulse generator or transmitter and three integrators for the respective formation of acceleration, velocity and displacement path, and wherein upon the appearance of clock pulses generated by the reference value clock pulse generator or transmitter the output of the third one of such integrators is supplied to a displacement path regulation circuit of the drive regulation apparatus or system.
In U.S. Pat. No. 4,337,847granted July 6, 1982, a drive control has become known which is concerned with a digital reference value generator of the aforementioned type in which the control store consists of a programmable read-only memory (ROM) which is supplied with set or reference value clock pulse signals or pulses by the clock pulse generator of a digital computer by way of a frequency divider. Upon the presence of reference value clock pulse signals the associated jerk or jolt values are called up and displacement path-reference values are produced by numerical integration having regard to the acceleration limiting values. With such displacement path-reference values, which are dependent only on permissible jerk and acceleration values, it is possible, for example in the case of passenger elevators, for travel curves to be generated by means of which optimal results in relation to travelling comfort and the duration of travel can be achieved.
On the other hand there are certain limitations to the application of such reference value transmitters, according to the kind of drive under consideration. For example, the running-up or acceleration of an asynchronous electric motor in the lower range of rotational speed can be well regulated because of a higher available torque. In the upper rotational speed range, however, the torque falls appreciably with increasing speed, and the motor requires substantially more time to achieve a predetermined rotational speed. It can therefore no longer follow the reference value transmitter hereinbefore described, working as it does with a definite, constant clock pulse frequency, so that the regulation deviation becomes greater and greater, and regulation of the motor is thrown out of gear.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the invention to eliminate these shortcomings.
Another important object of the present invention is to overcome these drawbacks and to approximate such a reference value transmitter, when operating in the higher range of motor speed, to the running-up high-speed characteristic curve of the motor, so that regulation is achieved over the entire rotational speed range or speed of the motor.
In order to achieve these and other objects of the present invention, which will become more readily apparent as the description proceeds, the regulation deviation is so controlled or monitored that when the greatest regulation deviation associated with the full power or control of the adjusting or positioning members is exceeded, the clock pulse frequency of the reference value generator is diminished proportionally to the excess. The set or reference values are supplied to the regulation circuit in correspondingly greater time intervals, until the greatest regulation deviation is fallen short of, whereupon the reference value transmitter continues to operate with the original clock pulse frequency.
The particular advantages manifested by a reference value generator according to the present invention are that even with simple, inexpensive motors, as for example those used in elevator drives, optimal movement or travel curves in relation to travel comfort and minimum journey time can be achieved. A further advantage, achieved by the approximation of the course of the set or reference value to the running-up or high-speed characteristic curve of the motor, is that the motor is not forced in the higher speed range, to follow the reference value generator, so that motors of smaller power or output can be employed.
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 schematic representation of the reference value transmitter according to the present invention, connected to a drive regulation apparatus or system;
FIG. 2 is a diagram against time of the course of the displacement path-reference values S S and of the displacement path-actual values S i , as well as of the corrected displacement path-reference values S S , during acceleration up to a maximum velocity; and
FIG. 3 is a diagram of the course, against time, of velocity reference values and actual values, V S V i as well as the regulation deviations ΔS resulting therefrom during acceleration to a maximum velocity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing not the drawings, in FIG. 1 a drive control apparatus or installation comprises an electric motor 1, a load 2 to be driven by it, a velocity actual value transmitter 3, a displacement path actual value transmitter 4, a velocity regulator 5, a displacement path or path regulator 6, an adjusting or positioning member 7 and a set or reference value transmitter 8. The velocity actual value transmitter 3 is coupled to the electric motor 1 and is connected to a first subtractor 9 for the formation of the velocity regulation deviation ΔV. The displacement path actual value transmitter 4 is connected to a second subtractor 10 for the formation of the displacement path or path-regulation deviation ΔS and is so connected to the load 2 that changes in position can be directly detected. The electric motor 1 may, for example, be an asynchronous motor, in which case the adjusting or positioning member 7 consists of controlled thyristors disposed in the stator circuit.
The set or reference value generator 8 consists of a control store or storage 11, three integrators 12, 13 and 14 generating the acceleration S, the velocity S and the displacement path S S , a correction member or circuit 15 and a reference value clock pulse generator or transmitter 16, for example in the form of a function generator with a controllable frequency. In the control store 11 permitted jerk or jolt values are stored and also threshold values of the acceleration and of the velocity, so that the jerk values are supplied to the first integrator 12 and the generated acceleration and velocity values are fed back to the control store 11 for the purpose of comparison with the threshold values. The output of the third integrator 14 is connected with the second subtractor 10 for the formation of the displacement path-regulation deviation ΔS. In the control store 11 there is furthermore stored at a storage place or storage means thereof a threshold value ΔS' of the displacement path-regulation deviation ΔS which corresponds to the greatest displacement path-regulation deviation which is present at full power of the thyristors of the adjusting or positioning member 7, and which is fed to an input 17a of the subtractor 17 and to an input 18a of a divider 18 of the correction member 15. The other input 18b of the divider 18 is connected to the output 17c of the subtractor 17, the second input 17b of which is connected with the output 10a of the subtractor 10 for the formation of the displacement path-regulation deviation ΔS. The correction member 15 further comprises a multiplier 19 and an adder 20, wherein one input 19a of the multiplier 19 is connected to the output 18c of the divider 18 and the other input 19b with an input 20a of the adder 20, and where the time T o of a period of the clock pulse is supplied to the latter two inputs 19b and 20a, for example in the form of a constant voltage. The output 19c of the multiplier 19 is connected to the other input 20b of the adder 20, and the output 20c thereof is connected to the input 16a of the reference value clock pulse transmitter 16.
In a preferred embodiment the set or reference value transmitter 8 as well as the regulators 5, 6 and the subtractors 9, 10 are integrated into a microcomputer system, wherein the control store 11 is a programmable read-only memory (ROM) and the functions of the integrators 12, 13, 14, of the correction member 15, and of the subtractors 9, 10 are performed by the arithmetic count of a microprocessor.
The set or reference value generator hereinbefore described operates as follows.
With the starting signal, for example for the movement of an elevator cabin, clock pulses are generated by the reference value clock pulse generator or transmitter 16 and are supplied to the control store 11. During a period of the clock pulse signal which will also be referred to as the set or reference value clock pulse, the associated jerk or jolt value S is taken from the control store 11 and is supplied to the first integrator 12. By means of continuous numerical integration determination takes place in the integrators 12, 13, 14 of the acceleration S, the velocity S and the displacement path S S , and when the threshold values of acceleration or velocity have been reached, in each case a new jerk value S is called up and supplied to the first integrator 12. The velocity threshold values have target or reference paths allocated to them, whereby a reference value series for the deceleration phase, determined by the velocity value at any time, is generated as described in the aforementioned U.S. Pat. No. 4,337,847, when there is conformity between a possible target path of the elevator cabin and the presence of a stop command. In this way, for example, and according to the following table, the jerk values S=+ 4 is called up during the reference value clock pulses 1, 2 and 3 and after reaching the acceleration threshold value S=12, the jerk value S=0 is called up. When the criteria appear for initiating the deceleration phase during the reference value clock pulse 5 and reaching the velocity threshold value S=42 of the reference value series, the jerk values S=-4 are called up. If the criteria only appear during the reference value clock pulse 6, the new jerk value S=-4 is called up on reaching the velocity threshold value S=54 of the following reference value series B.
__________________________________________________________________________Ref.valueRef. value clock pulsesseries1 2 3 4 5 6 7 8 9 10__________________________________________________________________________Jerk. . .SA +4 +4 +4 0 0 -4 -4 -4 -4 -4B +4 +4 +4 0 0 0 -4 -4 -4 -4C +4 +4 +4 0 0 0 0 -4 -4 -4Accel . .SA 4 8 12 12 12 8 4 0 -4 -4B 4 8 12 12 12 12 8 4 0 -4C 4 8 12 12 12 12 12 8 4 0Vel. .SA 2 8 18 30 42 52 58 60 58 52B 2 8 18 30 42 54 64 70 72 70C 2 8 18 30 42 54 66 76 82 84Path SA 1 6 19 43 79 126 181 240 299 354B 1 6 19 43 79 127 186 253 324 395C 1 6 19 43 79 127 187 258 337 420__________________________________________________________________________
It may now be assumed that in the first instance no stop command is received and the drive is accelerated to the revolutions corresponding to the rated velocity V max , where the rated velocity v max is, for example, reached with the reference value series C at S=84, which is characterized by the velocity threshold value S=66 (Table and FIG. 3). Here the jerk value S=-4 is called up during the reference value clock pulses 8, 9 and 10 and the displacement path-reference values S=258, 337 and 420 are formed, (Table and FIG. 3). As mentioned at the outset, the electric motor 1 cannot follow the reference value transmitter 8 in the upper range of its revolutions or rotational speed, when it operates all the time with a definite, constant pulse frequency f. Assuming that the displacement path-regulation deviation ΔS during reference value clock pulse 6 is still smaller than the threshold value ΔS', so that the output of the displacement path-reference value S=187 for the reference value clock pulse 7 appears after the time T o of a reference value pulse corresponding to the clock pulse frequency f (Time I and II, FIG. 3). Assume further that the threshold value ΔS' is exceeded at time II. During this a difference is formed in the subtractor 17 between the displacement path-regulation deviation ΔS and the threshold value ΔS' and a percentage deviation from the threshold value ΔS' is worked out in the divider 18 by division of this difference with the threshold or limiting value ΔS'. This percentage deviation is fed to the multiplier 19, by means of which a time deviation t is formed by multiplication by the time T o of a reference value clock pulse.
In the adder 20 a corrected time T o ' is obtained from this time deviation and the time T o , the reciprocal value of which is supplied to the reference value clock pulse transmitter 16 as an input voltage, where the pulse frequency f is reduced proportionally to this input voltage and the output of the displacement path-reference value S=258 for the reference value clock pulse 8 only takes place after the corrected time T o ' (Time III, FIG. 3). If at the point in time III the regulation deviation is still greater than the threshold value ΔS', then the displacement path-reference value S=337 for the reference value clock pulse 9 is also provided only after a corrected time T o ' (Time IV, FIG. 3). If the regulation deviation falls at time IV beneath the threshold value ΔS', then the reference value transmitter 16 again operates with the original clock pulse frequency f, where the displacement path-reference value S=420 for the reference value clock pulse 10 is provided after the original time T o (Time V, FIG. 3). In this way a characteristic line S S ' of the displacement path-reference value is generated, which is so approximated to the characteristic curve of the displacement path-actual value S i in such a way that regulation is provided over the whole range of rotational speeds of the electric motor 1. The displacement path-regulation deviation characteristic curve ΔS formed by the displacement path reference and actual values is supplied to the drive as a travel curve V S ' where, in accordance with FIG. 3, the displacement path-regulation deviation characteristic curve ΔS, also derived from the integral of the difference of the velocity reference and actual values V S , V i , has nearly the same form as the velocity reference value characteristic curve V S corresponding to the reference value series C of the above Table.
The figures shown in the above table for jerk, acceleration, velocity and path are comparative figures stored in the form of binary numbers; they therefore do not correspond to the actual values of the relevant physical magnitudes.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly, | With this set or reference value transmitter which is controlled by a set or reference value clock pulse generator or transmitter regulation of the running-up or acceleration of electric motors, such as asynchronous motors, can be kept under control also in the upper rotational speed ranges of the motor by adapting the displacement path-reference value characteristic curve to the displacement path-actual value characteristic curve. For this purpose the reference value transmitter comprises a correction member, by means of which the displacement path-regulation deviation is supervised in such a way that if the greatest displacement path-regulation deviation associated with the maximum power of the adjusting or positioning members is exceeded, the clock pulse frequency of the reference value clock pulse transmitter is reduced proportionally to the excess. The displacement path-reference values are supplied to the displacement path regulation circuit in correspondingly larger time intervals until the greatest displacement path-regulation deviation is fallen short of, whereupon the reference value transmitter continues to operate with the original clock pulse frequency. | 6 |
RELATED APPLICATIONS
This is a: CONTINUATION-IN-PART based on U.S. Utility patent application Ser. No. 10/435,258, filed: May 9, 2003 now U.S. Pat No.7,510,153.
FIELD OF THE INVENTION
The present invention is generally related to frames, blocks, brackets, or other structures for mounting fixtures to a wall. More particularly, the present invention is directed to a wall-mounting block that is used to easily lock over the siding of an exterior wall on which the mounting block is used.
BACKGROUND ART
Standard frame construction is used in virtually all residential and related construction in the United States, and in many other places throughout the world. This method of construction includes a wooden or steel framework of studs covered with a light sheathing of foam, light fiberboard or plywood, Celotex™, or any number of other light sheathing or substrate materials. Normally, heavy-duty fiberboard or plywood is not used throughout a frame construction due to the cost. Further, it has been found far more desirable to use a light-weight sheathing material that has some insulating or even waterproofing value. In most external wall systems some type of siding material is applied over the sheathing to provide water resistance and decorative features.
Sometimes the sheathing or substrate is of wood, and has substantial structural value. In other cases, the sheathing can be low-gauge vinyl supported by a foam backing, to obtain improved insulating properties, but having little structural value. The same types of materials can also be used for the overlying siding. In many cases, neither the siding nor the underlying sheathing is separately capable of supporting a fixture to be mounted on the exterior wall. Consequently, standard frame construction very often requires that both the sheathing and the siding be used in conjunction to support any fixtures to be added to the wall. This is especially important when apertures must be formed in substrate and siding to accommodate a fixture, but which weakens the wall. If the substrate and siding can't support the fixture it must be moved so as to be supported by a stud, or a more substantial portion of the wall.
As a result, the building industry has adopted a number of mounting blocks that utilize the combined strength of both the siding and the underlying substrate or sheathing. Conventionally, this is done by having a lower mounting frame attached, around an aperture (accommodating the fixture to be mounted), and directly attached to the sheathing. A second or upper mounting frame is attached to the already fixed lower mounting frame fixed to the sheathing. Normally this second frame is used to constitute the support for the external fixture, and is firmly connected to the sidewalls extending from the lower frame already mounted on the sheathing. The second mounting frame derives a great deal of its strength by firmly interfacing with the perpendicular sidewalls or framework of the lower mounting frame. Finally, there is a holding piece (or pieces) which attaches either to the upper frame (fixture support) or the lower mounting frame (in some cases both), to hold the siding and to utilize the structural capability of the siding around the overall mounting block.
By placing a solid framework around the aperture in the wall, and firmly interlocking all three of the mounting frame pieces, a moderately stable mounting support for a fixture can be effected, even on a relatively flimsy wall.
However, using conventional mounting blocks, this process has not always been easy to carry out. In many traditional arrangements, three (or more) different pieces must be fit together, in addition to the fixture. Consequently, the process can be extremely awkward, especially if unskilled labor is employed, or adverse conditions ensue.
Another problem, even for highly skilled workers, is the fact that conventional mounting blocks normally come in three separate pieces, often with separate connecting devices for each piece. Under the often-chaotic conditions of construction sites, pieces of the mounting blocks, especially the connectors, can be misplaced or lost. This results in delays or other difficulties, and often leads to the expedient of ordering redundant mounting blocks just to make certain that a full kit is available when needed.
This problem has been addressed in part by arrangements in which two of the three components are temporarily attached together. However, there have been difficulties with such arrangements since sometimes the attached components must be separated for one to be mounted, and then reattached to each other. This often leads to breakage.
In some arrangements, two of the components (lower frame and fixture support structure) are formed as one piece, alleviating some of the aforementioned difficulties. However, the upper holding piece which is used to hold the surrounding siding, is usually a separate piece in conventional mounting block designs. Otherwise, it would be very difficult to position and connect the holding piece to the wall using conventional mounting blocks. Unfortunately, this upper holding piece can be lost. In some cases, even if the upper holding piece is not lost, its connectors can be, thereby compromising the overall mounting block.
This drawback has been addressed in U.S. patent application Ser. No. 10/435,258, (Patent Publication No. 2004-0221522-A1) filed May 9, 2003, by the same inventor and incorporated herein by reference. In this arrangement, the pieces used for holding the siding are attached to a cap-like structure support that is used to support the fixture and has mounting flanges to attach to the substrate or underlayment of the wall. This mounting block is used by cutting away the siding around the aperture through which the fixture will pass through the substrate of the wall. The holding structures are arranged as two rotate able pieces that are permanently attached to the rest of the mounting block. When the mounting block is put in place, the holding pieces rotate opposite each other over the surrounding siding. The subject mounting block is easy to handle and to install. The rotating holding pieces provide a convenient handle for shifting and positioning the entire mounting block. The rotating holding pieces can lock into place around the support structure of the mounting block. The permanent attachment keeps the holding pieces from being lost, or otherwise separated from the rest of the mounting block.
While the overall structure and operation of the aforementioned subject mounting block is generally superior in all respects, there are some disadvantages that have been discovered. Under normal, expected usage, the plastic hinges of the subject mounting block are not at risk. However, as is so often the case on a construction site, abuse can occur and the hinges can break. Likewise, the connections between the rotating holding pieces and the rest of the mounting block can also be broken, creating a separation that might be very difficult to repair. Even if repair is possible, there is the possibility of water working its way past the water tight seals of the mounting block and into the vulnerable, underlying wall.
There are other drawbacks to this design. For example, the plastic hinges can be warped by heat, like any plastic mounting block. Further, the rotation of the holding pieces does not permit an optimum fit for locking purposes, even though a wide range of siding thicknesses can be accommodated for this particular design. As with any plastic design, general warping of the overall structure of the mounting block may lead to the intrusion of water at various points through and around the mounting block. Also, as is the case at any construction site, less than precise measurements may lead to installation efforts for siding sizes that are either too great or too small to be accommodated by the mounting block. This would result in a questionable lock between the rotating holding pieces and the rest of the mounting block, compromising both the fixture and the surrounding siding.
Accordingly, there is a substantial need for an improved wall-mounting block that overcomes the difficulties of the conventional mounting blocks. In particular, such an improved mounting block would alleviate the problems of lost parts, and facilitate easy installation. Also, an improved mounting block would provide for varying thicknesses of siding and sheathing while maintaining substantial resistance to water intrusion.
SUMMARY OF THE INVENTION
Accordingly, it is one object of the present invention to overcome the deficiencies of the conventional art.
It is another object of the present invention to simplify the installation of fixtures on frame walls, and other structures in which an aperture is used to accommodate the fixture.
It is a further object of the present invention to provide a wall-mounting block that is easily adjustable for a wide range of wall and siding thicknesses.
It is an additional object of the present invention to provide a wall-mounting block which is configured to avoid the loss of critical parts.
It is still another object of the present invention to provide a wall-mounting block that is more easily installed than conventional mounting blocks.
It is yet a further object of the present invention to provide a wall-mounting block that has the capability of utilizing all structural aspects of a wall to maintain a secure support for a fixture.
It is again an additional object of the present invention to provide a wall-mounting block having integral parts to facilitate handling of the mounting block during the mounting process.
It is still another object of the present invention to provide a wall-mounting block that is formed to be extremely robust.
It is again a further object of the present invention to provide a mounting block for wall vents and gable vents of varying sizes and shapes.
It is yet an additional object of the present invention to provide a mounting block for a wide variety of fixture types.
It is still another object of the present invention to provide a wall mounting block capable of superior structural strength over that of conventional mounting blocks, so that heavier fixtures can be safely mounted that is possible with many conventional designs.
It is again a further object of the present invention to provide a mounting block that is more highly resistant to water intrusion than many conventional mounting blocks.
It is yet an additional object of the present invention to provide a mounting block capable of uniform, reliable locking or latching over a wide range of siding thicknesses.
It is still another object of the present invention to provide a wall mounting block more highly resistant to warping and misalignment than conventional mounting blocks.
These and other goals and objects of the present invention are achieved by a two section mounting block, arranged to hold a fixture to a wall having a substrate and siding arranged over that substrate. The first section is a base section having at least one integrally formed mounting flange arranged to be positioned against the substrate. The base section is formed as a cap-like support structure including side walls extending perpendicularly from the mounting flange to a contiguous integrally formed upper interface surface. The interface surface includes a plurality of integrally formed connector recesses. The second section is a holding section having integrally formed contiguous side walls supporting perpendicularly extending, integrally formed holding flanges, and an upper support surface to form a cap-like structure arranged to fit over the cap-like support structure, the base section. The upper support surface has downwardly extending connecting prongs corresponding to the plurality of connector recesses in the base section.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side perspective view of the assembled wall-mounting block of the present invention.
FIG. 2 is a side perspective view of the wall-mounting block of the present invention, with the two sections separate.
FIG. 3 is a bottom perspective view of the upper section of the wall-mounting block of the present invention.
FIG. 4 is a bottom perspective view of the lower section of the wall-mounting block of the present invention.
FIG. 5 is a side perspective view of one part of a connecting mechanism used with the present invention.
FIG. 6 is a top perspective view of a second part of a connecting mechanism used with the present invention.
FIG. 7 is a side perspective view of the two parts of the connecting mechanism as they operate together when used with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The wall-mounting block 1 of the present invention is depicted in FIGS. 1-4 , which all use the same drawing designation numerals for the various parts of the wall-mounting block. The wall-mounting block of the present invention is meant in a first preferred embodiment to be mounted around an aperture in a wooden frame wall of standard construction. However, the aperture is not necessary for the proper operation of the present invention. It is the fixture that dictates the characteristics of the aperture.
The strength of the wall-mounting block 1 of the present invention allows it to be particularly effective even on walls constituted by flimsy materials. The present invention facilitates use with (or without) an aperture in almost any type of structural material. This can include anything from plastic foam to steel. Preferably the wall structure will have some sort of siding to help facilitate the locking of the mounting frame to the wall, thereby making use of all the benefits of the present invention.
In all of its embodiments, the present invention is made of two self-contained sections 2 , 3 , with no other parts. Manufacturing can be done by injection or spin molding to form each section 2 , 3 . Both the upper holding section 2 , and the lower or base section 3 are very similar to each other in both size and overall construction. Both share a cap-like configuration. Additional parts are not necessary since the connectors are self contained within each of the two sections.
In all embodiments of the present invention, the use of two self-contained pieces, provides many of the benefits of the present invention. In particular, crucial connecting parts cannot be lost since they are non-detachably formed as part of each sections 2 , 3 . This is a critical feature since at most construction sites, chaotic conditions ensue, and it is very common for parts from a box to become separated or lost.
In the FIG. 1 depiction, the wall-mounting block 1 is as it would be configured after being attached to the wall substrate (not shown) and after the upper or holding section 2 is locked down over the siding (not shown), which itself is permanently connected to the wall substrate. It should be noted that the mounting flanges 33 , which are part of base or first section 3 , are meant to slide under the siding (not shown) as part of the overall installation. It should be understood that pieces of the siding must be removed to accommodate mounting block 1 which is meant to fit over an aperture (not shown) in the wall substrate to accommodate the fixture.
The wall substrate is usually standard building sheathing, that can be constituted by a number of different materials. The siding is likewise standard material, usually, wood, vinyl, or aluminum. However, other materials can be used for the sheathing or siding with the present invention.
The lower or base section 3 has an interface surface 31 , which is used to interface with mounting surface 21 of upper or holding piece 2 , and to help hold the fixture (not shown). Normally fixtures have parts passing through an aperture in the wall substrate . The entire wall-mounting block 1 is meant to fit around the exterior of an aperture in both the siding and the substrate. Accordingly, both mounting surface 21 and interface surface 31 , must accommodate apertures. Interface surface 31 can be provided with a number of different holes or drilling arrangements 35 to facilitate easy passage therethrough of the fixture parts (not shown). Surface 31 is supported by support structure 32 , constituted by four sidewalls extending around the base section 3 to form a cap-like structure.
In one preferred embodiment, the sidewalls of support structure 32 are of a single height. However, this is not always the case. Rather, the sidewalls can be of a telescoping structure to accommodate different sizes of siding or different requirement of the fixtures (not shown) to be mounted on mounting block 1 .
During the installation of the base section 3 , mounting flanges 33 are slipped beneath siding pieces (not shown). Any different number of or size of connecting holes 333 , or configuration of those holes can be used to accommodate connectors to hold mounting flanges to the substrate. Mounting holes can be configured for a particular type of substrate and a particular type of connector (not shown) to be used. Of particular interest is the fact that mounting flange 33 extends well beyond holding piece 22 of the upper or holding section 2 . This arrangement provides a much larger footprint and thus more stable connection to the wall substrate. It also provides flexibility in that part of the mounting flange 33 can be cut or eliminated to help facilitate the instillation of mounting block 1 .
Fastening can be done by means of wood screws, nails, brads, staples or adhesives. If the wall substrate is plastic, ultrasonic welding can be used. If the wall substrate is metallic, appropriate means, such as machine screws, can be used for attaching the plastic mounting flange 33 to the metallic skin of the wall substrate. Most likely sheet metal screws, or even rivets would facilitate the mounting. Even glue can be used to hold the mounting flange 33 to the wall substrate.
A major attribute of the present invention is the oversized mounting flange which permits more of the wall substrate to be used to support both mounting block 1 and the accompanying fixture (not shown). Accordingly, a large variety of different fixtures can be supported in a stable mounting arrangement on virtually any type of wall.
It should be understood that the thickness of mounting flange 33 is not limited to any specific value. Rather, this can be made thicker or thinner in the manufacturing process to facilitate connection to a particular type of wall substrate. Also, the other parts of the wall-mounting block 1 can be modified to any size that is appropriate for a particular environment or application. The wall-mounting block 1 is preferably made of plastic using an injection-molding process, but other processes can be used Likewise, any number of different materials can be used, including: nylon, rubber, wood or metal.
A key attribute of the present invention resides in the contiguous support structure ( 32 , 23 - 24 , respectively) of each section 2 , 3 . These are constituted by the side walls and the upper surfaces of both the lower base section and the upper holding section. The side walls of both sections are contiguous with each other and with the upper surfaces of each section. The side walls of each section are also contiguous with their respective mounting flanges 33 and holding flanges 22 . This results in cap-like contiguous structures that are very stable and resist warping. As a result, water migration is severely curtailed due to a lack of openings in the overall structure constituted when the two sections 2 , 3 are combined as depicted in FIG. 1 .
The rigid side wall structures of the upper holding section 2 are divided into two sections, the upper 23 and the lower 24 . These are divided by the holding flange 22 which extends over the siding (not shown), holding it in place. The side walls 23 , 24 fit closely over the side walls 32 of the lower or base section 3 . Because both cap-like structures are relatively rigid, a close fit is easily effected. The close fit and contiguous nature of both sections 2 , 3 provide for a substantial resistance to the migration of water or other fluids. Also, because the side walls of the base section 3 are contiguous with the mounting flange 33 , opportunity for the migration of moisture is further limited Likewise, the fact that the holding flanges 22 are contiguous with the side walls 23 , 24 of the holding section 2 also eliminated another possible rout of moisture migration.
The two upper surfaces, interface surface 31 and mounting surface 21 of the two sections 2 , 3 , respectively are constituted by essentially solid structures, contiguous with their respective side walls ( 32 , 23 - 24 ). This arrangement provides not only proof against migration of moisture but also a very stable structure to support the fixture to be placed on the mounting block 1 . Because of the stability of the mounting block, efficient structural support exists to allow the use of pre drilled holes and apertures, such as the drilling pattern 26 in FIG. 3 . Both of the upper surfaces 21 , 31 have sufficient structural stability to support drilling patterns.
Likewise, either of the upper surfaces 21 , 31 can independently support the fixture to be arranged on the mounting block 1 . For the interface surface 31 to support the fixture (not shown). All that need be done is to form an aperture in mounting surface 21 sufficiently large to accommodate the fixture. This leads to a much higher level of versatility when dealing with unusual fixture sizes and shapes, or other mounting requirements.
This versatility is further ensured by the connector arrangements formed in each of the two upper surfaces 21 , 31 of the respective sections 2 , 3 .
A great deal of the installation flexibility enjoyed by the present invention resides in the nature of its connecting arrangement. In one embodiment of the present invention the upper holding section 2 has four connecting prongs 25 oriented downward from mounting surface 21 . These are preferably formed entirely as part of holding section 2 , and are configured with rough or ribbed surfaces so as to effect a friction fit with connector recesses 34 on base section 3 .
Base section 3 includes four complementary recesses 34 positioned to interface with the connecting prongs 25 of holding section 2 . The interior of these recesses are contoured so as to interact with the exterior of connecting prongs 25 in order to create a friction fit connection. The friction fit permits a secure connection between the two pieces 2 , 3 over a wide range of distances from each other. Because the connector recesses 34 are open ended, the connector prongs 25 can pass entirely therethrough when accommodating thinner sidings. Further, because the friction connection operates with very little length of connector prongs 25 within the connector recesses 34 substantial thicknesses of siding can also be accommodated. This increases the range of thicknesses of siding that can be accommodating by the mounting block 1 of the present invention.
Preferably, there are four sets of connectors ( 25 , 34 ) located at each corner of mounting block 1 . Because easily adjustable friction connectors are involved, continuous (also known as infinite) adjustment over most of the entire length of the connectors is easily facilitated. Further, adjustment takes place over the entire periphery of the mounting block 1 in a uniform manner. There is no rotational movement necessary as is common in many conventional mounting block systems.
The smooth, uniform adjustment of the two sections ( 2 , 3 ) of the mounting block 1 is also facilitated by the cap-like structures that closely fit over each other. Not only is the resulting structure easy to install (even in unskilled hands), it is also very robust and resistant to entry of moisture in the usual places.
If special thicknesses must be accommodated it is relatively simple to add extensions to connecting prongs 25 . This can be done in the molding process by welding plastic extensions or any other technique that would serve to extend the connecting prongs within the known plastic molding technology. Overly-long connecting prongs 25 can be trimmed to a desired length. However, too much trimming can lead to problems.
One alternative is found in the auxiliary connector arrangement depicted in FIGS. 5-7 . These embodiments are constituted by elongated extensions 5 and receivers 6 . Elongated extensions 5 can be inserted on the end of connecting prongs 25 . Receivers 6 can be placed within connector recesses 34 . Both extension 5 and receivers 6 are preferably made of any spring like material such as brass, steel, or aluminum. However, they can also be made of any semi-rigid plastic material such as nylon or thermal plastic. They are best applied to the present invention simply by placing extensions 5 on connecting prongs 25 and inserting receivers 6 into connecting recesses 34 .
The auxiliary connector arrangement of FIGS. 5-7 is not necessary for the practice of other preferred embodiments of the present invention. Rather, the auxiliary connector arrangement can be added for special circumstances imposed by environment or size requirements. This inventive connector arrangement can be added at the job-site to accommodate various unforeseen conditions or can be added at the factory when the mounting block 1 is built to a particular set of specifications. Preferably, parts 5 , 6 of the auxiliary connector arrangements are made to thicknesses so that are easily formed.
One embodiment of the auxiliary connector arrangement includes the elongated extension 5 in FIG. 5 . This extension is hollow and formed in three sections identified by physical configuration. The first part is preferably a hollow cylindrical base 51 , having ribs 52 to facilitate connection to other pieces. The base 51 can fit over a cylindrical extension (such as 25 ). Because of the ribbed construction, the cylindrical base 51 can also fit into a recess and be supported thereby. The next section is a smooth cylindrical part 53 . Extending from that is a conical part 54 . The entire extension 5 is split (either a single or double split) to facilitate adjustability and a spring-like action upon installation.
The extension 5 operates in conjunction with receiver 6 , having a cylindrical body, as depicted in FIG. 6 . The receiver 6 is constituted by upper spring protrusions 61 which are designed to be deflected by parts of the extension 5 . Because a spring-like material is used for the receiver, the upper spring protrusions tightly grip the structure that has deformed them, securely holding it. Receiver 6 also includes lower inner extensions 62 which can serve a variety of different purposes. For example, they can be bent inward to grip a cylindrical body around which the cylindrical receiver is mounted. They can also be used to stop travel of a mating connecting extension such as that of FIG. 5 . Further, they can be turned outward in case the receiver 6 is being received into a larger recess. The spring-like material constituting receiver 6 facilitates any of these operations easily.
FIG. 7 depicts the inter-action of extension 5 and receiver 6 when in use. This connecting arrangement can be substituted for that in previous embodiments of the previous embodiments of the present invention, or added thereto. The key attribute of the connecting arrangement is the additional flexibility and size accommodation provided to the other embodiments of the present invention.
While the examples depicted in the drawings have been square in shape, the present invention is not limited to this configuration. Rather, the shape of the mounting block 1 can be circular, half-circular, trapezoidal, or even triangular. Further, rather than providing a mounting surface for a fixture, the entire mounting frame can encompass the fixture. An example would be gable vents and dryer exhaust vents. The use of the present invention in such an embodiment would greatly simplify the mounting of gable vents, which can be somewhat problematic using conventional methods. A wide range of fixtures can be accommodated with the present invention. Accordingly, the present invention can be used with plumbing fixtures, such as wall-mounted valves or faucets, as well as lights, vents, decorative fixtures, and the like.
While a number of the embodiments of the present invention have been made by way of example, the present invention is not limited thereby. Rather, the present invention should be construed to include any and all modifications, variations, permutations, adaptations, derivations and embodiments that would occur to one skilled in this art and comprehending the teachings of the present invention. Accordingly, the present invention should be limited only by the following claims. | A wall-mounting block or frame is used to mount fixtures to exterior building walls having siding. The wall-mounting block includes two major parts, a first or base section and a second or holding section which are both configured as cap-like structures detachably connected to each other with integrated, adjustable connectors. The present design eliminates the need for special hardware to attach the holding section to the base section, and helps prevent awkward mounting situations. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to pneumatic conveying and more specifically to conveying milled materials such as flour from one point to another by means of negative pressure. The invention, which is a blender fitting, is utilized in pneumatic conveying systems for blending high volumes of suction air with the milled stock as a means of conveying the milled stock from one location to another. Blender fittings also have the function of an overload release means, also referred to as an anti-choke dump valve, which automatically releases the milled material in the system when it chokes or clogs.
DESCRIPTION OF THE PRIOR ART
Blender fittings of the prior art generally perform these functions. They have been available in the pneumatic conveying industry for many years and a typical example is applicant's own U.S. Pat. No. 3,198,584. There are also two blender fittings currently on the market, one of which is manufactured by the Henry Simon, Ltd. Company of Cheshire, England, and the second being a Swiss company by the name of Buhler. The basic problem which all of the above-mentioned blender fittings have, and the present invention has resolved, is the elimination of mill stock leakage around the joints of the relief gate. This leakage of milling stock, which takes place through joints in the fitting, is at a slow rate; however, in time it creates a substantial build-up on the floors and must be eventually dealt with.
Conveying milled materials such as flour from one point to another is best done by a negative pressure pneumatic conveying system since it is the most sanitary way of transporting a solid product. This is because all of the components of the system are in a negative pressure condition. Negative pressure in pneumatic systems of this type are well known in the art. The main components of such a system include a vacuum producer in the form of a centrifugal fan which draws the milled material from a source which could be grinding or sifting apparatus or merely a storage bin. Typically the storage bin feeds the material to be conveyed into the inlet conduit of a blender fitting for transmission. The material is then transmitted through the tubes of the system by the flow of large amounts of air induced or sucked into the blender fitting. Once the material is transported to its final location, a device such as a cyclone separator will separate the material from the negative pressure air for deposit in a storage bin. The suction means is provided by a centrifugal fan or the like which is connected to the cyclone separator. The milling stock materials thus are transported through the system in a stream of high velocity air which is allowed into the system through a blender fitting, such as the present invention. The milling stock is blended with the high velocity air stream, transmitting the product to its destination, whereupon the product and air are separated.
One of the major problems with pneumatic conveyers involves the stoppage or clogging of the conduits due to a variety of factors. If the milled material is fed at a too rapid rate, the system will clog, whereupon all flow ceases and the suction is lost. The conveying capacity rate of systems varies with factors such as moisture content of the material being conveyed, the atmospheric pressure, humidity, particle size and irregular product flow, as well as many other factors. Clogging can also occur with the momentary drop in air pressure within the system. This could be caused from a variety of reasons, including power failure or flow variations in the system. When pneumatic systems of this type become clogged or choked, the function of the blender fitting is to automatically dump the clogged material which has collected in the blender. Due to the weight of the clogged material, along with the lack of suction in the system, the relief gate will automatically open and dump all of the clogged milling stock in the blender and upstream thereof to the ground. Without the weight of the milling stock, the gate is so counterweighted that it will again close once the material has been dumped and the suction in the system will return since the point of clogging has now been removed.
SUMMARY OF THE PRESENT INVENTION
The blender fitting of the present invention eliminates this gradual leakage problem of the prior art blenders. This is accomplished by providing a channel-shaped relief gate which has side walls which substantially overlap with the side walls of the blender body to the extent that the inlet spout of milled material entering the blender body is below the upper edge of the relief gate side walls, thereby preventing any leakage in a relatively loose fitting negative pressure design. Another method of solving this leakage problem is to create an air-tight machined joint between the edges of the relief gate and the blender body, such as taught in the above mentioned Buhler blender. From a cost standpoint, precision made parts with machine edges cost substantially more to produce than the less expensive sheet metal design of the present invention. Applicant's blender body and relief gate are both constructed of fabricated steel sheet with a loose tolerance fit therebetween. In U.S. Pat. No. 3,198,584, the butt joint between door 28 and the edge of the blender body allows leakage whenever the pressure fluctuates. In the relief gate of the present invention, the product leakage is eliminated since the inlet spout enters below the side walls of the relief gate. The relief gate of the present invention also has a very compact, eccentric counterweight means which is adjustable to keep the gate closed under normal operating conditions and yet opens in the event of a clogging. When a conveying line is choked or an overload condition arises, the relief gate opens, dumping the milling stock until the line purges itself and is unplugged. The counterweight then returns the gate to the closed position. The positioning of the inlet conduit and spout directly over the relief gate prevents the stock from backing up at the spout, preceding the return of suction in the system. At the toe of the relief gate, there is a secondary fixed opening of air inlet which improves acceleration and lift of the product passing into the conveying line immediately downstream.
Located at the upper end or heel of the relief gate is an adjustable butterfly valve which adjusts the amount of inlet air for equipment preceding the blender, such as rollstands, sifters, or purifiers, since each of these require varying amounts of air flow. Closing the valve diverts air to the equipment. This adjustable air inlet opening provides for improved acceleration of the milled product across the gate and therefore decreases the pressure drop across the entire blender fitting.
Therefore, the principal object of the present invention is to provide a blender fitting which eliminates product leakage with a design which is simple and inexpensive to build, while providing an improved performance over the blender fittings of the prior art.
Another object of the present invention is to provide a blender fitting which localizes the area of blockage in a pneumatic system and is capable of automatically relieving and correcting said blockage.
Another object of the present invention is to provide a new blender fitting in a pneumatic system which provides improved air stream velocities therethrough to enhance its anti-clogging capability.
Other objects and advantages of the blender fitting will become apparent to those skilled in the art upon reading this disclosure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a negative pressure pneumatic system including the blender fitting of the present invention;
FIG. 2 is a side elevational view of the blender fitting of the present invention with the relief gate in the closed position;
FIG. 3 is a side elevational view in section with the relief gate in the open position;
FIG. 4 is a sectional view taken along lines 4--4, FIG. 1;
FIG. 5 is a front elevational view of the blender fitting; and
FIG. 6 is a sectional view to an enlarged scale taken along line 6--6 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and specifically to FIG. 1, the negative pressure pneumatic system of the present invention is generally described by the reference numeral 12. The system 12 includes a vacuum producer in the form of a centrifugal fan or the like, not shown in the drawing, connected to vacuum suction conduit 54. The suction produced in the line 54 draws air through the entire pneumatic system 12 which enters the system through blender fitting 10, the subject matter of the present invention. The milled product, such as flour, is initially stored in storage bin 50 or processed in a machine, and falls by gravity into the blender fitting 10 through inlet conduit 16. Blender fitting 10, shown in detail in FIGS. 2 and 3, provides an opening in the negative pressure system for sucking in atmospheric air through a variable air gap of 38, as best seen in FIG. 3. A secondary fixed air gap 36 is provided at the end of the relief gate 14 as best seen in FIGS. 2 and 5. The vacuum placed on the system draws air through the last mentioned gaps 38 and 36 which produce a high velocity and volume of air for transporting the milled product entering inlet conduit 16 through the entire system 12. At the end of the system, just upstream of the vacuum source, is a cyclone type separator 52 which separates the mill product from the air. Cyclone separators, well known in the art, basically swirl the air with the entrained material in a circular motion, causing the heavier milled material to move outward against the wall and settle in the bottom of the separator, while the lighter air is evacuated through conduit 54. The transported milled product can be withdrawn from the bottom of separator 52 through a conventional airlock 62 by gravity flow.
The negative pressure pneumatic system 12 of the present invention is used in the various milling operations since it is the most sanitary way to transport a milled material. They will transport the milled material through various runs of the system 12, including horizontal sections 56, elbows 64, vertical sections 58 and sightglass 60, before entering a cyclone separator 52 at the end of the line. The blender fitting 10, located basically at the beginning of the pneumatic system, performs two important functions, the first being controlling the volume of air moving through the system, and the second being a dump valve when the system clogs. While in the trade this fitting 10 is referred to as a blender fitting, it might likewise be called a dump valve in light of its automatic dumping function when the blender becomes clogged with milled material. These blender fittings have also been referred to as an "accelerator", a "pickup shoe", or a pneumatic boot.
The blender valve 10 of the present invention includes a blender body 20 positioned in a generally inclined angle with a vertically positioned inlet conduit 16 which passes through the planar top surface 30 of the blender body, as seen in FIG. 3, and extends downward into the body 20, terminating in spout 17. The blender body 20 further includes a horizontally positioned outlet conduit 18 of lesser diameter than the inlet conduit connected to the body through a transition section 19 while the bottom 28 of the blender body is open. Positioned in the open bottom 28 is a relief gate 14 which is hingedly mounted by pivot pin 22 to the body 20 at its upper or heel end. Relief gate 14 is channel-shaped in cross-section with a bottom 15 and a pair of upwardly standing side walls 26 and 27. The side walls 26 and 27 have upper edges 32. The side walls 26 and 27 are tapered from their heel end of gate 14 toward the toe end 34 to provide a gradually decreasing interior cross-section area of the blender body, when the gate is in its closed position as seen in FIG. 2. The toe 34 of the relief gate 14 has a slightly upturned bottom portion 35, as best seen in FIG. 3, to slightly deflect the high velocity air and entrained product as it reaches the end of the gate and flows out conduit 18. Also adjacent the toe 34 of the gate is a fixed air gap 36 as seen in FIGS. 2 and 6. This secondary air gap 36 provides additional high velocity air which improves acceleration and lift of the product into the system. Located at the heel end of the relief gate 14 is a counterweight 46 releasably held by a bolt 48 which passes through both side walls 26 and 27. The counterweight 46 comprises an eccentrically mounted metal bar. By rotating counterweight 46 closer to or farther away from pivot pin 22, the closing moment on gate 14 can be adjusted for the particular application. Also positioned in the heel end of relief gate 14 is a damper means or damper valve 40 of the butterfly type which is rotatably mounted to the side walls 26 and 27 of the relief gate 14 on shafts 42 which in turn carry handles 44. Damper valve 40 has variable air gaps 38 on both sides thereof to regulate the amount of suction air which is transmitted into the system 12. Damper valve 40 can be adjustably positioned as illustrated in FIGS. 2 and 3 to vary the amount of air entering the system, depending upon the particular requirements of the system. With the gate 14 in its closed position, as best seen in FIG. 6, the spout 17 on the end of inlet conduit 16 extends below the upper edge 32 of the side wall 26 of the gate 14. The spout 17 extends below the upper edge 32 of the side wall 27 with the gate 14 in its closed position. With the gate 14 in the closed position the upper edges 32 of the side walls 26 and 27 are in close proximity with the top surface 30 of the blender body 20. This particular geometry avoids the gravity leakage which takes place in other blender valves during operation and shut-down times. The tolerance fit between the blender body 20 and the relief gate 14 is quite loose as can best be seen in FIG. 6 wherein the side wall 26 completely overlaps the blender body side wall 24. The side wall 27 overlaps the blender body side wall 25. This overlap joint along the sides of the gate prevent any gravity leakage which might otherwise occur. The toe 34 of the gate 14 in its closed position extends slightly past the lower edge 29 of the blender body 20. The side walls 26 and 27 of the relief gate 14 in the closed position are located inside the side walls 24 and 25 of the blender body 20.
OPERATION
The counterweight 48 on relief gate 14 is adjustably positioned so that the closing moment provided by the counterweight provides enough moment to swing the gate 14 back to its closed position as seen in FIG. 2. Once milled material begins to build up in gate 14, the additional weight, if there is no air suction across the gate, would be adequate to swing the gate to its open position, as shown in FIG. 3, and dump the milled material collected both in gate 14 and inlet conduit 16. Once the milled material is fully dumped, the action of counterweight 46 will swing the gate 14 in a counter clockwise direction, as seen in FIG. 2, to its closed position.
The amount of air passing through the pneumatic system 12 can be adjusted by damper valve 40. For example, if an increased amount of milled material is desired to be moved through the system, the air flow through the system can be increased and the damper valve 40 opened wider. One of major problems in pneumatic systems of the present type involves clogging of the conduits with the material being conveyed. This is caused by various factors such as moisture content of the milled material, atmospheric pressure, humidity, particle size, irregular product flow, as well as other factors. Clogging also is effected by drops in negative pressure within the system which can be caused by a variety of reasons, including the opening and closing of various valves in the system. The system 12 is designed so that clogging will first take place in the horizontal pipe 56 and in the blender fitting 10 as the interior of blender body 20 begins to clog and fill the interior of the body. As this happens, the air flow ceases and the suction effect holding the gate 14 closed is lost and the weight of the milled material in gate 14 backed up in conduit 16 overcomes counterweight 46 and swings gate 14 to the open position as seen in FIG. 3. This dumps all of the milled material backed up in the blender and inlet conduit 16, and once it is fully dumped, gate 14 will swing back to its closed position of FIG. 2 due to the counter clockwise moment of counterweight 46 and increased negative pressure acting on the gate 14. With the blender valve now unclogged, the system 12 is again ready to draw milled product through conduit 16 and air through gaps 38 and 36 as the system returns to its normal operating condition.
While the invention has been described with a certain degree of particularity, it is manifest that many changes can be made in the details of construction and the changing of certain components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiment set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled. | An anti-choke blender fitting used in a pneumatic conveyor system utilizing a negative pressure to transport milling stock material, the fitting including a body with a top surface joined by downwardly extending side walls terminating in an open bottom with a channel-shaped relief gate with upwardly extending side walls hingedly mounted to the body with a closed position of the relief gate closing the open bottom of the body in a non air-tight relationship with the side walls of the gate extending above the spout of the inlet conduit, thereby minimizing the leakage of milling stock around the periphery of the relief gate in its closed position. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application is a continuation of U.S. application Ser. No. 12/496,985, filed Jul. 2, 2009 now U.S. Pat. No. 7,905,257, which is a continuation of U.S. application Ser. No. 11/527,775, filed Sep. 25, 2006 now U.S. Pat. No. 7,556,066, which is a continuation of U.S. application Ser. No. 11/103,803, filed Apr. 11, 2005, now U.S. Pat. No. 7,111,649, which is a continuation of U.S. application Ser. No. 10/600,525, filed Jun. 19, 2003, now U.S. Pat. No. 6,929,040, which claims priority to U.S. Provisional Application Ser. No. 60/390,212, filed Jun. 19, 2002, the contents of all of which are hereby expressly incorporated by reference in their entireties as part of the present disclosure.
FIELD OF THE INVENTION
The present invention relates to apparatus and methods for filling medicaments or other substances into containers, and more particularly, to apparatus and methods for sterile filling medicaments or other substances into hermetically sealed containers, such as vials or syringes.
BACKGROUND INFORMATION
A typical medicament dispenser includes a body defining a storage chamber, a fill opening in fluid communication with the body, and a stopper or cap for sealing the fill opening after filling the storage chamber to hermetically seal the medicament within the dispenser. In order to fill such prior art dispensers with a sterile fluid or other substance, such as a medicament, it is typically necessary to sterilize the unassembled components of the dispenser, such as by autoclaving the components and/or exposing the components to gamma radiation. The sterilized components then must be filled and assembled in an aseptic isolator of a sterile filling machine. In some cases, the sterilized components are contained within multiple sealed bags or other sterile enclosures for transportation to the sterile filling machine. In other cases, the sterilization equipment is located within the isolator of the sterile filling machine. In the isolator, the storage chamber is filled with the fluid or other substance, and then the sterilized stopper is assembled to the dispenser to plug the fill opening and hermetically seal the fluid or other substance in the dispenser.
One of the drawbacks of such prior art dispensers, and processes and equipment for filling such dispensers, is that the filling process is time consuming, and the processes and equipment are expensive. Further, the relatively complex nature of the filling processes and equipment can lead to more defectively filled dispensers than otherwise desired.
The present inventor has recognized the advantages of sterilizing a sealed, empty dispenser, and then filling the sterilized, sealed, empty dispenser under a laminar flow to maintain aseptic conditions during filling. For example, co-pending U.S. patent application Ser. No. 09/781,846, filed Nov. 25, 2002, entitled “Medicament Vial Having a Heat-Sealable Cap, and Apparatus and Method for Filling the Vial”, and U.S. Provisional Application Ser. No. 60/442,526, filed Jan. 28, 2003, entitled “Medicament Vial Having A Heat-Sealable Cap, And Apparatus And Method For Filling The Vial”, each of which is assigned to the Assignee of the present invention and is hereby expressly incorporated by reference as part of the present disclosure, disclose a vial including a resealable stopper. The resealable stopper is first sealed to the empty vial, and then the empty vial/stopper assembly is sterilized, such as by applying gamma radiation thereto. The sterilized, sealed, empty vial/stopper assembly is then filled by piercing the resealable stopper with a needle, and introducing the fluid or other substance through the needle and into the chamber of the vial. Then, the needle is withdrawn, and laser radiation is transmitted onto the penetrated region of the stopper to seal the needle hole and hermetically seal the sterile fluid or other substance within the vial/stopper assembly.
Although this resealable stopper, apparatus and method overcome many of the drawbacks and disadvantages associated with prior art equipment and processes for sterile filling, in certain applications it may be desirable to further avoid the possibility of contaminating the container between sterilization and filling of the container.
Accordingly, it is an object of the currently preferred embodiments of the present invention to overcome one or more of the above-described drawbacks and/or disadvantages and to provide an apparatus and method for needle filling a container including a resealable stopper in an e-beam chamber.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for sterile filling a container with a substance, wherein the container includes a resealable stopper and a chamber for receiving the substance therein. In one embodiment of the present invention, the apparatus comprises an e-beam chamber for receiving the container therein; and an e-beam source for directing an electron beam within the e-beam chamber onto a penetrable surface of the stopper to sterilize the penetrable surface. A filling member, such as a needle, may be mounted within the e-beam chamber and is movable into and out of engagement with the resealable stopper for piercing the resealable stopper and introducing a substance through the stopper and into the sealed chamber of the container. In one embodiment, the e-beam source and the needle are located within the e-beam chamber and are positioned relative to each other to cause e-beam radiation from the e-beam source to impinge on the needle and maintain needle sterility during filling of a plurality of containers. An energy source, such as a laser, is connectable in thermal communication with the penetrable surface of the resealable stopper for applying energy to the penetrable surface after withdrawing the needle therefrom to hermetically seal the penetrated surface.
In one embodiment of the present invention, the apparatus further comprises a radiation source, such as a gamma source, located external to the e-beam chamber, for generating radiation capable of penetrating through the stopper and chamber of the container and sterilizing the container prior to transporting the container through the e-beam chamber.
In one embodiment of the present invention, the apparatus further comprises a conveyor extending within the e-beam chamber, a motor drivingly coupled to the conveyor for moving the conveyor and, in turn, transporting the container on the conveyor through the e-beam chamber, and a control unit coupled to the e-beam source and the motor. The control unit controls at least one of the current, scan width, and energy of the e-beam source and the speed of the conveyor to achieve at least about a 3 log reduction, and preferably at least about a 6 log reduction, in bio-burden on the penetrable surface of the stopper.
In one embodiment of the present invention, the apparatus comprises a laser source for transmitting laser radiation at a predetermined wavelength and power, and a container including a resealable stopper and a chamber for receiving the substance therein. The resealable stopper includes a thermoplastic body defining (i) a predetermined wall thickness in an axial direction thereof, (ii) a predetermined color and opacity that substantially absorbs the laser radiation at the predetermined wavelength and substantially prevents the passage of the radiation through the predetermined wall thickness thereof, and (iii) a predetermined color and opacity that causes the laser radiation at the predetermined wavelength and power to hermetically seal a needle aperture formed in the needle penetration region thereof in a predetermined time period.
The present invention also is directed to a method for sterile filling a container with a substance, wherein the container includes a resealable stopper and a chamber for receiving the substance therein. In one embodiment, the method comprises the steps of:
(i) sealing the stopper to the container;
(ii) transporting the sealed, empty containers through an e-beam chamber;
(iii) directing an electron beam within the e-beam chamber onto a penetrable surface of the stopper to sterilize the penetrable surface;
(iv) introducing a needle within the e-beam chamber through the sterilized penetrable surface of the stopper;
(v) introducing through the needle a substance into the chamber of the container;
(vi) withdrawing the needle from the stopper upon introducing the substance through the needle and into the chamber;
(vii) transporting the filled containers out of the e-beam chamber; and
(viii) applying energy to the penetrated surface of the stopper and hermetically sealing same.
In one embodiment of the present invention, the method further comprises the step of subjecting the sealed, empty container to radiation, such as gamma radiation, that is capable of penetrating through the stopper and chamber and sterilizing the container, prior to transporting the container through the e-beam chamber.
One advantage of the illustrated embodiment of the apparatus and method of the present invention is that it substantially eliminates any risk of contaminating the containers between sterilization and filling because the needle or like filling member is located within the e-beam chamber.
Other advantages of the present invention will become more readily apparent in view of the following detailed description of the currently preferred embodiment and the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic plan view of a sterile filling machine embodying the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 , a sterile filling machine (“SFM”) embodying the present invention is indicated generally by the reference numeral 10 . In the currently preferred embodiment of the invention, the SFM 10 is used to fill vials or syringes for containing medicaments, such as vaccines or pharmaceutical products. However, as may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the SFM 10 equally may be used for filling any of numerous other types of containers or delivery devices with the same or other substances, such as cosmetics and food products. The SFM 10 comprises an infeed unit 12 for holding the vials, syringes or other containers 14 to be delivered into the SFM. In the illustrated embodiment of the present invention, the infeed unit 12 is in the form of a rotary table that holds a plurality of vials, syringes or other containers 14 , and delivers the containers at a predetermined rate into the SFM. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the infeed unit 12 may take the form of any of numerous devices that are currently, or later become known for performing the function of the infeed unit 12 , such as any of numerous different types of vibratory feed drives, or “pick and place” robotic systems.
Prior to installing the vials or other containers 14 on the infeed unit 12 , the sealed containers (e.g., the empty vials with the stoppers sealed thereto) are preferably sterilized, such as by exposing the containers to gamma radiation, in a manner known to those of ordinary skill in the pertinent art. In addition, the vial assemblies or other sealed, empty containers, may be enclosed, sterilized, and transported to the SFM 10 in accordance with the teachings of U.S. Pat. No. 5,186,772, entitled “Method of Transferring Articles, Transfer Pocket And Enclosure”, and U.S. patent application Ser. No. 10/241,249, filed Sep. 10, 2002, entitled “Transfer Port and Method for Transferring Sterile Items”, each of which is assigned to the Assignee of the present invention and is hereby expressly incorporated by reference as part of the present disclosure. Once loaded onto the SFM 10 , the vials or other containers 14 are sterilized again by e-beam radiation in order to further ensure absolute sterility of the requisite surfaces prior to filling and sealing, as described further below.
A conveyor 16 is coupled to the infeed unit 12 for receiving the vials or other containers 14 delivered by the infeed unit and for transporting the vials or other containers at a predetermined rate through the SFM 10 in the directions indicated by the arrows in FIG. 1 . In the illustrated embodiment of the present invention, the conveyor 16 preferably transports the containers 14 in a single file relative to each other. In the event the containers 14 are vials, each vial preferably defines a substantially “diabolo” shape formed by a base, a cap and a body extending between the base and cap, wherein the base and cap define a diameter or width that is greater than that of the body. The diabolo shape may facilitate securing and otherwise transporting the vials through the SFM 10 . Vials of this type are disclosed in co-pending U.S. Provisional Patent Application Ser. No. 60/408,068, filed Sep. 3, 2002, entitled “Sealed Containers and Methods of Making and Filling Same”, and U.S. patent application Ser. No. 29/166,810, filed Sep. 3, 2002, entitled “Vial”, each of which is assigned to the Assignee of the present invention and is hereby expressly incorporated by reference as part of the present disclosure.
The conveyor 16 may take the form of any of numerous different types of conveyers that are currently, or later become known, for performing the functions of the conveyor described herein. For example, the conveyor may take the form of a vibratory feed drive, or may take the form of an endless conveyor belt including, for example, a plurality of receptacles, such as cleats, for receiving or otherwise holding the vials or other containers 14 at predetermined positions on the conveyor. The conveyor 16 is drivingly connected to a motor or other suitable drive source 15 , which is controlled by a computer or other control unit 17 to start, stop, control the speed, and otherwise coordinate operation of the conveyor with the other components of the SFM.
The SFM 10 further includes an e-beam and needle filling assembly 18 comprising an e-beam housing 20 , at least one e-beam source 22 , and a needle filling station 24 mounted within the e-beam housing. The e-beam source 22 may be any of numerous different types of e-beam sources that are currently, or later become known, for performing the function of the e-beam source 22 described herein. E-beam radiation is a form of ionizing energy that is generally characterized by its low penetration and high dose rates. The electrons alter various chemical and molecular bonds upon contact with an exposed product, including the reproductive cells of microorganisms, and therefore e-beam radiation is particularly suitable for sterilizing vials, syringes and other containers for medicaments or other sterile substances. As indicated by the arrows in FIG. 1 , the e-beam source 22 produces an electron beam 26 that is formed by a concentrated, highly charged stream of electrons generated by the acceleration and conversion of electricity. Preferably, the electron beam 26 is focused onto a penetrable surface of each container 14 for piercing by a needle to thereby fill the container with a medicament or other substance. For example, in the case of vials, such as the vials including resealable stoppers as described, for example, in the above-mentioned co-pending patent applications, the electron beam 26 is focused onto the upper surface of the stopper to sterilize the penetrable surface of the stopper prior to insertion of the filling needle therethrough. In addition, reflective surfaces may be mounted on opposite sides of the conveyor relative to each other, or otherwise in a manner known to those of ordinary skill in the pertinent art based on the teachings herein, to reflect the e-beam, and/or the reflected and scattered electrons of the e-beam, onto the sides of the vials or other containers 14 to sterilize these surfaces as well. Alternatively, or in combination with such reflective surfaces, more than one e-beam source 22 may be employed, wherein each e-beam source is focused onto a respective surface or surface portion of the vials or other containers 14 to ensure sterilization of each surface or surface area of interest.
The e-beam housing 20 is constructed in a manner known to those of ordinary skill in the pertinent art based on the teachings herein to define an e-beam chamber 28 and means for preventing leakage of the electrons out of the chamber in accordance with applicable safety standards. As shown in FIG. 1 , the conveyor 16 defines an approximately U-shaped path within the e-beam chamber 28 , wherein the first leg of the U defines an inlet section and the portion of the chamber onto which the e-beam 26 is directed. In the currently preferred embodiment of the present invention, the current, scan width, position and energy of the e-beam 26 , the speed of the conveyor 16 , and/or the orientation and position of any reflective surfaces, are selected to achieve at least about a 3 log reduction, and preferably at least about a 6 log reduction in bio-burden testing on the upper surface of the vial's or other container's resealable stopper, i.e., the surface of the stopper defining the penetrable region that is pierced by a filling needle to fill the vial. In addition, as an added measure of caution, one or more of the foregoing variables also are preferably selected to achieve at least about a 3 log reduction on the sides of the vial or other container, i.e., on the surfaces of the vial that are not pierced by the needle during filling. These specific levels of sterility are only exemplary, however, and the sterility levels may be set as desired or otherwise required to validate a particular product under, for example, United States FDA or applicable European standards, such as the applicable Sterility Assurance Levels (“SAL”).
The e-beam and needle filling assembly 18 also preferably includes means 25 for visually inspecting the filling station 24 . This means may take the form of a beta-barrier window (i.e., a window that blocks any e-beam radiation but permits visual inspection therethrough), and/or a CCD, video or other camera mounted within the housing for transmitting to an external monitor (not shown) images of the filling station 24 . As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, these particular devices are only exemplary, and any of numerous other devices that are currently, or later become known, for performing the function of permitting visual inspection equally may be employed.
As shown in FIG. 1 , the needle filling station 24 is mounted on the opposite leg, or outlet side of the U-shaped conveyor path within the e-beam chamber 28 . In the illustrated embodiment of the present invention, the needle station 24 includes a plurality of needles 30 or other filling members mounted over the conveyor 16 , wherein each needle is drivingly mounted over the conveyor in the same manner as described, for example, in the above-mentioned co-pending patent applications. Accordingly, each needle 30 is movable into and out of engagement with the resealable stoppers to pierce the stoppers and fill the vials or other containers 14 with a medicament or other substance to be contained therein, and to then withdraw the needle upon filling the vial or other container. In the illustrated embodiment, the needle filling station 24 includes a bank of six needles 30 mounted in line with each other and overlying the conveyor 16 to allow the simultaneous piercing and in-line filling of six vials or other containers. The needles 30 may be mounted on a common drive unit, or each needle may be individually actuatable into and out of engagement with the resealable stoppers of the vials or other containers 14 . As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the needle filling station 24 may include any desired number of needles 30 , or may be mounted or driven in any of numerous different ways that are currently, or later become known, for performing the functions of the needle filling station described herein. Similarly, the SFM 10 may include a plurality of needle filling stations 24 mounted within the same e-beam chamber 28 , or a plurality of e-beam and needle filling assemblies, in order to increase or otherwise adjust the overall throughput of the SFM 10 . Preferably, the e-beam housing 20 defines a port 31 or other removable passageway to allow access to and/or repair and replacement of the needle filling station 24 . Each needle 30 is connected in fluid communication to a substance source 33 by one or more filling lines 35 for receiving therefrom a medicament of other substance to be filled into the vials or other containers 14 . The substance source 33 is preferably mounted external to the e-beam chamber 28 , and the filling line(s) 35 connected between the substance source 33 and needles 30 are protected by suitable shielding, an electron trap, and/or other arrangement that is currently, or later becomes known to those of ordinary skill in the pertinent art, to prevent radiation within the e-beam chamber 28 from degrading or otherwise damaging the substance flowing through the line(s) 35 from the substance source 31 to the needles 30 .
As can be seen in FIG. 1 , the e-beam and needle filling assembly 18 is configured so that the needles 30 of the needle filling station are mounted within the e-beam chamber 28 . As a result, the free electrons within the e-beam chamber will impinge upon the needles 30 . This, in combination with operation of the e-beam 26 which sterilizes the air throughout the e-beam chamber, functions to sterilize the needles and/or maintain the sterility of the needles throughout the filling process. Preferably, the current, scan width, relative position and energy of the e-beam 26 , and/or the orientation and position of any reflective surfaces, are selected to achieve at least about a 3 log reduction, and preferably at least about a 6 log reduction in bio-burden testing on the external surfaces of the needles 30 , including but not necessarily limited to, the surfaces of the needles that contact the resealable stoppers of the vials or other containers 14 . Further, these levels of sterility are achievable within the shadows of the needles 30 relative to the e-beam source 22 due to the electronic cloud of e-beam radiation formed within and around the needles. These specific levels of sterility are only exemplary, however, and the sterility levels may be set as desired or otherwise required to validate a particular product under, for example, United States FDA or applicable European standards, such as the applicable SAL.
Since the containers or other vials are filled within the e-beam chamber 28 , there is virtually no risk that the containers will become contaminated between e-beam sterilization and filling. If desired, the air within the e-beam chamber may be ionized to promote multiplication of the free electrons and further enhance the sterility of the filling station. Another advantage of the SFM of the present invention is that a laminar flow of air over the needles during filling may be unnecessary to achieve the requisite level of sterility. In addition, this feature of the present invention may further obviate the need for a laminar flow of air over the resealable stoppers during laser or other thermal sealing of the stoppers. In the illustrated embodiment of the present invention, there may be little, if any concern, that the filled vials or other containers will become contaminated during the brief period of transportation between the needle filling and laser sealing stations. Furthermore, this feature of the invention obviates any need for an isolator, as found in many prior art sterile filling machines.
The SFM 10 further includes a laser sealing station 32 mounted over the conveyor 16 immediately downstream the outlet of the e-beam and needle filling assembly 18 . In the illustrated embodiment of the invention, the laser sealing station 32 preferably includes a plurality of lasers, each mounted over a respective vial or other container 14 for transmitting a respective laser beam 34 onto the vial to heat seal the needle aperture in the resealable stopper. In the illustrated embodiment of the present invention, each laser is a diode laser fiber-optically coupled to a respective outlet port overlying the conveyor and focused onto a respective stopper position on the conveyor. For example, the lasers may take the form of the fiber coupled diode laser units manufactured by Semiconductor Laser International Corp. of Binghamton, N.Y., USA. A significant advantage of this type of laser system is that the lasers may be mounted remote from the laser sealing station 32 and mounted, for example, outside of any enclosure for the laser sealing station. As a result, any laser repair or replacement may be performed outside of the laser sealing or other enclosure facilitating a significantly less expensive and time consuming procedure than if the laser were mounted within the enclosure. The laser sealing station 32 also preferably includes a smoke removal unit of a type known to those of ordinary skill in the pertinent art for removing any smoke, vapors or gases generated upon heat sealing the stoppers. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, other types of laser, radiation, or other energy sources that are currently or later become known equally may be used to heat seal the penetrated regions of the stoppers.
In the illustrated embodiment of the invention, each resealable stopper is formed of a material defining a needle penetration region that is pierceable with a needle to form a needle aperture therethrough, and is resealable to hermetically seal the needle aperture by applying radiation at a predetermined wavelength and power thereto. Each stopper may comprise a thermoplastic body defining (i) a predetermined wall thickness in an axial direction thereof, (ii) a predetermined color and opacity that substantially absorbs the laser radiation at the predetermined wavelength and substantially prevents the passage of the radiation through the predetermined wall thickness thereof, and (iii) a predetermined color and opacity that causes the laser radiation at the predetermined wavelength and power to hermetically seal the needle aperture formed in the needle penetration region thereof in a predetermined time period and substantially without burning the needle penetration region (i.e., without creating an irreversible change in molecular structure or chemical properties of the material). In a currently preferred embodiment, the predetermined time period is approximately 2 seconds, and is most preferably less than or equal to about 1.5 seconds. Also in a currently preferred embodiment, the predetermined wavelength of the laser radiation is about 980 nm, and the predetermined power of each laser is preferably less than about 30 Watts, and most preferably less than or equal to about 10 Watts, or within the range of about 8 to about 10 Watts. Also in the currently preferred embodiment, the predetermined color of the material is gray, and the predetermined opacity is defined by a dark gray colorant added to the stopper material in an amount within the range of about 0.3% to about 0.6% by weight. In addition, the thermoplastic material may be a blend of a first material that is preferably a styrene block copolymer, such as the materials sold under either the trademarks KRATON or DYNAFLEX, and a second material that is preferably an olefin, such as the materials sold under either the trademarks ENGAGE or EXACT. In one embodiment of the invention, the first and second materials are blended within the range of about 50:50 by weight to about 90:10 by weight (i.e., first material:second material). In one embodiment of the invention, the blend of first and second materials is about 50:50 by weight. The benefits of the preferred blend over the first material by itself are improved water or vapor barrier properties, and thus improved product shelf life; improved heat sealability; a reduced coefficient of friction; improved moldability or mold flow rates; and a reduction in hystereses losses. Further, if desired, the material may include a medical grade silicone or other suitable lubricant to facilitate preventing the formation of particles upon penetrating the resealable stoppers with the needles. As may be recognized by those skilled in the pertinent art, however, these numbers and materials are only exemplary, and may be changed if desired or otherwise required in a particular system.
As shown in FIG. 1 , the SFM 10 includes one or more other stations 36 located downstream of the laser sealing station 32 . The other stations 36 may include a vision system of a type known to those of ordinary skill in the pertinent art for inspecting each laser or other seal, a level detection system for detecting the level of fluid or other substance within each vial or other container 14 to ensure that it is filled to the correct level, and a labeling station. In addition, as shown in FIG. 1 , the SFM 10 includes a rejection unit 38 for pulling off of the conveyer any vials or other containers 14 that are defective as detected, for example, by the laser or other seal inspection, level detection inspection, or due to mislabeling or defective labeling. Then, the acceptable vials or other containers are removed by a discharge unit 40 for discharging the vials or other containers into a collection unit 42 for packing and shipping. The rejection and discharge units may take the forms of star wheels, pick and place robots, or any of numerous other devices that are currently or later become known for performing the functions of these units described herein.
A significant advantage of the present invention is that it enables true sterile filling and not only aseptic filling. Another advantage of the illustrated embodiment of the present invention is that the medicament or other substance is filled after subjecting the containers to gamma and direct e-beam radiation, thus preventing the radiation from degrading the medicament or other substance to be contained within the container. Yet another advantage of the present invention is that there is substantially zero possibility of contaminating the vials or other containers between the sterilization and filling steps.
As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above-described and other embodiments of the invention without departing from its scope as defined in the claims. For example, the form and configuration of many of the components of the SFM disclosed herein may change, or any number of stations may be added to the SFM to provide additional functionality. In addition, the containers may take the form of any of numerous different vials, syringes or other containers. Accordingly, this detailed description of preferred embodiments is to be taken in an illustrative as opposed to a limiting sense. | A sterile filling machine and related method are provided for sterile filling a container with a substance. The container includes a resealable stopper or portion and a chamber for receiving the substance therein. The sealed, empty containers are subjected to radiation capable of penetrating through the resealable portion and chamber for sterilizing the container. The previously sterilized containers are then transported through another sterilizing chamber, such as an e-beam chamber, to sterilize the penetrable surface. A filling member is moved into engagement with the resealable portion to pierce the sterilized penetrable surface of the resealable portion and inject the substance through the filling member and into the chamber of the container. Energy is then transmitted onto the stopper to hermetically re-seal the penetration in the resealable portion. | 1 |
TECHNICAL FIELD
[0001] Example aspects described herein relate to bearing assemblies, particularly of tapered roller bearing assemblies that contain additional rolling elements to reduce friction in the axial or thrust direction.
BACKGROUND
[0002] Bearing assemblies are typically circular in shape, and generally comprise of rolling elements, normally contained by a cage, disposed between inner and outer raceways. Rolling elements take many forms, including spherical balls, cylindrical rollers, needle rollers, or various other configurations, such as cone-shaped tapered rollers or barrel-shaped spherical rollers. Cages are often used to contain the rolling elements and guide them throughout the rotating motion of the bearing, but are not a necessity in some configurations. The material of a cage can vary from steel to plastic, depending on the application, duty cycle, along with noise and weight requirements.
[0003] The type of bearing used for a particular application depends on multiple factors including the magnitude of the load and the load direction. Angular contact ball bearings are able to withstand combined radial and axial loads. Tapered roller bearings are also able to withstand combined radial and axial loads, but, for a given bearing envelope size, have a higher load capacity than angular contact ball bearings. The design of tapered roller bearings is such that the inner and outer raceways are angled with respect to the central axis of the bearing. For a given width of envelope space, the angled raceway increases the amount of line contact between the roller and raceway which increases the load capacity of the bearing. The angled raceway also allows the tapered roller bearing to carry combinations of radial and thrust loads. Resultant loads on a tapered roller bearing generate a force that pushes the roller against the large rib of the inner raceway as shown in FIG. 7 , which is a source of friction that this invention addresses.
SUMMARY OF THE INVENTION
[0004] A new design for a tapered roller bearing is disclosed that reduces the inherent friction that occurs between the roller and the large rib of the inner raceway. In one example embodiment of the invention, needle rollers are placed between the large diameter end of the tapered roller and the corresponding large rib interface of the inner raceway in order to reduce the friction.
BRIEF DESCRIPTION OF DRAWINGS
[0005] The above mentioned and other features and advantages of the embodiments described herein, and the manner of attaining them, will become apparent and be better understood by reference to the following descriptions of multiple example embodiments in conjunction with the accompanying drawings. A brief description of the drawings now follows.
[0006] FIG. 1 is a perspective view of a first example embodiment of a tapered roller bearing assembly with a needle roller placed between the large diameter end of the tapered roller and the large rib of the inner ring.
[0007] FIG. 2 is a perspective view of the inner ring of the tapered roller bearing assembly of FIG. 1 .
[0008] FIG. 3 is a perspective view of the outer ring of the tapered roller bearing assembly of FIG. 1 .
[0009] FIG. 4 is a sectioned view of the tapered roller bearing assembly of FIG. 1 .
[0010] FIG. 5 is a sectioned view of a second example embodiment of a tapered roller bearing assembly with nested balls placed between the large diameter end of the tapered roller and the large rib of the inner ring.
[0011] FIG. 6 is a sectioned view of a third example embodiment of a tapered roller bearing assembly with a thrust washer placed between the large diameter end of the tapered roller and the large rib of the inner ring.
[0012] FIG. 7 is a sectioned view of a prior art tapered roller bearing assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Identically labeled elements appearing in different figures refer to the same elements but may not be referenced in the description for all figures. The exemplification set out herein illustrates embodiments which should not be construed as limiting the scope of the claims in any manner. A radially inward direction is from an outer radial surface of the outer raceway, toward the central axis or radial center of the outer raceway. Conversely, a radial outward direction indicates the direction from the central axis or radial center of the outer raceway toward the outer surface. Axially refers to directions along a diametric central axis.
[0014] FIG. 7 is a sectioned view of a prior art tapered roller bearing assembly 100 . The bearing assembly comprises of the outer ring 101 , tapered rollers 102 , cage 103 , and inner ring 104 . The inner ring 104 contains a large rib 105 for contact with the tapered rollers. Contact at this interface and the subsequent resultant sliding friction occurs in most tapered roller bearings.
[0015] FIG. 1 is a perspective view of a tapered roller bearing assembly according to a first example embodiment. FIGS. 2 and 3 are perspective views of the respective inner and outer rings of the bearing of FIG. 1 . FIG. 4 is a sectioned view of the bearing of FIG. 1 . The following description should be viewed in light of FIGS. 1-4 . The bearing assembly 1 consists of an outer ring 12 , tapered rollers 14 , tapered roller cage 16 , inner ring 18 , needle rollers 30 and needle roller cage 26 . Outer ring 12 contains an angled outer raceway 13 which is a direct interface for the tapered rollers. Inner ring 18 contains an angled raceway 17 that is recessed within the inner ring such that a small rib 15 and large rib 11 are formed at the ends of the raceway. The thrust surfaces of the small rib and large rib are approximately perpendicular to the angled raceway 17 . Angled raceway 17 is a direct interface for the tapered rollers. Needle rollers 30 and needle roller cage 26 are located between the end of the tapered rollers and the large rib of the inner ring. Under application loads as the tapered rollers orbit around central axis 10 , the tapered rollers are pushed against the needle rollers to facilitate a rolling interface as opposed to a sliding interface between the tapered roller end and the large rib that occurs in the prior art bearing. Therefore, a lower friction condition exists with the presence of a needle roller placed between the tapered roller and the large rib of the inner ring.
[0016] FIG. 5 is a sectioned view of a tapered roller bearing assembly according to a second example embodiment. This embodiment utilizes balls 31 placed between the tapered rollers 14 and large rib 11 , however, the inner ring 22 contains a flange 23 on the large rib that extends axially such that the balls are captured, and, as shown, a cage can be optionally omitted resulting in a full complement configuration. Rolling elements other than balls can also be used in this embodiment.
[0017] FIG. 6 is a sectioned view of a tapered roller bearing assembly according to a third example embodiment, in which a thrust washer 33 is utilized between the ends of the tapered rollers 14 and the large rib 25 of the inner ring 24 . The use of a thrust washer eliminates the need for expensive finish machining operations, such as grinding and honing, that are typically applied to the large rib of the inner ring to ensure a robust thrust interface for the tapered roller. Therefore, the application of a thrust washer, with the appropriate hardness and surface characteristics, provides a means of reducing the cost of the tapered roller bearing.
[0018] In the foregoing description, example embodiments are described. The specification and drawings are accordingly to be regarded in an illustrative rather than in a restrictive sense. It will, however, be evident that various modifications and changes may be made thereto, without departing from the broader spirit and scope of the present invention.
[0019] In addition, it should be understood that the figures illustrated in the attachments, which highlight the functionality and advantages of the example embodiments, are presented for example purposes only. The architecture or construction of example embodiments described herein is sufficiently flexible and configurable, such that it may be utilized (and navigated) in ways other than that shown in the accompanying figures.
[0020] Although example embodiments have been described herein, many additional modifications and variations would be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present example embodiments should be considered in all respects as illustrative and not restrictive.
LIST OF REFERENCE SYMBOLS
[0021] 1 Tapered Roller Bearing Assembly, Needle Roller Design
[0022] 3 Tapered Roller Bearing Assembly, Nested Ball Design
[0023] 4 Tapered Roller Bearing Assembly, Thrust Washer Design
[0024] 10 Central Axis, Needle Roller Design
[0025] 11 Large Rib, Needle Roller Design
[0026] 12 Outer Ring, Needle Roller Design
[0027] 13 Outer Raceway, Needle Roller Design
[0028] 14 Tapered Rollers
[0029] 15 Small Rib, Needle Roller Design
[0030] 16 Cage, Tapered Roller
[0031] 17 Inner Raceway, Needle Roller Design
[0032] 18 Inner Ring, Needle Roller Design
[0033] 22 Inner Ring, Nested Ball Design
[0034] 23 Flange on Large Rib, Nested Ball Design
[0035] 24 Inner Ring, Thrust Washer Design
[0036] 26 Cage, Needle Roller Design
[0037] 30 Needle Rollers
[0038] 31 Balls
[0039] 33 Thrust Washer
[0040] 100 Prior Art Tapered Roller Bearing Assembly
[0041] 101 Outer Ring
[0042] 102 Tapered Roller
[0043] 103 Cage
[0044] 104 Inner Ring
[0045] 105 Thrust Contact Surface | A low friction tapered roller bearing is provided that implements either needle rollers, nested needle rollers, nested balls, or a thrust washer between the tapered rollers and the large rib of the inner ring. The nested needle rollers and balls options can either be cage guided or full complement. | 8 |
FIELD OF THE INVENTION
[0001] The invention concerns a gearbox arrangement with a gear box housing, a gearbox chamber enclosed by the gearbox housing, a first shaft supported in bearings in the gearbox housing, a cavity configured eccentrically to the axis of rotation with the center of gravity of its cross section, a second shaft supported in bearings, free to rotate, in the cavity of the first shaft which is provided with at least one area of gear teeth and a shaft end section projecting axially out of the cavity of the first shaft a, and a third shaft supported in bearings in the gearbox housing whose axis of rotation extends at an angle to the plane lying on the axis of rotation of the first shaft.
BACKGROUND OF THE INVENTION
[0002] Gearbox arrangements are known in the state of the art that are provided with gear rations arranged at angles to each other with gearbox shafts arranged within each other. Gearbox arrangements with gearbox shafts arranged within each other represent, among other factors, compact configuration and the possibility of attaining eccentric drives. Gearbox arrangements with eccentric drives are applied, for example, in agriculture for drives of cutterheads on front mowing attachments for combines.
[0003] Such a gearbox arrangement is disclosed, for example in U.S. Pat. No. 6,273,214 B1. The gearbox arrangement is provided with a gearbox housing in which a gearbox shaft is supported in bearings that can be driven by an angle drive stage and is provided with a cavity that is located eccentrically. An eccentric shaft is supported in bearings in the cavity and is connected with a journal. The gearbox arrangement disclosed is operated with lubricating grease. In order to assure a sufficiently large supply of lubricating grease to the cavity, a channel is provided that connects a region of the gearbox arrangement with the cavity of the shaft. The lubricating grease deposited in the gearbox chamber can reach the cavity through the channel. The difficulty here lies in the sealing of the cavity relative to the gearbox housing or the sealing of the eccentric shaft relative to the gear box shaft, which requires a costly configuration for the axial securing of the eccentric shaft and a large assembly cost connected with it. Moreover, a further disadvantage results from the fact that the lubricating grease can escape through the openings of the gearbox housing or the gearbox shaft after only a few hours of operation and that topping off of the lubricating grease results in very short maintenance intervals. Furthermore, it is difficult to verify whether there still is a sufficient supply of lubricating grease in the interior of the gearbox arrangement.
[0004] The purpose of the invention is seen in the need to define a gearbox arrangement of the type noted initially, through which one or more of the aforementioned problems are overcome.
SUMMARY OF THE INVENTION
[0005] According to the present invention, there is provided an improved gearbox arrangement, especially an arrangement for reliably containing lubricating grease.
[0006] According to the invention, a gearbox arrangement of the kind noted initially is configured in such a way that the gearbox arrangement is provided with a plate fastened to the first shaft, fixed against rotation, for immobilizing the second shaft in the axial direction, where an opening is provided in the plate for the shaft end region and that openings of the gearbox housing as well as the opening in the plate are provided with sealing devices that seal the lubricant located in the gearbox housing in order to prevent its escape between the gearbox housing and the first and the third shaft or between the plate and the second shaft. Since a plate is provided to immobilize the second shaft in the axial direction, on the one hand the cost of the assembly can be reduced considerably and poorly accessible snap rings can be avoided, and on the other hand, a sealing device can be placed in the opening, that seals the second shaft to the outside so that no lubricant can escape through a clearance gap between the second and the first shaft. The other sealing devices at the openings of the housing at the exits of the first and second shaft correspondingly seal the gearbox housing as effectively. All told, the sealing devices prevent leakage of lubricant which require short maintenance intervals at gear box arrangements known in the state of the art. With a gearbox arrangement according to the invention, the loss of lubricant through leakage and the cost of assembly can be reduced considerably and the maintenance intervals can be lengthened significantly.
[0007] In a preferred embodiment of the invention, the plate is bolted to the end face of a shaft end region of the first shaft. The plate can be assembled and disassembled easily by the use of threaded bores distributed over the circumference at the edge of the end face of the first shaft, preferably three bores are used. Moreover, a further sealing device can be provided between the end face of the first shaft and the plate so that here, too, an escape of lubricant can be prevented. In addition to accommodating the sealing device for the second shaft, the plate is also used to protect the clearance gap against intruding dirt.
[0008] Preferably, the gearbox housing is provided with one or more closure plugs arranged along the axis of rotation of the first shaft. The closure plugs are used to fill the gearbox arrangement with lubricant, to check the quantity of lubricant remaining or to create a drain opening for the lubricant. In that way, a closure plug arranged at a relatively high level can be used to fill the housing with lubricant, on the other hand a closure plug arranged at a relatively lower level can be opened to permit a drainage of lubricant or to check whether lubricant drains out of that opening. If no lubricant drains from that closure plug, then there is insufficient lubricant in the housing and must be topped off. Thereby, a costly disassembly of components during the maintenance can be avoided.
[0009] Alternatively, a measuring rod can also be arranged on the housing wall that extends into the interior of the housing.
[0010] The sealing devices are preferably configured as shaft sealing rings, for example, as radial packing rings that are inserted into the gearbox housing or in the cavity of the first shaft and are forced by ring-shaped garter springs against sealing sleeves of oil-resistant artificial rubber and are used to seal openings for shafts against leakage of lubricant or entry of dust. However, other sealing devices can be applied that seal a rotating shaft relative to an opening.
[0011] A gearbox arrangement according to the invention has the advantage that gear oil can be used as a lubricant so that the entire gearbox arrangement can be operated with gear oil. In contrast to lubricating grease, gear oil has more advantageous temperature characteristics. Moreover, the maintenance process is simplified by the use of gear oil for the lubrication of the gear arrangement, since with the use of the closure plugs the filling up, measurement of the oil level and draining of the gear oil can be performed without any cost. Due to the arrangement according to the invention of corresponding shaft sealing rings, or other sealing devices, any leakage of gear oil is prevented. It should be noted here that other types of lubricants, particularly lubricating grease, can also be applied for the operation of the gearbox arrangement.
[0012] The plate provided for the immobilizing of the second shaft and for the location of a sealing device for the sealing of the second shaft is preferably arranged in such a way that a bearing arranged in the first bearing region of the second shaft is immobilized axially at the first shaft by the plate. Thereby, snap rings for the immobilizing of the bearing of the second shaft in the axial direction that are poorly accessible or other costly attachment measures for the bearing of the second shaft can be omitted. By pressing the plate, the bearing located in the bearing region of the second shaft is forced against a step of the first shaft and retained there or immobilized.
[0013] The second shaft is supported in bearings, free to rotate, in the cavity of the first shaft, where the second shaft is preferably configured as a one-piece component. Since the second shaft is configured as a one-piece component and, in particular, the shaft end region is configured as a part of the shaft, connecting components are omitted, the susceptibility to failure is reduced and the manufacturing process and the assembly are simplified. Preferably the second bearing region is arranged between the gear tooth area and the shaft end region. The second shaft may be supported bin bearings by two bearing seats spaced axially in the cavity of the first shaft. Preferably, the first bearing region of the second shaft is equipped with a rolling contact bearing, particularly a needle bearing, where the first bearing seat is preferably arranged in the area of the cavity opening of the channel in the interior of the gearbox interior of the first shaft. In view of the relatively small dimensions of a needle bearing, a compact configuration can be attained. The second bearing seat for a second rolling contact bearing is preferably arranged at a cavity opening located at the outside of the first shaft. The second rolling contact bearing is configured, for example, as a ball bearing and is located in the second bearing region of the second shaft. Obviously other combinations are conceivable with other types of rolling contact bearings. Moreover, it is conceivable that the bearing areas are also arranged directly alongside each other so that the shaft end region as well as the gear tooth area are freely arranged in bearings. Preferably the second shaft is configured in such a way that the maximum outside diameters in the various regions increase towards the shaft end region. Thereby, a shaft end region with a relatively large outside diameter is attained whereby a shaft step towards the shaft end region is used as an axial security device for the second rolling contact bearing. Moreover, a simple pre-assembly of the second rolling contact bearing on the shaft is thereby attained, so that the second shaft can be assembled in one working cycle and particularly the assembly time or the maintenance time for the gearbox arrangement are shortened.
[0014] The gear tooth region configured between the at least one bearing region and the shaft end region meshes with a set of gear teeth connected to the gearbox housing, fixed against rotation, preferably an internal gear. For this purpose, the cavity of the first shaft is provided with a radial opening that extends over a part of the circumference of the first shaft and partially frees the gear tooth region.
[0015] A rotation of the second shaft can be attained in itself in the cavity of the first shaft by the meshing of the gear tooth region with the set of gear teeth connected, fixed against rotation, with the gearbox housing, so that a superposition of an eccentric movement of the second shaft about the axis of rotation of the first shaft can be attained with a rotational movement of the second shaft about its own axis of rotation.
[0016] The gearbox arrangement is provided with a third shaft, supported in bearings in the gearbox housing, whose axis of rotation extends at an angle to the plane lying on the axis of rotation of the first shaft. Preferably, the third shaft is arranged in such a way that the axes of rotation of the first shaft and that of the third shaft intersect in a point and thereby lie in a common plane and extend at an angle of approximately 90°. It is also possible, however, to arrange the third shaft in an offset position, so that the axes of rotation of the first and the third shafts do not lie in a common plane. Moreover, it is also possible to arrange the shafts so that they extend at a larger or a smaller angle to each other.
[0017] The third shaft is preferably supported in bearings axially loose in a first bearing, where the first bearing of the third shaft is configured as a roller bearing, in particular a needle bearing. Here is it also possible to apply other types of rolling contact bearings, for example, a ball bearing that is immobilized axially in both directions on a shaft or in a bearing seat and the shaft is supported in bearings so that it is axially loose. The use of a needle bearing as a loose bearing has the advantage that the shaft can be configured very compactly and simply.
[0018] The third shaft is preferably immobilized axially in both directions in the gearbox housing in a second bearing. Preferably the second bearing of the third shaft is configured as a rolling contact bearing, particularly a ball bearing, that is immobilized axially by a step on the gearbox housing towards the interior of the gearbox housing and by a snap ring at the gearbox housing to the outside of the gearbox housing. By immobilizing it in both directions of the gearbox hosing by means of a snap ring, it is possible to pre-assemble the third shaft and to insert it into the gearbox housing in a single working cycle. Thereby, assembly time and maintenance time can be reduced.
[0019] The gearbox arrangement is provided with a gear arranged on the third shaft that can be immobilized in one direction axially by a snap ring. With the use of a snap ring for the fastening of a gear, a step on the shaft that is costly to manufacture can be avoided whereby the entire shaft can be configured more simply and as a result the manufacturing cost can be reduced.
[0020] A gear fastened to the first shaft meshes with the gear fastened to the third shaft, where the gear of the first shaft is immobilized in the first bearing of the first shaft radically to the axis of rotation of the first shaft and applies an axial force with respect to the third shaft.
[0021] The third shaft is immobilized in both directions by the axial force and the snap ring arranged at the gearbox housing for the second bearing of the third shaft.
[0022] The interior of the gearbox hosing is connected with the surroundings of the gearbox housing by a ventilation arrangement provided on the gearbox housing, for example, on a gearbox hosing cover, the ventilation arrangement may be a ventilation opening, a small ventilation tube, a ventilation valve, an over-pressure valve or the like. Through the connection with the surroundings, a pressure equalization can take place between the interior of the gearbox arrangement and the surroundings, so that operating temperatures can be reduced and the durability can be increased.
[0023] The gearbox arrangement is preferably provided with a journal that extends axially out of the shaft end section axially and eccentrically to the axis of rotation of the second shaft. Here the journal may be a part of the on-piece second shaft or it may be connected to the second shaft by connecting devices. The rotation of the first and the second shafts results in a superposition of an eccentric rotational movement of the axis of rotation of the second shaft about the axis of rotation of the first shaft and an additional eccentric rotational movement of the journal about the axis of rotation of the second shaft. Thereby, the journal is used to transmit the superimposed eccentric movements into corresponding linear movements on an arrangement that can be drive, for example, a cutter head.
[0024] In order to transmit the rotational movements, the journal is preferably equipped with a rolling contact bearing that can be connected with a bearing pan which is connected with an arrangement that can be driven. Depending on the rotational speed of the journal or the shafts and the forces to be transmitted, a sliding bearing could be used instead of the rolling contact bearing, the sliding contact bearing may, for example, be provided in the form of a sliding bushing. The rolling contact bearing of the journal may be configured as a roller bearing. The rolling contact bearing is enclosed in a bushing that is preferably configured in the shape of a ring and is provided with a spherically bowed outer surface. The rolling contact bearing is taken up in the bushing by means of a race of the rolling contact bearing that is pressed into the inner surface of the bushing. The spherically bowed outer surface in turn, is taken up by a bearing pan that is configured with an inner surface congruent to the outer surface of the bushing. The spherical surfaces permit a relative movement of the parts to each other so that an angle of inclination of the parts to each other can be adjusted between the journal and the arrangement to be driven or between the longitudinal axis of the journal and the rotational axis of symmetry of the bearing pan, whereby tolerance problems during the transmission of movements can be overcome. Moreover, it is possible to configure the bearing as a ball bearing whose outer race is engaged in a corresponding bushing. Here a needle bearing is used that includes an outer race with a spherically bowed outer surface. Another type of rolling contact bearing could also be used, for example, a ball bearing or a roller bearing could be provided with an outer race with such a shape.
[0025] The bushing that engages the outer race as well as the bearing pan that encloses the bushing are configured as closed around their circumference. Recesses or openings are provided on the bearing pan located opposite each other in the radial direction and that extend axially to the axis of rotational symmetry of the bearing pan along the inner surface of the bearing pan. The openings are dimensioned in such a way that when the bushing engages the bearing pan the bushing can be inserted in its width transverse to its axis of rotational symmetry and by pivoting through 90° the outer surface of the bushing is oriented to the inner surface of the bearing pan and brought into bearing position. Previous configurations are provided with a bushing that is open around its circumference or is slotted, mostly of plastic, that is engaged by a bearing pan with an open configuration. The slotted bushing is stretched around the rolling contact bearing of the journal by a stretching arrangement at the bearing pan. Since the bushing and the bearing pan are configured as closed around their circumference, on the one hand the connection between the rolling contact bearing and the bushing or the bearing pan can be made without any costly stretching arrangements, on the other hand stronger materials and materials more resistant to wear can be used and thereby the maintenance intervals can be lengthened and the susceptibility to failure can be reduced. Moreover, the result is also a lower bearing clearance. A gearbox arrangement with a rolling contact bearing for the journal and the use of a bushing and a bearing pan that are configured as closed in the above described configuration and are provided with spherical surfaces, can be seen as an independent invention
[0026] The bearing pan for the rolling contact bearing of the journal is preferably connected to connecting devices, particularly connecting devices for the connection with a cutter head. For example, the bearing pan is connected directly with a guide rod or a drive rod, through which a cutter movement is brought about. The connection with the bearing pan can be made, for example, by welding or bolting. Moreover, it is possible to configure the bearing pan and the connecting device as a one-piece component, for example, to forge or to cast it.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The drawing shows and embodiment of the invention on the basis of which the invention as well as its advantages and the advantageous further developments and embodiments of the invention shall be explained and described in greater detail in the following.
[0028] FIG. 1 is a cross sectional view of a gearbox arrangement constructed in accordance with the principles of the present invention.
[0029] FIG. 2 is a side view of the gearbox arrangement of FIG. 1 .
[0030] FIG. 3 is a perspective view of the gearbox arrangement of FIG. 1 .
[0031] FIG. 4 is a detailed view of the second shaft of the gearbox arrangement of FIG. 1 .
[0032] FIG. 5 is a plan view of the shaft end section of the second shaft shown if FIG. 4 .
[0033] FIG. 6 is a side view of a journal arrangement of the gearbox arrangement of FIG. 1 .
[0034] FIG. 7 is a plan view of the journal arrangement of FIG. 6 .
[0035] FIG. 8 is a plan view of the plate of the gearbox arrangement of FIG. 1 with an opening for the second shaft.
[0036] FIG. 9 is a cross sectional view of the plate shown in FIG. 8 .
[0037] FIG. 10 is a cross sectional view of a bearing for a journal of the gearbox arrangement shown in FIG. 1
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0038] FIGS. 1 through 3 show a gearbox arrangement 10 constructed in accordance with the present invention, with a gearbox chamber 12 of an angle gearbox 14 being surrounded by a housing 16 . The gearbox housing 16 extends generally rotationally symmetrical along an axis of rotation 18 of a first shaft 20 , where the axis of rotation 18 defines the longitudinal direction of the gearbox arrangement 10 . the gearbox chamber 12 is subdivided into a first gearbox chamber region 22 , that generally surrounds the first shaft 20 , and a second gearbox chamber region 24 , that generally surrounds a third shaft 26 arranged transverse to the longitudinal direction. The gearbox chamber regions 22 , 24 are configured as adjoining each other in the longitudinal direction and are provided with a common cylindrical transition region 28 , that is arranged approximately in the center of the longitudinal extent of the gearbox housing 16 and coaxially to the axis of rotation 18 , and through which an axial connection of the gearbox chamber regions 22 , 24 is defined.
[0039] The gearbox housing 16 is provided with a first cylindrical opening 30 in the first gearbox chamber region 22 , that is oriented coaxially to the axis of rotation 18 and that opens the first gearbox chamber region 22 axially to the outside. Moreover, the gearbox housing 16 is provided with first, second and third cylindrical openings 32 , 34 and 36 , respectively, in the second gearbox chamber region 24 . The second opening 32 is oriented coaxially to the axis of rotation 18 and opens the second gearbox chamber region 24 axially to the outside. the third and fourth openings 34 , and 36 , respectively are arranged to either side of the axis of rotation 18 and coaxially to an axis of rotation at the third shaft 26 arranged transverse to the axis of rotation 18 .
[0040] A first bearing 40 is arranged in the common transition region 28 , and a second bearing 42 is arranged in the first opening 30 in the first gear box chamber region 22 for the first shaft 20 . A step 44 is formed onto the common transition region 24 which axially immobilizes the bearing 40 in the direction of the first opening 30 . A step 46 is formed onto the first opening 30 that axially immobilizes the bearing 42 in the direction of the common transition region 28 . The bearings 40 , 42 are preferably configured as rolling contact bearings and as an example are pictured in FIG. 1 as ball bearings. The first shaft 20 is supported in the bearings 40 and 42 , free to rotate, in the gearbox housing 16 or the first gearbox chamber region 22 . Moreover, a first shaft seal ring 47 , for example, a radial packing ring, is provided at the first opening 30 adjacent to the second bearing 42 that seals the clearance gap between the first opening 30 and the first shaft 20 to the outside.
[0041] A housing cover 48 is provided in the second gearbox chamber region 24 at the second opening 32 that encloses the second gearbox chamber 12 axially to the surroundings.
[0042] A first bearing 49 is arranged in the second gearbox chamber region 24 at the third opening 34 , and a second bearing 50 in the fourth opening 36 for the third shaft 26 . A step 52 is formed onto the fourth opening 36 that axially immobilizes the bearing 50 in the direction of the third opening 34 . Moreover, a ring groove 56 is formed onto the fourth opening 36 and is provided with a snap ring 54 , whereby the bearing 50 is also immobilized in the opposite direction. The bearing 49 is freely supported and arranged in the third opening 34 . The bearings 49 , 50 are preferably configured as rolling contact bearings, where in the case of the bearing 49 a roller bearing in the form of a needle bearing is used, as can be seen in FIG. 1 . In the form pictured, the bearing 50 is configured as a ball bearing, where here a roller bearing could also be applied. The third shaft 26 engages the bearing 49 and 50 and is supported in these bearings, free to rotate, in the gearbox housing 16 or in the second gearbox chamber region 24 . Moreover, a second shaft sealing ring 57 , for example, a radial packing ring sealing to the outside, is arranged at the fourth opening 36 adjacent to the snap ring 54 , that seals the clearance gap between the fourth opening 36 and the third shaft 26 . A bearing bushing 58 , provided at the third opening 34 , seals the third opening 34 to the outside.
[0043] Moreover, a further step 59 is provided in the first gearbox chamber region 22 between the bearings 40 , 42 , to which an internal gear 60 is fastened. The internal gear 60 is bolted to the gearbox housing 16 by means of screws 62 distributed around the circumference of the step 59 (see FIG. 2 ).
[0044] The first shaft 20 extends through the entire first gearbox chamber region 22 and is provided with a shaft end region 64 that projects out of the first opening 30 and essentially covers the entire diameter of the first opening 30 . Starting from the shaft end region 64 , a first shaft step 65 adjoins a shaft seal ring region 65 ′ for the first shaft seal ring 47 . Starting from the shaft end region 64 a second shaft step 66 is formed that adjoins a bearing region 68 for the second bearing 42 . A third shaft step 70 is formed adjoining the bearing region 68 that in turn adjoins a central shaft region 72 . The central shaft region 72 ends in a fourth shaft step 74 . The fourth shaft step 74 is followed by a fifth shaft step 76 that, in turn, adjoins a shaft journal 78 , where the shaft journal 78 extends through the common transition region 28 in the second gearbox chamber region 24 . A first bevel gear 80 is supported in bearings on the shaft journal 78 , it is connected, fixed against rotation, by means of a spring/groove connection 82 to the first shaft 20 or the shaft journal 78 . The shaft journal 78 is equipped with a shaft nut 84 . A bearing region 86 is configured on the first bevel gear 80 through which the first shaft 20 is engaged in the first bearing 40 .
[0045] The first shaft 20 is provided with a cavity 88 . The cavity 88 is configured generally cylindrical about an axis of rotation 90 where the axis of rotation 90 is arranged parallel to the axis of rotation 18 and eccentrically to the first shaft 20 . The cavity 88 is provided with a cylindrical opening 92 that opens the cavity 88 to the shaft end 64 of the first shaft 20 axially to the axis of rotation 90 . Starting from the opening 92 , the cavity 88 is provided with first and second steps 94 , 96 and ends in a cavity floor 98 . Between the first and the second steps 94 , 96 , the cavity 88 is provided with an opening 100 at the level of the internal gear 60 , opening 100 extends radially and axially to the axis of rotation 90 along the wall of the cavity and opens a partial region of the wall of the cavity towards the internal gear 60 .
[0046] A first bearing seat 102 is a configured to accept a first bearing 104 for a second shaft 206 between the second step 96 and the cavity 88 and the cavity floor 98 . A second bearing seat 108 is configured to accept a second bearing 110 for the second shaft 106 between the opening 92 of the cavity 88 and the step 94 . The second bearing 110 is secured axially by means of a plate 112 bolted to the end face 11 of the shaft end region 64 , in that the outer race of the second bearing 110 is pressed against the first step 94 .
[0047] The first and second bearings 104 , 110 for the second shaft 106 are configured as rolling contact bearings, where for the first bearing 104 a roller bearing is provided in the form of a needle bearing, and for the second bearing 110 a ball bearing is provided, as is shown in FIG. 1 .
[0048] The second shaft 106 extends through the entire cavity 88 of the first shaft 20 and is provided with a shaft end region 113 projecting out of the first opening 92 of the first shaft 20 (see FIG. 4 ). Starting from the shaft end region 113 , the second shaft 106 is provided with a first shaft step 114 that adjoins a bearing region 116 for the second bearing 110 . Adjoining the bearing region 116 , a ring groove 116 is configured that accepts a snap ring 120 (shown in FIG. 1 ). The ring groove 118 adjoins a second shaft step 122 that ends in a gear tooth area 124 of the second shaft 106 . The gear tooth region 124 of the second shaft 106 extends axially between the shaft steps 94 , 96 of the cavity 88 and ends in a third shaft step 126 . The third shaft step 126 adjoins a shaft journal 128 on which a bearing region 130 for the first bearing 104 is provided.
[0049] The third shaft 26 extends through the entire second gearbox chamber region 24 and is provided with a shaft end region 132 projecting out of the fourth opening 36 (see FIG. 1 ). The shaft end region 132 is provided with a shaft nut 134 . Starting from the shaft end region 132 , the third shaft 26 is provided with a shaft region 136 that adjoins a ring groove 138 where a part of the shaft region 136 projects out of the fourth opening 36 . The ring groove 138 accommodates a snap ring 140 . A shaft step 142 is provided between the ring groove 138 and the third opening 34 , it adjoins a shaft journal 144 . A bearing region 146 is provided on the shaft journal 144 that engages the first bearing 49 of the second gearbox chamber region 24 . a second bevel gear 148 is supported in bearings on the shaft region 136 , it is connected with the third shaft 26 , fixed against rotation, by means of a spring/groove connection 150 . A bearing region 152 is configured on the second bevel gear 148 by means of which the third shaft is engaged in the second bearing 50 . Moreover, a belt pulley 154 is provided on the part of the shaft region 136 projecting out of the fourth opening 36 , the belt pulley is also connected to the third shaft 26 , fixed against rotation, by means of the spring/groove connection 150 .
[0050] The shaft journal 78 of the first shaft 20 is equipped with a channel 156 that is provided, starting from the end of the shaft journal 78 , with a gearbox chamber opening 158 and a cavity opening 160 .
[0051] The gearbox chamber opening 158 is arranged concentrically to the axis of rotation 18 of the first shaft 20 . The cavity opening 160 of the channel 156 is arranged eccentrically to the axis of rotation 18 of the first shaft 20 in the area of the cavity floor 98 . The gearbox chamber opening 158 is provided with a thread 161 and a component 162 , in particular a closure plug that is configured as an internal hex head or Allen head screw. The component 162 is provided with a bore 164 . The component 162 and the bore 164 are arranged concentrically to the axis of rotation 18 .
[0052] The housing cover 48 is provided with a bore 166 into which a ventilation arrangement 168 is inserted. The ventilating arrangement 168 is configured in the form of a pipe arrangement and extends into the interior of the second gearbox chamber region 24 (see FIG. 1 ). A filter 172 is arranged in the head 170 of the ventilating arrangement.
[0053] The plate 112 arranged for the immobilizing of the second shaft 106 is pictured in FIGS. 8 and 9 . Corresponding to the diameter of the shaft end region 64 , the plate 112 is configured cylindricalloy and concentric to the axis of rotation 18 and is provided with an opening 174 for the projection of the shaft end region 113 of the second shaft 106 . Corresponding to the eccentric movement of the second shaft 106 , the opening 174 is arranged eccentrically to the axis of rotation 18 . The opening 174 is provided with a step 176 in which a third shaft seal ring 178 is arranged, sealing to the outside, for example, a radial packing ring. The shaft seal ring 178 seals the clearance gap between the opening 174 and the second shaft 106 . Moreover, the plate 112 is provided with bores 180 that are arranged distributed around its circumference. In the embodiment shown, three bores 180 are provided. The bores 180 are used for the bolting of the plate 112 into threaded bores 182 provided correspondingly in the shaft end region 64 . A sealing layer or a coating(not shown) may be provided for the sealing of the plate 112 with respect to the end face 11 that prevents an escape of lubricant between the plate 112 and end face 111 .
[0054] The shaft end region 113 of the second shaft 106 is provided with connecting devices 190 that are configured in the form of a flange arrangement connected radially, as is shown in FIGS. 4 and . The connecting devices 190 include U-shaped projections 192 projecting axially from the shaft end region 113 of the second shaft 106 which are provided with two legs 194 extending transverse to the axis of rotation 90 on the end face of the shaft end region 113 . A free space 196 is developed between the legs 194 . Threaded bores 198 are provided on the end faces of the legs 194 , where the end faces of the legs 194 extend at an angle to the floor of the free space 196 that is less than 90°. The end face of the shaft region 113 is provided with a threaded bore 200 .
[0055] Moreover, the gearbox arrangement 10 is provided with a journal arrangement 202 that is connected with the shaft end region 113 of the second shaft 106 . The journal arrangement 202 is shown in greater detail in FIGS. 6 and 7 . The journal arrangement 202 is provided with a journal 204 with a journal axis 206 and connecting devices 208 in the form of a flange arrangement that provides a radial connection. The connecting devices 208 include a plate 210 on which a bridge 212 extended in the radial direction to the axis of the journal 2006 . The plate 210 is located at a height that corresponds generally to the height of the U-shaped projection 192 . The journal 204 extends axially to the journal axis 206 from the plate 210 . The bridge 212 is configured in such a way that it is generally provided with the shape and the height of the free space 196 . Connecting surfaces 214 are configured to the sides of the bridge 212 , these connecting surfaces being slightly chamfered relative to the faces of the legs 194 . The plate 210 is provided with bores 216 that conform in size and spacing to the threaded bores 198 . Moreover, the journal 204 is provided with a threaded bore 217 arranged on its end face concentric to the journal axis 206 .
[0056] The journal arrangement 202 or the journal 204 is equipped with a bearing arrangement 232 (see FIG. 10 ), it is connected by means of connecting devices 234 for the operation of a cutter head (not shown). The bearing arrangement 232 includes a rolling contact bearing 236 with an inner race 237 , and outer race 238 and a bushing 240 that is closed around its circumference, a bearing pan 242 closed around its circumference, where the bearing pan 242 establishes the connection with the connecting devices 234 , an attachment plate 244 and an attaching screw 246 . The rolling contact bearing 236 is configured as a roller bearing and engages the journal 204 with its inner race 237 . The bushing 240 engages the outer race 238 . The bushing 240 is supported in bearings in the bearing pan 242 . The bushing 240 is provided with an outer surface that is configured spherically curved to the outside and arranged radially to the axis of rotation 206 of the journal 204 . The bearing pan 242 is provided with an inner surface that is curved spherically inward congruent to the outer surface of the bushing 240 radially to the axis of rotation 206 of the journal 204 . The bearing pan 242 is provided with recesses located radially opposite each other (not shown) that extend axially to the axis of the journal 206 along the inner surface of the bearing pan 242 . Here the curvature of the spherical surfaces of the bushing 240 or the bearing pan 242 are provided with a radius of curvature that corresponds to the maximum outer radius of the bushing 240 or the maximum inner radius of the bearing pan 242 . The recesses are used for the insertion of the bushing 240 into the bearing pan 242 . The connecting device 234 is configured in the form of a guide rod that is rigidly connected to the bearing pan 242 or is configured as a one-piece component with the bearing pan 242 . The connecting device 234 is connected by means of a connecting rod and screws to a cuter head mechanism (not shown).
[0057] The following will briefly go into the assembly as well as the relevant advantages of the gearbox arrangement 10 .
[0058] Starting from the gearbox housing 16 , this is equipped with the fre space 60 and provided with the second bearing 42 for the first shaft 20 as well as the first shaft seal ring 47 . Following this, the first shaft is inserted into the first gearbox chamber region 22 through the first opening 30 , the first bevel gear 80 , preassembled with the second bearing 40 is guided over the shaft journal 78 over the second opening 32 of the second gearbox chamber region 24 . The bevel gear 80 and the shaft step 76 are clamped axially by the shaft nut 94 and the shaft step 76 and the first shaft 20 is secured axially.
[0059] The second shaft 106 is preassembled with the first bearing 104 and the second bearing 110 , where the second bearing 110 is secured axially by the snap ring 120 in the ring groove 118 . The preassembled second shaft 106 is conducted into the cavity 88 of the first shaft 20 and immobilized axially by the plate 112 that was preassembled with the third shaft seal ring 178 .
[0060] The third shaft 26 is preassembled to such a degree that the shaft journal 144 is equipped with the first bearing 49 and the second bevel gear 148 with the preassembled second bearing 50 is forced against the snap ring 140 fastened on the third shaft 26 in the ring groove 138 . Immediately following, the preassembled third shaft 26 is conducted over the fourth opening 36 in the second gearbox chamber region 24 and the second bearing 50 is immobilized with the snap ring 54 in the ring groove 56 . After installing the second shaft seal ring 57 , the belt pulley 154 is conducted over the shaft end 132 and forced against the second bevel gear 148 . The belt pulley 154 and the second bevel gear 148 are clamped against each other axially on the third shaft 26 by the shaft nut 134 and the snap ring 140
[0061] The connecting devices 190 , 208 of the shaft end region 113 and the journal arrangement 202 are connected to each other by inserting the bridge 212 into the free space 196 and by bolting the plate 210 to the legs 194 over the bores 198 and 216 . By connecting the connecting devices 190 , 208 the journal 204 is immobilized eccentrically to the axis of rotation 90 of the second shaft 106 .
[0062] The bearing arrangement 232 and the journal 202 are assembled by inserting the journal 202 into the inner race 237 of the rolling contact bearing 236 . The bushing 240 is inserted transverse to the bearing pan 242 into the recesses, so that the radii of the bushing 240 and the bearing pan 242 extend perpendicularly to each other, (until the center of the bushing lies approximately at the level of the center of the bearing pan). By subsequently orienting the busing 240 toward the bearing pan 242 , (so that the radii of the bushing 240 and the bearing pan 242 extend parallel to each other, then the bushing is brought into a position in which it is immobilized by the bearing pan 242 axially and radially to the axis of rotation of the journal 206 . However, the busing 240 may be rotated about any desirable axis of rotation that extends through the center of the bearing pan, that is located perpendicular to the axis of rotation 206 . Immediately following thereto the bushing 240 is slid over the outer race 238 and connected to the journal 204 along with the rolling contact bearing 236 together with the bushing 240 by means of the fastening disk 244 and the fastening screw 246 . The spherical configuration of the bushing 240 or the bearing pan 242 permits an equalization movement of the connecting devices 234 or the connecting rod about an axis extending perpendicularly to the axis of rotation 206 of the journal 204 . The closed configuration of the bushing 240 and the bearing pan 242 increase the stability and the resistance to wear of the bearing arrangement 232 and simplify the assembly, since conventional clamping arrangements for the bearing pan 242 can be omitted.
[0063] The gearbox arrangement 10 is driven by means of the belt pulley 154 on the third shaft 26 . The first shaft 20 is driven about the axis of rotation 18 by means of the angle gearbox configured by the two bevel gears 80 , 148 . The rotational movement of the first shaft 20 brings about, on the one hand, a rotational movement of the second shaft 106 itself about the axis of rotation 90 , since the second shaft 106 meshes with the cavity 60 over the gear tooth region 124 through the cavity opening 100 . The journal 204 connected to the shaft end region 113 of the second shaft 106 by means of the connecting devices 19 , 208 , which is arranged eccentrically to the axis of rotation of the second shaft 106 , thereby experiences an eccentric rotational movement about the axis of rotation 18 of the first shaft 20 that is superimposed by an eccentric rotational movement about the rotational axis 90 of the second shaft 106 .
[0064] As shown in FIGS. 2 and 3 , closure plugs 252 , 254 are provided that are spaced at intervals along the axis of rotation 18 , where an upper closure plug 252 is provided for the filling of the housing 16 with lubricant or gear oil, and a lower closure plug 254 is provided for draining the lubricant or gear oil. The closure plugs 252 , 254 may be configured as screws that are screwed into the housing 16 . The position of the upper closure plug 252 represents a maximum fill level for the lubricant or gear oil and is selected in such a way that the gearbox housing 16 can be filled with lubricant or gear oil so as to reach the region of the third shaft 26 , on the other hand, the position of the lower closure plug 254 represents a minimum fill level for the lubricant or gear oil that is arranged in the common cylindrical transition region 28 . The cross section passage area of the channel 156 is clearly reduced by the component 162 inserted into the gearbox chamber opening 158 or the bore 164 provided in the component 162 . Since the cavity opening 160 is arranged eccentrically to the gearbox chamber opening 158 or to the axis of rotation 18 , a suction develops when the first shaft 20 rotates which conveys the existing lubricant from the gearbox chamber opening 158 through the channel 156 to the cavity opening 160 . The cross section passage area of the channel 156 reduced by the component 162 has the effect that a reduced amount of lubricant reaches the cavity 88 . By having the bore 164 conform to the needs, the lubricating effect can be made to conform to the power requirements of the gearbox arrangement in a simple manner so that the lubricant conveyed through the channel corresponds to an optimum amount.
[0065] The ventilation arrangement 168 inserted into the housing cover 48 is used for the ventilation of the gearbox arrangement 10 . In contrast to conventional arrangements, it has the advantage that the pipe section is configured very long in comparison to the diameter of the head 170 . Thereby, the contamination of the filter element 172 can be slowed since, on the one hand, lubricant vapor ascending through the pipe can be deposited on the inside will of the pipe, one the other hand, foaming or splashing lubricant does not reach the filter so as directly to contaminate it.
[0066] All in all, the embodiments according to the invention of the gearbox arrangement permit the maintenance intervals to be lengthened, the temperature and pressure relationships in the gearbox housing 16 to be clearly improved and the cost of assembly to be significantly reduced.
[0067] Although the invention has been described on the basis of only one embodiment, anyone skilled in the art will perceive many varied alternative, modifications and variations, in the light of the foregoing description as well as the drawing, all of which fall under the present invention.
[0068] Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | A gearbox arrangement includes a gearbox housing, a first shaft supported in bearings in the housing, the first shaft containing a cavity which extends eccentrically to the axis of rotation of the first shaft, a second shaft supported in the cavity for rotation and having an end region projecting from the cavity and being provided with gear teeth, and a third shaft supported in the gear box housing for rotation, with the axis of rotation of the third shaft cooperating with the axis of rotation of the first shaft to define a plane. Leakage of lubricant from the housing is prevented by fastening a plate to the first shaft so as to prevent axial movement of the second shaft while containing an opening for the end region of the second shaft. Sealing devices are provided for all of the openings of the gearbox housing as well as for the opening in the plate in order to prevent the escape of lubricant from the gearbox housing. | 8 |
RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 635,753 filed Dec. 28, 1990, now U.S. Pat. No. 5,173,010.
1. Field Of The Invention
This invention relates generally to methods, devices and apparatus for laying cables. More particularly, this invention relates to methods, devices and apparatus for laying cables additionally or newly inside and/or outside a building, a factory, a station or the like.
2. Background Of The Invention
Presently, a plurality of cables are laid on a installed cable ladder or ladders.
Conventionally, cable layers pull up and drag a cable on cable ladders.
Alternatively, cable layers first lay a messenger rope through a cable ladder. The message rope is then connected to the cable and dragged by a traction motor.
In order to lay a cable at a high position by the prior art process a greater number of cable layers are required for the operation, and ladder hanging bolts often hinder the operation, requiring more time and cost for the operation.
Also, in some cases a message rope must be dragged by cable layers who have to change positions as required, and in order to lay a plurality of cables, these processes have to be repeated. Ladder hanging bolts hinder the operation in these cases as well.
Japanese patent publication No. 63-144707, laid open unexamined, discloses a resolution to those problems, in which a guide wire is installed like a loop preparedly on a cable ladder. A messenger rope and a cable connected to the messenger rope are dragged on the cable ladder as the guide wire connected to the messenger rope is dragged. This device, however, requires a complicated set of apparatus and their strenuous installation.
Japanese patent publication Nos. 61-231812 and 63-18911, laid open unexamined, also disclose a resolution to the aforementioned problems. The devices disclosed in those publications use draggers at certain intervals along the cable route which pass on a guide bar to which a cable is connected.
This type of device does not require the use of a messenger rope, however, a plurality of draggers and their strenuous installation are required. The removal work of the draggers is also strenuous. The apparatus to securely guide a guide bar from dragger to dragger are costly as well.
Therefore, it has been desired to have a method, a device and an apparatus which enables an efficient and easy operation for laying a cable which are often as long as 100 meters.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of this invention to provide methods for laying cables and the devices as well as the apparatus which make it possible to easily, efficiently and economically lay cables.
It is another object of this invention to provide methods for laying cables and the devices as well as the apparatus which makes it possible to easily, efficiently and economically lay cables in addition to existing cables.
The invention provides a method for laying comprising the steps of:
a) installing a cable receiver;
b) installing at least one chute, said chute having a slit extending in the longitudinal direction thereof, said cable receiver and said chute being separately attached to a wall or a ceiling and substantially parallel to each other;
c) inserting into said chute at a starting pint a shuttle to which is connected a first rope hard enough to push itself in said chute, said shuttle having a cable connecting means for travel within said slit,
d) pushing said shuttle through said chute by means of said rope,
e) connecting a cable to said shuttle at an ending point after said shuttle is sent through said chute,
f) drawing back said shuttle to said starting point through said chute with said rope and carrying said cable along said cable receiver, and
g) releasing said cable from said shuttle and laying said cable on said cable receiver.
The chute can comprise a single part or a plurality of parts each having a slit capable of alignment to form one continuous chute. Means is also provided on at least the end parts or separate from the parts to attach the chute to a wall or ceiling.
Similarly, the cable receiver can comprise one or more parts with attachment means or separate means for attaching a continuous chute substantially parallel to the chute on a ceiling or walls.
The invention further provides a cable laying device comprising:
1) a cable receiver formed from one or more units,
2) a chute having a slit extending in a longitudinal direction, said chute comprising one or more units, and
3) a cable laying means comprising a shuttle for traveling within said chute, said shuttle having connecting means for connecting a cable or a second rope, and a rope which is hard enough to push itself along said chute.
Advantageously, means is provided for connecting the cable receiver and/or the chute to a ceiling or walls.
For the sake of providing better understanding, drawings and numerals corresponding to each member are referred to hereinafter to describe each aspect of the invention. The drawings and the members represented by the numerals, however, must be considered as illustrative and not restrictive, and the present invention must be considered as claimed in the appended claims and may be modified within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention that are believed to be novel are set forth in the appended claims. The invention, together with the objects and advantages, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIGS. 1 to 5 are diagrammatic side views showing a process to lay a cable in accordance with the present invention,
FIG. 6 to 12 are diagrammatic side views showing another process to lay a cable in accordance with the present invention,
FIGS. 13-15 are perspective views showing cable receiver of the invention.
FIGS. 16a and 16b are perspective views showing chutes and cable laying means,
FIGS. 17 and 18 are perspective views showing cable laying kits as inserted in a cable receiver,
FIG. 19 is a partial front view showing a cable laying kit as inserted in a chute of an embodiment,
FIG. 20 is a perspective view showing a cable laying kit as shown in FIG. 19,
FIG. 21 is a perspective view showing a disassembled cable laying kit,
FIG. 22 is a perspective view showing another cable laying kit as inserted in a chute of an embodiment,
FIG. 23 is a perspective view showing a cable laying device to lay a plurality of cables at a time,
FIGS. 24 and 25 are perspective views showing an assembly of a cable laying device with attachment plates to be attached to a cable receiver for laying a plurality of cables as seen in FIG. 23,
FIGS. 26 and 27 are perspective views showing cable laying devices with an attachment portion to be attached to a cable receiver,
FIG. 28 is a perspective view showing an assembly of a chute as shown in FIG. 26.,
FIGS. 29 and 30 are perspective views showing other cable laying devices,
FIGS. 31 and 32 are perspective views showing cable laying devices comprising a chute with an attachment portion to be attached to a wall,
FIG. 33 is a perspective view of a cable laying device comprising a chute with a attachment portion to be attached to a wall;
FIG. 34 is a perspective view showing a cable laying device comprising a chute with an attachment portion to be attached to a wall,
FIG. 35 is a sectional view showing a cable laying device as shown in FIG. 34;
FIG. 36 to 38 are perspective views showing cable laying devices such as shown in FIG. 34,
FIG. 39 is a sectional view showing a cable laying device as shown in FIG. 38,
FIG. 40 is a perspective view showing another cable laying device comprising a chute with an attachment portion to be attached to a wall,
FIG. 41 is a sectional view showing a cable laying device as shown in FIG. 40,
FIG. 42 is a perspective view showing a cable laying device comprising a chute attached to a frame,
FIG. 43 is a front view showing a cable laying device as shown in FIG. 42,
FIG. 44 is a perspective view showing a cable laying device as shown in FIG. 42 as a cable is drawn,
FIG. 45 is a front view showing another type of a frame,
FIG. 46 is a perspective view showing still another cable laying device comprising a cable receiver.
The processes of laying cables according to the present invention are represented by the following groups of Figures: FIGS. 1 to 5, FIGS. 6 to 12, FIGS. 13 to 18 and FIGS. 19 to 24.
The group of FIGS. 1 to 5 shows a first process. As shown in FIG. 1, a cable receiver comprising one or more units for receiving a cable (c) and a chute 2 comprising one or more units with a slit i the longitudinal direction are separately attached from the cable receiver 1. The cable receiver, and the chute 2 can be hung on a wall or from a ceiling.
As shown in FIG. 2, a shuttle 3 with a rope 4 which is hard enough to push itself into a chute is inserted into the chute 2 at a starting point (S). As shown in FIG. 3, a cable (C) is connected to the shuttle 3 at an ending point (E). As shown in FIG. 4, the shuttle 3 is drawn back to the starting point (S) and the cable (C) connected to the shuttle 3 is drawn onto the cable receiver 1. Then as shown in FIG. 5 the cable (C) is released from the shuttle 3 to be laid on the cable receiver 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A starting point (S) and an ending point (E) can be any place on the chute 2. For example, they can be at a winding corner of a chute 2 in case the chute 2 is not straight. In such a case, a starting point (S) and an ending point (E) are identical, which means that a starting point (S) also becomes an ending point (E) for the subsequent cable laying operation.
Even in the case of a straight chute 2, a starting point (S) an ending point (E) can also be in a middle point of the chute 2. In such a case, too, a starting point (S) and an ending point (E) are identical.
The group of FIGS. 6 to 12 shows a second process. As shown in FIG. 6, a cable receiver 1 to receive a cable (C) and a chute 2 with a slit in the longitudinal direction are separately attached either on a wall or a ceiling. As shown in FIG. 7, a shuttle 3 with a rope 4 is inserted into a shuttle 2 at a starting point (S).
As shown in FIG. 8, a second rope 8 is connected to a shuttle 3 at an ending point (E). As shown in FIG. 9, as the second rope 8 is dragged, the shuttle 3 is also dragged and comes back to the starting point (S). As such, the second rope 8 is laid on a cable receiver 1 between the starting point (S) and the ending point (E).
The second rope 8 is released from the shuttle 3, as shown in FIG. 10, and the second rope 8 is drawn by a traction motor 100, as shown in FIG. 11, and a cable (C) connected o the second rope 8 is drawn onto a cable receiver 1.
A second rope 8 and a cable (C) may be connected either before the second rope 8 is laid on a cable receiver 1 or after the second rope 8 is laid on a cable receiver 1. Alternatively, a second rope 8 and a cable (C) may be preparedly connected.
As shown in FIG. 12, the cable (C) is laid on the cable receiver 1 after the removal of the cable (C) from the second rope 8. The untied end of the second rope 8 may be connected to a traction motor, which drags the second rope 8 and then the cable (C) connected to the second rope 8 onto the cable receiver 1.
As in the case of the second process, the connection of a second rope 8 and a cable (C) may be performed either before the second rope 8 is laid on a cable receiver 1 or after the second rope 8 is laid on a cable receiver 1. Alternatively, a second rope 8 and a cable (C) may be preparedly connected.
As set forth above, a cable can be easily and efficiently laid according to the present invention.
In the following are described devices and apparatus in accordance with the present invention.
The cable receiver of the invention comprises, for example, one or more main frames 11 which comprises side parts and auxiliary frames 12 which constitute bottom parts, as shown in FIG. 13. A cable receiver may be a cable ladder type, an L or U shape type as shown in FIG. 14 or a wire rod bent, for example, like the one shown in FIG. 15. A plurality of such wire type cable receivers are distributed at certain intervals along cable routes.
These cable receivers are fixed securely either to a wall or to a ceiling.
FIG. 16a shows a chute 2 formed cylindrical in which a shuttle 3 and a rope 4 go through. A chute 2 may take any shape as long as a shuttle 3 or a rope 4 can go through the chute 2. Such a chute 2 is usually made of either corrosion-resisting metal such as aluminum or synthetic resin produced by extrusion-molding, press-forming or the like. A chute 2 should have as long a length as possible but not necessarily be straight. The chute can comprise one or more of the units wherein the slits are aligned.
A chute 2 as shown in FIG. 16a has a continuous slit 20 in the longitudinal direction. The slit 20 is needed to move a shuttle 3 which has a tongue 31 with a connecting hole 32. The slit 20 is also needed to move a shuttle 3 when a connection rope to connect a cable is connected to the shuttle 3 or to move a shuttle 3 connected with the connection rope or the second rope when a second rope to drag a cable is connected to the shuttle 3.
As such, a chute 2 is used as a guide to send forth or drag back a cable laying kit comprising a shuttle 3 and a rope 4 an is also used to move a cable or a shuttle 3 with a 20 second rope to drag a cable.
Opening 19 may be prepared at certain intervals of the chute(s) besides a slit 20 on a chute 2, as are shown in FIG. 16b, which allow a cable laying kit of a shuttle 3 and a rope 4 to go through. In such a chute 2, a cable laying kit is inserted into the chute 2 at one of the opening 19 and is taken out through another opening 19, giving an advantage of free selection of an insertion point of a cable.
Such a chute 2 may be prepared together with a cable receiver 1, or may be attached to a cable receiver before a cable laying operation or fixed to a wall or bolts separately.
A detailed description on a shuttle and a rope is given in the following:
A shuttle 3 is used to connect a cable or a second rope, as shown in FIG. 16a. A shuttle can be cylindrical or partly conical. A cylindrical shuttle with a reduced end part is preferred since a shuttle of such a shape can move in a chute 2 more smoothly. A light weight shuttle is also preferred since a shuttle has to move both forward and backward in the chute 2.
A rope 4 ought to have hardness enough to push itself into a chute 2 and must be tough enough to bear the tension of drawing a cable. Such a rope may comprise a steel wire, a rope made of a plurality of finer steel wires, stick-shaped synthetic resin, synthetic resin fibers, an FRP (Fiber Reinforced Plastics) rope or the like. A rope 4 is preferred to be light weight.
A shuttle 3 and a rope 4 can be preparedly attached together or prepared separately to be connected together before the use.
A second rope, which is preferably light weight, is to be laid on a cable receiver before a cable is drawn and used to draw a cable. A second rope, is especially useful in laying a relatively heavy cable.
A shuttle 3 and a rope 4 can go through a chute 2 as shown in FIGS. 17 and 18. A chute 2 may be circular in cross section or rectangular in cross section.
A chute 2 comprises a slit 20 in the longitudinal direction. A slit 20 is formed on the cable receiving side of a cable receiver.
A cable receiver 1 usually has a length of several meters and in case it is necessary to extend the cable route, a plurality of cable receivers 1 are connected in succession. Cable receivers 1 may be connected with couplers, bolts and nuts, or the like. Cable receivers 1 need be so connected that a shuttle 3 and a rope 4 can travel through these cable receivers 1.
Cable receivers 1 can be attached to or hung from a ceiling with bolts directly attached to a wall.
As shown in FIGS. 17 and 18 a shuttle 3 is shaped bullet-like so as to be easily sent through a chute 2.
A shuttle 3 as shown in FIGS. 17 and 18 has a projecting tongue 31. A tongue 31 has a connection hole 32 to be used to connect a connecting rope or a second rope to the tongue 31. A tongue 31 moves in a chute 2 as it projects from a slit 20. A tongue 31 should take a shape to best fit the shape of a corresponding slit 20. A tongue 31, for example, is to bent like the ones as shown in FIGS. 19 and 20.
A tongue 31 may be provided with a roller which rolls on a side or the bottom wall of a cable receiver 1, in order to smoothly move a shuttle 3 in a chute 2. FIG. 21 shows a disassembled shuttle 3 with a tongue 31 having a roller 33. A roller 33 may be provided to run in a slit 20 as shown in FIG. 22, which enables smooth drawing of a cable onto a cable receiver 1.
In case a pair of shuttles 3 which are provided with a tongue 31, as shown in FIG. 23 are used, a pair of chutes 2 are provided to both the side walls and a cable receiver 1. A pair of shuttles 3 inserted in the chutes 2 have a common tongue 31 bridged between both the shuttles 3. The tongue 31 has a plurality of connecting holes 32. A plurality of cables (C) are connected to the connecting holes 32 by means of connecting ropes. As the ropes 4 in the chutes 2 are dragged, cables (C) are also dragged.
As shown in FIGS. 24 to 30, a chute 2 can be used in the cable laying device which has attachment portions 21 that are to be attached to the side walls or the bottom of a cable receiver 1 as shown in FIGS. 24 and 30, or to be attached to the main frame 11 and/or the auxiliary frames 12 of a cable receiver 1 as shown in FIGS. 26, 27 and 28.
A plate shape attachment portion 21 is formed on a chute 2 extending in longitudinal direction of the chute 2 as shown in FIG. 24. The chute 2 can be attached to each side wall of the cable receiver 1 by means of screws 81 as shown in FIG. 25.
Attachment portions 21 are ribs extending in the longitudinal direction as shown in FIG. 26. The chute can be attached to the auxiliary frame 12 of the cable receiver 1 by means of a fastener 83 having hooking portions to the ribs and a bolt 83 is used to securely fasten the fastener 82.
Plate shape attachments 21 are provided to the top and the bottom of the chute 2. The chute 2 is inserted and tightened in a recess 11a formed in the main frame 11 as shown in FIG. 27.
Besides screws 81 or the like, bolts, nuts, binding wires or the like may be utilized to attach the chute 2 to the cable receiver 1.
The chute 2 can be removed from the cable receiver 1 and be used in another cable receiver 1 after an operation which helps reduce work cost.
It is desired that a chute 2 is so made that it can be connected to another. A chute 2 as shown in FIG. 26 has insertion openings 25 extending in the longitudinal direction as shown in FIG. 28 and connecting pins 26 are to be inserted in the insertion openings 25. The chutes may be connected with each other by means of a connector 27 having screw holes and the slits 20 of the chutes can be aligned.
Attachment portions 21 are provided to a chute 2, as shown in FIG. 29. The chute 2 is then attached to an auxiliary frame 12 by means of bolts 85 and nuts 86. A cable receiving table 34 is provided to the top part of a plate shaped tongue 31 projecting from a shuttle 3. A cable (C) is laid on the cable receiving table 34 by means of a connecting rope inserted through a connection hole 36. A rail 24 is provided to each edge part of the attachment portion 21. Wheels 35 are provided to the tongue 31 so as to run on the rails 24. As the wheels 35 run on the rails 24, the cable (C) laid on the cable receiving table 34 is drawn onto the cable receiver 1.
Attachment portions 21 as shown in FIG. 30 are provided to a chute 2. The chute 2 is attached to the bottom wall of a cable receiver 1 by means of bolts 87 and nuts 88. A cable hanger 37 is provided to the top of a plate shape tongue 31 of a shuttle 3. The cable hanger 37 hands and holds cables (C) by means of connecting ropes inserted in connecting holes 38.
In operation, a chute 2 is attached to a cable receiver 1. A shuttle 3 and a rope 4 are inserted into the chute 2. A cable (C) is connected to the shuttle 3 by means of a connecting rope or the like. The rope 4 is dragged to draw back the shuttle 3 and the cable (C) is drawn as well onto the cable receiver 1. The cable (C) is then released from the shuttle 3 and is laid on the cable receiver 1.
As illustrated in FIGS. 31 to 53 a chute 2 has an attachment portion or portions 22 to be attached to a wall (W) or a ceiling. The wall (W) may be of a material such as concrete, wood, plastic or the like, or a panel or the like. The wall (W) may also comprise a plate material or bar materials attached thereto for fixing a chute 2.
A plate shape attachment portion 22 is provided to a chute 2 as shown in FIGS. 31 to 33. The chute 2 is fixed to a wall (W) with the attachment portion 22 by means of screws 89. A cable receiver 1 is attached to wall (W) by means of screws 90. The chute 2 may also be attached by means of adhesive or the like. Regardless of the shape of a cable receiver 1, the cable laying operation using the above mentioned kit is performed without receiving any adverse influence.
A chute 2 is formed a few meters long each or formed to have a length corresponding to that of a cable receiver 1. A plurality of chutes 2 are connected and installed. Slits 20 should be all aligned.
FIGS. 34 to 41 show cable laying devices each having a plurality of cable receivers 1 arranged in the cable laying direction. The cable receivers 1 are formed of thick wire material or plate material.
Such a cable laying device has a pipe portion and a block shape attachment portions 22 to hold the pipe portion. A screw hole is provided to the block shape attachment portion 22. The chute 2 is fixed to a wall (W) by means of the screws 89 as shown in FIG. 35. The block shape attachment portion 22 of the chute 2 is used to attach a cable receiver 1. As shown in FIG. 36, a shuttle 3 having a rope 4 is inserted in the chute 2. A tongue 31 of the shuttle 3 projects from a slit 20. A cable (C) is connected to the tongue 31 by means of a connecting rope. The rope 4 is dragged to draw the shuttle 3 and then the cable (C). As shown in FIG. 37, the cable (C) is laid on the cable receiver 1 as result of the operation.
A plate shape attachment portion 22 is formed on a chute 2 extending as shown in FIGS. 38 and 39. The chute 2 may be attached to a wall (W) with a screw 89. The cable receiver 1 formed of a bent wire material is fixedly held between the attachment portion 22 and the wall (W).
The top part of a chute 2 is so made as to be a flat attachment portion 22 a shown in FIGS. 40 and 41. The pipe portion of the chute 2 wherein a shuttle 3 is to be inserted has flat hooking portions. The bent ends of a cable receiver 1 can be hooked on the flat hooking portions and the chute 2 is fixed to a wall (W) with screws 89.
When cable receivers 1 as shown in FIGS. 34 to 41 are used, the installment of cable receivers 1 is relatively easy.
A cable laying device as illustrated in FIGS. 42 to 45 can comprise an installment bar 5 distributed above a cable receiver 1, a chute 2 which is attached to the installment bar 5, a shuttle 3 and a rope 4.
An installment bar 5 is needed to distribute a chute 2 above a cable receiver 1, which can take a shape of circular, rectangular or virtually any in cross section. An installment bar 5 may be made of metal, wood, synthetic resin or the like. As shown in FIG. 42, an installment bar 5 is attached to a hanging bolt (B) by means of a fastener 91. The hanging bolt (B) supports the cable receiver 1 and the installment bar 5 may be attached to a steel material or the like which is distributed at a ceiling wall or a wall other than a hanging bolt (B). The installment bar 5 may also be bridged over a cable receiver 1 between the side walls of the cable receiver 1.
A chute 2 is attached to the installment bar 5 by means of an attachment fastener 51 as shown in FIG. 42. The chute 2 can be slided on the installment bar 5 to a desired position above the cable receiver 1 by loosening the screws of the attachment fastener 51 as shown in FIG. 33. As shown in FIG. 39, a shuttle 3 and a rope 4 are inserted in the chute 2. A cable (C) is connected to a plate shape tongue 31 projecting from the shuttle 3 so that the cable (C) is drawn onto the cable receiver 1.
An installment bar 5 can have a plurality of recesses 52 made in a shape corresponding to the shape of a chute 2, such that the chute 2 can be distributed in the recesses 52 as shown in FIG. 44. With the distribution of the chute 2 in a recess 52, the chute 2 is attached to the installment bar 5.
As shown in FIG. 45, a cable receiver 1 is formed with a bent wire material. A chute 2 has pipe portion wherein a shuttle 3 is to be inserted and also a block shape attachment portion 23. The cable receiver 1 and the chute 2 are attached together to an installment bar 5 which is attached to a hanging bolt (B).
Although only several embodiments of the present invention have been set forth, it should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims. | The invention relates to an apparatus and a method for laying cable utilizing a cable receiver, a chute and a cable laying device. The cable laying device comprises a shuttle which is intended to travel through the chute and which has connected to it a cable and a rope. The rope pushes the shuttle along the chute and lays the cable. | 7 |
CROSS-REFERENCE
The present application is a continuation of U.S. patent application Ser. No. 12/349,358 now U.S. Pat. No. 8,285,093 filed Jan. 6, 2009, which is a continuation of U.S. patent application Ser. No. 11/796,498 now U.S. Pat. No. 7,474,820 filed Apr. 26, 2007, which is a non-provisional of, and claims the benefit of U.S. Provisional Application No. 60/795,986 filed Apr. 27, 2006; the entire contents of each of which is incorporated herein by reference.
FIELD OF THE INVENTIONS
The inventions described below relate to the field of surgical illumination and more specifically to Micro Structured Optical adapters and end caps for surgical illumination.
BACKGROUND OF THE INVENTION
Illumination devices, such as fiber optics, have many applications and generally employ conventional methods such as reflective surfaces or total internal reflection to deflect or focus the light energy. Some devices also have modifications of the distal end or tip geometry to generate focused or defocused beams. Tip modifications for optical fibers are typically produced by polishing or grinding of the fiber tip or the end of a bundle of fibers. Conventional techniques have also included use of high temperatures such as with use of a fusion splicer to create ball tip structures generated by melting the core of an optical fiber.
The limitation of these techniques is that they require accurate manipulation of the device resulting in a modified section which is then left unprotected. For optical fibers, the techniques for polishing or manipulating the tip are costly, time consuming and result in a fragile end product. The techniques available for creating lensing surfaces using the device itself are limited and generate limited optical output lensing options.
Illumination devices such as laser fibers for medical use are frequently used either in direct contact with tissue or in a fluid medium. In these settings, focus of the laser beam emanating from the fiber is difficult to control due to the similar indices of refraction of the various media and the fiber.
What is needed is a versatile technique for terminating illumination devices, or for adapting illumination devices to optimize the light energy and provide desired optical performance.
SUMMARY OF THE INVENTION
A micro structured optical adapter or tip according to the present disclosure may incorporate optical lensing structures to be placed over the end of any suitable illumination device such as fiber optic laser delivery devices. The cap or adapter may incorporate micro structured optical components such as for example gratings, prisms and or diffusers to operate as precision optics for customized delivery of the light energy. These components may be formed as injection molded plastic or glass parts to allow for inexpensive modification of the output light and also serve to protect the end of the device, such as a cleaved fiber optic bundle. The micro structured optical components may also be incorporated in an adapter to tailor the light energy to the subsequent devices. The micro structured optical components may also be used to polarize and/or filter the light energy entering or exiting the illumination device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cutaway view of a laser fiber and micro structure optical end cap according to the present disclosure.
FIG. 2 is a cutaway view of an alternate micro structure optical end cap according to the present disclosure.
FIG. 3 is a cutaway view of another alternate micro structure optical end cap according to the present disclosure.
FIG. 4 is a cutaway view of a micro structure optical adapter according to the present disclosure.
FIG. 5 is a cutaway view of a micro structure optical adapter and end element according to the present disclosure.
FIG. 6 is a cross section view of the micro structure optical adapter of FIG. 5 taken along A-A.
FIG. 7 is a cross section view of the micro structure optical adapter of FIG. 5 taken along B-B.
FIG. 8 is a side view of a micro structure optical adapter and an end element according to the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 medical illumination fiber 10 engages an end cap such as cap 14 to form an optical path with one or more micro structure optical surfaces such as inner optical surface 14 A or outer optical surface 14 B and or one or more air gaps such as gap 16 and or index matching material to control light 12 . Any suitable surface such as inner an outer optical surfaces 14 A and 14 B or a portion of an inner or outer surface may be formed to include micro structure optical structures such as structure 18 A and or 18 B thereon. Cap 14 may be made of glass, plastic or any other suitable material and may be sized to enable bore 13 to frictionally engage optical fiber 10 . Arrow 10 a illustrates that cap 14 is slidably coupled with the optical fiber 10 .
Input and or output micro optical structures such as structure 18 A or structure 18 B may adopt any suitable configuration to accomplish one or more of the functions of diffracting, deflecting, refracting or polarizing light passing through the micro structure optical component. Such structures individually or in combination may be used to adjust the intensity and or the phase of the light energy similar to holographic film which may also be used.
Referring now to FIG. 2 illumination fiber 10 includes a light management cap such as cap 22 engaging end 24 of fiber 10 . A light management cap according to the present disclosure such as cap 22 may engage a fiber along engagement zone 21 mechanically, frictionally, or using adhesives or any other suitable technique. Matching zone 23 of cap 22 may be an air gap, or be filled with any suitable material such as adapter material 26 to achieve a suitable index transition between illumination fiber 10 and cap 22 . Body zone 25 of cap 22 may be composed of solid cap material, or any suitable combination of air gaps or inserted components may also be used. Cap zone or output zone 27 may be formed in any suitable shape and may include microstructure such as structures 18 A and 18 B to achieve desired output light management.
Referring to FIG. 3 , light management cap 30 may include one or more chambers or other inserted structures to control light emanating from illumination fiber 10 . Chamber 32 may be filled with air or other suitable material to achieve the desired light management. Incident surface 33 and outlet surface 35 of chamber 32 may be formed to have any suitable surface characteristics such as surfaces 18 A and 18 B.
Referring now to FIG. 4 , fiber adapter 36 includes an input bore 36 A and an output bore 36 B. Input bore 36 A may adopt any suitable geometry to engage a first element such as illumination fiber 10 having a dimension 34 and couple it to a second element such as fiber 20 having a dimension 38 . Dimensions 34 and 38 may be the same or different. Surfaces 37 and 39 may be formed to have any suitable surface characteristics such as micro structure optical surfaces 18 A and 18 B. A fiber adapter such as adapter 36 may also include one or more energy conforming elements such as elements 40 and 42 . Elements 40 and 42 may be solid or hollow with one or more surfaces including conventional shapes and or micro structure optical components. Adapters such as adapter 36 may also be used to connect an illumination fiber to an end element having any suitable dimensions and geometry. End elements may have round, oval, rectangular, and polygonal or any other suitable cross section. Adapters such as adapter 36 may also incorporate a flexible center section or light conduit such as center section 36 C, thereby allowing element 20 to be oriented in any position relative to illumination fiber 10 . This allows element 20 to be oriented in a selected direction to accommodate selected use or selected mounting on auxiliary equipment. Center section 36 c may be fabricated from optical fibers, silicone or other suitable flexible material. Elements 40 and 42 may serve to couple light into and out of this flexible section, for example, as suitably designed lenses.
Flexible adapter 36 may be constructed entirely of flexible material, for example, injection molded silicone, or it may be fabricated as an assembly including an input connector, flexible light conduit, and output connector using suitable fabrication and assembly techniques. A flexible adapter may be incorporated as a permanent component of an illumination input, for example as part of a fiber optic light guide cable using adhesive or other suitable joining technique, thereby allowing end elements to be changed without fear of disengaging the adapter from the illumination input. Conversely, a flexible adapter may be incorporated as a permanent component of an end element or illumination device using suitable joining techniques, thereby allowing different end element devices to be used with the same illumination input without fear of disengaging the adapter or without the added step of replacing an adapter for each new device to be used.
Referring to FIG. 5 , FIG. 6 and FIG. 7 adapter 44 engages a generally round illumination fiber at receptacle 54 . Receptacle 56 engages device 46 having a generally rectangular cross-section. As discussed above surface 48 of device 46 may incorporate suitable micro structure optical components to enhance light coupling into device 46 . Facets such as facet 50 may also incorporate micro structure optical components or other coatings such as polarizing coating 52 . Adapter 44 may also include a flexible middle portion that conducts light, thereby allowing device 46 to be oriented in any direction relative to an illumination input at receptacle 54 .
Polarized coating 52 emits polarized light to optimize viewing of site 60 . Use of a complementary polarization microstructure or coating such as microstructure 58 on lens 62 permits any suitable light receiver such as camera 64 to receive only properly polarized light 66 and reject other reflected light such as light 68 thus minimizing distracting reflections and glare.
Referring now to FIG. 8 , adapter 69 is coupled to end element 70 . End element 70 may include one or more light emission facets such as facets 72 , 73 , 74 and 76 for output of light energy. Input surface 71 of end element 70 may incorporate polarizing microstructure 71 A. Each light emission facet may have a polarizing microstructure or coating such as microstructures 72 A, 73 A, 74 A and 76 A, and two or more of the light emission facets may have similarly oriented polarization. Controlling the orientation of a polarized input may allow light to be emitted from one or more facets having complimentary polarization. For example, adapter 69 may be made to rotate relative to end element 70 such that this rotation causes separate polarizing structures formed in adapter 69 to line up with at least part of input surface 71 , without polarizing microstructure 71 A, such that light emits from complementary polarization facet 72 at zero degrees of relative rotation of adapter 69 , but that light emits from separate complimentary polarization facet 74 at 90 degrees of relative rotation of adapter 69 .
End element 70 or any adapter or end cap may also be formed to include one or more constituent elements to cause end element 70 to filter and or polarize the light energy input into end element 70 and cause emitted light 78 to have a desired frequency or combination of frequencies and or polarization orientation. End element 70 may also be treated to cause its constituent element or elements to operate as a light filter enabling chromatography. End element 70 may include co-molded element 73 that splits the incoming light such that a fraction of the light exits facet 72 , which may have a filtering microstructure or coating 72 A, a fraction exits facet 74 incorporating redirecting microstructure prism 74 A, and a fraction exits normally through facet 76 .
A micro structured optical cap may also contain one or more gas or air filled chambers that allows the light to refract prior to reaching the tissue or fluid. A cap or adapter may also operate as a filter to pass a desired frequency or frequencies of light by selecting the gas filling and or additives to be incorporated with the material of the cap or adapter.
A micro structured optical adapter or tip according to the present disclosure may use micro structured optical components to manage or adapt the light output of an illumination fiber. By making a device or adapter consisting of one or more micro structured optical components injection molded onto a flat window, which can be attached to a standard fiber, the light output of the illumination fiber may be controlled without the need to polish the tip of the fiber.
In another aspect, one or more surfaces in the optical path of an adapter or cap may include a predetermined micro structured optical components. Different optical light output shapes may be achieved by creating specific microstructure surfaces or patterns.
It is also possible to apply the microstructure technology to deflect light as well as focus it into a particular shape. Microstructures may be applied to the back and or the front of a refractive element to deflect the beam as well as shape it. Microstructure surfaces may also be combined with one or more air gaps and or conventional surface shaping to achieve desired optical performance.
Other potential configurations can be designed to engage and secure the caps to the end of a fiber. This can be done using adhesive with index matching glue, or it could be done mechanically leaving an air space. The cap could be made from glass or plastic, or other suitable optical material.
A micro structure optical adapter according to the present disclosure may be used to adapt any suitable illumination energy from a conventional round source such as an optical fiber or fiber bundle to an end element having any suitable cross section. This adapter may be flexible, allowing the user to preferably orient the end element relative to the source. The use of micro structure optical components and or conventional diffraction and or refraction elements may permit optimal transfer of light energy from the fiber to the end element. These structures can be part of an injection mold or may be applied as a separate film.
In a still further aspect of the present disclosure one or more surfaces in an illumination path may be polarized using any suitable technique such as an injection molded micro structure optical component, thin film coating or other. Use of polarized light in a surgical environment may provide superior illumination and coupled with the use of complementary crossed polarized material on viewing devices such as video or still cameras, surgical loupes, microscopes, face shields or surgeons glasses may reduce reflected glare providing less visual distortion and more accurate color resolution of the surgical site.
Due to an expensive and complex process, standard fiber optic bundles do not preserve polarization. Therefore, polarized light that is transmitted through a fiber optic bundle will become depolarized. The application of a tip device with polarization structures would still allow polarized light to be delivered.
In a still further aspect of the present disclosure use of a micro structure optical tip or adapter incorporating filtering additives such as dyes or structures such as for example diffraction gratings, may produce light of a selected frequency. The frequency of the light output may be selected to provide selective reflection and or absorption to enhance surgery, therapy and or diagnosis.
While polarizing and filtering components may be fabricated in adapters and or tips that are subsequently applied to an illumination device, another further aspect of this disclosure is the fabrication of these components directly in the illumination device. As noted, optical fibers are very difficult to modify to form these components, but modern tooling and injection molding processes provide that capability, for example, with plastic waveguides or light pipes. Facets may be formed in an injection molded illumination device wherein the facet face, which may normally act as a refraction surface, may be modified to include micro structure optical components that perform polarization and or filtering functions. For example, such structures may be molded into the input face to polarize light as it enters the illumination device so that the light exiting the device is polarized.
Furthermore, micro structure optical components may also be formed of metal or other suitable materials, e.g., beam splitters or polarization grids, then co-molded into a plastic illumination device. For example, a beam splitter co-molded in the center of a plastic light pipe may force part of an incoming light beam out of a facet with a green filter grating molded in and part of the light beam out of a second facet with a red filter grating molded in. The user may simply reposition the light pipe to use either color light for a particular purpose.
In typical application, an adapter may be disposed between a light source, such as a fiber optic light guide cable, and an end element illumination device, such as a fiber optic light pipe or a plastic waveguide or light pipe. A tip may be used instead of the adapter for certain functions, for example, providing a polarizing tip to a standard fiber optic light pipe. The user may remove and replace adaptors and tips as needed for specific light output needs, but the process of removing and replacing adapters and tips may be troublesome, for example, during a surgical procedure.
In another further embodiment, a polarization rotator such as a half-wave plate which can rotate polarized light by a predetermined angle may provide different angles of polarization to be combined with matching polarized facets on an end element device or polarized sections in a tip. Each facet or section might be directed in different visual angles or may have a filtering film applied. As the polarization rotator is adjusted to a particular polarizing angle, polarized light travels down the end element to the facet or tip section that has a matching polarization. Light then exits from this matched output facet or section, but not other facets or sections due to the polarization effect. This may be used to selectively illuminate certain areas of a visual field or to select certain filters for better visualization of elements in a visual field. For example, in a surgical procedure, the adjustable polarizer could be adjusted so that light only shines out of a tip section that provides filtered light suitable for visualization of blood vessels, while a different setting on the adjustable polarizer causes light to shine out of a separate tip section that provides a different color of light suitable for visualization of nerves.
Thus, while the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims. | A microstructure optical adapter or tip according to the present disclosure may incorporate precision micro structure optical components engaging the input or output end of light energy delivery devices for customized light delivery of the light energy. The incorporation of precision micro structure optical components in injection molded plastic or glass parts will allow for inexpensive modification of the output light while also serving to protect the end of the illumination device. The micro structure optical components may also be incorporated in an adapter to tailor the light energy to the subsequent device. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. patent application Ser. No. 14/165,214, filed Jan. 27, 2014, now U.S. Pat. No. 9,034,629, which claims priority to U.S. Provisional Application No. 61/756,973, filed Jan. 25, 2013; the entire disclosure of each of which is hereby incorporated by reference in its entirety for all purposes.
SEQUENCE LISTING
The instant application contains a Sequence Listing which has been submitted via EFS-Web and is hereby incorporated by reference in its entirety. Said ASCII copy, created on Apr. 9, 2015, is named 29253US_sequencelisting.txt, and is 90,236 bytes in size.
BACKGROUND
Many existing photoautotrophic organisms (i.e., plants, algae, and photosynthetic bacteria) are poorly suited for industrial bioprocessing and have therefore not demonstrated commercial viability. Recombinant photosynthetic microorganisms have been engineered to produce hydrocarbons and alcohols in amounts that exceed the levels produced naturally by the organism.
SUMMARY
Described herein is an engineered microorganism, wherein said engineered microorganism comprises one or more recombinant genes encoding one or more enzymes having enzyme activities which catalyze the production of medium chain-length alkanes, wherein the enzyme activities comprise: an alkane deformylative monooxygenase activity, a thioesterase activity, a carboxylic acid reductase activity, and a phosphopanthetheinyl transferase activity; and/or an alkane deformylative monooxygenase activity, a thioesterase activity, a long-chain fatty acid CoA-ligase activity, and a long-chain acyl-CoA reductase activity.
In some aspects, the enzymes comprise an alkane deformylative monooxygenase, a thioesterase, a carboxylic acid reductase, and a phosphopanthetheinyl transferase. In some aspects, the alkane deformylative monooxygenase has EC number 4.1.99.5, the thioesterase has EC number 3.1.2.14, the carboxylic acid reductase has EC number 1.2.99.6, and the phosphopanthetheinyl transferase has EC number 2.7.8.7. In some aspects, the alkane deformylative monooxygenase is encoded by adm, the thioesterase is encoded by fatB or fatB2, the carboxylic acid reductase is encoded by carB, and the phosphopanthetheinyl transferase is encoded by entD.
In some aspects, the enzyme having alkane deformylative monooxygenase activity has EC number 4.1.99.5. In some aspects, the enzyme having thioesterase activity has EC number 3.1.2.14. In some aspects, the enzyme having carboxylic acid reductase activity has EC number 1.2.99.6. In some aspects, the enzyme having phosphopanthetheinyl transferase activity has EC number 2.7.8.7.
In some aspects, the enzymes comprise an alkane deformylative monooxygenase, a thioesterase, a long-chain fatty acid CoA-ligase, and a long-chain acyl-CoA reductase. In some aspects, the alkane deformylative monooxygenase has EC number 4.1.99.5, the thioesterase has EC number 3.1.2.14, the long-chain fatty acid CoA-ligase has EC number 6.2.1.3, and the long-chain acyl-CoA reductase has EC number 1.2.1.50. In some aspects, the alkane deformylative monooxygenase is encoded by adm, the thioesterase is encoded by fatB or fatB2, the long-chain fatty acid CoA-ligase is encoded by fadD, and the long-chain acyl-CoA reductase is encoded by acrM.
In some aspects, the enzyme having alkane deformylative monooxygenase activity has EC number 4.1.99.5. In some aspects, the enzyme having thioesterase activity has EC number 3.1.2.14. In some aspects, the enzyme having long-chain fatty acid CoA-ligase activity has EC number 6.2.1.3. In some aspects, the enzyme having long-chain acyl-CoA reductase activity has EC number 1.2.1.50.
In some aspects, the one or more recombinant genes comprise a recombinant gene encoding a thioesterase that catalyzes the conversion of acyl-ACP to a fatty acid. In some aspects, the one or more recombinant genes comprises a recombinant gene encoding a phosphopanthetheinyl transferase that phosphopatetheinylates the ACP moiety of a protein encoded by a carboxylic acid reductase gene. In some aspects, the one or more recombinant genes comprise a recombinant gene encoding a carboxylic acid reductase that catalyzes the conversion of fatty acid to fatty aldehyde. In some aspects, the one or more recombinant genes comprise a recombinant gene encoding a alkane deformylative monooxygenase that catalyzes the conversion of fatty aldehyde to an alkane or alkene. In some aspects, the one or more recombinant genes comprise a recombinant gene encoding a fatty acid CoA-ligase that catalyzes the conversion of fatty acid to acyl-CoA. In some aspects, the one or more recombinant genes comprise a recombinant gene encoding an acyl-CoA reductase that catalyzes the conversion of acyl-CoA to fatty aldehyde.
In some aspects, said microorganism is a bacterium. In some aspects, said microorganism is a gram-negative bacterium. In some aspects, said microorganism is E. coli.
In some aspects, said microorganism is a photosynthetic microorganism. In some aspects, said microorganism is a cyanobacterium . In some aspects, said microorganism is a thermotolerant cyanobacterium . In some aspects, said microorganism is a Synechococcus species.
In some aspects, expression of an operon comprising the one or more recombinant genes is controlled by a recombinant promoter, and wherein the promoter is constitutive or inducible. In some aspects, said operon is integrated into the genome of said microorganism. In some aspects, said operon is extrachromosomal.
In some aspects, said medium chain-length alkanes are less than or equal to 11 carbon atoms in length. In some aspects, said medium chain-length alkanes are 7 to 11 carbon atoms in length. In some aspects, said medium chain-length alkanes are 7, 8, 9, 10, or 11 carbon atoms in length.
In some aspects, said recombinant genes are at least 90% or at least 95% identical to a sequence shown in the Tables.
Also described herein is a cell culture comprising a culture medium and a microorganism described herein.
Also described herein is a method for producing hydrocarbons, comprising: culturing an engineered microorganism described herein in a culture medium, wherein said engineered microorganism produces increased amounts of medium chain-length alkanes relative to an otherwise identical microorganism, cultured under identical conditions, but lacking said recombinant genes. In some aspects, the method further includes allowing medium chain-length alkanes to accumulate in the culture medium or in the organism. In some aspects, the method further includes isolating at least a portion of the medium chain-length alkanes. In some aspects, the method further includes processing the isolated medium chain-length alkanes to produce a processed material.
Also described herein is a method for producing hydrocarbons, comprising: (i) culturing an engineered microorganism described herein in a culture medium; and (ii) exposing said engineered microorganism to light and inorganic carbon, wherein said exposure results in the conversion of said inorganic carbon by said microorganism into medium chain-length alkanes, wherein said medium chain-length alkanes are produced in an amount greater than that produced by an otherwise identical microorganism, cultured under identical conditions, but lacking said recombinant genes. In some aspects, the method further includes allowing medium chain-length alkanes to accumulate in the culture medium or in the organism. In some aspects, the method further includes isolating at least a portion of the medium chain-length alkanes. In some aspects, the method further includes processing the isolated medium chain-length alkanes to produce a processed material.
Also described herein is a composition comprising medium chain-length alkanes, wherein said medium chain-length alkanes are produced by a method described herein. In some aspects, the composition comprises at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, at least 95%, or at least 99% medium chain-length alkanes.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 . SDS-PAGE gel showing the overexpression of AcrM protein in E. coli.
FIG. 2 . TIC chromatograms of assays with ( FIG. 2A ) decanoyl-CoA, ( FIG. 2B ) lauroyl-CoA. Solid line: wild type BL21(DE3); dotted line: acrM-expressing BL21(DE3).
FIG. 3 . GC/FID chromatogram showing the detection of C13 and C15 alkanes produced by Synechococcus sp. PCC 7002 strain expressing Adm, CarB, TesA and EntD proteins. Grey trace: control strain (does not express CarB protein); solid black trace: Standards of C13, C14, and C15 n-alkanes; dashed black trace: Synechococcus sp. PCC 7002 strain expressing Adm, CarB, TesA, and EntD proteins.
FIG. 4 . TIC chromatograms of samples from acid-fed (dashed lines) or control (solid lines) Synechococcus sp. PCC 7002 expressing Adm and CarB. FIG. 4A and FIG. 4D : octanoic acid feeding, FIG. 4B and FIG. 4E : decanoic acid feeding, FIG. 4C and FIG. 4F : dodecanoic acid feeding.
FIG. 5 . GC/FID chromatogram showing the detection of nonane produced by Synechococcus sp. PCC 7002 strain expressing Adm, CarB, FatB2 and EntD proteins at 12 h ( FIG. 5A ) and 72 h ( FIG. 5B ). Solid trace: control strain (wild type); dotted trace: Synechococcus sp. PCC 7002 strain expressing Adm, CarB, FatB2, and EntD proteins.
FIG. 6 . Examples of pathways for production of medium chain-length alkanes. Note that the use of carB can be facilitated by the product of entD (phosphopatetheinyl transferase), which phosphopatetheinylates the ACP moiety of the CarB protein. For example, one can use the Bacillus entD, whose enzyme product has a wide substrate spectrum that includes CarB.
DETAILED DESCRIPTION
Unless otherwise defined herein, scientific and technical terms used in connection with the present invention shall have the meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include the plural and plural terms shall include the singular. Generally, nomenclatures used in connection with, and techniques of, biochemistry, enzymology, molecular and cellular biology, microbiology, genetics and protein and nucleic acid chemistry and hybridization described herein are those well known and commonly used in the art.
The methods and techniques of the present invention are generally performed according to conventional methods well known in the art and as described in various general and more specific references that are cited and discussed throughout the present specification unless otherwise indicated. See, e.g., Sambrook et al., Molecular Cloning: A Laboratory Manual, 2d ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989); Ausubel et al., Current Protocols in Molecular Biology , Greene Publishing Associates (1992, and Supplements to 2002); Harlow and Lane, Antibodies: A Laboratory Manual , Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1990); Taylor and Drickamer, Introduction to Glycobiology , Oxford Univ. Press (2003); Worthington Enzyme Manual , Worthington Biochemical Corp., Freehold, N.J.; Handbook of Biochemistry: Section A Proteins , Vol I, CRC Press (1976); Handbook of Biochemistry: Section A Proteins, Vol II, CRC Press (1976); Essentials of Glycobiology , Cold Spring Harbor Laboratory Press (1999).
All publications, patents and other references mentioned herein are hereby incorporated by reference in their entireties.
The following terms, unless otherwise indicated, shall be understood to have the following meanings:
The term “polynucleotide” or “nucleic acid molecule” refers to a polymeric form of nucleotides of at least 10 bases in length. The term includes DNA molecules (e.g., cDNA or genomic or synthetic DNA) and RNA molecules (e.g., mRNA or synthetic RNA), as well as analogs of DNA or RNA containing non-natural nucleotide analogs, non-native intemucleoside bonds, or both. The nucleic acid can be in any topological conformation. For instance, the nucleic acid can be single-stranded, double-stranded, triple-stranded, quadruplexed, partially double-stranded, branched, hairpinned, circular, or in a padlocked conformation.
Unless otherwise indicated, and as an example for all sequences described herein under the general format “SEQ ID NO:”, “nucleic acid comprising SEQ ID NO:1” refers to a nucleic acid, at least a portion of which has either (i) the sequence of SEQ ID NO:1, or (ii) a sequence complementary to SEQ ID NO:1. The choice between the two is dictated by the context. For instance, if the nucleic acid is used as a probe, the choice between the two is dictated by the requirement that the probe be complementary to the desired target.
An “isolated” RNA, DNA or a mixed polymer is one which is substantially separated from other cellular components that naturally accompany the native polynucleotide in its natural host cell, e.g., ribosomes, polymerases and genomic sequences with which it is naturally associated.
As used herein, an “isolated” organic molecule (e.g., an alkane) is one which is substantially separated from the cellular components (membrane lipids, chromosomes, proteins) of the host cell from which it originated, or from the medium in which the host cell was cultured. The term does not require that the biomolecule has been separated from all other chemicals, although certain isolated biomolecules may be purified to near homogeneity.
The term “recombinant” refers to a biomolecule, e.g., a gene or protein, that (1) has been removed from its naturally occurring environment, (2) is not associated with all or a portion of a polynucleotide in which the gene is found in nature, (3) is operatively linked to a polynucleotide which it is not linked to in nature, or (4) does not occur in nature. The term “recombinant” can be used in reference to cloned DNA isolates, chemically synthesized polynucleotide analogs, or polynucleotide analogs that are biologically synthesized by heterologous systems, as well as proteins and/or mRNAs encoded by such nucleic acids.
As used herein, an endogenous nucleic acid sequence in the genome of an organism (or the encoded protein product of that sequence) is deemed “recombinant” herein if a heterologous sequence is placed adjacent to the endogenous nucleic acid sequence, such that the expression of this endogenous nucleic acid sequence is altered. In this context, a heterologous sequence is a sequence that is not naturally adjacent to the endogenous nucleic acid sequence, whether or not the heterologous sequence is itself endogenous (originating from the same host cell or progeny thereof) or exogenous (originating from a different host cell or progeny thereof). By way of example, a promoter sequence can be substituted (e.g., by homologous recombination) for the native promoter of a gene in the genome of a host cell, such that this gene has an altered expression pattern. This gene would now become “recombinant” because it is separated from at least some of the sequences that naturally flank it.
A nucleic acid is also considered “recombinant” if it contains any modifications that do not naturally occur to the corresponding nucleic acid in a genome. For instance, an endogenous coding sequence is considered “recombinant” if it contains an insertion, deletion or a point mutation introduced artificially, e.g., by human intervention. A “recombinant nucleic acid” also includes a nucleic acid integrated into a host cell chromosome at a heterologous site and a nucleic acid construct present as an episome.
As used herein, the phrase “degenerate variant” of a reference nucleic acid sequence encompasses nucleic acid sequences that can be translated, according to the standard genetic code, to provide an amino acid sequence identical to that translated from the reference nucleic acid sequence. The term “degenerate oligonucleotide” or “degenerate primer” is used to signify an oligonucleotide capable of hybridizing with target nucleic acid sequences that are not necessarily identical in sequence but that are homologous to one another within one or more particular segments.
The term “percent sequence identity” or “identical” in the context of nucleic acid sequences refers to the residues in the two sequences which are the same when aligned for maximum correspondence. The length of sequence identity comparison may be over a stretch of at least about nine nucleotides, usually at least about 20 nucleotides, more usually at least about 24 nucleotides, typically at least about 28 nucleotides, more typically at least about 32 nucleotides, and preferably at least about 36 or more nucleotides. There are a number of different algorithms known in the art which can be used to measure nucleotide sequence identity. For instance, polynucleotide sequences can be compared using FASTA, Gap or Bestfit, which are programs in Wisconsin Package Version 10.0, Genetics Computer Group (GCG), Madison, Wis. FASTA provides alignments and percent sequence identity of the regions of the best overlap between the query and search sequences. Pearson, Methods Enzymol. 183:63-98 (1990) (hereby incorporated by reference in its entirety). For instance, percent sequence identity between nucleic acid sequences can be determined using FASTA with its default parameters (a word size of 6 and the NOPAM factor for the scoring matrix) or using Gap with its default parameters as provided in GCG Version 6.1, herein incorporated by reference. Alternatively, sequences can be compared using the computer program, BLAST (Altschul et al., J. Mol. Biol. 215:403-410 (1990); Gish and States, Nature Genet. 3:266-272 (1993); Madden et al., Meth. Enzymol. 266:131-141 (1996); Altschul et al., Nucleic Acids Res. 25:3389-3402 (1997); Zhang and Madden, Genome Res. 7:649-656 (1997)), especially blastp or tblastn (Altschul et al., Nucleic Acids Res. 25:3389-3402 (1997)).
The term “substantial homology” or “substantial similarity,” when referring to a nucleic acid or fragment thereof, indicates that, when optimally aligned with appropriate nucleotide insertions or deletions with another nucleic acid (or its complementary strand), there is nucleotide sequence identity in at least about 76%, 80%, 85%, preferably at least about 90%, and more preferably at least about 95%, 96%, 97%, 98% or 99% of the nucleotide bases, as measured by any well-known algorithm of sequence identity, such as FASTA, BLAST or Gap, as discussed above.
Alternatively, substantial homology or similarity exists when a nucleic acid or fragment thereof hybridizes to another nucleic acid, to a strand of another nucleic acid, or to the complementary strand thereof, under stringent hybridization conditions. “Stringent hybridization conditions” and “stringent wash conditions” in the context of nucleic acid hybridization experiments depend upon a number of different physical parameters. Nucleic acid hybridization will be affected by such conditions as salt concentration, temperature, solvents, the base composition of the hybridizing species, length of the complementary regions, and the number of nucleotide base mismatches between the hybridizing nucleic acids, as will be readily appreciated by those skilled in the art. One having ordinary skill in the art knows how to vary these parameters to achieve a particular stringency of hybridization.
In general, “stringent hybridization” is performed at about 25° C. below the thermal melting point (T m ) for the specific DNA hybrid under a particular set of conditions. “Stringent washing” is performed at temperatures about 5° C. lower than the T m for the specific DNA hybrid under a particular set of conditions. The T m is the temperature at which 50% of the target sequence hybridizes to a perfectly matched probe. See Sambrook et al., Molecular Cloning: A Laboratory Manual, 2d ed., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y. (1989), page 9.51, hereby incorporated by reference. For purposes herein, “stringent conditions” are defined for solution phase hybridization as aqueous hybridization (i.e., free of formamide) in 6×SSC (where 20×SSC contains 3.0 M NaCl and 0.3 M sodium citrate), 1% SDS at 65° C. for 8-12 hours, followed by two washes in 0.2×SSC, 0.1% SDS at 65° C. for 20 minutes. It will be appreciated by the skilled worker that hybridization at 65° C. will occur at different rates depending on a number of factors including the length and percent identity of the sequences which are hybridizing.
The nucleic acids (also referred to as polynucleotides) of this present invention may include both sense and antisense strands of RNA, cDNA, genomic DNA, and synthetic forms and mixed polymers of the above. They may be modified chemically or biochemically or may contain non-natural or derivatized nucleotide bases, as will be readily appreciated by those of skill in the art. Such modifications include, for example, labels, methylation, substitution of one or more of the naturally occurring nucleotides with an analog, intemucleotide modifications such as uncharged linkages (e.g., methyl phosphonates, phosphotriesters, phosphoramidates, carbamates, etc.), charged linkages (e.g., phosphorothioates, phosphorodithioates, etc.), pendent moieties (e.g., polypeptides), intercalators (e.g., acridine, psoralen, etc.), chelators, alkylators, and modified linkages (e.g., alpha anomeric nucleic acids, etc.) Also included are synthetic molecules that mimic polynucleotides in their ability to bind to a designated sequence via hydrogen bonding and other chemical interactions. Such molecules are known in the art and include, for example, those in which peptide linkages substitute for phosphate linkages in the backbone of the molecule. Other modifications can include, for example, analogs in which the ribose ring contains a bridging moiety or other structure such as the modifications found in “locked” nucleic acids.
The term “mutated” when applied to nucleic acid sequences means that nucleotides in a nucleic acid sequence may be inserted, deleted or changed compared to a reference nucleic acid sequence. A single alteration may be made at a locus (a point mutation) or multiple nucleotides may be inserted, deleted or changed at a single locus. In addition, one or more alterations may be made at any number of loci within a nucleic acid sequence. A nucleic acid sequence may be mutated by any method known in the art including but not limited to mutagenesis techniques such as “error-prone PCR” (a process for performing PCR under conditions where the copying fidelity of the DNA polymerase is low, such that a high rate of point mutations is obtained along the entire length of the PCR product; see, e.g., Leung et al., Technique, 1:11-15 (1989) and Caldwell and Joyce, PCR Methods Applic. 2:28-33 (1992)); and “oligonucleotide-directed mutagenesis” (a process which enables the generation of site-specific mutations in any cloned DNA segment of interest; see, e.g., Reidhaar-Olson and Sauer, Science 241:53-57 (1988)).
The term “attenuate” as used herein generally refers to a functional deletion, including a mutation, partial or complete deletion, insertion, or other variation made to a gene sequence or a sequence controlling the transcription of a gene sequence, which reduces or inhibits production of the gene product, or renders the gene product non-functional. In some instances a functional deletion is described as a knockout mutation. Attenuation also includes amino acid sequence changes by altering the nucleic acid sequence, placing the gene under the control of a less active promoter, down-regulation, expressing interfering RNA, ribozymes or antisense sequences that target the gene of interest, or through any other technique known in the art. In one example, the sensitivity of a particular enzyme to feedback inhibition or inhibition caused by a composition that is not a product or a reactant (non-pathway specific feedback) is lessened such that the enzyme activity is not impacted by the presence of a compound. In other instances, an enzyme that has been altered to be less active can be referred to as attenuated.
Deletion: The removal of one or more nucleotides from a nucleic acid molecule or one or more amino acids from a protein, the regions on either side being joined together.
Knock-out: A gene whose level of expression or activity has been reduced to zero. In some examples, a gene is knocked-out via deletion of some or all of its coding sequence. In other examples, a gene is knocked-out via introduction of one or more nucleotides into its open reading frame, which results in translation of a non-sense or otherwise non-functional protein product.
The term “vector” as used herein is intended to refer to a nucleic acid molecule capable of transporting another nucleic acid to which it has been linked. One type of vector is a “plasmid,” which generally refers to a circular double stranded DNA loop into which additional DNA segments may be ligated, but also includes linear double-stranded molecules such as those resulting from amplification by the polymerase chain reaction (PCR) or from treatment of a circular plasmid with a restriction enzyme. Other vectors include cosmids, bacterial artificial chromosomes (BAC) and yeast artificial chromosomes (YAC). Another type of vector is a viral vector, wherein additional DNA segments may be ligated into the viral genome (discussed in more detail below). Certain vectors are capable of autonomous replication in a host cell into which they are introduced (e.g., vectors having an origin of replication which functions in the host cell). Other vectors can be integrated into the genome of a host cell upon introduction into the host cell, and are thereby replicated along with the host genome. Moreover, certain preferred vectors are capable of directing the expression of genes to which they are operatively linked. Such vectors are referred to herein as “recombinant expression vectors” (or simply “expression vectors”).
“Operatively linked” or “operably linked” expression control sequences refers to a linkage in which the expression control sequence is contiguous with the gene of interest to control the gene of interest, as well as expression control sequences that act in trans or at a distance to control the gene of interest.
The term “expression control sequence” as used herein refers to polynucleotide sequences which are necessary to affect the expression of coding sequences to which they are operatively linked. Expression control sequences are sequences which control the transcription, post-transcriptional events and translation of nucleic acid sequences. Expression control sequences include appropriate transcription initiation, termination, promoter and enhancer sequences; efficient RNA processing signals such as splicing and polyadenylation signals; sequences that stabilize cytoplasmic mRNA; sequences that enhance translation efficiency (e.g., ribosome binding sites); sequences that enhance protein stability; and when desired, sequences that enhance protein secretion. The nature of such control sequences differs depending upon the host organism; in prokaryotes, such control sequences generally include promoter, ribosomal binding site, and transcription termination sequence. The term “control sequences” is intended to include, at a minimum, all components whose presence is essential for expression, and can also include additional components whose presence is advantageous, for example, leader sequences and fusion partner sequences.
The term “recombinant host cell” (or simply “host cell”), as used herein, is intended to refer to a cell into which a recombinant vector has been introduced. It should be understood that such terms are intended to refer not only to the particular subject cell but to the progeny of such a cell. Because certain modifications may occur in succeeding generations due to either mutation or environmental influences, such progeny may not, in fact, be identical to the parent cell, but are still included within the scope of the term “host cell” as used herein. A recombinant host cell may be an isolated cell or cell line grown in culture or may be a cell which resides in a living tissue or organism.
The term “peptide” as used herein refers to a short polypeptide, e.g., one that is typically less than about 50 amino acids long and more typically less than about 30 amino acids long. The term as used herein encompasses analogs and mimetics that mimic structural and thus biological function.
The term “polypeptide” encompasses both naturally-occurring and non-naturally-occurring proteins, and fragments, mutants, derivatives and analogs thereof. A polypeptide may be monomeric or polymeric. Further, a polypeptide may comprise a number of different domains each of which has one or more distinct activities.
The term “isolated protein” or “isolated polypeptide” is a protein or polypeptide that by virtue of its origin or source of derivation (1) is not associated with naturally associated components that accompany it in its native state, (2) exists in a purity not found in nature, where purity can be adjudged with respect to the presence of other cellular material (e.g., is free of other proteins from the same species) (3) is expressed by a cell from a different species, or (4) does not occur in nature (e.g., it is a fragment of a polypeptide found in nature or it includes amino acid analogs or derivatives not found in nature or linkages other than standard peptide bonds). Thus, a polypeptide that is chemically synthesized or synthesized in a cellular system different from the cell from which it naturally originates will be “isolated” from its naturally associated components. A polypeptide or protein may also be rendered substantially free of naturally associated components by isolation, using protein purification techniques well known in the art. As thus defined, “isolated” does not necessarily require that the protein, polypeptide, peptide or oligopeptide so described has been physically removed from its native environment.
The term “polypeptide fragment” as used herein refers to a polypeptide that has a deletion, e.g., an amino-terminal and/or carboxy-terminal deletion compared to a full-length polypeptide. In a preferred embodiment, the polypeptide fragment is a contiguous sequence in which the amino acid sequence of the fragment is identical to the corresponding positions in the naturally-occurring sequence. Fragments typically are at least 5, 6, 7, 8, 9 or 10 amino acids long, preferably at least 12, 14, 16 or 18 amino acids long, more preferably at least 20 amino acids long, more preferably at least 25, 30, 35, 40 or 45, amino acids, even more preferably at least 50 or 60 amino acids long, and even more preferably at least 70 amino acids long.
A “modified derivative” refers to polypeptides or fragments thereof that are substantially homologous in primary structural sequence but which include, e.g., in vivo or in vitro chemical and biochemical modifications or which incorporate amino acids that are not found in the native polypeptide. Such modifications include, for example, acetylation, carboxylation, phosphorylation, glycosylation, ubiquitination, labeling, e.g., with radionuclides, and various enzymatic modifications, as will be readily appreciated by those skilled in the art. A variety of methods for labeling polypeptides and of substituents or labels useful for such purposes are well known in the art, and include radioactive isotopes such as 125 I, 32 P, 35 S, and 3 H, ligands which bind to labeled antiligands (e.g., antibodies), fluorophores, chemiluminescent agents, enzymes, and antiligands which can serve as specific binding pair members for a labeled ligand. The choice of label depends on the sensitivity required, ease of conjugation with the primer, stability requirements, and available instrumentation. Methods for labeling polypeptides are well known in the art. See, e.g., Ausubel et al., Current Protocols in Molecular Biology , Greene Publishing Associates (1992, and Supplements to 2002) (hereby incorporated by reference).
The term “fusion protein” refers to a polypeptide comprising a polypeptide or fragment coupled to heterologous amino acid sequences. Fusion proteins are useful because they can be constructed to contain two or more desired functional elements from two or more different proteins. A fusion protein comprises at least 10 contiguous amino acids from a polypeptide of interest, more preferably at least 20 or 30 amino acids, even more preferably at least 40, 50 or 60 amino acids, yet more preferably at least 75, 100 or 125 amino acids. Fusions that include the entirety of the proteins of the present invention have particular utility. The heterologous polypeptide included within the fusion protein of the present invention is at least 6 amino acids in length, often at least 8 amino acids in length, and usefully at least 15, 20, and 25 amino acids in length. Fusions that include larger polypeptides, such as an IgG Fc region, and even entire proteins, such as the green fluorescent protein (“GFP”) chromophore-containing proteins, have particular utility. Fusion proteins can be produced recombinantly by constructing a nucleic acid sequence which encodes the polypeptide or a fragment thereof in frame with a nucleic acid sequence encoding a different protein or peptide and then expressing the fusion protein. Alternatively, a fusion protein can be produced chemically by crosslinking the polypeptide or a fragment thereof to another protein.
The term “non-peptide analog” refers to a compound with properties that are analogous to those of a reference polypeptide. A non-peptide compound may also be termed a “peptide mimetic” or a “peptidomimetic.” See, e.g., Jones, Amino Acid and Peptide Synthesis , Oxford University Press (1992); Jung, Combinatorial Peptide and Nonpeptide Libraries: A Handbook , John Wiley (1997); Bodanszky et al., Peptide Chemistry—A Practical Textbook , Springer Verlag (1993); Synthetic Peptides: A Users Guide , (Grant, ed., W. H. Freeman and Co., 1992); Evans et al., J. Med. Chem. 30:1229 (1987); Fauchere, J. Adv. Drug Res. 15:29 (1986); Veber and Freidinger, Trends Neurosci., 8:392-396 (1985); and references sited in each of the above, which are incorporated herein by reference. Such compounds are often developed with the aid of computerized molecular modeling. Peptide mimetics that are structurally similar to useful peptides of the present invention may be used to produce an equivalent effect and are therefore envisioned to be part of the present invention.
A “polypeptide mutant” or “mutein” refers to a polypeptide whose sequence contains an insertion, duplication, deletion, rearrangement or substitution of one or more amino acids compared to the amino acid sequence of a native or wild-type protein. A mutein may have one or more amino acid point substitutions, in which a single amino acid at a position has been changed to another amino acid, one or more insertions and/or deletions, in which one or more amino acids are inserted or deleted, respectively, in the sequence of the naturally-occurring protein, and/or truncations of the amino acid sequence at either or both the amino or carboxy termini. A mutein may have the same but preferably has a different biological activity compared to the naturally-occurring protein.
A mutein has at least 85% overall sequence homology to its wild-type counterpart. Even more preferred are muteins having at least 90% overall sequence homology to the wild-type protein.
In an even more preferred embodiment, a mutein exhibits at least 95% sequence identity, even more preferably 98%, even more preferably 99% and even more preferably 99.9% overall sequence identity.
Sequence homology may be measured by any common sequence analysis algorithm, such as Gap or Bestfit.
Amino acid substitutions can include those which: (1) reduce susceptibility to proteolysis, (2) reduce susceptibility to oxidation, (3) alter binding affinity for forming protein complexes, (4) alter binding affinity or enzymatic activity, and (5) confer or modify other physicochemical or functional properties of such analogs.
As used herein, the twenty conventional amino acids and their abbreviations follow conventional usage. See Immunology—A Synthesis (Golub and Gren eds., Sinauer Associates, Sunderland, Mass., 2 nd ed. 1991), which is incorporated herein by reference. Stereoisomers (e.g., D-amino acids) of the twenty conventional amino acids, unnatural amino acids such as α-,α-disubstituted amino acids, N-alkyl amino acids, and other unconventional amino acids may also be suitable components for polypeptides of the present invention. Examples of unconventional amino acids include: 4-hydroxyproline, γ-carboxyglutamate, ε-N,N,N-trimethyllysine, ε-N-acetyllysine, 0-phosphoserine, N-acetylserine, N-formylmethionine, 3-methylhistidine, 5-hydroxylysine, N-methylarginine, and other similar amino acids and imino acids (e.g., 4-hydroxyproline). In the polypeptide notation used herein, the left-hand end corresponds to the amino terminal end and the right-hand end corresponds to the carboxy-terminal end, in accordance with standard usage and convention.
A protein has “homology” or is “homologous” to a second protein if the nucleic acid sequence that encodes the protein has a similar sequence to the nucleic acid sequence that encodes the second protein. Alternatively, a protein has homology to a second protein if the two proteins have “similar” amino acid sequences. (Thus, the term “homologous proteins” is defined to mean that the two proteins have similar amino acid sequences.) As used herein, homology between two regions of amino acid sequence (especially with respect to predicted structural similarities) is interpreted as implying similarity in function.
When “homologous” is used in reference to proteins or peptides, it is recognized that residue positions that are not identical often differ by conservative amino acid substitutions. A “conservative amino acid substitution” is one in which an amino acid residue is substituted by another amino acid residue having a side chain (R group) with similar chemical properties (e.g., charge or hydrophobicity). In general, a conservative amino acid substitution will not substantially change the functional properties of a protein. In cases where two or more amino acid sequences differ from each other by conservative substitutions, the percent sequence identity or degree of homology may be adjusted upwards to correct for the conservative nature of the substitution. Means for making this adjustment are well known to those of skill in the art. See, e.g., Pearson, 1994 , Methods Mol. Biol. 24:307-31 and 25:365-89 (herein incorporated by reference).
The following six groups each contain amino acids that are conservative substitutions for one another: 1) Serine (S), Threonine (T); 2) Aspartic Acid (D), Glutamic Acid (E); 3) Asparagine (N), Glutamine (Q); 4) Arginine (R), Lysine (K); 5) Isoleucine (I), Leucine (L), Methionine (M), Alanine (A), Valine (V), and 6) Phenylalanine (F), Tyrosine (Y), Tryptophan (W).
Sequence homology for polypeptides, which is also referred to as percent sequence identity, is typically measured using sequence analysis software. See, e.g., the Sequence Analysis Software Package of the Genetics Computer Group (GCG), University of Wisconsin Biotechnology Center, 910 University Avenue, Madison, Wis. 53705. Protein analysis software matches similar sequences using a measure of homology assigned to various substitutions, deletions and other modifications, including conservative amino acid substitutions. For instance, GCG contains programs such as “Gap” and “Bestfit” which can be used with default parameters to determine sequence homology or sequence identity between closely related polypeptides, such as homologous polypeptides from different species of organisms or between a wild-type protein and a mutein thereof. See, e.g., GCG Version 6.1.
A preferred algorithm when comparing a particular polypeptide sequence to a database containing a large number of sequences from different organisms is the computer program BLAST (Altschul et al., J. Mol. Biol. 215:403-410 (1990); Gish and States, Nature Genet. 3:266-272 (1993); Madden et al., Meth. Enzymol. 266:131-141 (1996); Altschul et al., Nucleic Acids Res. 25:3389-3402 (1997); Zhang and Madden, Genome Res. 7:649-656 (1997)), especially blastp or tblastn (Altschul et al., Nucleic Acids Res. 25:3389-3402 (1997)).
Preferred parameters for BLASTp are: Expectation value: 10 (default); Filter: seg (default); Cost to open a gap: 11 (default); Cost to extend a gap: 1 (default); Max. alignments: 100 (default); Word size: 11 (default); No. of descriptions: 100 (default); Penalty Matrix: BLOWSUM62.
The length of polypeptide sequences compared for homology will generally be at least about 16 amino acid residues, usually at least about 20 residues, more usually at least about 24 residues, typically at least about 28 residues, and preferably more than about 35 residues. When searching a database containing sequences from a large number of different organisms, it is preferable to compare amino acid sequences. Database searching using amino acid sequences can be measured by algorithms other than blastp known in the art. For instance, polypeptide sequences can be compared using FASTA, a program in GCG Version 6.1. FASTA provides alignments and percent sequence identity of the regions of the best overlap between the query and search sequences. Pearson, Methods Enzymol. 183:63-98 (1990) (incorporated by reference herein). For example, percent sequence identity between amino acid sequences can be determined using FASTA with its default parameters (a word size of 2 and the PAM250 scoring matrix), as provided in GCG Version 6.1, herein incorporated by reference.
“Specific binding” refers to the ability of two molecules to bind to each other in preference to binding to other molecules in the environment. Typically, “specific binding” discriminates over adventitious binding in a reaction by at least two-fold, more typically by at least 10-fold, often at least 100-fold. Typically, the affinity or avidity of a specific binding reaction, as quantified by a dissociation constant, is about 10 −7 M or stronger (e.g., about 10 −8 M, 10 −9 M or even stronger).
The term “region” as used herein refers to a physically contiguous portion of the primary structure of a biomolecule. In the case of proteins, a region is defined by a contiguous portion of the amino acid sequence of that protein.
The term “domain” as used herein refers to a structure of a biomolecule that contributes to a known or suspected function of the biomolecule. Domains may be co-extensive with regions or portions thereof; domains may also include distinct, non-contiguous regions of a biomolecule. Examples of protein domains include, but are not limited to, an Ig domain, an extracellular domain, a transmembrane domain, and a cytoplasmic domain.
As used herein, the term “molecule” means any compound, including, but not limited to, a small molecule, peptide, protein, sugar, nucleotide, nucleic acid, lipid, etc., and such a compound can be natural or synthetic.
“Carbon-based Products of Interest” include alcohols such as ethanol, propanol, isopropanol, butanol, fatty alcohols, fatty acid esters, wax esters; hydrocarbons and alkanes such as propane, octane, diesel, Jet Propellant 8 (JP8); polymers such as terephthalate, 1,3-propanediol, 1,4-butanediol, polyols, Polyhydroxyalkanoates (PHA), poly-beta-hydroxybutyrate (PHB), acrylate, adipic acid, ε-caprolactone, isoprene, caprolactam, rubber; commodity chemicals such as lactate, Docosahexaenoic acid (DHA), 3-hydroxypropionate, γ-valerolactone, lysine, serine, aspartate, aspartic acid, sorbitol, ascorbate, ascorbic acid, isopentenol, lanosterol, omega-3 DHA, lycopene, itaconate, 1,3-butadiene, ethylene, propylene, succinate, citrate, citric acid, glutamate, malate, 3-hydroxypropionic acid (HPA), lactic acid, THF, gamma butyrolactone, pyrrolidones, hydroxybutyrate, glutamic acid, levulinic acid, acrylic acid, malonic acid; specialty chemicals such as carotenoids, isoprenoids, itaconic acid; pharmaceuticals and pharmaceutical intermediates such as 7-aminodeacetoxycephalosporanic acid (7-ADCA)/cephalosporin, erythromycin, polyketides, statins, paclitaxel, docetaxel, terpenes, peptides, steroids, omega fatty acids and other such suitable products of interest. Such products are useful in the context of biofuels, industrial and specialty chemicals, as intermediates used to make additional products, such as nutritional supplements, neutraceuticals, polymers, paraffin replacements, personal care products and pharmaceuticals.
Biofuel: A biofuel refers to any fuel that derives from a biological source. Biofuel can refer to one or more hydrocarbons, one or more alcohols (such as ethanol), one or more fatty esters, or a mixture thereof.
Hydrocarbon: The term generally refers to a chemical compound that consists of the elements carbon (C), hydrogen (H) and optionally oxygen (O). There are essentially three types of hydrocarbons, e.g., aromatic hydrocarbons, saturated hydrocarbons and unsaturated hydrocarbons such as alkenes, alkynes, and dienes. The term also includes fuels, biofuels, plastics, waxes, solvents and oils. Hydrocarbons encompass biofuels, as well as plastics, waxes, solvents and oils.
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 present invention pertains. Exemplary methods and materials are described below, although methods and materials similar or equivalent to those described herein can also be used in the practice of the present invention and will be apparent to those of skill in the art. All publications and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. The materials, methods, and examples are illustrative only and not intended to be limiting.
Throughout this specification and claims, the word “comprise” or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.
Nucleic Acid Sequences
The present invention provides isolated nucleic acid molecules for genes encoding enzymes, and variants thereof. Exemplary full-length nucleic acid sequences for genes encoding enzymes and the corresponding amino acid sequences are presented in Tables 1 and 2.
In one embodiment, the present invention provides an isolated nucleic acid molecule having a nucleic acid sequence comprising or consisting of a gene coding for an alkane deformylative monooxygenase, a thioesterase, a carboxylic acid reductase, a phosphopanthetheinyl transferase, a long-chain fatty acid CoA-ligase, and/or a long-chain acyl-CoA reductase and homologs, variants and derivatives thereof expressed in a host cell of interest. The present invention also provides a nucleic acid molecule comprising or consisting of a sequence which is a codon-optimized version of the alkane deformylative monooxygenase, a thioesterase, a carboxylic acid reductase, a phosphopanthetheinyl transferase, a long-chain fatty acid CoA-ligase, and/or a long-chain acyl-CoA reductase genes described herein. In a further embodiment, the present invention provides a nucleic acid molecule and homologs, variants and derivatives of the molecule comprising or consisting of a sequence which is a variant of the alkane deformylative monooxygenase, a thioesterase, a carboxylic acid reductase, a phosphopanthetheinyl transferase, a long-chain fatty acid CoA-ligase, and/or a long-chain acyl-CoA reductase gene having at least 80% identity to the wild-type gene. The nucleic acid sequence can be preferably greater than 80%, 85%, 90%, 95%, 98%, 99%, 99.9% or even higher identity to the wild-type gene.
In another embodiment, the nucleic acid molecule of the present invention encodes a polypeptide having an amino acid sequence disclosed in Tables 1 and 2. Preferably, the nucleic acid molecule of the present invention encodes a polypeptide sequence of at least 50%, 60, 70%, 80%, 85%, 90% or 95% identity to the amino acid sequences shown in Tables 1 and 2 and the identity can even more preferably be 96%, 97%, 98%, 99%, 99.9% or even higher.
The present invention also provides nucleic acid molecules that hybridize under stringent conditions to the above-described nucleic acid molecules. As defined above, and as is well known in the art, stringent hybridizations are performed at about 25° C. below the thermal melting point (T m ) for the specific DNA hybrid under a particular set of conditions, where the T m is the temperature at which 50% of the target sequence hybridizes to a perfectly matched probe. Stringent washing is performed at temperatures about 5° C. lower than the T m for the specific DNA hybrid under a particular set of conditions.
Nucleic acid molecules comprising a fragment of any one of the above-described nucleic acid sequences are also provided. These fragments preferably contain at least 20 contiguous nucleotides. More preferably the fragments of the nucleic acid sequences contain at least 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100 or even more contiguous nucleotides.
The nucleic acid sequence fragments of the present invention display utility in a variety of systems and methods. For example, the fragments may be used as probes in various hybridization techniques. Depending on the method, the target nucleic acid sequences may be either DNA or RNA. The target nucleic acid sequences may be fractionated (e.g., by gel electrophoresis) prior to the hybridization, or the hybridization may be performed on samples in situ. One of skill in the art will appreciate that nucleic acid probes of known sequence find utility in determining chromosomal structure (e.g., by Southern blotting) and in measuring gene expression (e.g., by Northern blotting). In such experiments, the sequence fragments are preferably detectably labeled, so that their specific hydridization to target sequences can be detected and optionally quantified. One of skill in the art will appreciate that the nucleic acid fragments of the present invention may be used in a wide variety of blotting techniques not specifically described herein.
It should also be appreciated that the nucleic acid sequence fragments disclosed herein also find utility as probes when immobilized on microarrays. Methods for creating microarrays by deposition and fixation of nucleic acids onto support substrates are well known in the art. Reviewed in DNA Microarrays: A Practical Approach (Practical Approach Series), Schena (ed.), Oxford University Press (1999) (ISBN: 0199637768); Nature Genet. 21(1)(suppl):1-60 (1999); Microarray Biochip: Tools and Technology , Schena (ed.), Eaton Publishing Company/BioTechniques Books Division (2000) (ISBN: 1881299376), the disclosures of which are incorporated herein by reference in their entireties. Analysis of, for example, gene expression using microarrays comprising nucleic acid sequence fragments, such as the nucleic acid sequence fragments disclosed herein, is a well-established utility for sequence fragments in the field of cell and molecular biology. Other uses for sequence fragments immobilized on microarrays are described in Gerhold et al., Trends Biochem. Sci. 24:168-173 (1999) and Zweiger, Trends Biotechnol. 17:429-436 (1999); DNA Microarrays: A Practical Approach (Practical Approach Series), Schena (ed.), Oxford University Press (1999) (ISBN: 0199637768); Nature Genet. 21(1)(suppl):1-60 (1999); Microarray Biochip: Tools and Technology , Schena (ed.), Eaton Publishing Company/BioTechniques Books Division (2000) (ISBN: 1881299376), the disclosure of each of which is incorporated herein by reference in its entirety.
As is well known in the art, enzyme activities can be measured in various ways. For example, the pyrophosphorolysis of OMP may be followed spectroscopically (Grubmeyer et al., (1993) J. Biol. Chem. 268:20299-20304). Alternatively, the activity of the enzyme can be followed using chromatographic techniques, such as by high performance liquid chromatography (Chung and Sloan, (1986) J. Chromatogr. 371:71-81). As another alternative the activity can be indirectly measured by determining the levels of product made from the enzyme activity. These levels can be measured with techniques including aqueous chloroform/methanol extraction as known and described in the art (Cf M. Kates (1986) Techniques of Lipidology; Isolation, analysis and identification of Lipids . Elsevier Science Publishers, New York (ISBN: 0444807322)). More modern techniques include using gas chromatography linked to mass spectrometry (Niessen, W. M. A. (2001). Current practice of gas chromatography—mass spectrometry . New York, N.Y.: Marcel Dekker. (ISBN: 0824704738)). Additional modern techniques for identification of recombinant protein activity and products including liquid chromatography-mass spectrometry (LCMS), high performance liquid chromatography (HPLC), capillary electrophoresis, Matrix-Assisted Laser Desorption Ionization time of flight-mass spectrometry (MALDI-TOF MS), nuclear magnetic resonance (NMR), near-infrared (NIR) spectroscopy, viscometry (Knothe, G (1997) Am. Chem. Soc. Symp. Series, 666: 172-208), titration for determining free fatty acids (Komers (1997) Fett/Lipid, 99(2): 52-54), enzymatic methods (Bailer (1991) Fresenius J. Anal. Chem. 340(3): 186), physical property-based methods, wet chemical methods, etc. can be used to analyze the levels and the identity of the product produced by the organisms of the present invention. Other methods and techniques may also be suitable for the measurement of enzyme activity, as would be known by one of skill in the art.
Vectors
Also provided are vectors, including expression vectors, which comprise the above nucleic acid molecules of the present invention, as described further herein. In a first embodiment, the vectors include the isolated nucleic acid molecules described above. In an alternative embodiment, the vectors of the present invention include the above-described nucleic acid molecules operably linked to one or more expression control sequences. The vectors of the instant invention may thus be used to express a polypeptide contributing to alkane producing activity by a host cell.
Vectors useful for expression of nucleic acids in prokaryotes are well known in the art.
Isolated Polypeptides
According to another aspect of the present invention, isolated polypeptides (including muteins, allelic variants, fragments, derivatives, and analogs) encoded by the nucleic acid molecules of the present invention are provided. In one embodiment, the isolated polypeptide comprises the polypeptide sequence corresponding to a polypeptide sequence shown in Table 1 or 2. In an alternative embodiment of the present invention, the isolated polypeptide comprises a polypeptide sequence at least 85% identical to a polypeptide sequence shown in Table 1 or 2. Preferably the isolated polypeptide of the present invention has at least 50%, 60, 70%, 80%, 85%, 90%, 95%, 98%, 98.1%, 98.2%, 98.3%, 98.4%, 98.5%, 98.6%, 98.7%, 98.8%, 98.9%, 99%, 99.1%, 99.2%, 99.3%, 99.4%, 99.5%, 99.6%, 99.7%, 99.8%, 99.9% or even higher identity to a polypeptide sequence shown in Table 1 or 2.
According to other embodiments of the present invention, isolated polypeptides comprising a fragment of the above-described polypeptide sequences are provided. These fragments preferably include at least 20 contiguous amino acids, more preferably at least 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, 100 or even more contiguous amino acids.
The polypeptides of the present invention also include fusions between the above-described polypeptide sequences and heterologous polypeptides. The heterologous sequences can, for example, include sequences designed to facilitate purification, e.g. histidine tags, and/or visualization of recombinantly-expressed proteins. Other non-limiting examples of protein fusions include those that permit display of the encoded protein on the surface of a phage or a cell, fusions to intrinsically fluorescent proteins, such as green fluorescent protein (GFP), and fusions to the IgG Fc region.
Host Cell Transformants
In another aspect of the present invention, host cells transformed with the nucleic acid molecules or vectors of the present invention, and descendants thereof, are provided. In some embodiments of the present invention, these cells carry the nucleic acid sequences of the present invention on vectors, which may but need not be freely replicating vectors. In other embodiments of the present invention, the nucleic acids have been integrated into the genome of the host cells.
In an alternative embodiment, the host cells of the present invention can be mutated by recombination with a disruption, deletion or mutation of the isolated nucleic acid of the present invention so that the activity of one or more enzyme(s) in the host cell is reduced or eliminated compared to a host cell lacking the mutation.
Selected or Engineered Microorganisms for the Production of Carbon-Based Products of Interest
Microorganism: Includes prokaryotic and eukaryotic microbial species from the Domains Archaea, Bacteria and Eucarya, the latter including yeast and filamentous fungi, protozoa, algae, or higher Protista. The terms “microbial cells” and “microbes” are used interchangeably with the term microorganism.
A variety of host organisms can be transformed to produce a product of interest. Photoautotrophic organisms include eukaryotic plants and algae, as well as prokaryotic cyanobacteria, green-sulfur bacteria, green non-sulfur bacteria, purple sulfur bacteria, and purple non-sulfur bacteria.
Extremophiles are also contemplated as suitable organisms. Such organisms withstand various environmental parameters such as temperature, radiation, pressure, gravity, vacuum, desiccation, salinity, pH, oxygen tension, and chemicals. They include hyperthermophiles, which grow at or above 80° C. such as Pyrolobus fumarii ; thermophiles, which grow between 60-80° C. such as Synechococcus lividis ; mesophiles, which grow between 15-60° C. and psychrophiles, which grow at or below 15° C. such as Psychrobacter and some insects. Radiation tolerant organisms include Deinococcus radiodurans . Pressure-tolerant organisms include piezophiles, which tolerate pressure of 130 MPa. Weight-tolerant organisms include barophiles. Hypergravity (e.g., >1 g) hypogravity (e.g., <1 g) tolerant organisms are also contemplated. Vacuum tolerant organisms include tardigrades, insects, microbes and seeds. Dessicant tolerant and anhydrobiotic organisms include xerophiles such as Artemia salina ; nematodes, microbes, fungi and lichens. Salt-tolerant organisms include halophiles (e.g., 2-5 M NaCl) Halobacteriacea and Dunaliella salina . pH-tolerant organisms include alkaliphiles such as Natronobacterium, Bacillus firmus OF4 , Spirulina spp. (e.g., pH>9) and acidophiles such as Cyanidium caldarium, Ferroplasma sp. (e.g., low pH). Anaerobes, which cannot tolerate O 2 such as Methanococcus jannaschii ; microaerophils, which tolerate some O 2 such as Clostridium and aerobes, which require O 2 are also contemplated. Gas-tolerant organisms, which tolerate pure CO 2 include Cyanidium caldarium and metal tolerant organisms include metalotolerants such as Ferroplasma acidarmanus (e.g., Cu, As, Cd, Zn), Ralstonia sp. CH34 (e.g., Zn, Co, Cd, Hg, Pb). Gross, Michael. Life on the Edge: Amazing Creatures Thriving in Extreme Environments . New York: Plenum (1998) and Seckbach, J. “Search for Life in the Universe with Terrestrial Microbes Which Thrive Under Extreme Conditions.” In Cristiano Batalli Cosmovici, Stuart Bowyer, and Dan Wertheimer, eds., Astronomical and Biochemical Origins and the Search for Life in the Universe , p. 511. Milan: Editrice Compositori (1997).
Plants include but are not limited to the following genera: Arabidopsis, Beta, Glycine, Jatropha, Miscanthus, Panicum, Phalaris, Populus, Saccharum, Salix, Simmondsia and Zea.
Algae and cyanobacteria include but are not limited to the following genera: Acanthoceras, Acanthococcus, Acaryochloris, Achnanthes, Achnanthidium, Actinastrum, Actinochloris, Actinocyclus, Actinotaenium, Amphichrysis, Amphidinium, Amphikrikos, Amphipleura, Amphiprora, Amphithrix, Amphora, Anabaena, Anabaenopsis, Aneumastus, Ankistrodesmus, Ankyra, Anomoeoneis, Apatococcus, Aphanizomenon, Aphanocapsa, Aphanochaete, Aphanothece, Apiocystis, Apistonema, Arthrodesmus, Artherospira, Ascochloris, Asterionella, Asterococcus, Audouinella, Aulacoseira, Bacillaria, Balbiania, Bambusina, Bangia, Basichlamys, Batrachospermum, Binuclearia, Bitrichia, Blidingia, Botrdiopsis, Botrydium, Botryococcus, Botryosphaerella, Brachiomonas, Brachysira, Brachytrichia, Brebissonia, Bulbochaete, Bumilleria, Bumilleriopsis, Caloneis, Calothrix, Campylodiscus, Capsosiphon, Carteria, Catena, Cavinula, Centritractus, Centronella, Ceratium, Chaetoceros, Chaetochloris, Chaetomorpha, Chaetonella, Chaetonema, Chaetopeltis, Chaetophora, Chaetosphaeridium, Chamaesiphon, Chara, Characiochloris, Characiopsis, Characium, Charales, Chilomonas, Chlainomonas, Chlamydoblepharis, Chlamydocapsa, Chlamydomonas, Chlamydomonopsis, Chlamydomyxa, Chlamydonephris, Chlorangiella, Chlorangiopsis, Chlorella, Chlorobotrys, Chlorobrachis, Chlorochytrium, Chlorococcum, Chlorogloea, Chlorogloeopsis, Chlorogonium, Chlorolobion, Chloromonas, Chlorophysema, Chlorophyta, Chlorosaccus, Chlorosarcina, Choricystis, Chromophyton, Chromulina, Chroococcidiopsis, Chroococcus, Chroodactylon, Chroomonas, Chroothece, Chrysamoeba, Chrysapsis, Chrysidiastrum, Chrysocapsa, Chrysocapsella, Chrysochaete, Chrysochromulina, Chrysococcus, Chrysocrinus, Chrysolepidomonas, Chrysolykos, Chrysonebula, Chrysophyta, Chrysopyxis, Chrysosaccus, Chrysophaerella, Chrysostephanosphaera, Clodophora, Clastidium, Closteriopsis, Closterium, Coccomyxa, Cocconeis, Coelastrella, Coelastrum, Coelosphaerium, Coenochloris, Coenococcus, Coenocystis, Colacium, Coleochaete, Collodictyon, Compsogonopsis, Compsopogon, Conjugatophyta, Conochaete, Coronastrum, Cosmarium, Cosmioneis, Cosmocladium, Crateriportula, Craticula, Crinalium, Crucigenia, Crucigeniella, Cryptoaulax, Cryptomonas, Cryptophyta, Ctenophora, Cyanodictyon, Cyanonephron, Cyanophora, Cyanophyta, Cyanothece, Cyanothomonas, Cyclonexis, Cyclostephanos, Cyclotella, Cylindrocapsa, Cylindrocystis, Cylindrospermum, Cylindrotheca, Cymatopleura, Cymbella, Cymbellonitzschia, Cystodinium Dactylococcopsis, Debarya, Denticula, Dermatochrysis, Dermocarpa, Dermocarpella, Desmatractum, Desmidium, Desmococcus, Desmonema, Desmosiphon, Diacanthos, Diacronema, Diadesmis, Diatoma, Diatomella, Dicellula, Dichothrix, Dichotomococcus, Dicranochaete, Dictyochloris, Dictyococcus, Dictyosphaerium, Didymocystis, Didymogenes, Didymosphenia, Dilabifilum, Dimorphococcus, Dinobryon, Dinococcus, Diplochloris, Diploneis, Diplostauron, Distrionella, Docidium, Draparnaldia, Dunaliella, Dysmorphococcus, Ecballocystis, Elakatothrix, Ellerbeckia, Encyonema, Enteromorpha, Entocladia, Entomoneis, Entophysalis, Epichrysis, Epipyxis, Epithemia, Eremosphaera, Euastropsis, Euastrum, Eucapsis, Eucocconeis, Eudorina, Euglena, Euglenophyta, Eunotia, Eustigmatophyta, Eutreptia, Fallacia, Fischerella, Fragilaria, Fragilariforma, Franceia, Frustulia, Curcilla, Geminella, Genicularia, Glaucocystis, Glaucophyta, Glenodiniopsis, Glenodinium, Gloeocapsa, Gloeochaete, Gloeochrysis, Gloeococcus, Gloeocystis, Gloeodendron, Gloeomonas, Gloeoplax, Gloeothece, Gloeotila, Gloeotrichia, Gloiodictyon, Golenkinia, Golenkiniopsis, Gomontia, Gomphocymbella, Gomphonema, Gomphosphaeria, Gonatozygon, Gongrosia, Gongrosira, Goniochloris, Gonium, Gonyostomum, Granulochloris, Granulocystopsis, Groenbladia, Gymnodinium, Gymnozyga, Gyrosigma, Haematococcus, Hafniomonas, Hallassia, Hammatoidea, Hannaea, Hantzschia, Hapalosiphon, Haplotaenium, Haptophyta, Haslea, Hemidinium, Hemitoma, Heribaudiella, Heteromastix, Heterothrix, Hibberdia, Hildenbrandia, Hillea, Holopedium, Homoeothrix, Hormanthonema, Hormotila, Hyalobrachion, Hyalocardium, Hyalodiscus, Hyalogonium, Hyalotheca, Hydrianum, Hydrococcus, Hydrocoleum, Hydrocoryne, Hydrodictyon, Hydrosera, Hydrurus, Hyella, Hymenomonas, Isthmochloron, Johannesbaptistia, Juranyiella, Karayevia, Kathablepharis, Katodinium, Kephyrion, Keratococcus, Kirchneriella, Klebsormidium, Kolbesia, Koliella, Komarekia, Korshikoviella, Kraskella, Lagerheimia, Lagynion, Lamprothamnium, Lemanea, Lepocinclis, Leptosira, Lobococcus, Lobocystis, Lobomonas, Luticola, Lyngbya, Malleochloris, Mallomonas, Mantoniella, Marssoniella, Martyana, Mastigocoleus, Gastogloia, Melosira, Merismopedia, Mesostigma, Mesotaenium, Micractinium, Micrasterias, Microchaete, Microcoleus, Microcystis, Microglena, Micromonas, Microspora, Microthamnion, Mischococcus, Monochrysis, Monodus, Monomastix, Monoraphidium, Monostroma, Mougeotia, Mougeotiopsis, Myochloris, Myromecia, Myxosarcina, Naegeliella, Nannochloris, Nautococcus, Navicula, Neglectella, Neidium, Nephroclamys, Nephrocytium, Nephrodiella, Nephroselmis, Netrium, Nitella, Nitellopsis, Nitzschia, Nodularia, Nostoc, Ochromonas, Oedogonium, Oligochaetophora, Onychonema, Oocardium, Oocystis, Opephora, Ophiocytium, Orthoseira, Oscillatoria, Oxyneis, Pachycladella, Palmella, Palmodictyon, Pnadorina, Pannus, Paralia, Pascherina, Paulschulzia, Pediastrum, Pedinella, Pedinomonas, Pedinopera, Pelagodictyon, Penium, Peranema, Peridiniopsis, Peridinium, Peronia, Petroneis, Phacotus, Phacus, Phaeaster, Phaeodermatium, Phaeophyta, Phaeosphaera, Phaeothamnion, Phormidium, Phycopeltis, Phyllariochloris, Phyllocardium, Phyllomitas, Pinnularia, Pitophora, Placoneis, Planctonema, Planktosphaeria, Planothidium, Plectonema, Pleodorina, Pleurastrum, Pleurocapsa, Pleurocladia, Pleurodiscus, Pleurosigma, Pleurosira, Pleurotaenium, Pocillomonas, Podohedra, Polyblepharides, Polychaetophora, Polyedriella, Polyedriopsis, Polygoniochloris, Polyepidomonas, Polytaenia, Polytoma, Polytomella, Porphyridium, Posteriochromonas, Prasinochloris, Prasinocladus, Prasinophyta, Prasiola, Prochlorphyta, Prochlorothrix, Protoderma, Protosiphon, Provasoliella, Prymnesium, Psammodictyon, Psammothidium, Pseudanabaena, Pseudenoclonium, Psuedocarteria, Pseudochate, Pseudocharacium, Pseudococcomyxa, Pseudodictyosphaerium, Pseudokephyrion, Pseudoncobyrsa, Pseudoquadrigula, Pseudosphaerocystis, Pseudostaurastrum, Pseudostaurosira, Pseudotetrastrum, Pteromonas, Punctastruata, Pyramichlamys, Pyramimonas, Pyrrophyta, Quadrichloris, Quadricoccus, Quadrigula, Radiococcus, Radiofilum, Raphidiopsis, Raphidocelis, Raphidonema, Raphidophyta, Peimeria, Rhabdoderma, Rhabdomonas, Rhizoclonium, Rhodomonas, Rhodophyta, Rhoicosphenia, Rhopalodia, Rivularia, Rosenvingiella, Rossithidium, Roya, Scenedesmus, Scherffelia, Schizochlamydella, Schizochlamys, Schizomeris, Schizothrix, Schroederia, Scolioneis, Scotiella, Scotiellopsis, Scourfieldia, Scytonema, Selenastrum, Selenochloris, Sellaphora, Semiorbis, Siderocelis, Diderocystopsis, Dimonsenia, Siphononema, Sirocladium, Sirogonium, Skeletonema, Sorastrum, Spermatozopsis, Sphaerellocystis, Sphaerellopsis, Sphaerodinium, Sphaeroplea, Sphaerozosma, Spiniferomonas, Spirogyra, Spirotaenia, Spirulina, Spondylomorum, Spondylosium, Sporotetras, Spumella, Staurastrum, Stauerodesmus, Stauroneis, Staurosira, Staurosirella, Stenopterobia, Stephanocostis, Stephanodiscus, Stephanoporos, Stephanosphaera, Stichococcus, Stichogloea, Stigeoclonium, Stigonema, Stipitococcus, Stokesiella, Strombomonas, Stylochrysalis, Stylodinium, Styloyxis, Stylosphaeridium, Surirella, Sykidion, Symploca, Synechococcus, Synechocystis, Synedra, Synochromonas, Synura, Tabellaria, Tabularia, Teilingia, Temnogametum, Tetmemorus, Tetrachlorella, Tetracyclus, Tetradesmus, Tetraedriella, Tetraedron, Tetraselmis, Tetraspora, Tetrastrum, Thalassiosira, Thamniochaete, Thorakochloris, Thorea, Tolypella, Tolypothrix, Trachelomonas, Trachydiscus, Trebouxia, Trentepholia, Treubaria, Tribonema, Trichodesmium, Trichodiscus, Trochiscia, Tryblionella, Ulothrix, Uroglena, Uronema, Urosolenia, Urospora, Uva, Vacuolaria, Vaucheria, Volvox, Volvulina, Westella, Woloszynskia, Xanthidium, Xanthophyta, Xenococcus, Zygnema, Zygnemopsis, and Zygonium . Cyanobacteria include members of the genus Chamaesiphon, Chroococcus, Cyanobacterium, Cyanobium, Cyanothece, Dactylococcopsis, Gloeobacter, Gloeocapsa, Gloeothece, Microcystis, Prochlorococcus, Prochloron, Synechococcus, Synechocystis, Cyanocystis, Dermocarpella, Stanieria, Xenococcus, Chroococcidiopsis, Myxosarcina, Arthrospira, Borzia, Crinalium, Geitlerinemia, Leptolyngbya, Limnothrix, Lyngbya, Microcoleus, Oscillatoria, Planktothrix, Prochiorothrix, Pseudanabaena, Spirulina, Starria, Symploca, Trichodesmium, Tychonema, Anabaena, Anabaenopsis, Aphanizomenon, Cyanospira, Cylindrospermopsis, Cylindrospermum, Nodularia, Nostoc, Scylonema, Calothrix, Rivularia, Tolypothrix, Chlorogloeopsis, Fischerella, Geitieria, Iyengariella, Nostochopsis, Stigonema and Thermosynechococcus.
Green non-sulfur bacteria include but are not limited to the following genera: Chloroflexus, Chloronema, Oscillochloris, Heliothrix, Herpetosiphon, Roseiflexus , and Thermomicrobium.
Green sulfur bacteria include but are not limited to the following genera: Chlorobium, Clathrochloris , and Prosthecochloris.
Purple sulfur bacteria include but are not limited to the following genera: Allochromatium, Chromatium, Halochromatium, Isochromatium, Marichromatium, Rhodovulum, Thermochromatium, Thiocapsa, Thiorhodococcus , and Thiocystis,
Purple non-sulfur bacteria include but are not limited to the following genera: Phaeospirillum, Rhodobaca, Rhodobacter, Rhodomicrobium, Rhodopila, Rhodopseudomonas, Rhodothalassium, Rhodospirillum, Rodovibrio , and Roseospira.
Aerobic chemolithotrophic bacteria include but are not limited to nitrifying bacteria such as Nitrobacteraceae sp., Nitrobacter sp., Nitrospina sp., Nitrococcus sp., Nitrospira sp., Nitrosomonas sp., Nitrosococcus sp., Nitrosospira sp., Nitrosolobus sp., Nitrosovibrio sp.; colorless sulfur bacteria such as, Thiovulum sp., Thiobacillus sp., Thiomicrospira sp., Thiosphaera sp., Thermothrix sp.; obligately chemolithotrophic hydrogen bacteria such as Hydrogenobacter sp., iron and manganese-oxidizing and/or depositing bacteria such as Siderococcus sp., and magnetotactic bacteria such as Aquaspirillum sp.
Archaeobacteria include but are not limited to methanogenic archaeobacteria such as Methanobacterium sp., Methanobrevibacter sp., Methanothermus sp., Methanococcus sp., Methanomicrobium sp., Methanospirillum sp., Methanogenium sp., Methanosarcina sp., Methanolobus sp., Methanothrix sp., Methanococcoides sp., Methanoplanus sp.; extremely thermophilic S-Metabolizers such as Thermoproteus sp., Pyrodictium sp., Sulfolobus sp., Acidianus sp. and other microorganisms such as, Bacillus subtilis, Saccharomyces cerevisiae, Streptomyces sp., Ralstonia sp., Rhodococcus sp., Corynebacteria sp., Brevibacteria sp., Mycobacteria sp., and oleaginous yeast.
Preferred organisms for the manufacture of alkanes according to the methods disclosed herein include: Arabidopsis thaliana, Panicum virgatum, Miscanthus giganteus , and Zea mays (plants); Botryococcus braunii, Chlamydomonas reinhardtii and Dunaliela salina (algae); Synechococcus sp PCC 7002 , Synechococcus sp. PCC 7942, Synechocystis sp. PCC 6803 , Thermosynechococcus elongatus BP-1 (cyanobacteria); Chlorobium tepidum (green sulfur bacteria), Chloroflexus auranticus (green non-sulfur bacteria); Chromatium tepidum and Chromatium vinosum (purple sulfur bacteria); Rhodospirillum rubrum, Rhodobacter capsulatus , and Rhodopseudomonas palusris (purple non-sulfur bacteria).
Yet other suitable organisms include synthetic cells or cells produced by synthetic genomes as described in Venter et al. US Pat. Pub. No. 2007/0264688, and cell-like systems or synthetic cells as described in Glass et al. US Pat. Pub. No. 2007/0269862.
Still, other suitable organisms include microorganisms that can be engineered to fix carbon dioxide bacteria such as Escherichia coli, Acetobacter aceti, Bacillus subtilis , yeast and fungi such as Clostridium ljungdahlii, Clostridium thermocellum, Penicillium chrysogenum, Pichia pastoris, Saccharomyces cerevisiae, Schizosaccharomyces pombe, Pseudomonas fluorescens , or Zymomonas mobilis.
A suitable organism for selecting or engineering is capable of autotrophic fixation of CO 2 to products. This would cover photosynthesis and methanogenesis. Acetogenesis, encompassing the three types of CO 2 fixation; Calvin cycle, acetyl-CoA pathway and reductive TCA pathway is also covered. The capability to use carbon dioxide as the sole source of cell carbon (autotrophy) is found in almost all major groups of prokaryotes. The CO 2 fixation pathways differ between groups, and there is no clear distribution pattern of the four presently-known autotrophic pathways. See, e.g., Fuchs, G. 1989 . Alternative pathways of autotrophic CO 2 fixation , p. 365-382. In H. G. Schlegel, and B. Bowien (ed.), Autotrophic bacteria . Springer-Verlag, Berlin, Germany. The reductive pentose phosphate cycle (Calvin-Bassham-Benson cycle) represents the CO 2 fixation pathway in almost all aerobic autotrophic bacteria, for example, the cyanobacteria.
Alkane production via engineered cyanobacteria, e.g., a Synechococcus or Thermosynechococcus species, is preferred. Other preferred organisms include Synechocystis, Klebsiella oxytoca, Escherichia coli or Saccharomyces cerevisiae . Other prokaryotic, archaea and eukaryotic host cells are also encompassed within the scope of the present invention.
In some aspects, alkane production via a photosynthetic organism can be carried out using the compositions, materials, and methods described in: PCT/US2009/035937 (filed Mar. 3, 2009); and PCT/US2009/055949 (filed Sep. 3, 2009); each of which is herein incorporated by reference in its entirety, for all purposes.
Carbon-Based Products of Interest: Hydrocarbons & Alcohols
In various embodiments of the invention, desired hydrocarbons and/or alcohols of certain chain length or a mixture thereof can be produced. In certain aspects, the host cell produces at least one of the following carbon-based products of interest: medium chain-length alkanes such as heptane, nonane, and/or undecane. In other aspects, the carbon chain length ranges from C 2 to C 20 . Accordingly, the invention provides production of various chain lengths of alkanes suitable for use as fuels & chemicals.
In preferred aspects, the methods provide culturing host cells for direct product secretion for easy recovery without the need to extract biomass. These carbon-based products of interest are secreted directly into the medium. Since the invention enables production of various defined chain length of hydrocarbons and alcohols, the secreted products are easily recovered or separated. The products of the invention, therefore, can be used directly or used with minimal processing.
Fuel Compositions
In various embodiments, compositions produced by the methods of the invention are used as fuels. Such fuels comply with ASTM standards, for instance, standard specifications for diesel fuel oils D 975-09b, and Jet A, Jet A-1 and Jet B as specified in ASTM Specification D. 1655-68. Fuel compositions may require blending of several products to produce a uniform product. The blending process is relatively straightforward, but the determination of the amount of each component to include in a blend is much more difficult. Fuel compositions may, therefore, include aromatic and/or branched hydrocarbons, for instance, 75% saturated and 25% aromatic, wherein some of the saturated hydrocarbons are branched and some are cyclic. Preferably, the methods of the invention produce an array of hydrocarbons, such as C 2 -C 17 or C 10 -C 15 to alter cloud point. Furthermore, the compositions may comprise fuel additives, which are used to enhance the performance of a fuel or engine. For example, fuel additives can be used to alter the freezing/gelling point, cloud point, lubricity, viscosity, oxidative stability, ignition quality, octane level, and flash point. Fuels compositions may also comprise, among others, antioxidants, static dissipater, corrosion inhibitor, icing inhibitor, biocide, metal deactivator and thermal stability improver.
In addition to many environmental advantages of the invention such as CO 2 conversion and renewable source, other advantages of the fuel compositions disclosed herein include low sulfur content, low emissions, being free or substantially free of alcohol and having high cetane number.
Example 1
Crude Extract of E. coli Cells Overexpressing acrM Convert Lauroyl-CoA to Dodecanal and Decanoyl-CoA to Decanal
Acinetobacter sp. M-1 acyl coenzyme A reductase, acrM, was codon-optimized for E. coli expression and synthesized by DNA2.0 (Menlo Park, Calif.; SEQ ID NO. 1) with a NdeI site on the 5′ end and an EcoRI site on the 3′-end. The obtained gene was subcloned into a pET28a vector (Novagen) by digestion with NdeI and EcoRI and subsequent ligation. The resulting plasmid, pET28a-acrM (SEQ ID NO. 2), containing an N-terminal His 6 -tagged acrM, was transformed into a BL21(DE3) E. coli strain, which was subsequently grown with shaking in Luria-Bertani medium supplemented with 100 μg/mL of kanomycin in a volume of 1 L to OD 600 =0.8 before induction with 0.25 mM IPTG for 5 hours in a 2-L shaker flask at 37° C. An SDS-PAGE gel demonstrating the overexpression of AcrM protein in pET28a-acrM containing BL21(DE3) E. coli cells is shown in FIG. 1 .
The E. coli cells containing overexpressed AcrM were collected by centrifugation, resuspended in HEPES buffer (100 mM HEPES, 10% glycerol, pH 7.5) at a 1:3 (w/v) ratio and lysed by sonication. 200 μL of buffer solution containing 100 μL total lysate, 1 mM acyl-CoA, 3 mM NADH (Sigma-Aldrich), 100 mM HEPES, 10% glycerol at pH 7.5 was incubated at 37° C. for 30 min, extracted with 100 μL ethyl acetate and analyzed by GC/MS equipped with a HP-5ms column (Agilent, Santa Clara, Calif.). Total ion chromatography (TIC) indicated the detection of aldehydes produced from corresponding acyl-CoA substrates by the AcrM-containing cell extract in the presence of supplemented NADH, as shown in FIG. 2 .
Example 2
Feeding Fatty Acid to Synechococcus Sp. PCC 7002 Strain Expressing Adm-carB-entD Results in Detection of Corresponding Aldehyde and Alkane
The carboxylic acid reductase (carB) gene (SEQ ID NO. 3) was PCR-amplified from Mycobacterium smegmatis and verified by sequencing with multiple primers by Genewiz (South Plainfield, N.J.). Cyanothece adm, E. coli leaderless tesA and E. coli entD genes were codon-optimized for E. coli overexpression and synthesized by DNA 2.0 (Menlo Park, Calif.; SEQ ID NO. 4 and 5) with an individual ribosome binding site in front of each gene. All four genes were subcloned into a pUC 19 vector containing an ammonia-repressible P(nir07) promoter, upstream/downstream homology regions, and a spectinomycin marker. The resulting plasmid, pAQ3::P(nir07)-adm-carB-tesA-entD-SpecR (SEQ ID NO. 6), was transformed into wild-type Synechococcus sp. PCC 7002 and segregated in the presence of spectinomycin.
The expression and activity of the Adm, CarB, TesA, and EntD proteins were demonstrated by detection of tridecane and pentadecane in the transformed Synechococcus sp. PCC 7002 strain by GC/FID ( FIG. 3 ).
The Synechococcus sp. PCC 7002 cultures were grown to OD 730 ˜5 before 1 mM fatty acid (100 mM stock in ethanol) was added and were then shaken at 150 rpm, 37° C. for ˜3 hours in the absence (lauric acid feeding) or presence (octanoic acid and decanoic acid feeding) of a pentadecane overlay (6 mL culture with 1 mL overlay). The pentadecane overlay from the octanoic acid-fed culture ( FIGS. 4A and 4D ), or decanoic acid culture ( FIGS. 4B and 4E ) was analyzed by GC/MS equipped with an HP-5ms column. For the lauric acid feeding assay, 1 mL culture was extracted with 400 μL hexane by vortexing for 1 min before being analyzed by GC/MS ( FIG. 4C, 4F ). Note that the pAQ3::P(nir07)-adm-carB-tesA-entD-SpecR expressing Synechococcus sp. PCC 7002 strain can produce a detectable level of undecane even without feeding dodecanoic acid.
Example 3
Synechococcus sp. PCC 7002 Strain Expressing Adm-carB-fatB2-entD Results in Increased Detection of Nonane in Pentadecane Overlay
The E. coli leaderless tesA of pAQ3::P(nir07)-adm-carB-tesA-entD-SpecR, was replaced by Cuphea hookeriana leaderless fatB2 (a medium-chain acyl-ACP thioesterase), which was codon-optimized for E. coli overexpression and synthesized by DNA 2.0 (Menlo Park, Calif.; SEQ ID NO. 7), with an individual ribosome binding site in front of the gene, a 5′ Kpn I restriction site and a 3′ Hind III restriction site. The resulting plasmid, pAQ3::P(nir07)-adm-carB-fatB2-entD-SpecR (SEQ ID NO. 8), was transformed into wild-type Synechococcus sp. PCC 7002 and segregated in the presence of spectinomycin.
The wild type Synechococcus sp. PCC 7002 and pAQ3::P(nir07)-adm-carB-fatB2-entD-SpecR expressing Synechococcus sp. PCC 7002 cultures (35 mL) were grown to OD 730 ˜3 (in the presence of 2 mM urea) before a 10 mL pentadecane overlay was added. The cultures were shaken at 150 rpm, 37° C. for 3 more days continuously. 100 μL pentadecane overlay samples from each flask were taken 12 hours ( FIG. 5A ) or 72 hours ( FIG. 5B ) after pentadecane addition, respectively, and analyzed directly by GC/FID equipped with a 20 meter hp-5ms column. An increase of nonane production was detected in the pAQ3::P(nir07)-adm-carB-fatB2-entD-SpecR expressing Synechococcus sp. PCC 7002 cultures but not in the wild type control ones. A relative increase in octane and heptanes production was also detected in the pAQ3::P(nir07)-adm-carB-fatB2-entD-SpecR expressing Synechococcus sp. PCC 7002 cultures (data not shown).
Example 4
Medium Chain-Length Alkane Production
One or more recombinant genes encoding one or more enzymes having enzyme activities which catalyze the production of medium chain-length alkanes are identified and selected. The enzyme activities include: an alkane deformylative monooxygenase activity, a thioesterase activity, a carboxylic acid reductase activity, and a phosphopanthetheinyl transferase activity, a long-chain fatty acid CoA-ligase activity, and/or a long-chain acyl-CoA reductase activity. Such genes and enzymes can be those described in Tables 1 and 2.
The selected genes are cloned into an expression vector. For example, adm-carB-entD-fatB or adm-acrM-fadD-fatB (or combinations of homologs thereof) are cloned into one or more vectors. See FIG. 6 . The genes can be under inducible control (such as the urea-repressible nir07 promoter or the cumate-inducible cum02 promoter). The genes may or may not be expressed operonically; and one or more of the genes can be placed under constitutive control such that when the other gene(s) are induced, the genes under constitutive control are already expressed. For example, one might express adm, carB, and entD constitutively while placing fatty-acid-generating fatB under inducible control; thus when fatty acids are made by fatB after induction, the remainder of the pathway is already present.
One or more vectors are selected and transformed into a microorganism (e.g., cyanobacteria). The cells are grown to a suitable optical density. In some instances cells are grown to a suitable optical density in an uninduced state, and then an induction signal is applied to commence alkane production.
Alkanes are produced by the transformed cells. The alkanes generally have 7, 8, 9, 10, or 11 carbon atoms. In some instances, alkanes are detected. In some instances, alkanes are quantified. In some instances, alkanes are collected.
In some aspects, a thioesterase such as fatB can be used. To test downstream of fatB, fatty acids of various chain lengths are fed along with inorganic carbon (e.g., CO 2 ) to cells, and alkane production is monitored. After fatB addition, cells are provided with inorganic carbon (e.g., CO 2 ) and alkane production is monitored.
TABLES
TABLE 1
SEQ
ID
NO
DESCRIPTION
SEQUENCE
1
acrM (from
ATGAATGCAAAACTGAAGAAATTGTTCCAGCAGAAAGTAGACGGCAAGACCATCAT
Acinetobacter
CGTGACCGGTGCAAGCAGCGGTATTGGCTTGACCGTGAGCAAATACCTGGCTCAGG
sp. M-1),
CGGGTGCACACGTGCTGCTGCTGGCGCGTACGAAAGAGAAACTGGATGAGGTCAAG
codon-
GCGGAGATTGAAGCGGAAGGCGGTAAGGCTACTGTTTTCCCGTGCGATTTGAATGA
optimized for
CATGGAATCCATTGACGCAGTCAGCAAAGAGATCCTGGCAGCCGTTGATCATATCG
E. coli
ACATTCTGGTGAATAACGCGGGTCGCAGCATCCGTCGCGCGGTCCACGAAAGCGTG
GATCGCTTCCATGACTTTGAGCGTACCATGCAACTGAATTACTTCGGTGCCGTTCG
TCTGGTCCTGAATGTTCTGCCGCACATGATGCAGCGCAAAGATGGCCAAATCATTA
ACATTAGCAGCATTGGCGTTTTGGCGAACGCGACGCGTTTCAGCGCGTATGTGGCG
AGCAAGGCTGCACTGGATGCCTTCTCCCGTTGTCTGAGCGCCGAGGTCCATTCGCA
CAAGATTGCGATTACCTCTATCTATATGCCGCTGGTTCGTACCCCGATGATTGCGC
CGACGAAGATCTACAAGTATGTCCCAACGTTGTCCCCGGAAGAGGCGGCTGACCTG
ATTGCTTATGCGATCGTTAAACGTCCGAAAAAGATCGCCACCAATCTGGGTCGCCT
GGCAAGCATCACCTACGCGATTGCCCCGGACATCAACAACATCCTGATGAGCATCG
GCTTTAACCTGTTTCCGTCTAGCACGGCGAGCGTGGGTGAGCAAGAAAAGCTGAAC
CTGATTCAACGTGCCTACGCACGTCTGTTTCCTGGTGAACACTGGTAA
2
Plasmid
TGGCGAATGGGACGCGCCCTGTAGCGGCGCATTAAGCGCGGCGGGTGTGGTGGTTA
pET28a-acrM
CGCGCAGCGTGACCGCTACACTTGCCAGCGCCCTAGCGCCCGCTCCTTTCGCTTTC
TTCCCTTCCTTTCTCGCCACGTTCGCCGGCTTTCCCCGTCAAGCTCTAAATCGGGG
GCTCCCTTTAGGGTTCCGATTTAGTGCTTTACGGCACCTCGACCCCAAAAAACTTG
ATTAGGGTGATGGTTCACGTAGTGGGCCATCGCCCTGATAGACGGTTTTTCGCCCT
TTGACGTTGGAGTCCACGTTCTTTAATAGTGGACTCTTGTTCCAAACTGGAACAAC
ACTCAACCCTATCTCGGTCTATTCTTTTGATTTATAAGGGATTTTGCCGATTTCGG
CCTATTGGTTAAAAAATGAGCTGATTTAACAAAAATTTAACGCGAATTTTAACAAA
ATATTAACGTTTACAATTTCAGGTGGCACTTTTCGGGGAAATGTGCGCGGAACCCC
TATTTGTTTATTTTTCTAAATACATTCAAATATGTATCCGCTCATGAATTAATTCT
TAGAAAAACTCATCGAGCATCAAATGAAACTGCAATTTATTCATATCAGGATTATC
AATACCATATTTTTGAAAAAGCCGTTTCTGTAATGAAGGAGAAAACTCACCGAGGC
AGTTCCATAGGATGGCAAGATCCTGGTATCGGTCTGCGATTCCGACTCGTCCAACA
TCAATACAACCTATTAATTTCCCCTCGTCAAAAATAAGGTTATCAAGTGAGAAATC
ACCATGAGTGACGACTGAATCCGGTGAGAATGGCAAAAGTTTATGCATTTCTTTCC
AGACTTGTTCAACAGGCCAGCCATTACGCTCGTCATCAAAATCACTCGCATCAACC
AAACCGTTATTCATTCGTGATTGCGCCTGAGCGAGACGAAATACGCGATCGCTGTT
AAAAGGACAATTACAAACAGGAATCGAATGCAACCGGCGCAGGAACACTGCCAGCG
CATCAACAATATTTTCACCTGAATCAGGATATTCTTCTAATACCTGGAATGCTGTT
TTCCCGGGGATCGCAGTGGTGAGTAACCATGCATCATCAGGAGTACGGATAAAATG
CTTGATGGTCGGAAGAGGCATAAATTCCGTCAGCCAGTTTAGTCTGACCATCTCAT
CTGTAACATCATTGGCAACGCTACCTTTGCCATGTTTCAGAAACAACTCTGGCGCA
TCGGGCTTCCCATACAATCGATAGATTGTCGCACCTGATTGCCCGACATTATCGCG
AGCCCATTTATACCCATATAAATCAGCATCCATGTTGGAATTTAATCGCGGCCTAG
AGCAAGACGTTTCCCGTTGAATATGGCTCATAACACCCCTTGTATTACTGTTTATG
TAAGCAGACAGTTTTATTGTTCATGACCAAAATCCCTTAACGTGAGTTTTCGTTCC
ACTGAGCGTCAGACCCCGTAGAAAAGATCAAAGGATCTTCTTGAGATCCTTTTTTT
CTGCGCGTAATCTGCTGCTTGCAAACAAAAAAACCACCGCTACCAGCGGTGGTTTG
TTTGCCGGATCAAGAGCTACCAACTCTTTTTCCGAAGGTAACTGGCTTCAGCAGAG
CGCAGATACCAAATACTGTCCTTCTAGTGTAGCCGTAGTTAGGCCACCACTTCAAG
AACTCTGTAGCACCGCCTACATACCTCGCTCTGCTAATCCTGTTACCAGTGGCTGC
TGCCAGTGGCGATAAGTCGTGTCTTACCGGGTTGGACTCAAGACGATAGTTACCGG
ATAAGGCGCAGCGGTCGGGCTGAACGGGGGGTTCGTGCACACAGCCCAGCTTGGAG
CGAACGACCTACACCGAACTGAGATACCTACAGCGTGAGCTATGAGAAAGCGCCAC
GCTTCCCGAAGGGAGAAAGGCGGACAGGTATCCGGTAAGCGGCAGGGTCGGAACAG
GAGAGCGCACGAGGGAGCTTCCAGGGGGAAACGCCTGGTATCTTTATAGTCCTGTC
GGGTTTCGCCACCTCTGACTTGAGCGTCGATTTTTGTGATGCTCGTCAGGGGGGCG
GAGCCTATGGAAAAACGCCAGCAACGCGGCCTTTTTACGGTTCCTGGCCTTTTGCT
GGCCTTTTGCTCACATGTTCTTTCCTGCGTTATCCCCTGATTCTGTGGATAACCGT
ATTACCGCCTTTGAGTGAGCTGATACCGCTCGCCGCAGCCGAACGACCGAGCGCAG
CGAGTCAGTGAGCGAGGAAGCGGAAGAGCGCCTGATGCGGTATTTTCTCCTTACGC
ATCTGTGCGGTATTTCACACCGCATATATGGTGCACTCTCAGTACAATCTGCTCTG
ATGCCGCATAGTTAAGCCAGTATACACTCCGCTATCGCTACGTGACTGGGTCATGG
CTGCGCCCCGACACCCGCCAACACCCGCTGACGCGCCCTGACGGGCTTGTCTGCTC
CCGGCATCCGCTTACAGACAAGCTGTGACCGTCTCCGGGAGCTGCATGTGTCAGAG
GTTTTCACCGTCATCACCGAAACGCGCGAGGCAGCTGCGGTAAAGCTCATCAGCGT
GGTCGTGAAGCGATTCACAGATGTCTGCCTGTTCATCCGCGTCCAGCTCGTTGAGT
TTCTCCAGAAGCGTTAATGTCTGGCTTCTGATAAAGCGGGCCATGTTAAGGGCGGT
TTTTTCCTGTTTGGTCACTGATGCCTCCGTGTAAGGGGGATTTCTGTTCATGGGGG
TAATGATACCGATGAAACGAGAGAGGATGCTCACGATACGGGTTACTGATGATGAA
CATGCCCGGTTACTGGAACGTTGTGAGGGTAAACAACTGGCGGTATGGATGCGGCG
GGACCAGAGAAAAATCACTCAGGGTCAATGCCAGCGCTTCGTTAATACAGATGTAG
GTGTTCCACAGGGTAGCCAGCAGCATCCTGCGATGCAGATCCGGAACATAATGGTG
CAGGGCGCTGACTTCCGCGTTTCCAGACTTTACGAAACACGGAAACCGAAGACCAT
TCATGTTGTTGCTCAGGTCGCAGACGTTTTGCAGCAGCAGTCGCTTCACGTTCGCT
CGCGTATCGGTGATTCATTCTGCTAACCAGTAAGGCAACCCCGCCAGCCTAGCCGG
GTCCTCAACGACAGGAGCACGATCATGCGCACCCGTGGGGCCGCCATGCCGGCGAT
AATGGCCTGCTTCTCGCCGAAACGTTTGGTGGCGGGACCAGTGACGAAGGCTTGAG
CGAGGGCGTGCAAGATTCCGAATACCGCAAGCGACAGGCCGATCATCGTCGCGCTC
CAGCGAAAGCGGTCCTCGCCGAAAATGACCCAGAGCGCTGCCGGCACCTGTCCTAC
GAGTTGCATGATAAAGAAGACAGTCATAAGTGCGGCGACGATAGTCATGCCCCGCG
CCCACCGGAAGGAGCTGACTGGGTTGAAGGCTCTCAAGGGCATCGGTCGAGATCCC
GGTGCCTAATGAGTGAGCTAACTTACATTAATTGCGTTGCGCTCACTGCCCGCTTT
CCAGTCGGGAAACCTGTCGTGCCAGCTGCATTAATGAATCGGCCAACGCGCGGGGA
GAGGCGGTTTGCGTATTGGGCGCCAGGGTGGTTTTTCTTTTCACCAGTGAGACGGG
CAACAGCTGATTGCCCTTCACCGCCTGGCCCTGAGAGAGTTGCAGCAAGCGGTCCA
CGCTGGTTTGCCCCAGCAGGCGAAAATCCTGTTTGATGGTGGTTAACGGCGGGATA
TAACATGAGCTGTCTTCGGTATCGTCGTATCCCACTACCGAGATATCCGCACCAAC
GCGCAGCCCGGACTCGGTAATGGCGCGCATTGCGCCCAGCGCCATCTGATCGTTGG
CAACCAGCATCGCAGTGGGAACGATGCCCTCATTCAGCATTTGCATGGTTTGTTGA
AAACCGGACATGGCACTCCAGTCGCCTTCCCGTTCCGCTATCGGCTGAATTTGATT
GCGAGTGAGATATTTATGCCAGCCAGCCAGACGCAGACGCGCCGAGACAGAACTTA
ATGGGCCCGCTAACAGCGCGATTTGCTGGTGACCCAATGCGACCAGATGCTCCACG
CCCAGTCGCGTACCGTCTTCATGGGAGAAAATAATACTGTTGATGGGTGTCTGGTC
AGAGACATCAAGAAATAACGCCGGAACATTAGTGCAGGCAGCTTCCACAGCAATGG
CATCCTGGTCATCCAGCGGATAGTTAATGATCAGCCCACTGACGCGTTGCGCGAGA
AGATTGTGCACCGCCGCTTTACAGGCTTCGACGCCGCTTCGTTCTACCATCGACAC
CACCACGCTGGCACCCAGTTGATCGGCGCGAGATTTAATCGCCGCGACAATTTGCG
ACGGCGCGTGCAGGGCCAGACTGGAGGTGGCAACGCCAATCAGCAACGACTGTTTG
CCCGCCAGTTGTTGTGCCACGCGGTTGGGAATGTAATTCAGCTCCGCCATCGCCGC
TTCCACTTTTTCCCGCGTTTTCGCAGAAACGTGGCTGGCCTGGTTCACCACGCGGG
AAACGGTCTGATAAGAGACACCGGCATACTCTGCGACATCGTATAACGTTACTGGT
TTCACATTCACCACCCTGAATTGACTCTCTTCCGGGCGCTATCATGCCATACCGCG
AAAGGTTTTGCGCCATTCGATGGTGTCCGGGATCTCGACGCTCTCCCTTATGCGAC
TCCTGCATTAGGAAGCAGCCCAGTAGTAGGTTGAGGCCGTTGAGCACCGCCGCCGC
AAGGAATGGTGCATGCAAGGAGATGGCGCCCAACAGTCCCCCGGCCACGGGGCCTG
CCACCATACCCACGCCGAAACAAGCGCTCATGAGCCCGAAGTGGCGAGCCCGATCT
TCCCCATCGGTGATGTCGGCGATATAGGCGCCAGCAACCGCACCTGTGGCGCCGGT
GATGCCGGCCACGATGCGTCCGGCGTAGAGGATCGAGATCTCGATCCCGCGAAATT
AATACGACTCACTATAGGGGAATTGTGAGCGGATAACAATTCCCCTCTAGAAATAA
TTTTGTTTAACTTTAAGAAGGAGATATACCATGGGCAGCAGCCATCATCATCATCA
TCACAGCAGCGGCCTGGTGCCGCGCGGCAGCCAT ATGAATGCAAAACTGAAGAAAT
TGTTCCAGCAGAAAGTAGACGGCAAGACCATCATCGTGACCGGTGCAAGCAGCGGT
ATTGGCTTGACCGTGAGCAAATACCTGGCTCAGGCGGGTGCACACGTGCTGCTGCT
GGCGCGTACGAAAGAGAAACTGGATGAGGTCAAGGCGGAGATTGAAGCGGAAGGCG
GTAAGGCTACTGTTTTCCCGTGCGATTTGAATGACATGGAATCCATTGACGCAGTC
AGCAAAGAGATCCTGGCAGCCGTTGATCATATCGACATTCTGGTGAATAACGCGGG
TCGCAGCATCCGTCGCGCGGTCCACGAAAGCGTGGATCGCTTCCATGACTTTGAGC
GTACCATGCAACTGAATTACTTCGGTGCCGTTCGTCTGGTCCTGAATGTTCTGCCG
CACATGATGCAGCGCAAAGATGGCCAAATCATTAACATTAGCAGCATTGGCGTTTT
GGCGAACGCGACGCGTTTCAGCGCGTATGTGGCGAGCAAGGCTGCACTGGATGCCT
TCTCCCGTTGTCTGAGCGCCGAGGTCCATTCGCACAAGATTGCGATTACCTCTATC
TATATGCCGCTGGTTCGTACCCCGATGATTGCGCCGACGAAGATCTACAAGTATGT
CCCAACGTTGTCCCCGGAAGAGGCGGCTGACCTGATTGCTTATGCGATCGTTAAAC
GTCCGAAAAAGATCGCCACCAATCTGGGTCGCCTGGCAAGCATCACCTACGCGATT
GCCCCGGACATCAACAACATCCTGATGAGCATCGGCTTTAACCTGTTTCCGTCTAG
CACGGCGAGCGTGGGTGAGCAAGAAAAGCTGAACCTGATTCAACGTGCCTACGCAC
GTCTGTTTCCTGGTGAACACTGGTAA GAATTCGAGCTCCGTCGACAAGCTTGCGGC
CGCACTCGAGCACCACCACCACCACCACTGAGATCCGGCTGCTAACAAAGCCCGAA
AGGAAGCTGAGTTGGCTGCTGCCACCGCTGAGCAATAACTAGCATAACCCCTTGGG
GCCTCTAAACGGGTCTTGAGGGGTTTTTTGCTGAAAGGAGGAACTATATCCGGAT
3
carboxylic
GAGCTCGAGGAGGTTTTTACA ATGACCAGCGATGTTCACGACGCCACAGACGGCGT
acid
CACCGAAACCGCACTCGACGACGAGCAGTCGACCCGCCGCATCGCCGAGCTGTACG
reductase
CCACCGATCCCGAGTTCGCCGCCGCCGCACCGTTGCCCGCCGTGGTCGACGCGGCG
amplified
CACAAACCCGGGCTGCGGCTGGCAGAGATCCTGCAGACCCTGTTCACCGGCTACGG
from
TGACCGCCCGGCGCTGGGATACCGCGCCCGTGAACTGGCCACCGACGAGGGCGGGC
Mycobacterium
GCACCGTGACGCGTCTGCTGCCGCGGTTCGACACCCTCACCTACGCCCAGGTGTGG
smegmatis .
TCGCGCGTGCAAGCGGTCGCCGCGGCCCTGCGCCACAACTTCGCGCAGCCGATCTA
CCCCGGCGACGCCGTCGCGACGATCGGTTTCGCGAGTCCCGATTACCTGACGCTGG
ATCTCGTATGCGCCTACCTGGGCCTCGTGAGTGTTCCGCTGCAGCACAACGCACCG
GTCAGCCGGCTCGCCCCGATCCTGGCCGAGGTCGAACCGCGGATCCTCACCGTGAG
CGCCGAATACCTCGACCTCGCAGTCGAATCCGTGCGGGACGTCAACTCGGTGTCGC
AGCTCGTGGTGTTCGACCATCACCCCGAGGTCGACGACCACCGCGACGCACTGGCC
CGCGCGCGTGAACAACTCGCCGGCAAGGGCATCGCCGTCACCACCCTGGACGCGAT
CGCCGACGAGGGCGCCGGGCTGCCGGCCGAACCGATCTACACCGCCGACCATGATC
AGCGCCTCGCGATGATCCTGTACACCTCGGGTTCCACCGGCGCACCCAAGGGTGCG
ATGTACACCGAGGCGATGGTGGCGCGGCTGTGGACCATGTCGTTCATCACGGGTGA
CCCCACGCCGGTCATCAACGTCAACTTCATGCCGCTCAACCACCTGGGCGGGCGCA
TCCCCATTTCCACCGCCGTGCAGAACGGTGGAACCAGTTACTTCGTACCGGAATCC
GACATGTCCACGCTGTTCGAGGATCTCGCGCTGGTGCGCCCGACCGAACTCGGCCT
GGTTCCGCGCGTCGCCGACATGCTCTACCAGCACCACCTCGCCACCGTCGACCGCC
TGGTCACGCAGGGCGCCGACGAACTGACCGCCGAGAAGCAGGCCGGTGCCGAACTG
CGTGAGCAGGTGCTCGGCGGACGCGTGATCACCGGATTCGTCAGCACCGCACCGCT
GGCCGCGGAGATGAGGGCGTTCCTCGACATCACCCTGGGCGCACACATCGTCGACG
GCTACGGGCTCACCGAGACCGGCGCCGTGACACGCGACGGTGTGATCGTGCGGCCA
CCGGTGATCGACTACAAGCTGATCGACGTTCCCGAACTCGGCTACTTCAGCACCGA
CAAGCCCTACCCGCGTGGCGAACTGCTGGTCAGGTCGCAAACGCTGACTCCCGGGT
ACTACAAGCGCCCCGAGGTCACCGCGAGCGTCTTCGACCGGGACGGCTACTACCAC
ACCGGCGACGTCATGGCCGAGACCGCACCCGACCACCTGGTGTACGTGGACCGTCG
CAACAACGTCCTCAAACTCGCGCAGGGCGAGTTCGTGGCGGTCGCCAACCTGGAGG
CGGTGTTCTCCGGCGCGGCGCTGGTGCGCCAGATCTTCGTGTACGGCAACAGCGAG
CGCAGTTTCCTTCTGGCCGTGGTGGTCCCGACGCCGGAGGCGCTCGAGCAGTACGA
TCCGGCCGCGCTCAAGGCCGCGCTGGCCGACTCGCTGCAGCGCACCGCACGCGACG
CCGAACTGCAATCCTACGAGGTGCCGGCCGATTTCATCGTCGAGACCGAGCCGTTC
AGCGCCGCCAACGGGCTGCTGTCGGGTGTCGGAAAACTGCTGCGGCCCAACCTCAA
AGACCGCTACGGGCAGCGCCTGGAGCAGATGTACGCCGATATCGCGGCCACGCAGG
CCAACCAGTTGCGCGAACTGCGGCGCGCGGCCGCCACACAACCGGTGATCGACACC
CTCACCCAGGCCGCTGCCACGATCCTCGGCACCGGGAGCGAGGTGGCATCCGACGC
CCACTTCACCGACCTGGGCGGGGATTCCCTGTCGGCGCTGACACTTTCGAACCTGC
TGAGCGATTTCTTCGGTTTCGAAGTTCCCGTCGGCACCATCGTGAACCCGGCCACC
AACCTCGCCCAACTCGCCCAGCACATCGAGGCGCAGCGCACCGCGGGTGACCGCAG
GCCGAGTTTCACCACCGTGCACGGCGCGGACGCCACCGAGATCCGGGCGAGTGAGC
TGACCCTGGACAAGTTCATCGACGCCGAAACGCTCCGGGCCGCACCGGGTCTGCCC
AAGGTCACCACCGAGCCACGGACGGTGTTGCTCTCGGGCGCCAACGGCTGGCTGGG
CCGGTTCCTCACGTTGCAGTGGCTGGAACGCCTGGCACCTGTCGGCGGCACCCTCA
TCACGATCGTGCGGGGCCGCGACGACGCCGCGGCCCGCGCACGGCTGACCCAGGCC
TACGACACCGATCCCGAGTTGTCCCGCCGCTTCGCCGAGCTGGCCGACCGCCACCT
GCGGGTGGTCGCCGGTGACATCGGCGACCCGAATCTGGGCCTCACACCCGAGATCT
GGCACCGGCTCGCCGCCGAGGTCGACCTGGTGGTGCATCCGGCAGCGCTGGTCAAC
CACGTGCTCCCCTACCGGCAGCTGTTCGGCCCCAACGTCGTGGGCACGGCCGAGGT
GATCAAGCTGGCCCTCACCGAACGGATCAAGCCCGTCACGTACCTGTCCACCGTGT
CGGTGGCCATGGGGATCCCCGACTTCGAGGAGGACGGCGACATCCGGACCGTGAGC
CCGGTGCGCCCGCTCGACGGCGGATACGCCAACGGCTACGGCAACAGCAAGTGGGC
CGGCGAGGTGCTGCTGCGGGAGGCCCACGATCTGTGCGGGCTGCCCGTGGCGACGT
TCCGCTCGGACATGATCCTGGCGCATCCGCGCTACCGCGGTCAGGTCAACGTGCCA
GACATGTTCACGCGACTCCTGTTGAGCCTCTTGATCACCGGCGTCGCGCCGCGGTC
GTTCTACATCGGAGACGGTGAGCGCCCGCGGGCGCACTACCCCGGCCTGACGGTCG
ATTTCGTGGCCGAGGCGGTCACGACGCTCGGCGCGCAGCAGCGCGAGGGATACGTG
TCCTACGACGTGATGAACCCGCACGACGACGGGATCTCCCTGGATGTGTTCGTGGA
CTGGCTGATCCGGGCGGGCCATCCGATCGACCGGGTCGACGACTACGACGACTGGG
TGCGTCGGTTCGAGACCGCGTTGACCGCGCTTCCCGAGAAGCGCCGCGCACAGACC
GTACTGCCGCTGCTGCACGCGTTCCGCGCTCCGCAGGCACCGTTGCGCGGCGCACC
CGAACCCACGGAGGTGTTCCACGCCGCGGTGCGCACCGCGAAGGTGGGCCCGGGAG
ACATCCCGCACCTCGACGAGGCGCTGATCGACAAGTACATACGCGATCTGCGTGAG
TTCGGTCTGATCTGA GGTACC
4
codon-
CAT ATGCAAGAACTGGCCCTGAGAAGCGAGCTGGACTTCAATAGCGAAACCTATAA
optimized
AGATGCGTATAGCCGTATTAACGCCATTGTGATCGAAGGCGAGCAAGAAGCATACC
Cyanothece
AAAACTACCTGGACATGGCGCAACTGCTGCCGGAGGACGAGGCTGAGCTGATTCGT
adm .
TTGAGCAAGATGGAGAACCGTCACAAAAAGGGTTTTCAAGCGTGCGGCAAGAACCT
CAATGTGACTCCGGATATGGATTATGCACAGCAGTTCTTTGCGGAGCTGCACGGCA
ATTTTCAGAAGGCTAAAGCCGAGGGTAAGATTGTTACCTGCCTGCTCATCCAAAGC
CTGATCATCGAGGCGTTTGCGATTGCAGCCTACAACATTTACATTCCAGTGGCTGA
TCCGTTTGCACGTAAAATCACCGAGGGTGTCGTCAAGGATGAGTATACCCACCTGA
ATTTCGGCGAAGTTTGGTTGAAGGAACATTTTGAAGCAAGCAAGGCGGAGTTGGAG
GACGCCAACAAAGAGAACTTACCGCTGGTCTGGCAGATGTTGAACCAGGTCGAAAA
GGATGCCGAAGTGCTGGGTATGGAGAAAGAGGCTCTGGTGGAGGACTTTATGATTA
GCTATGGTGAGGCACTGAGCAACATCGGCTTTTCTACGAGAGAAATCATGAAGATG
AGCGCGTACGGTCTGCGTGCAGCATAA GAGCTC
5
codon-
GAGCTCGAGGAGGTTTTTACA ATGACCAGCGATGTTCACGACGCCACAGACGGCGT
optimized E.
CACCGAAACCGCACTCGACGACGAGCAGTCGACCCGCCGCATCGCCGAGCTGTACG
coli tesA and
CCACCGATCCCGAGTTCGCCGCCGCCGCACCGTTGCCCGCCGTGGTCGACGCGGCG
E. coli entD
CACAAACCCGGGCTGCGGCTGGCAGAGATCCTGCAGACCCTGTTCACCGGCTACGG
genes.
TGACCGCCCGGCGCTGGGATACCGCGCCCGTGAACTGGCCACCGACGAGGGCGGGC
GCACCGTGACGCGTCTGCTGCCGCGGTTCGACACCCTCACCTACGCCCAGGTGTGG
TCGCGCGTGCAAGCGGTCGCCGCGGCCCTGCGCCACAACTTCGCGCAGCCGATCTA
CCCCGGCGACGCCGTCGCGACGATCGGTTTCGCGAGTCCCGATTACCTGACGCTGG
ATCTCGTATGCGCCTACCTGGGCCTCGTGAGTGTTCCGCTGCAGCACAACGCACCG
GTCAGCCGGCTCGCCCCGATCCTGGCCGAGGTCGAACCGCGGATCCTCACCGTGAG
CGCCGAATACCTCGACCTCGCAGTCGAATCCGTGCGGGACGTCAACTCGGTGTCGC
AGCTCGTGGTGTTCGACCATCACCCCGAGGTCGACGACCACCGCGACGCACTGGCC
CGCGCGCGTGAACAACTCGCCGGCAAGGGCATCGCCGTCACCACCCTGGACGCGAT
CGCCGACGAGGGCGCCGGGCTGCCGGCCGAACCGATCTACACCGCCGACCATGATC
AGCGCCTCGCGATGATCCTGTACACCTCGGGTTCCACCGGCGCACCCAAGGGTGCG
ATGTACACCGAGGCGATGGTGGCGCGGCTGTGGACCATGTCGTTCATCACGGGTGA
CCCCACGCCGGTCATCAACGTCAACTTCATGCCGCTCAACCACCTGGGCGGGCGCA
TCCCCATTTCCACCGCCGTGCAGAACGGTGGAACCAGTTACTTCGTACCGGAATCC
GACATGTCCACGCTGTTCGAGGATCTCGCGCTGGTGCGCCCGACCGAACTCGGCCT
GGTTCCGCGCGTCGCCGACATGCTCTACCAGCACCACCTCGCCACCGTCGACCGCC
TGGTCACGCAGGGCGCCGACGAACTGACCGCCGAGAAGCAGGCCGGTGCCGAACTG
CGTGAGCAGGTGCTCGGCGGACGCGTGATCACCGGATTCGTCAGCACCGCACCGCT
GGCCGCGGAGATGAGGGCGTTCCTCGACATCACCCTGGGCGCACACATCGTCGACG
GCTACGGGCTCACCGAGACCGGCGCCGTGACACGCGACGGTGTGATCGTGCGGCCA
CCGGTGATCGACTACAAGCTGATCGACGTTCCCGAACTCGGCTACTTCAGCACCGA
CAAGCCCTACCCGCGTGGCGAACTGCTGGTCAGGTCGCAAACGCTGACTCCCGGGT
ACTACAAGCGCCCCGAGGTCACCGCGAGCGTCTTCGACCGGGACGGCTACTACCAC
ACCGGCGACGTCATGGCCGAGACCGCACCCGACCACCTGGTGTACGTGGACCGTCG
CAACAACGTCCTCAAACTCGCGCAGGGCGAGTTCGTGGCGGTCGCCAACCTGGAGG
CGGTGTTCTCCGGCGCGGCGCTGGTGCGCCAGATCTTCGTGTACGGCAACAGCGAG
CGCAGTTTCCTTCTGGCCGTGGTGGTCCCGACGCCGGAGGCGCTCGAGCAGTACGA
TCCGGCCGCGCTCAAGGCCGCGCTGGCCGACTCGCTGCAGCGCACCGCACGCGACG
CCGAACTGCAATCCTACGAGGTGCCGGCCGATTTCATCGTCGAGACCGAGCCGTTC
AGCGCCGCCAACGGGCTGCTGTCGGGTGTCGGAAAACTGCTGCGGCCCAACCTCAA
AGACCGCTACGGGCAGCGCCTGGAGCAGATGTACGCCGATATCGCGGCCACGCAGG
CCAACCAGTTGCGCGAACTGCGGCGCGCGGCCGCCACACAACCGGTGATCGACACC
CTCACCCAGGCCGCTGCCACGATCCTCGGCACCGGGAGCGAGGTGGCATCCGACGC
CCACTTCACCGACCTGGGCGGGGATTCCCTGTCGGCGCTGACACTTTCGAACCTGC
TGAGCGATTTCTTCGGTTTCGAAGTTCCCGTCGGCACCATCGTGAACCCGGCCACC
AACCTCGCCCAACTCGCCCAGCACATCGAGGCGCAGCGCACCGCGGGTGACCGCAG
GCCGAGTTTCACCACCGTGCACGGCGCGGACGCCACCGAGATCCGGGCGAGTGAGC
TGACCCTGGACAAGTTCATCGACGCCGAAACGCTCCGGGCCGCACCGGGTCTGCCC
AAGGTCACCACCGAGCCACGGACGGTGTTGCTCTCGGGCGCCAACGGCTGGCTGGG
CCGGTTCCTCACGTTGCAGTGGCTGGAACGCCTGGCACCTGTCGGCGGCACCCTCA
TCACGATCGTGCGGGGCCGCGACGACGCCGCGGCCCGCGCACGGCTGACCCAGGCC
TACGACACCGATCCCGAGTTGTCCCGCCGCTTCGCCGAGCTGGCCGACCGCCACCT
GCGGGTGGTCGCCGGTGACATCGGCGACCCGAATCTGGGCCTCACACCCGAGATCT
GGCACCGGCTCGCCGCCGAGGTCGACCTGGTGGTGCATCCGGCAGCGCTGGTCAAC
CACGTGCTCCCCTACCGGCAGCTGTTCGGCCCCAACGTCGTGGGCACGGCCGAGGT
GATCAAGCTGGCCCTCACCGAACGGATCAAGCCCGTCACGTACCTGTCCACCGTGT
CGGTGGCCATGGGGATCCCCGACTTCGAGGAGGACGGCGACATCCGGACCGTGAGC
CCGGTGCGCCCGCTCGACGGCGGATACGCCAACGGCTACGGCAACAGCAAGTGGGC
CGGCGAGGTGCTGCTGCGGGAGGCCCACGATCTGTGCGGGCTGCCCGTGGCGACGT
TCCGCTCGGACATGATCCTGGCGCATCCGCGCTACCGCGGTCAGGTCAACGTGCCA
GACATGTTCACGCGACTCCTGTTGAGCCTCTTGATCACCGGCGTCGCGCCGCGGTC
GTTCTACATCGGAGACGGTGAGCGCCCGCGGGCGCACTACCCCGGCCTGACGGTCG
ATTTCGTGGCCGAGGCGGTCACGACGCTCGGCGCGCAGCAGCGCGAGGGATACGTG
TCCTACGACGTGATGAACCCGCACGACGACGGGATCTCCCTGGATGTGTTCGTGGA
CTGGCTGATCCGGGCGGGCCATCCGATCGACCGGGTCGACGACTACGACGACTGGG
TGCGTCGGTTCGAGACCGCGTTGACCGCGCTTCCCGAGAAGCGCCGCGCACAGACC
GTACTGCCGCTGCTGCACGCGTTCCGCGCTCCGCAGGCACCGTTGCGCGGCGCACC
CGAACCCACGGAGGTGTTCCACGCCGCGGTGCGCACCGCGAAGGTGGGCCCGGGAG
ACATCCCGCACCTCGACGAGGCGCTGATCGACAAGTACATACGCGATCTGCGTGAG
TTCGGTCTGATCTGA GGTACCAGGAGGTTTTTACA ATGGCTGATACTTTGTTGATT
TTGGGTGATTCTCTCTCTGCAGGCTACCGTATGTCCGCGAGCGCGGCATGGCCGGC
TCTGCTGAACGATAAGTGGCAGAGCAAGACCAGCGTGGTCAATGCGAGCATCAGCG
GCGATACCAGCCAGCAGGGTCTGGCACGTCTGCCAGCGCTGCTGAAGCAACACCAG
CCGCGTTGGGTGCTGGTTGAACTGGGCGGCAATGACGGTCTGCGTGGTTTTCAGCC
GCAGCAGACCGAACAAACGTTGCGTCAGATTCTGCAGGACGTCAAGGCGGCTAACG
CGGAACCGCTGCTGATGCAAATTCGCCTGCCGGCGAATTATGGTCGTCGTTACAAC
GAGGCTTTCAGCGCCATTTATCCTAAACTGGCTAAAGAGTTTGACGTGCCGCTGCT
GCCGTTCTTCATGGAAGAGGTCTACCTGAAACCGCAATGGATGCAAGACGACGGTA
TTCATCCGAATCGTGATGCACAACCTTTCATCGCGGATTGGATGGCGAAGCAATTG
CAACCGCTGGTGAACCATGACTCGTAAAAGCTTGTTGCTGCATGCAGGAGGTTTTT
ACAATGAAAACGACCCACACCAGCTTACCATTTGCCGGCCACACGTTACATTTCGT
CGAATTTGATCCGGCGAACTTTTGTGAACAAGACCTGTTGTGGCTGCCGCATTATG
CCCAGCTGCAGCACGCAGGCCGTAAGCGTAAAACTGAACATCTGGCCGGTCGCATT
GCGGCAGTGTATGCCCTGCGCGAGTACGGCTACAAATGCGTGCCGGCCATTGGTGA
ACTGCGTCAACCGGTTTGGCCGGCAGAAGTTTACGGTTCCATCTCCCACTGCGGTA
CTACCGCGTTGGCGGTTGTGTCTCGCCAGCCGATCGGTATTGATATTGAAGAGATA
TTCTCTGTCCAGACGGCACGCGAGCTGACGGACAACATCATTACCCCGGCAGAGCA
CGAGCGTCTGGCGGACTGTGGTCTGGCGTTCAGCCTGGCGCTGACCCTGGCATTCA
GCGCAAAAGAGAGCGCGTTCAAGGCTTCCGAGATCCAAACCGATGCGGGCTTCCTG
GATTATCAAATCATCAGCTGGAACAAGCAACAGGTTATCATTCACCGTGAGAATGA
GATGTTTGCCGTCCATTGGCAGATTAAAGAGAAAATCGTTATCACCCTGTGCCAGC
ACGACTGA GAATTC
6
plasmid
AAAAGCAGAGCATTACGCTGACTTGACGGGACGGCGCAAGCTCATGACCAAAATCC
pAQ3: : Pnir07_
CTTAACGTGAGTTACGCGCGCGTCGTTCCACTGAGCGTCAGACCCCGTAGAAAAGA
adm_carB_tesA_
TCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTGCTTGCAAACA
entD_SpecR.
AAAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCT
TTTTCCGAAGGTAACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTTCTTCTAG
TGTAGCCGTAGTTAGCCCACCACTTCAAGAACTCTGTAGCACCGCCTACATACCTC
GCTCTGCTAATCCTGTTACCAGTGGCTGCTGCCAGTGGCGATAAGTCGTGTCTTAC
CGGGTTGGACTCAAGACGATAGTTACCGGATAAGGCGCAGCGGTCGGGCTGAACGG
GGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACACCGAACTGAGATAC
CTACAGCGTGAGCTATGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCGGACAG
GTATCCGGTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGG
GAAACGCCTGGTATCTTTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGT
CGATTTTTGTGATGCTCGTCAGGGGGGCGGAGCCTATGGAAAAACGCCAGCAACGC
GGCCTTTTTACGGTTCCTGGCCTTTTGCTGGCCTTTTGCTCACATGTTCTTTCCTG
CGTTATCCCCTGATTCTGTGGATAACCGTATTACCGCCTTTGAGTGAGCTGATACC
GCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGGAAGCGGAAGG
CGAGAGTAGGGAACTGCCAGGCATCAAACTAAGCAGAAGGCCCCTGACGGATGGCC
TTTTTGCGTTTCTACAAACTCTTTCTGTGTTGTAAAACGACGGCCAGTCTTAAGCT
CGGGCCCCCTGGGCGGTTCTGATAACGAGTAATCGTTAATCCGCAAATAACGTAAA
AACCCGCTTCGGCGGGTTTTTTTATGGGGGGAGTTTAGGGAAAGAGCATTTGTCAG
AATATTTAAGGGCGCCTGTCACTTTGCTTGATATATGAGAATTATTTAACCTTATA
AATGAGAAAAAAGCAACGCACTTTAAATAAGATACGTTGCTTTTTCGATTGATGAA
CACCTATAATTAAACTATTCATCTATTATTTATGATTTTTTGTATATACAATATTT
CTAGTTTGTTAAAGAGAATTAAGAAAATAAATCTCGAAAATAATAAAGGGAAAATC
AGTTTTTGATATCAAAATTATACATGTCAACGATAATACAAAATATAATACAAACT
ATAAGATGTTATCAGTATTTATTATGCATTTAGAATAAATTTTGTGTCGCCCTTCG
CTGAACCTGCAGGCGAGCATTTCAACGATGATGAATGGGACGGCGAACCCACTGAA
CCCGTCGCCATTGACCCAGAACCGCGCAAAGAACGGGAAAAAATTGATCTCGATCT
GGAGGATGAACCAGAGGAAAACCGCAAACCGCAAAAAATCAAAGTGAAGTTAGCCG
ATGGGAAAGAGCGGGAACTCGCCCATACTCAAACCACAACTTTTTGGGATGCTGAT
GGTAAACCCATTTCCGCCCAAGAATTTATCGAAAAGCTATTTGGCGACCTGCCCGA
CCTCTTCAAGGATGAAGCCGAACTACGCACCATCTGGGGGAAACCCGATACCCGTA
AATCGTTCCTGACCGGACTCGCGGAAAAAGGCTACGGTGACACCCAACTGAAGGCG
ATCGCACGCATTGCCGAAGCGGAAAAAAGTGATGTCTATGATGTCCTGACTTGGGT
TGCCTACAACACCAAACCCATTAGCAGAGAAGAGCGAGTAATTAAGCATCGAGATC
TGATTTTCTCGAAGTACACCGGAAAGCAGCAAGAATTTTTAGATTTTGTCCTAGAC
CAATACATTCGAGAAGGAGTGGAGGAACTTGATCGGGGGAAACTGCCTACCCTCAT
CGAAATCAAATACCAAACCGTTAATGAAGGTTTAGTGATCTTGGGTCAGGATATCG
GTCAAGTATTCGCAGATTTTCAGGCGGATTTATATACCGAAGATGTGGCATAAAAA
AGGACGGCGATCGCCGGGGGCGTTGCCTGCCTTGAGCGGCCGCTTGTAGCAATTGC
TACTAAAAACTGCGATCGCTGCTGAAATGAGCTGGAATTTTGTCCCTCTCAGCTCA
AAAAGTATCAATGATTACTTAATGTTTGTTCTGCGCAAACTTCTTGCAGAACATGC
ATGATTTACAAAAAGTTGTAGTTTCTGTTACCAATTGCGAATCGAGAACTGCCTAA
TCTGCCGAGTATGCGATCCTTTAGCAGGAGGAAAACCATATGCAAGAACTGGCCCT
GAGAAGCGAGCTGGACTTCAATAGCGAAACCTATAAAGATGCGTATAGCCGTATTA
ACGCCATTGTGATCGAAGGCGAGCAAGAAGCATACCAAAACTACCTGGACATGGCG
CAACTGCTGCCGGAGGACGAGGCTGAGCTGATTCGTTTGAGCAAGATGGAGAACCG
TCACAAAAAGGGTTTTCAAGCGTGCGGCAAGAACCTCAATGTGACTCCGGATATGG
ATTATGCACAGCAGTTCTTTGCGGAGCTGCACGGCAATTTTCAGAAGGCTAAAGCC
GAGGGTAAGATTGTTACCTGCCTGCTCATCCAAAGCCTGATCATCGAGGCGTTTGC
GATTGCAGCCTACAACATTTACATTCCAGTGGCTGATCCGTTTGCACGTAAAATCA
CCGAGGGTGTCGTCAAGGATGAGTATACCCACCTGAATTTCGGCGAAGTTTGGTTG
AAGGAACATTTTGAAGCAAGCAAGGCGGAGTTGGAGGACGCCAACAAAGAGAACTT
ACCGCTGGTCTGGCAGATGTTGAACCAGGTCGAAAAGGATGCCGAAGTGCTGGGTA
TGGAGAAAGAGGCTCTGGTGGAGGACTTTATGATTAGCTATGGTGAGGCACTGAGC
AACATCGGCTTTTCTACGAGAGAAATCATGAAGATGAGCGCGTACGGTCTGCGTGC
AGCATAAGAGCTCGAGGAGGTTTTTACAATGACCAGCGATGTTCACGACGCCACAG
ACGGCGTCACCGAAACCGCACTCGACGACGAGCAGTCGACCCGCCGCATCGCCGAG
CTGTACGCCACCGATCCCGAGTTCGCCGCCGCCGCACCGTTGCCCGCCGTGGTCGA
CGCGGCGCACAAACCCGGGCTGCGGCTGGCAGAGATCCTGCAGACCCTGTTCACCG
GCTACGGTGACCGCCCGGCGCTGGGATACCGCGCCCGTGAACTGGCCACCGACGAG
GGCGGGCGCACCGTGACGCGTCTGCTGCCGCGGTTCGACACCCTCACCTACGCCCA
GGTGTGGTCGCGCGTGCAAGCGGTCGCCGCGGCCCTGCGCCACAACTTCGCGCAGC
CGATCTACCCCGGCGACGCCGTCGCGACGATCGGTTTCGCGAGTCCCGATTACCTG
ACGCTGGATCTCGTATGCGCCTACCTGGGCCTCGTGAGTGTTCCGCTGCAGCACAA
CGCACCGGTCAGCCGGCTCGCCCCGATCCTGGCCGAGGTCGAACCGCGGATCCTCA
CCGTGAGCGCCGAATACCTCGACCTCGCAGTCGAATCCGTGCGGGACGTCAACTCG
GTGTCGCAGCTCGTGGTGTTCGACCATCACCCCGAGGTCGACGACCACCGCGACGC
ACTGGCCCGCGCGCGTGAACAACTCGCCGGCAAGGGCATCGCCGTCACCACCCTGG
ACGCGATCGCCGACGAGGGCGCCGGGCTGCCGGCCGAACCGATCTACACCGCCGAC
CATGATCAGCGCCTCGCGATGATCCTGTACACCTCGGGTTCCACCGGCGCACCCAA
GGGTGCGATGTACACCGAGGCGATGGTGGCGCGGCTGTGGACCATGTCGTTCATCA
CGGGTGACCCCACGCCGGTCATCAACGTCAACTTCATGCCGCTCAACCACCTGGGC
GGGCGCATCCCCATTTCCACCGCCGTGCAGAACGGTGGAACCAGTTACTTCGTACC
GGAATCCGACATGTCCACGCTGTTCGAGGATCTCGCGCTGGTGCGCCCGACCGAAC
TCGGCCTGGTTCCGCGCGTCGCCGACATGCTCTACCAGCACCACCTCGCCACCGTC
GACCGCCTGGTCACGCAGGGCGCCGACGAACTGACCGCCGAGAAGCAGGCCGGTGC
CGAACTGCGTGAGCAGGTGCTCGGCGGACGCGTGATCACCGGATTCGTCAGCACCG
CACCGCTGGCCGCGGAGATGAGGGCGTTCCTCGACATCACCCTGGGCGCACACATC
GTCGACGGCTACGGGCTCACCGAGACCGGCGCCGTGACACGCGACGGTGTGATCGT
GCGGCCACCGGTGATCGACTACAAGCTGATCGACGTTCCCGAACTCGGCTACTTCA
GCACCGACAAGCCCTACCCGCGTGGCGAACTGCTGGTCAGGTCGCAAACGCTGACT
CCCGGGTACTACAAGCGCCCCGAGGTCACCGCGAGCGTCTTCGACCGGGACGGCTA
CTACCACACCGGCGACGTCATGGCCGAGACCGCACCCGACCACCTGGTGTACGTGG
ACCGTCGCAACAACGTCCTCAAACTCGCGCAGGGCGAGTTCGTGGCGGTCGCCAAC
CTGGAGGCGGTGTTCTCCGGCGCGGCGCTGGTGCGCCAGATCTTCGTGTACGGCAA
CAGCGAGCGCAGTTTCCTTCTGGCCGTGGTGGTCCCGACGCCGGAGGCGCTCGAGC
AGTACGATCCGGCCGCGCTCAAGGCCGCGCTGGCCGACTCGCTGCAGCGCACCGCA
CGCGACGCCGAACTGCAATCCTACGAGGTGCCGGCCGATTTCATCGTCGAGACCGA
GCCGTTCAGCGCCGCCAACGGGCTGCTGTCGGGTGTCGGAAAACTGCTGCGGCCCA
ACCTCAAAGACCGCTACGGGCAGCGCCTGGAGCAGATGTACGCCGATATCGCGGCC
ACGCAGGCCAACCAGTTGCGCGAACTGCGGCGCGCGGCCGCCACACAACCGGTGAT
CGACACCCTCACCCAGGCCGCTGCCACGATCCTCGGCACCGGGAGCGAGGTGGCAT
CCGACGCCCACTTCACCGACCTGGGCGGGGATTCCCTGTCGGCGCTGACACTTTCG
AACCTGCTGAGCGATTTCTTCGGTTTCGAAGTTCCCGTCGGCACCATCGTGAACCC
GGCCACCAACCTCGCCCAACTCGCCCAGCACATCGAGGCGCAGCGCACCGCGGGTG
ACCGCAGGCCGAGTTTCACCACCGTGCACGGCGCGGACGCCACCGAGATCCGGGCG
AGTGAGCTGACCCTGGACAAGTTCATCGACGCCGAAACGCTCCGGGCCGCACCGGG
TCTGCCCAAGGTCACCACCGAGCCACGGACGGTGTTGCTCTCGGGCGCCAACGGCT
GGCTGGGCCGGTTCCTCACGTTGCAGTGGCTGGAACGCCTGGCACCTGTCGGCGGC
ACCCTCATCACGATCGTGCGGGGCCGCGACGACGCCGCGGCCCGCGCACGGCTGAC
CCAGGCCTACGACACCGATCCCGAGTTGTCCCGCCGCTTCGCCGAGCTGGCCGACC
GCCACCTGCGGGTGGTCGCCGGTGACATCGGCGACCCGAATCTGGGCCTCACACCC
GAGATCTGGCACCGGCTCGCCGCCGAGGTCGACCTGGTGGTGCATCCGGCAGCGCT
GGTCAACCACGTGCTCCCCTACCGGCAGCTGTTCGGCCCCAACGTCGTGGGCACGG
CCGAGGTGATCAAGCTGGCCCTCACCGAACGGATCAAGCCCGTCACGTACCTGTCC
ACCGTGTCGGTGGCCATGGGGATCCCCGACTTCGAGGAGGACGGCGACATCCGGAC
CGTGAGCCCGGTGCGCCCGCTCGACGGCGGATACGCCAACGGCTACGGCAACAGCA
AGTGGGCCGGCGAGGTGCTGCTGCGGGAGGCCCACGATCTGTGCGGGCTGCCCGTG
GCGACGTTCCGCTCGGACATGATCCTGGCGCATCCGCGCTACCGCGGTCAGGTCAA
CGTGCCAGACATGTTCACGCGACTCCTGTTGAGCCTCTTGATCACCGGCGTCGCGC
CGCGGTCGTTCTACATCGGAGACGGTGAGCGCCCGCGGGCGCACTACCCCGGCCTG
ACGGTCGATTTCGTGGCCGAGGCGGTCACGACGCTCGGCGCGCAGCAGCGCGAGGG
ATACGTGTCCTACGACGTGATGAACCCGCACGACGACGGGATCTCCCTGGATGTGT
TCGTGGACTGGCTGATCCGGGCGGGCCATCCGATCGACCGGGTCGACGACTACGAC
GACTGGGTGCGTCGGTTCGAGACCGCGTTGACCGCGCTTCCCGAGAAGCGCCGCGC
ACAGACCGTACTGCCGCTGCTGCACGCGTTCCGCGCTCCGCAGGCACCGTTGCGCG
GCGCACCCGAACCCACGGAGGTGTTCCACGCCGCGGTGCGCACCGCGAAGGTGGGC
CCGGGAGACATCCCGCACCTCGACGAGGCGCTGATCGACAAGTACATACGCGATCT
GCGTGAGTTCGGTCTGATCTGAGGTACCAGGAGGTTTTTACAATGGCTGATACTTT
GTTGATTTTGGGTGATTCTCTCTCTGCAGGCTACCGTATGTCCGCGAGCGCGGCAT
GGCCGGCTCTGCTGAACGATAAGTGGCAGAGCAAGACCAGCGTGGTCAATGCGAGC
ATCAGCGGCGATACCAGCCAGCAGGGTCTGGCACGTCTGCCAGCGCTGCTGAAGCA
ACACCAGCCGCGTTGGGTGCTGGTTGAACTGGGCGGCAATGACGGTCTGCGTGGTT
TTCAGCCGCAGCAGACCGAACAAACGTTGCGTCAGATTCTGCAGGACGTCAAGGCG
GCTAACGCGGAACCGCTGCTGATGCAAATTCGCCTGCCGGCGAATTATGGTCGTCG
TTACAACGAGGCTTTCAGCGCCATTTATCCTAAACTGGCTAAAGAGTTTGACGTGC
CGCTGCTGCCGTTCTTCATGGAAGAGGTCTACCTGAAACCGCAATGGATGCAAGAC
GACGGTATTCATCCGAATCGTGATGCACAACCTTTCATCGCGGATTGGATGGCGAA
GCAATTGCAACCGCTGGTGAACCATGACTCGTAAAAGCTTGTTGCTGCATGCAGGA
GGTTTTTACAATGAAAACGACCCACACCAGCTTACCATTTGCCGGCCACACGTTAC
ATTTCGTCGAATTTGATCCGGCGAACTTTTGTGAACAAGACCTGTTGTGGCTGCCG
CATTATGCCCAGCTGCAGCACGCAGGCCGTAAGCGTAAAACTGAACATCTGGCCGG
TCGCATTGCGGCAGTGTATGCCCTGCGCGAGTACGGCTACAAATGCGTGCCGGCCA
TTGGTGAACTGCGTCAACCGGTTTGGCCGGCAGAAGTTTACGGTTCCATCTCCCAC
TGCGGTACTACCGCGTTGGCGGTTGTGTCTCGCCAGCCGATCGGTATTGATATTGA
AGAGATATTCTCTGTCCAGACGGCACGCGAGCTGACGGACAACATCATTACCCCGG
CAGAGCACGAGCGTCTGGCGGACTGTGGTCTGGCGTTCAGCCTGGCGCTGACCCTG
GCATTCAGCGCAAAAGAGAGCGCGTTCAAGGCTTCCGAGATCCAAACCGATGCGGG
CTTCCTGGATTATCAAATCATCAGCTGGAACAAGCAACAGGTTATCATTCACCGTG
AGAATGAGATGTTTGCCGTCCATTGGCAGATTAAAGAGAAAATCGTTATCACCCTG
TGCCAGCACGACTGAGAATTCGGTTTTCCGTCCTGTCTTGATTTTCAAGCAAACAA
TGCCTCCGATTTCTAATCGGAGGCATTTGTTTTTGTTTATTGCAAAAACAAAAAAT
ATTGTTACAAATTTTTACAGGCTATTAAGCCTACCGTCATAAATAATTTGCCATTT
ACTAGTTTTTAATTAACCAGAACCTTGACCGAACGCAGCGGTGGTAACGGCGCAGT
GGCGGTTTTCATGGCTTGTTATGACTGTTTTTTTGGGGTACAGTCTATGCCTCGGG
CATCCAAGCAGCAAGCGCGTTACGCCGTGGGTCGATGTTTGATGTTATGGAGCAGC
AACGATGTTACGCAGCAGGGCAGTCGCCCTAAAACAAAGTTAAACATCATGAGGGA
AGCGGTGATCGCCGAAGTATCGACTCAACTATCAGAGGTAGTTGGCGTCATCGAGC
GCCATCTCGAACCGACGTTGCTGGCCGTACATTTGTACGGCTCCGCAGTGGATGGC
GGCCTGAAGCCACACAGTGATATTGATTTGCTGGTTACGGTGACCGTAAGGCTTGA
TGAAACAACGCGGCGAGCTTTGATCAACGACCTTTTGGAAACTTCGGCTTCCCCTG
GAGAGAGCGAGATTCTCCGCGCTGTAGAAGTCACCATTGTTGTGCACGACGACATC
ATTCCGTGGCGTTATCCAGCTAAGCGCGAACTGCAATTTGGAGAATGGCAGCGCAA
TGACATTCTTGCAGGTATCTTCGAGCCAGCCACGATCGACATTGATCTGGCTATCT
TGCTGACAAAAGCAAGAGAACATAGCGTTGCCTTGGTAGGTCCAGCGGCGGAGGAA
CTCTTTGATCCGGTTCCTGAACAGGATCTATTTGAGGCGCTAAATGAAACCTTAAC
GCTATGGAACTCGCCGCCCGACTGGGCTGGCGATGAGCGAAATGTAGTGCTTACGT
TGTCCCGCATTTGGTACAGCGCAGTAACCGGCAAAATCGCGCCGAAGGATGTCGCT
GCCGACTGGGCAATGGAGCGCCTGCCGGCCCAGTATCAGCCCGTCATACTTGAAGC
TAGACAGGCTTATCTTGGACAAGAAGAAGATCGCTTGGCCTCGCGCGCAGATCAGT
TGGAAGAATTTGTCCACTACGTGAAAGGCGAGATCACCAAGGTAGTCGGCAAATAA
TGTCTAACAATTCGTTCAAGCCGACGCCGCTTCGCGGCGCGGCTTAACTCAAGCGT
TAGATGCACTAAGCACATAATTGCTCACAGCCAAACTATCAGGTCAAGTCTGCTTT
TATTATTTTTAAGCGTGCATAATAAGCCCTACACAAATTGGGAGATATATCATGAG
GCGCGCCACGAGAAAGAGTTATGACAAATTAAAATTCTGACTCTTAGATTATTTCC
AGAGAGGCTGATTTTCCCAATCTTTGGGAAAGCCTAAGTTTTTAGATTCTATTTCT
GGATACATCTCAAAAGTTCTTTTTAAATGCTGTGCAAAATTATGCTCTGGTTTAAT
TCTGTCTAAGAGATACTGAATACAACATAAGCCAGTGAAAATTTTACGGCTGTTTC
TTTGATTAATATCCTCCAATACTTCTCTAGAGAGCCATTTTCCTTTTAACCTATCA
GGCAATTTAGGTGATTCTCCTAGCTGTATATTCCAGAGCCTTGAATGATGAGCGCA
AATATTTCTAATATGCGACAAAGACCGTAACCAAGATATAAAAAACTTGTTAGGTA
ATTGGAAATGAGTATGTATTTTTTGTCGTGTCTTAGATGGTAATAAATTTGTGTAC
ATTCTAGATAACTGCCCAAAGGCGATTATCTCCAAAGCCATATATGACGGCGGTAG
TAGAGGATTTGTGTACTTGTTTCGATAATGCCCGATAAATTCTTCTACTTTTTTAG
ATTGGCAATATTGAGTAATCGAATCGATTAATTCTTGATGCTTCCCAGTGTCATAA
AATAAACTTTTATTCAGATACCAATGAGGATCATAATCATGGGAGTAGTGATAAAT
CATTTGAGTTCTGACTGCTACTTCTATCGACTCCGTAGCATTAAAAATAAGCATTC
TCAAGGATTTATCAAACTTGTATAGATTTGGCCGGCCCGTCAAAAGGGCGACACCC
CATAATTAGCCCGGGCGAAAGGCCCAGTCTTTCGACTGAGCCTTTCGTTTTATTTG
ATGCCTGGCAGTTCCCTACTCTCGCATGGGGAGTCCCCACACTACCATCGGCGCTA
CGGCGTTTCACTTCTGAGTTCGGCATGGGGTCAGGTGGGACCACCGCGCTACTGCC
GCCAGGCAAACAAGGGGTGTTATGAGCCATATTCAGGTATAAATGGGCTCGCGATA
ATGTTCAGAATTGGTTAATTGGTTGTAACACTGACCCCTATTTGTTTATTTTTCTA
AATACATTCAAATATGTATCCGCTCATGAGACAATAACCCTGATAAATGCTTCAAT
AATATTGAAAAAGGAAGAATATGAGTATTCAACATTTCCGTGTCGCCCTTATTCCC
TTTTTTGCGGCATTTTGCCTTCCTGTTTTTGCTCACCCAGAAACGCTGGTGAAAGT
AAAAGATGCTGAAGATCAGTTGGGTGCACGAGTGGGTTACATCGAACTGGATCTCA
ACAGCGGTAAGATCCTTGAGAGTTTTCGCCCCGAAGAACGTTTTCCAATGATGAGC
ACTTTTAAAGTTCTGCTATGTGGCGCGGTATTATCCCGTATTGACGCCGGGCAAGA
GCAACTCGGTCGCCGCATACACTATTCTCAGAATGACTTGGTTGAGTACTCACCAG
TCACAGAAAAGCATCTTACGGATGGCATGACAGTAAGAGAATTATGCAGTGCTGCC
ATAACCATGAGTGATAACACTGCGGCCAACTTACTTCTGACAACGATCGGAGGACC
GAAGGAGCTAACCGCTTTTTTGCACAACATGGGGGATCATGTAACTCGCCTTGATC
GTTGGGAACCGGAGCTGAATGAAGCCATACCAAACGACGAGCGTGACACCACGATG
CCTGTAGCGATGGCAACAACGTTGCGCAAACTATTAACTGGCGAACTACTTACTCT
AGCTTCCCGGCAACAATTAATAGACTGGATGGAGGCGGATAAAGTTGCAGGACCAC
TTCTGCGCTCGGCCCTTCCGGCTGGCTGGTTTATTGCTGATAAATCCGGAGCCGGT
GAGCGTGGTTCTCGCGGTATCATCGCAGCGCTGGGGCCAGATGGTAAGCCCTCCCG
TATCGTAGTTATCTACACGACGGGGAGTCAGGCAACTATGGATGAACGAAATAGAC
AGATCGCTGAGATAGGTGCCTCACTGATTAAGCATTGGT
7
codon-
GGTACCAGGAGGTTTTTAC ATGGACCGTAAAAGCAAGCGTCCGGACATGCTGGTTG
optimized
ATTCCTTTGGTCTGGAAAGCACCGTGCAGGACGGTCTGGTTTTCCGTCAGTCTTTC
Cuphea
TCCATTCGTAGCTATGAGATTGGTACTGATCGTACCGCCTCTATCGAAACCCTGAT
hookeriana
GAATCACCTGCAAGAAACCTCTCTGAACCATTGTAAGTCTACTGGCATCCTGCTGG
leaderless
ACGGTTTCGGTCGTACCCTGGAGATGTGCAAACGCGACCTGATTTGGGTAGTGATC
fatB2 gene.
AAAATGCAGATCAAAGTTAACCGTTATCCGGCATGGGGTGATACCGTTGAAATCAA
CACCCGCTTTTCTCGTCTGGGCAAAATCGGTATGGGCCGTGACTGGCTGATCTCTG
ACTGTAACACTGGTGAAATTCTGGTTCGTGCTACTAGCGCATACGCGATGATGAAC
CAGAAAACCCGTCGCCTGAGCAAGCTGCCGTACGAGGTCCACCAGGAGATTGTTCC
GCTGTTTGTAGACAGCCCAGTGATTGAGGATTCTGACCTGAAAGTGCATAAATTCA
AAGTGAAGACCGGTGACAGCATCCAAAAAGGCCTGACCCCAGGTTGGAACGATCTG
GACGTTAACCAGCACGTTTCCAACGTGAAGTATATCGGTTGGATTCTGGAGAGCAT
GCCGACCGAGGTCCTGGAAACCCAGGAGCTGTGTTCCCTGGCGCTGGAGTACCGCC
GTGAGTGCGGCCGTGACAGCGTGCTGGAGTCTGTGACCGCTATGGACCCAAGCAAA
GTTGGTGTTCGTAGCCAGTACCAGCACCTGCTGCGTCTGGAAGACGGTACTGCTAT
CGTGAACGGTGCAACTGAATGGCGTCCTAAAAACGCGGGTGCAAACGGTGCTATCA
GCACCGGTAAAACCTCTAACGGTAACTCCGTGAGCTAA AAGCTT
8
plasmid
AAAAGCAGAGCATTACGCTGACTTGACGGGACGGCGCAAGCTCATGACCAAAATCC
pAQ3: : P(nir07)_
CTTAACGTGAGTTACGCGCGCGTCGTTCCACTGAGCGTCAGACCCCGTAGAAAAGA
adm_carB_fatB2_
TCAAAGGATCTTCTTGAGATCCTTTTTTTCTGCGCGTAATCTGCTGCTTGCAAACA
entD_Spec
AAAAAACCACCGCTACCAGCGGTGGTTTGTTTGCCGGATCAAGAGCTACCAACTCT
R.
TTTTCCGAAGGTAACTGGCTTCAGCAGAGCGCAGATACCAAATACTGTTCTTCTAG
TGTAGCCGTAGTTAGCCCACCACTTCAAGAACTCTGTAGCACCGCCTACATACCTC
GCTCTGCTAATCCTGTTACCAGTGGCTGCTGCCAGTGGCGATAAGTCGTGTCTTAC
CGGGTTGGACTCAAGACGATAGTTACCGGATAAGGCGCAGCGGTCGGGCTGAACGG
GGGGTTCGTGCACACAGCCCAGCTTGGAGCGAACGACCTACACCGAACTGAGATAC
CTACAGCGTGAGCTATGAGAAAGCGCCACGCTTCCCGAAGGGAGAAAGGCGGACAG
GTATCCGGTAAGCGGCAGGGTCGGAACAGGAGAGCGCACGAGGGAGCTTCCAGGGG
GAAACGCCTGGTATCTTTATAGTCCTGTCGGGTTTCGCCACCTCTGACTTGAGCGT
CGATTTTTGTGATGCTCGTCAGGGGGGCGGAGCCTATGGAAAAACGCCAGCAACGC
GGCCTTTTTACGGTTCCTGGCCTTTTGCTGGCCTTTTGCTCACATGTTCTTTCCTG
CGTTATCCCCTGATTCTGTGGATAACCGTATTACCGCCTTTGAGTGAGCTGATACC
GCTCGCCGCAGCCGAACGACCGAGCGCAGCGAGTCAGTGAGCGAGGAAGCGGAAGG
CGAGAGTAGGGAACTGCCAGGCATCAAACTAAGCAGAAGGCCCCTGACGGATGGCC
TTTTTGCGTTTCTACAAACTCTTTCTGTGTTGTAAAACGACGGCCAGTCTTAAGCT
CGGGCCCCCTGGGCGGTTCTGATAACGAGTAATCGTTAATCCGCAAATAACGTAAA
AACCCGCTTCGGCGGGTTTTTTTATGGGGGGAGTTTAGGGAAAGAGCATTTGTCAG
AATATTTAAGGGCGCCTGTCACTTTGCTTGATATATGAGAATTATTTAACCTTATA
AATGAGAAAAAAGCAACGCACTTTAAATAAGATACGTTGCTTTTTCGATTGATGAA
CACCTATAATTAAACTATTCATCTATTATTTATGATTTTTTGTATATACAATATTT
CTAGTTTGTTAAAGAGAATTAAGAAAATAAATCTCGAAAATAATAAAGGGAAAATC
AGTTTTTGATATCAAAATTATACATGTCAACGATAATACAAAATATAATACAAACT
ATAAGATGTTATCAGTATTTATTATGCATTTAGAATAAATTTTGTGTCGCCCTTCG
CTGAACCTGCAGGCGAGCATTTCAACGATGATGAATGGGACGGCGAACCCACTGAA
CCCGTCGCCATTGACCCAGAACCGCGCAAAGAACGGGAAAAAATTGATCTCGATCT
GGAGGATGAACCAGAGGAAAACCGCAAACCGCAAAAAATCAAAGTGAAGTTAGCCG
ATGGGAAAGAGCGGGAACTCGCCCATACTCAAACCACAACTTTTTGGGATGCTGAT
GGTAAACCCATTTCCGCCCAAGAATTTATCGAAAAGCTATTTGGCGACCTGCCCGA
CCTCTTCAAGGATGAAGCCGAACTACGCACCATCTGGGGGAAACCCGATACCCGTA
AATCGTTCCTGACCGGACTCGCGGAAAAAGGCTACGGTGACACCCAACTGAAGGCG
ATCGCACGCATTGCCGAAGCGGAAAAAAGTGATGTCTATGATGTCCTGACTTGGGT
TGCCTACAACACCAAACCCATTAGCAGAGAAGAGCGAGTAATTAAGCATCGAGATC
TGATTTTCTCGAAGTACACCGGAAAGCAGCAAGAATTTTTAGATTTTGTCCTAGAC
CAATACATTCGAGAAGGAGTGGAGGAACTTGATCGGGGGAAACTGCCTACCCTCAT
CGAAATCAAATACCAAACCGTTAATGAAGGTTTAGTGATCTTGGGTCAGGATATCG
GTCAAGTATTCGCAGATTTTCAGGCGGATTTATATACCGAAGATGTGGCATAAAAA
AGGACGGCGATCGCCGGGGGCGTTGCCTGCCTTGAGCGGCCGCTTGTAGCAATTGC
TACTAAAAACTGCGATCGCTGCTGAAATGAGCTGGAATTTTGTCCCTCTCAGCTCA
AAAAGTATCAATGATTACTTAATGTTTGTTCTGCGCAAACTTCTTGCAGAACATGC
ATGATTTACAAAAAGTTGTAGTTTCTGTTACCAATTGCGAATCGAGAACTGCCTAA
TCTGCCGAGTATGCGATCCTTTAGCAGGAGGAAAACCATATGCAAGAACTGGCCCT
GAGAAGCGAGCTGGACTTCAATAGCGAAACCTATAAAGATGCGTATAGCCGTATTA
ACGCCATTGTGATCGAAGGCGAGCAAGAAGCATACCAAAACTACCTGGACATGGCG
CAACTGCTGCCGGAGGACGAGGCTGAGCTGATTCGTTTGAGCAAGATGGAGAACCG
TCACAAAAAGGGTTTTCAAGCGTGCGGCAAGAACCTCAATGTGACTCCGGATATGG
ATTATGCACAGCAGTTCTTTGCGGAGCTGCACGGCAATTTTCAGAAGGCTAAAGCC
GAGGGTAAGATTGTTACCTGCCTGCTCATCCAAAGCCTGATCATCGAGGCGTTTGC
GATTGCAGCCTACAACATTTACATTCCAGTGGCTGATCCGTTTGCACGTAAAATCA
CCGAGGGTGTCGTCAAGGATGAGTATACCCACCTGAATTTCGGCGAAGTTTGGTTG
AAGGAACATTTTGAAGCAAGCAAGGCGGAGTTGGAGGACGCCAACAAAGAGAACTT
ACCGCTGGTCTGGCAGATGTTGAACCAGGTCGAAAAGGATGCCGAAGTGCTGGGTA
TGGAGAAAGAGGCTCTGGTGGAGGACTTTATGATTAGCTATGGTGAGGCACTGAGC
AACATCGGCTTTTCTACGAGAGAAATCATGAAGATGAGCGCGTACGGTCTGCGTGC
AGCATAAGAGCTCGAGGAGGTTTTTACAATGACCAGCGATGTTCACGACGCCACAG
ACGGCGTCACCGAAACCGCACTCGACGACGAGCAGTCGACCCGCCGCATCGCCGAG
CTGTACGCCACCGATCCCGAGTTCGCCGCCGCCGCACCGTTGCCCGCCGTGGTCGA
CGCGGCGCACAAACCCGGGCTGCGGCTGGCAGAGATCCTGCAGACCCTGTTCACCG
GCTACGGTGACCGCCCGGCGCTGGGATACCGCGCCCGTGAACTGGCCACCGACGAG
GGCGGGCGCACCGTGACGCGTCTGCTGCCGCGGTTCGACACCCTCACCTACGCCCA
GGTGTGGTCGCGCGTGCAAGCGGTCGCCGCGGCCCTGCGCCACAACTTCGCGCAGC
CGATCTACCCCGGCGACGCCGTCGCGACGATCGGTTTCGCGAGTCCCGATTACCTG
ACGCTGGATCTCGTATGCGCCTACCTGGGCCTCGTGAGTGTTCCGCTGCAGCACAA
CGCACCGGTCAGCCGGCTCGCCCCGATCCTGGCCGAGGTCGAACCGCGGATCCTCA
CCGTGAGCGCCGAATACCTCGACCTCGCAGTCGAATCCGTGCGGGACGTCAACTCG
GTGTCGCAGCTCGTGGTGTTCGACCATCACCCCGAGGTCGACGACCACCGCGACGC
ACTGGCCCGCGCGCGTGAACAACTCGCCGGCAAGGGCATCGCCGTCACCACCCTGG
ACGCGATCGCCGACGAGGGCGCCGGGCTGCCGGCCGAACCGATCTACACCGCCGAC
CATGATCAGCGCCTCGCGATGATCCTGTACACCTCGGGTTCCACCGGCGCACCCAA
GGGTGCGATGTACACCGAGGCGATGGTGGCGCGGCTGTGGACCATGTCGTTCATCA
CGGGTGACCCCACGCCGGTCATCAACGTCAACTTCATGCCGCTCAACCACCTGGGC
GGGCGCATCCCCATTTCCACCGCCGTGCAGAACGGTGGAACCAGTTACTTCGTACC
GGAATCCGACATGTCCACGCTGTTCGAGGATCTCGCGCTGGTGCGCCCGACCGAAC
TCGGCCTGGTTCCGCGCGTCGCCGACATGCTCTACCAGCACCACCTCGCCACCGTC
GACCGCCTGGTCACGCAGGGCGCCGACGAACTGACCGCCGAGAAGCAGGCCGGTGC
CGAACTGCGTGAGCAGGTGCTCGGCGGACGCGTGATCACCGGATTCGTCAGCACCG
CACCGCTGGCCGCGGAGATGAGGGCGTTCCTCGACATCACCCTGGGCGCACACATC
GTCGACGGCTACGGGCTCACCGAGACCGGCGCCGTGACACGCGACGGTGTGATCGT
GCGGCCACCGGTGATCGACTACAAGCTGATCGACGTTCCCGAACTCGGCTACTTCA
GCACCGACAAGCCCTACCCGCGTGGCGAACTGCTGGTCAGGTCGCAAACGCTGACT
CCCGGGTACTACAAGCGCCCCGAGGTCACCGCGAGCGTCTTCGACCGGGACGGCTA
CTACCACACCGGCGACGTCATGGCCGAGACCGCACCCGACCACCTGGTGTACGTGG
ACCGTCGCAACAACGTCCTCAAACTCGCGCAGGGCGAGTTCGTGGCGGTCGCCAAC
CTGGAGGCGGTGTTCTCCGGCGCGGCGCTGGTGCGCCAGATCTTCGTGTACGGCAA
CAGCGAGCGCAGTTTCCTTCTGGCCGTGGTGGTCCCGACGCCGGAGGCGCTCGAGC
AGTACGATCCGGCCGCGCTCAAGGCCGCGCTGGCCGACTCGCTGCAGCGCACCGCA
CGCGACGCCGAACTGCAATCCTACGAGGTGCCGGCCGATTTCATCGTCGAGACCGA
GCCGTTCAGCGCCGCCAACGGGCTGCTGTCGGGTGTCGGAAAACTGCTGCGGCCCA
ACCTCAAAGACCGCTACGGGCAGCGCCTGGAGCAGATGTACGCCGATATCGCGGCC
ACGCAGGCCAACCAGTTGCGCGAACTGCGGCGCGCGGCCGCCACACAACCGGTGAT
CGACACCCTCACCCAGGCCGCTGCCACGATCCTCGGCACCGGGAGCGAGGTGGCAT
CCGACGCCCACTTCACCGACCTGGGCGGGGATTCCCTGTCGGCGCTGACACTTTCG
AACCTGCTGAGCGATTTCTTCGGTTTCGAAGTTCCCGTCGGCACCATCGTGAACCC
GGCCACCAACCTCGCCCAACTCGCCCAGCACATCGAGGCGCAGCGCACCGCGGGTG
ACCGCAGGCCGAGTTTCACCACCGTGCACGGCGCGGACGCCACCGAGATCCGGGCG
AGTGAGCTGACCCTGGACAAGTTCATCGACGCCGAAACGCTCCGGGCCGCACCGGG
TCTGCCCAAGGTCACCACCGAGCCACGGACGGTGTTGCTCTCGGGCGCCAACGGCT
GGCTGGGCCGGTTCCTCACGTTGCAGTGGCTGGAACGCCTGGCACCTGTCGGCGGC
ACCCTCATCACGATCGTGCGGGGCCGCGACGACGCCGCGGCCCGCGCACGGCTGAC
CCAGGCCTACGACACCGATCCCGAGTTGTCCCGCCGCTTCGCCGAGCTGGCCGACC
GCCACCTGCGGGTGGTCGCCGGTGACATCGGCGACCCGAATCTGGGCCTCACACCC
GAGATCTGGCACCGGCTCGCCGCCGAGGTCGACCTGGTGGTGCATCCGGCAGCGCT
GGTCAACCACGTGCTCCCCTACCGGCAGCTGTTCGGCCCCAACGTCGTGGGCACGG
CCGAGGTGATCAAGCTGGCCCTCACCGAACGGATCAAGCCCGTCACGTACCTGTCC
ACCGTGTCGGTGGCCATGGGGATCCCCGACTTCGAGGAGGACGGCGACATCCGGAC
CGTGAGCCCGGTGCGCCCGCTCGACGGCGGATACGCCAACGGCTACGGCAACAGCA
AGTGGGCCGGCGAGGTGCTGCTGCGGGAGGCCCACGATCTGTGCGGGCTGCCCGTG
GCGACGTTCCGCTCGGACATGATCCTGGCGCATCCGCGCTACCGCGGTCAGGTCAA
CGTGCCAGACATGTTCACGCGACTCCTGTTGAGCCTCTTGATCACCGGCGTCGCGC
CGCGGTCGTTCTACATCGGAGACGGTGAGCGCCCGCGGGCGCACTACCCCGGCCTG
ACGGTCGATTTCGTGGCCGAGGCGGTCACGACGCTCGGCGCGCAGCAGCGCGAGGG
ATACGTGTCCTACGACGTGATGAACCCGCACGACGACGGGATCTCCCTGGATGTGT
TCGTGGACTGGCTGATCCGGGCGGGCCATCCGATCGACCGGGTCGACGACTACGAC
GACTGGGTGCGTCGGTTCGAGACCGCGTTGACCGCGCTTCCCGAGAAGCGCCGCGC
ACAGACCGTACTGCCGCTGCTGCACGCGTTCCGCGCTCCGCAGGCACCGTTGCGCG
GCGCACCCGAACCCACGGAGGTGTTCCACGCCGCGGTGCGCACCGCGAAGGTGGGC
CCGGGAGACATCCCGCACCTCGACGAGGCGCTGATCGACAAGTACATACGCGATCT
GCGTGAGTTCGGTCTGATCTGAGGTACCAGGAGGTTTTTACATGGACCGTAAAAGC
AAGCGTCCGGACATGCTGGTTGATTCCTTTGGTCTGGAAAGCACCGTGCAGGACGG
TCTGGTTTTCCGTCAGTCTTTCTCCATTCGTAGCTATGAGATTGGTACTGATCGTA
CCGCCTCTATCGAAACCCTGATGAATCACCTGCAAGAAACCTCTCTGAACCATTGT
AAGTCTACTGGCATCCTGCTGGACGGTTTCGGTCGTACCCTGGAGATGTGCAAACG
CGACCTGATTTGGGTAGTGATCAAAATGCAGATCAAAGTTAACCGTTATCCGGCAT
GGGGTGATACCGTTGAAATCAACACCCGCTTTTCTCGTCTGGGCAAAATCGGTATG
GGCCGTGACTGGCTGATCTCTGACTGTAACACTGGTGAAATTCTGGTTCGTGCTAC
TAGCGCATACGCGATGATGAACCAGAAAACCCGTCGCCTGAGCAAGCTGCCGTACG
AGGTCCACCAGGAGATTGTTCCGCTGTTTGTAGACAGCCCAGTGATTGAGGATTCT
GACCTGAAAGTGCATAAATTCAAAGTGAAGACCGGTGACAGCATCCAAAAAGGCCT
GACCCCAGGTTGGAACGATCTGGACGTTAACCAGCACGTTTCCAACGTGAAGTATA
TCGGTTGGATTCTGGAGAGCATGCCGACCGAGGTCCTGGAAACCCAGGAGCTGTGT
TCCCTGGCGCTGGAGTACCGCCGTGAGTGCGGCCGTGACAGCGTGCTGGAGTCTGT
GACCGCTATGGACCCAAGCAAAGTTGGTGTTCGTAGCCAGTACCAGCACCTGCTGC
GTCTGGAAGACGGTACTGCTATCGTGAACGGTGCAACTGAATGGCGTCCTAAAAAC
GCGGGTGCAAACGGTGCTATCAGCACCGGTAAAACCTCTAACGGTAACTCCGTGAG
CTAAAAGCTTGTTGCTGCATGCAGGAGGTTTTTACAATGAAAACGACCCACACCAG
CTTACCATTTGCCGGCCACACGTTACATTTCGTCGAATTTGATCCGGCGAACTTTT
GTGAACAAGACCTGTTGTGGCTGCCGCATTATGCCCAGCTGCAGCACGCAGGCCGT
AAGCGTAAAACTGAACATCTGGCCGGTCGCATTGCGGCAGTGTATGCCCTGCGCGA
GTACGGCTACAAATGCGTGCCGGCCATTGGTGAACTGCGTCAACCGGTTTGGCCGG
CAGAAGTTTACGGTTCCATCTCCCACTGCGGTACTACCGCGTTGGCGGTTGTGTCT
CGCCAGCCGATCGGTATTGATATTGAAGAGATATTCTCTGTCCAGACGGCACGCGA
GCTGACGGACAACATCATTACCCCGGCAGAGCACGAGCGTCTGGCGGACTGTGGTC
TGGCGTTCAGCCTGGCGCTGACCCTGGCATTCAGCGCAAAAGAGAGCGCGTTCAAG
GCTTCCGAGATCCAAACCGATGCGGGCTTCCTGGATTATCAAATCATCAGCTGGAA
CAAGCAACAGGTTATCATTCACCGTGAGAATGAGATGTTTGCCGTCCATTGGCAGA
TTAAAGAGAAAATCGTTATCACCCTGTGCCAGCACGACTGAGAATTCGGTTTTCCG
TCCTGTCTTGATTTTCAAGCAAACAATGCCTCCGATTTCTAATCGGAGGCATTTGT
TTTTGTTTATTGCAAAAACAAAAAATATTGTTACAAATTTTTACAGGCTATTAAGC
CTACCGTCATAAATAATTTGCCATTTACTAGTTTTTAATTAACCAGAACCTTGACC
GAACGCAGCGGTGGTAACGGCGCAGTGGCGGTTTTCATGGCTTGTTATGACTGTTT
TTTTGGGGTACAGTCTATGCCTCGGGCATCCAAGCAGCAAGCGCGTTACGCCGTGG
GTCGATGTTTGATGTTATGGAGCAGCAACGATGTTACGCAGCAGGGCAGTCGCCCT
AAAACAAAGTTAAACATCATGAGGGAAGCGGTGATCGCCGAAGTATCGACTCAACT
ATCAGAGGTAGTTGGCGTCATCGAGCGCCATCTCGAACCGACGTTGCTGGCCGTAC
ATTTGTACGGCTCCGCAGTGGATGGCGGCCTGAAGCCACACAGTGATATTGATTTG
CTGGTTACGGTGACCGTAAGGCTTGATGAAACAACGCGGCGAGCTTTGATCAACGA
CCTTTTGGAAACTTCGGCTTCCCCTGGAGAGAGCGAGATTCTCCGCGCTGTAGAAG
TCACCATTGTTGTGCACGACGACATCATTCCGTGGCGTTATCCAGCTAAGCGCGAA
CTGCAATTTGGAGAATGGCAGCGCAATGACATTCTTGCAGGTATCTTCGAGCCAGC
CACGATCGACATTGATCTGGCTATCTTGCTGACAAAAGCAAGAGAACATAGCGTTG
CCTTGGTAGGTCCAGCGGCGGAGGAACTCTTTGATCCGGTTCCTGAACAGGATCTA
TTTGAGGCGCTAAATGAAACCTTAACGCTATGGAACTCGCCGCCCGACTGGGCTGG
CGATGAGCGAAATGTAGTGCTTACGTTGTCCCGCATTTGGTACAGCGCAGTAACCG
GCAAAATCGCGCCGAAGGATGTCGCTGCCGACTGGGCAATGGAGCGCCTGCCGGCC
CAGTATCAGCCCGTCATACTTGAAGCTAGACAGGCTTATCTTGGACAAGAAGAAGA
TCGCTTGGCCTCGCGCGCAGATCAGTTGGAAGAATTTGTCCACTACGTGAAAGGCG
AGATCACCAAGGTAGTCGGCAAATAATGTCTAACAATTCGTTCAAGCCGACGCCGC
TTCGCGGCGCGGCTTAACTCAAGCGTTAGATGCACTAAGCACATAATTGCTCACAG
CCAAACTATCAGGTCAAGTCTGCTTTTATTATTTTTAAGCGTGCATAATAAGCCCT
ACACAAATTGGGAGATATATCATGAGGCGCGCCACGAGAAAGAGTTATGACAAATT
AAAATTCTGACTCTTAGATTATTTCCAGAGAGGCTGATTTTCCCAATCTTTGGGAA
AGCCTAAGTTTTTAGATTCTATTTCTGGATACATCTCAAAAGTTCTTTTTAAATGC
TGTGCAAAATTATGCTCTGGTTTAATTCTGTCTAAGAGATACTGAATACAACATAA
GCCAGTGAAAATTTTACGGCTGTTTCTTTGATTAATATCCTCCAATACTTCTCTAG
AGAGCCATTTTCCTTTTAACCTATCAGGCAATTTAGGTGATTCTCCTAGCTGTATA
TTCCAGAGCCTTGAATGATGAGCGCAAATATTTCTAATATGCGACAAAGACCGTAA
CCAAGATATAAAAAACTTGTTAGGTAATTGGAAATGAGTATGTATTTTTTGTCGTG
TCTTAGATGGTAATAAATTTGTGTACATTCTAGATAACTGCCCAAAGGCGATTATC
TCCAAAGCCATATATGACGGCGGTAGTAGAGGATTTGTGTACTTGTTTCGATAATG
CCCGATAAATTCTTCTACTTTTTTAGATTGGCAATATTGAGTAATCGAATCGATTA
ATTCTTGATGCTTCCCAGTGTCATAAAATAAACTTTTATTCAGATACCAATGAGGA
TCATAATCATGGGAGTAGTGATAAATCATTTGAGTTCTGACTGCTACTTCTATCGA
CTCCGTAGCATTAAAAATAAGCATTCTCAAGGATTTATCAAACTTGTATAGATTTG
GCCGGCCCGTCAAAAGGGCGACACCCCATAATTAGCCCGGGCGAAAGGCCCAGTCT
TTCGACTGAGCCTTTCGTTTTATTTGATGCCTGGCAGTTCCCTACTCTCGCATGGG
GAGTCCCCACACTACCATCGGCGCTACGGCGTTTCACTTCTGAGTTCGGCATGGGG
TCAGGTGGGACCACCGCGCTACTGCCGCCAGGCAAACAAGGGGTGTTATGAGCCAT
ATTCAGGTATAAATGGGCTCGCGATAATGTTCAGAATTGGTTAATTGGTTGTAACA
CTGACCCCTATTTGTTTATTTTTCTAAATACATTCAAATATGTATCCGCTCATGAG
ACAATAACCCTGATAAATGCTTCAATAATATTGAAAAAGGAAGAATATGAGTATTC
AACATTTCCGTGTCGCCCTTATTCCCTTTTTTGCGGCATTTTGCCTTCCTGTTTTT
GCTCACCCAGAAACGCTGGTGAAAGTAAAAGATGCTGAAGATCAGTTGGGTGCACG
AGTGGGTTACATCGAACTGGATCTCAACAGCGGTAAGATCCTTGAGAGTTTTCGCC
CCGAAGAACGTTTTCCAATGATGAGCACTTTTAAAGTTCTGCTATGTGGCGCGGTA
TTATCCCGTATTGACGCCGGGCAAGAGCAACTCGGTCGCCGCATACACTATTCTCA
GAATGACTTGGTTGAGTACTCACCAGTCACAGAAAAGCATCTTACGGATGGCATGA
CAGTAAGAGAATTATGCAGTGCTGCCATAACCATGAGTGATAACACTGCGGCCAAC
TTACTTCTGACAACGATCGGAGGACCGAAGGAGCTAACCGCTTTTTTGCACAACAT
GGGGGATCATGTAACTCGCCTTGATCGTTGGGAACCGGAGCTGAATGAAGCCATAC
CAAACGACGAGCGTGACACCACGATGCCTGTAGCGATGGCAACAACGTTGCGCAAA
CTATTAACTGGCGAACTACTTACTCTAGCTTCCCGGCAACAATTAATAGACTGGAT
GGAGGCGGATAAAGTTGCAGGACCACTTCTGCGCTCGGCCCTTCCGGCTGGCTGGT
TTATTGCTGATAAATCCGGAGCCGGTGAGCGTGGTTCTCGCGGTATCATCGCAGCG
CTGGGGCCAGATGGTAAGCCCTCCCGTATCGTAGTTATCTACACGACGGGGAGTCA
GGCAACTATGGATGAACGAAATAGACAGATCGCTGAGATAGGTGCCTCACTGATTA
AGCATTGGT
9
carB
MTSDVHDATDGVTETALDDEQSTRRIAELYATDPEFAAAAPLPAVVDAAHKPGLRL
Mycobacterium
AEILQTLFTGYGDRPALGYRARELATDEGGRTVTRLLPRFDTLTYAQVWSRVQAVA
smegmatis
AALRHNFAQPIYPGDAVATIGFASPDYLTLDLVCAYLGLVSVPLQHNAPVSRLAPI
LAEVEPRILTVSAEYLDLAVESVRDVNSVSQLVVFDHHPEVDDHRDALARAREQLA
GKGIAVTTLDAIADEGAGLPAEPIYTADHDQRLAMILYTSGSTGAPKGAMYTEAMV
ARLWTMSFITGDPTPVINVNFMPLNHLGGRIPISTAVQNGGTSYFVPESDMSTLFE
DLALVRPTELGLVPRVADMLYQHHLATVDRLVTQGADELTAEKQAGAELREQVLGG
RVITGFVSTAPLAAEMRAFLDITLGAHIVDGYGLTETGAVTRDGVIVRPPVIDYKL
IDVPELGYFSTDKPYPRGELLVRSQTLTPGYYKRPEVTASVFDRDGYYHTGDVMAE
TAPDHLVYVDRRNNVLKLAQGEFVAVANLEAVFSGAALVRQIFVYGNSERSFLLAV
VVPTPEALEQYDPAALKAALADSLQRTARDAELQSYEVPADFIVETEPFSAANGLL
SGVGKLLRPNLKDRYGQRLEQMYADIAATQANQLRELRRAAATQPVIDTLTQAAAT
ILGTGSEVASDAHFTDLGGDSLSALTLSNLLSDFFGFEVPVGTIVNPATNLAQLAQ
HIEAQRTAGDRRPSFTTVHGADATEIRASELTLDKFIDAETLRAAPGLPKVTTEPR
TVLLSGANGWLGRFLTLQWLERLAPVGGTLITIVRGRDDAAARARLTQAYDTDPEL
SRRFAELADRHLRVVAGDIGDPNLGLTPEIWHRLAAEVDLVVHPAALVNHVLPYRQ
LFGPNVVGTAEVIKLALTERIKPVTYLSTVSVAMGIPDFEEDGDIRTVSPVRPLDG
GYANGYGNSKWAGEVLLREAHDLCGLPVATFRSDMILAHPRYRGQVNVPDMFTRLL
LSLLITGVAPRSFYIGDGERPRAHYPGLTVDFVAEAVTTLGAQQREGYVSYDVMNP
HDDGISLDVFVDWLIRAGHPIDRVDDYDDWVRRFETALTALPEKRRAQTVLPLLHA
FRAPQAPLRGAPEPTEVFHAAVRTAKVGPGDIPHLDEALIDKYIRDLREFGLI
10
entD E. coli
MKTTHTSLPFAGHTLHFVEFDPANFCEQDLLWLPHYAQLQHAGRKRKTEHLAGRIA
AVYALREYGYKCVPAIGELRQPVWPAEVYGSISHCGTTALAVVSRQPIGIDIEEIF
SVQTARELTDNIITPAEHERLADCGLAFSLALTLAFSAKESAFKASEIQTDAGFLD
YQIISWNKQQVIIHRENEMFAVHWQIKEKIVITLCQHD
11
acrM
MNAKLKKLFQQKVDGKTIIVTGASSGIGLTVSKYLAQAGAHVLLLARTKEKLDEVK
Acinetobacter
AEIEAEGGKATVFPCDLNDMESIDAVSKEILAAVDHIDILVNNAGRSIRRAVHESV
sp. M-1
DRFHDFERTMQLNYFGAVRLVLNVLPHMMQRKDGQIINISSIGVLANATRFSAYVA
SKAALDAFSRCLSAEVHSHKIAITSIYMPLVRTPMIAPTKIYKYVPTLSPEEAADL
IAYAIVKRPKKIATNLGRLASITYAIAPDINNILMSIGFNLFPSSTASVGEQEKLN
LIQRAYARLFPGEHW
12
fadD E. coli
MKKVWLNRYPADVPTEINPDRYQSLVDMFEQSVARYADQPAFVNMGEVMTFRKLEE
RSRAFAAYLQQGLGLKKGDRVALMMPNLLQYPVALFGILRAGMIVVNVNPLYTPRE
LEHQLNDSGASAIVIVSNFAHTLEKVVDKTAVQHVILTRMGDQLSTAKGTVVNFVV
KYIKRLVPKYHLPDAISFRSALHNGYRMQYVKPELVPEDLAFLQYTGGTTGVAKGA
MLTHRNMLANLEQVNATYGPLLHPGKELVVTALPLYHIFALTINCLLFIELGGQNL
LITNPRDIPGLVKELAKYPFTAITGVNTLFNALLNNKEFQQLDFSSLHLSAGGGMP
VQQVVAERWVKLTGQYLLEGYGLTECAPLVSVNPYDIDYHSGSIGLPVPSTEAKLV
DDDDNEVPPGQPGELCVKGPQVMLGYWQRPDATDEIIKNGWLHTGDIAVMDEEGFL
RIVDRKKDMILVSGFNVYPNEIEDVVMQHPGVQEVAAVGVPSGSSGEAVKIFVVKK
DPSLTEESLVTFCRRQLTGYKVPKLVEFRDELPKSNVGKILRRELRDEARGKVDNK
A
13
fatB(C12
MATTSLASAFCSMKAVMLARDGRGMKPRSSDLQLRAGNAPTSLKMINGTKFSYTES
fatty acid)
LKRLPDWSMLFAVITTIFSAAEKQWTNLEWKPKPKLPQLLDDHFGLHGLVFRRTFA
Umbellularia
IRSYEVGPDRSTSILAVMNHMQEATLNHAKSVGILGDGFGTTLEMSKRDLMWVVRR
californica
THVAVERYPTWGDTVEVECWIGASGNNGMRRDFLVRDCKTGEILTRCTSLSVLMNT
RTRRLSTIPDEVRGEIGPAFIDNVAVKDDEIKKLQKLNDSTADYIQGGLTPRWNDL
DVNQHVNNLKYVAWVFETVPDSIFESHHISSFTLEYRRECTRDSVLRSLTTVSGGS
SEAGLVCDHLLQLEGGSEVLRARTEWRPKLTDSFRGISVIPAEPRV
14
fatBmat(fatB
MEWKPKPKLPQLLDDHFGLHGLVFRRTFAIRSYEVGPDRSTSILAVMNHMQEATLN
without
HAKSVGILGDGFGTTLEMSKRDLMWVVRRTHVAVERYPTWGDTVEVECWIGASGNN
leader
GMRRDFLVRDCKTGEILTRCTSLSVLMNTRTRRLSTIPDEVRGEIGPAFIDNVAVK
sequence)
DDEIKKLQKLNDSTADYIQGGLTPRWNDLDVNQHVNNLKYVAWVFETVPDSIFESH
Umbellularia
HISSFTLEYRRECTRDSVLRSLTTVSGGSSEAGLVCDHLLQLEGGSEVLRARTEWR
californica
PKLTDSFRGISVIPAEPRV
15
fatB2(C8 C10
MVAAAASSAFFPVPAPGASPKPGKFGNWPSSLSPSFKPKSIPNGGFQVKANDSAHP
fatty acid)
KANGSAVSLKSGSLNTQEDTSSSPPPRTFLHQLPDWSRLLTAITTVFVKSKRPDMH
Cuphea
DRKSKRPDMLVDSFGLESTVQDGLVFRQSFSIRSYEIGTDRTASIETLMNHLQETS
hookeriana
LNHCKSTGILLDGFGRTLEMCKRDLIWVVIKMQIKVNRYPAWGDTVEINTRFSRLG
KIGMGRDWLISDCNTGEILVRATSAYAMMNQKTRRLSKLPYEVHQEIVPLFVDSPV
IEDSDLKVHKFKVKTGDSIQKGLTPGWNDLDVNQHVSNVKYIGWILESMPTEVLET
QELCSLALEYRRECGRDSVLESVTAMDPSKVGVRSQYQHLLRLEDGTAIVNGATEW
RPKNAGANGAISTGKTSNGNSVS
16
fatB2mat(fatB
MDRKSKRPDMLVDSFGLESTVQDGLVFRQSFSIRSYEIGTDRTASIETLMNHLQET
2 without
SLNHCKSTGILLDGFGRTLEMCKRDLIWVVIKMQIKVNRYPAWGDTVEINTRFSRL
leader
GKIGMGRDWLISDCNTGEILVRATSAYAMMNQKTRRLSKLPYEVHQEIVPLFVDSP
sequence)
VIEDSDLKVHKFKVKTGDSIQKGLTPGWNDLDVNQHVSNVKYIGWILESMPTEVLE
Cuphea
TQELCSLALEYRRECGRDSVLESVTAMDPSKVGVRSQYQHLLRLEDGTAIVNGATE
hookeriana
WRPKNAGANGAISTGKTSNGNSVS
17
kivd
MYTVGDYLLDRLHELGIEEIFGVPGDYNLQFLDQIISRKDMKWVGNANELNASYMA
Lactococcus
DGYARTKKAAAFLTTFGVGELSAVNGLAGSYAENLPVVEIVGSPTSKVQNEGKFVH
lactis
HTLADGDFKHFMKMHEPVTAARTLLTAENATVEIDRVLSALLKERKPVYINLPVDV
AAAKAEKPSLPLKKENPTSNTSDQEILNKIQESLKNAKKPIVITGHEIISFGLENT
VTQFISKTKLPITTLNFGKSSVDETLPSFLGIYNGKLSEPNLKEFVESADFILMLG
VKLTDSSTGAFTHHLNENKMISLNIDEGKIFNESIQNFDFESLISSLLDLSGIEYK
GKYIDKKQEDFVPSNALLSQDRLWQAVENLTQSNETIVAEQGTSFFGASSIFLKPK
SHFIGQPLWGSIGYTFPAALGSQIADKESRHLLFIGDGSLQLTVQELGLAIREKIN
PICFIINNDGYTVEREIHGPNQSYNDIPMWNYSKLPESFGATEERVVSKIVRTENE
FVSVMKEAQADPNRMYWIELVLAKEDAPKVLKKMGKLFAEQNKS
TABLE 2
General
Enzyme
Gene
Accession
Enzyme Activity
Activity
Enzyme
EC #
Name
Organism
Number
1
Alkane
An aldehyde +
alkane
4.1.99.5
adm
Cyanothece sp.
YP_001802195
deformylative
O2 + 2 NADPH +
deformylative
ATCC 51142
monooxygenase
2 H+ = an (n-1)
monooxygenase
adm
Nostoc
YP_001865325
activity
alkane +
punctiforme
formate + H2O +
adm
Prochlorococcus
YP_397029
2 NADP+
marinus MIT 9312
adm
Thermosynechococcus
NP_682103
elongatus
BP-1
2
Carboxylic acid
An aldehyde +
carboxylic acid
1.2.99.6
carB
Mycobacterium
YP_889972
reductase activity
acceptor + H2O =
reductase
smegmatis str.
a carboxylate +
MC2 155
reduced acceptor
car
Nocardia
AAR91681
iowensis
fadD9
Mycobacterium
YP_001850422
marinum M
3
Phosphopanthetheinyl
CoA-[4′-
phosphopanthetheinyl
2.7.8.7
entD
Escherichia
coli
NP_415115
transferase
phosphopantetheine] +
transferase
sfp
Bacillus
subtilis
ZP_12673024
activity
apo-[acyl-carrier
subsp. subtilis str.
protein] =
SC-8
adenosine 3′,5′-
bisphosphate +
holo-[acyl-
carrier protein]
4
Thioesterase
A fatty acyl-
thioesterase
3.1.2.14
fatB2
Cuphea
AAC49269
activity
[acyl-carrier
hookeriana
protein] + H2O =
tesA
Escherichia
coli
NP_415027
[acyl-carrier
FatB3
Cocos
nucifera
AEM72521
protein] + a
fatty acid
Ua-
Ulmus
americana
AAB71731
FatB1
5
Long-chain acyl-
An aldehyde +
long-chain acyl-
1.2.1.50
acrM
Acinetobacter sp.
BAB85476
CoA reductase
CoA + NADP+ =
CoA reductase
M-1
activity
an acyl-CoA +
ucpA
Escherichia
coli
NP_416921
NADPH + H+
ybbO
Escherichia
coli
NP_415026
luxC
Photorhabdus
NP_929340
luminescens
subsp. laumondii
TTO1
acr1
Acinetobacter sp.
YP_047869
ADP-1
6
Long-chain fatty
ATP + a long-
long-chain fatty
6.2.1.3
fadD
Escherichia
coli
NP_416319
acid CoA-ligase
chain fatty acid +
acid CoA-ligase
fadD
Synechococcus
YP_001733936
activity
CoA = AMP +
elongatus
diphosphate +
TTC0079
Thermus
YP_004054
an acyl-CoA
thermophilus
HB27 | The present disclosure identifies methods and compositions for modifying photoautotrophic organisms as hosts, such that the organisms efficiently produce alkanes, and in particular the use of such organisms for the commercial production of alkanes and related molecules. Other materials, methods, and compositions are also described. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 11/404,572, filed on Apr. 14, 2006, of like title.
BACKGROUND OF THE INVENTION
[0002] The invention herein relates to table card games. More particularly it relates to poker games and apparatus used for the play thereof, and particularly adapted for use in casinos.
[0003] In the past there been numerous poker games played in the conventional manner in which the individual players play against each other and where the position of the dealer rotates among the players. Cardhouse/casino poker games may have a house dealer sit in to deal the cards but the dealer is not involved in the game itself, and the players still play only against each other. Conversely there are other games such as Caribbean poker in which each player plays only against the house dealer and the specific hand held by each of the players is of little consequence to the other players. Games in which a player can play simultaneously with a single hand against both a dealer and the other players are seldom found. However, such games are anticipated to be highly popular with players because the games give them the opportunity to have two winnings with each hand, one against the house dealer and the other against the other players.
[0004] Similarly, in the past there have been games which have been played with distorted decks of cards, such as games in which one or more cards, card values or card suites are removed from the deck before hands are dealt. Such games are not relevant to the present invention, since the playing of poker requires that all 52 cards be in the deck from which the hands are dealt, so that all of the possible card combinations expected by players in poker games are capable of being dealt from the deck in each hand. (The inclusion of one or two jokers as additional cards in the deck does not alter this requirement. The joker does not diminish the number of natural poker card combinations that can potentially be dealt from the deck, it merely increases the number of ways those combinations can be dealt.) While games utilizing such non-standard decks may be enjoyable to their players, they cannot be considered to be poker or relevant to poker.
[0005] There have also long been methods of dealing cards from a deck in sequences other than the randomized card order which follows a thorough shuffle of the deck. Among the most common of these distorted dealing sequences occurs when a dealer deals a card from the bottom of the deck or deals the second card in the deck rather than dealing the first card, i.e., the card on the top of the deck. By using such “crooked deals” dishonest dealers have intended to cheat other players in the card game, such as by providing one or more of the other players with poorer value hands than they would otherwise have had, or by providing a better value hand to one player (usually a confederate of the dealer or a shill for the house) than that player would otherwise have had, all in order to increase the winnings of the dealer, the confederate and/or the house. Since such forms of dealing are intended to cheat players in a game, they are of course also intended to be kept secret from the players who are being cheated. They are also uniformly considered illegal. Therefore, notwithstanding that such forms of dealing might theoretically be labeled as “biased,” they are not relevant to the “biased deal” concept included in the present invention, where the purpose is to enhance the overall opportunities for all of the players in a poker game and the nature and presence of the biased dealing are known to all players and are considered by the players to be both essential and desired.
SUMMARY OF THE INVENTION
[0006] The invention herein is a unique poker card game, particularly adapted for casino play, in which each player in a given game, using only a single dealt hand, plays simultaneously separately against the dealer (the house) and against the other players. Betting for the two lines of play may be separate or may be linked, and a player can elect to play only against the dealer or to play both lines together. A player can fold against the other players without also folding against the dealer, but cannot fold against the dealer without thereby also folding against the other players.
[0007] The game is played as a form of five-card stud starting with an ante and an initial two-card deal face up to all players and the dealer, and progresses with subsequent one-card deals, also face up, with betting before each deal. At the end of each hand a player's status as to whether he/she beat the dealer, beat the other players or both, is determined and displayed, and winners are paid accordingly. Any or all of the players may be winners against the dealer. With respect to the players' pool pot, several alternatives are possible, and any one may be chosen or two or more combined for specific games at the selection of the house or of the players. The preferred alternative is that only the player with the highest ranking hand will win the pool pot, but only if that player also beats the dealer. Another alternative is that only the player with the highest ranking hand will win the pool pot, but that player need not also beat the dealer. Yet another alternative is that if no player beats the dealer on a hand, the money in the pot rolls over to the next hand and is incorporated into that hand's pot. Still another alternative is that two or more players share the pot, under conditions which may include whether or not one or more has also beaten the dealer on the hand, how the players' hands ranked compared to each other, and whether shares are to be equal or divided in accordance with predetermined ratios based on relative hand rankings. It will be evident that two or more of these alternatives may in some cases be combined, as long as the combination conditions are consistent. While the dealer does not bet into or otherwise participate in the players' pool pot, the casino or house may have a rake on that pot for a small percentage (often with a dollar amount cap) or a flat amount, which the dealer collects after the hand is completed but before the pot is distributed. The players' pool pot rake will be separate from amounts lost by the players when playing against the dealer.
[0008] Conventional dealing may be used, but it is preferred that a biased deal, which reduces the proportion of weak poker hands from that produced by normal non-biased deals and thereby enhances the opportunities for players to be dealt reasonably good poker hands, be used to encourage players to play complete hands (i.e., not fold during a hand).
[0009] While the game may be played manually with dealt cards laid face up on a poker table surface, the game is primarily intended to be played as an electronic casino game, using a specially configured table with computer monitors built into the table at the dealer's position and at each player's position. All of the monitors are connected to a central (usually dedicated) computer processing unit which may also be built into the table. The software which runs on the processing unit and operates the play of the game is controlled from the dealer's monitor which includes a touch screen controller. The players' monitors can also have touch screens to communicate with the processor, but usually only for the purpose of indicating that a player wishes to bet or fold prior to a deal. Preferably the players' monitors will be for viewing only and players will announce verbally at the table whether they are betting or folding prior to each deal, and after each player has verbally announced the dealer will enter any folds into the system via his/her touch screen and then activate the deal of the next card, also from the touch screen.
[0010] The game as designed has great attractiveness to players because of its ability to generate multiple winners on each hand. Each player has the chance on a single hand to be both a winner against the dealer (house) and also the players' pot winner. Multiple players can win on a single hand against the dealer. If the house or table rules permit, there can also be a variation where multiple players can split the players' pot. The use of a biased deal enhances the attractiveness, since all players can expect to be dealt hands that are good enough in ranking to be worth playing through an entire hand or at least through the first or second additional dealt cards. Because players stay in each hand longer, larger player pots are built, and players find the potential rewards of playing and winning to be a significant enticement to play the game, as compared to prior art casino poker games.
[0011] In the description of the invention herein, the term “game” will be used in two senses. In the broad discussion “game” will mean the overall inventive concept of the described variation of poker in which players can obtain two winnings on a single hand of cards. In this sense, players may participate in the “game” over a period of time (e.g., several hours) repeatedly dealing, betting and playing an extended sequence of dealt hands. Thus players would, say, spend an evening “playing the game.” Alternatively, in the description of play herein “game” will mean a single round of deals and bets to determine the outcomes of a single hand for each player against the dealer's hand and the other players' hands. In this sense, each round of dealing of a five-card hand to the dealer and each player, with the resultant payout of winnings against the dealer and distribution of the pool pot, constitutes a “game” and the players and dealer thereafter start another “game” with another dealt hand to the dealer and each player. This second usage is to avoid possible confusion with the use of the term “hand” when the latter refers to the cards dealt to each player and the dealer. The distinction is that each player and the dealer receives, evaluates and plays their own individual “hands” within a single “game” and then, following the completion of the “game” using those “hands,” they proceed to a next “game” with a new round of “hands.” The context will make evident the intended meaning of each of the terms where they appear.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan view of a casino table configured for playing the poker game of the present invention showing the dealer's positions, positions for up to six players and a typical position for the accumulation of the chips in the players' pool pot.
[0013] FIG. 2 is a diagram of the dealer's monitor screen prior to start of a game.
[0014] FIG. 3 is a diagram of a player's table position prior to start of a game, showing both the player's monitor screen and the markers indicating locations for placement of bets by the player.
[0015] FIG. 4 is a diagram of the dealer's monitor screen after the antes have been placed and the initial two cards dealt. The Xs in columns 1 and 6 indicate that there are no players at those positions for this game.
[0016] FIG. 5 is a diagram of a typical example of one player's monitor screen and table position (using the example of Player 2 ) after the antes have been made and the initial two cards dealt. The players ante chip(s) cover the first bet marker.
[0017] FIGS. 6 , 7 , 10 and 11 are diagrams showing the cards indicated on all of the players' monitor screens and the dealers monitor screen following, respectively, the ante deal and three subsequent card deals showing the progress of example hands of the game of the present invention.
[0018] FIGS. 8 and 9 are diagrams, respectively, of the monitor screen of a player (here exemplified by Player 4 ) and the dealer's monitor screen following that player's folding during the example game.
[0019] FIG. 12 is a diagram of the monitor screen at the end of the game of a player (in this example Player 3 ) who has both beaten the dealer and also won the pot against the other players. The monitor screens of the other players who complete the game will be similar with the applicable “WIN” or “LOSE” indicated for each player with respect to the “dealer hand” and the “player pot”.
[0020] FIG. 13 is a diagram of the dealer's monitor screen following the end of the exemplary game, showing the dealer's final hand and the “WIN”, “LOSE” or “FOLD” status of each player upon conclusion of the game.
[0021] FIGS. 14A and 14B (collectively “FIGS. 14A/B”) are a schematic flow diagram of the software logic for playing of a single hand of the game of the invention. FIG. 14A shows the initiation of the hand and dealing of the initial two cards, while FIG. 14B shows the dealing of the remainder of the cards and completion of the hand.
[0022] FIG. 15 is a pictorial diagram of the computer hardware used as the electronic part of the apparatus of the game.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The present invention is best understood by reference to the Figures and the subsequent recitation of the play of an example game. FIGS. 1 and 15 show the apparatus used for playing of the game. FIG. 1 illustrates the typical arrangement of a casino table 20 configured for the present game with up to six players and a dealer. The players' positions are indicated by the circles numbered 1 - 6 along the curved perimeter of the table 20 , proceeding counter-clockwise starting on the dealer's right. There may be fewer or more player positions, up to eight (the maximum allowable for single-deck poker), depending on the configuration of the table and space available on the casino floor; five or six positions would be the normal number of table positions in most casinos. Playing of the game is not dependent upon players occupying all of the available positions. Conveniently the conventional half-circle casino card game table 20 is used, although other table configurations are suitable depending on the number of players and the ability of each player to see the other players' and dealer's monitor screens showing their hands. Adjacent to the dealer's position is a conventional poker chip rack 26 and a marked area 28 for collection of chips bet into pool pot.
[0024] In front of the dealer's position and each of the players' positions is a computer monitor screen 22 or 24 built into the tabletop. All the players' screens 24 have the same configuration, which includes a card viewing portion 25 in which images of the player's cards appear. It is preferred that at all times during a hand five card images remain on each player's screen in portion 25 so that each player can easily follow the play of the game. At the start of a hand all cards will be face down, so the screen image will show only the backs of all five cards, as indicated in FIG. 3 . As each hand progresses, successive cards will be “dealt” face up, so the images of the “dealt” cards will change to images of the faces of those cards, as indicated in, e.g., FIGS. 6 , 7 , 10 and 11 , until the game is completed and all the values of all “dealt” cards are revealed. An equivalent display of the dealer's cards appears in portion 30 of the dealer's monitor screen 22 .
[0025] In other regards, however, the dealers screen 22 is significantly different from the players' screens. The dealers screen 22 , which is shown in FIG. 2 in its configuration prior to initial dealing of the hands, is a touch control screen which allows the dealer to operate the computer software which controls the play and flow of the game. The upper portion 30 of the dealer's screen, which is closest to the players, shows the cards being played in the dealer's hand. Three of the four lower rows 32 , 34 , 36 , 38 (the control rows) of the dealer's screen 22 are variable: and allow the dealer to run the game. In the initial configuration the upper part 30 of the dealer's screen 22 , where the cards in play will be shown during the hand, will either be blank or, as illustrated, show the backs of up to five cards. (Alternatively a casino may elect to have some other indicia shown in portion 30 between games, such as the casino logo or promotional material, but such is not recommended because of the likely effect of being distracting to the players as they prepare for the subsequent game.) The first control row 32 below the card display portion 30 shows the control button 40 for starting a new game as well as the lighted indicators 42 and 44 which show, respectively, whether a new game is in progress or the previous game has ended. The second ( 34 ), third ( 36 ) and fourth ( 38 ) control rows on the dealer's screen 22 are divided into the same number of columns as there are positions at the table 20 for potential players (illustrated in this example as six columns and players), with each player's column designated in the second control row 34 by the player's seating position number 1 - 6 . This row 34 of control buttons does not change its appearance; the buttons are normally used to close out a player's position column if no player is seated at that position or a seated, player folds during a hand. Below the position number row 34 in each of the columns there is a touch control button in third row 36 for the dealer to signal to the software as to whether or not the respective player wishes to bet on the next card in the player's individual game against the dealer, and another control button in fourth row 38 for the dealer to signal to the software as to whether or not the player wishes to bet on the next card against the other players in the players pot. If there is no player at a particular position the dealer's control buttons for that player's position in the third and fourth rows 36 and 38 show the letter X (or some other “non-playing” indicia such as the casino logo) as illustrated in FIG. 4 . In FIG. 2 for convenience in describing the invention there is shown an asterisk for each of the player position control buttons in rows 36 and 38 at the start of the game, but in actual practice there would probably be some decorative indicia shown such as the casino's logo in place of the asterisk.
[0026] The overall configuration and interconnection of the electronic devices used in the apparatus are illustrated in FIG. 15 . The central processing unit (CPU) 15 is loaded with the necessary software (which is described in FIGS. 14 A/B) for conduct of the game and operation of the display of all of the monitors 22 and 24 . Routing of the signals to the various monitors 22 and 24 as directed by the software is accomplished through router 17 . CPU 15 and router 17 are interconnected with each other, and each is also interconnected with each of the monitors. The monitors, however, need not be interconnected with each other. Each player, and the dealer can thus communicate with the software from his/her respective monitor 22 or 24 . Preferably the software does not allow for direct communication among the players' monitors 24 . The software may allow each player's monitor 24 may to communicate directly with the dealer's monitor 22 but preferably all communication from any player's monitor 24 to the dealer's monitor 22 will be routed through the router 17 , which will also permit the communication (such as a “fold” signal from a player via his/her monitor touch screen) to appear on both the dealer's monitor 22 and also on the monitors' 22 of the other players. A general purpose computer 19 may also be present to provide means of configuration of the game software running on the CPU 15 . It is not necessary that the computer 19 be permanently interconnected with the CPU 15 ; rather conventional connection means such as a USB connection may be provided so that the computer 19 can be temporarily connected to CPU 15 as needed but disconnected and used for other purposes at other times. It is contemplated that the electronic apparatus and the table 20 can be used for playing of other electronic games, including card games, by running of appropriate software on CPU 15 . For the purpose of the present invention, however, the description herein will be based on having the CPU 15 running the software defined in connection with FIGS. 14 A/B.
[0027] In the exemplary play of a game described herein, a game with four players present, seated at positions 2 - 5 , is illustrated. Each player's screen 24 prior to dealing of a hand is normally blank or merely shows the backs of up to five cards, as illustrated in FIG. 3 . On the table surface above the each of the players' screens in the area indicated as 46 are marked the letter P and below that a row of the numerals 1 - 4 . The letter P is the marked location for each player to place his or her chips' to bet in the player pool and the numbers 1 - 4 are the marked locations for placing of the ante and the following bets on the successive individual cards dealt in each player's individual game against the dealer.
[0028] The game is started by each of the players anteing by placing one or more chips 50 on the 1 marker in front of each player position, as illustrated in FIG. 5 . If a player also wishes to play in the player pot aspect of the game he or she also places one or more chips (not shown) on the letter P marker. The dealer inputs to the software through the dealer's screen 22 whether each player is playing against the dealer/house only or also against the other players for the players' pool pot. The amount of betting and/or raising during the play of a hand may or may not be limited according to the house or table rules for the particular game being played. As will be discussed below, various alternatives are contemplated. In one preferred embodiment, either the ante or the first bet by the first player fixes at that amount the bets that all other players must call, if they do not wish to fold. In this embodiment that first bet also fixes at that amount the bets allowable in the subsequent rounds of that game. Raising is not allowed. In other alternatives subsequent players in a round may raise, and that raise maybe limited to a predetermined amount; and/or the bet on each subsequent round may be reset by the bet on the ranking player in that round; and/or checking by the ranking and subsequent players in a round may be allowed, with a subsequent player in the round starting the betting. It will be evident that any level of betting, calling and/or raising may be specified by rules for a game, series of games or an entire period of play.
[0029] Once all players have anteed the dealer moves the pot chips from the P markers in front of the players to the “Pot” area 28 of the table close to the dealer and then presses the “start game” button 40 on the dealer's control screen so that the apparatus “deals” the first two cards electronically to the dealer and each player face up. The deal may be a regular poker deal or it may be a biased deal as will also be discussed below. At the end of this first deal the dealers screen changes to the configuration shown in FIG. 4 to show the dealers initial cards and each players screen shows the initial cards dealt to the player as indicated in FIG. 5 . Each player can now see the status of the other players' hands as well as the dealer's hand as diagramed in FIG. 6 (in which the players' positions are shown as in FIG. 1 , with Player 2 at the dealers right and the other Players 3 , 4 and 5 in sequence counter-clockwise, ending with Player 5 on the dealers left). Note that the dealers cards are oriented so as to face the players (reading the cards conventionally from left to right) while the players' screens also have the same orientation, so that all card hands are facing the players.
[0030] Customarily as in other poker games the player with the highest ranking hand shown (in the example this is Player 3 with cards A-K) starts the betting for the deal of the next card, by placing the appropriate chips on the 2 position marker. Each of the other players in sequence around the table then decides whether to call the bet, raise the bet or fold his/her hand, depending on the rules of the game. The dealer neither bets nor folds throughout the hand. In the example game each of the player is shown as continuing with a bet (but no raise) in order to obtain a third card in this round. If a player betting also bets into the pot by placing additional chip(s) on the letter P in front of him/her all other players must also bet into the pot if they wish to continue in the player pool pot. A player may at any time stop placing any further chips into the pool pot but if he/she does so his/her chips already played into the pot in this game are forfeited and he/she is not permitted to reenter the pool pot on subsequent card rounds in this game. However, the player continues to play against the dealer unless he/she subsequently folds.
[0031] When all bets are placed the dealer again collects the pot chips placed on the P markers, moves them into the “pot” 28 and then presses the “deal” button 48 on his control screen 22 and the apparatus deals a third card to the dealer and each of the continuing players. The configuration of the screens after this second deal is shown in FIG. 7 . Once again the then-highest ranking player (in the example this is still player 3 now with A-K-K) starts the next round of betting by checking or placing a bet on the 3 marker on the table in front of him/her. Each player in sequence again decides whether to bet, call, raise or fold in the conventional poker manner. At this stage in the example Player 4 decides to fold his/her hand. The dealer will then collect that folded player's chips on the player's 1 and 2 markers and the player's chips placed in the player pot by the player will be forfeited to the pot. The dealer also then presses the bet and pot buttons in column 4 of the dealer's screen, which causes the word “FOLD” to be displayed on the dealer's screen 22 in column 4 as shown in FIG. 9 and the word “FOLDED” to be displayed across Player 4 's cards on his/her screen 24 as shown in FIG. 8 , so that the continuing players have a visual indication that Player 4 has folded and is no longer participating in the game.
[0032] The last two rounds follow in the same manner with the status of the hands being as shown in FIGS. 10 and 11 . In the example all the remaining Players 2 , 3 and 5 are shown to have elected to continue through the final deal. It will be seen from FIG. 11 that the dealer ended with a straight with J-10 high. Player 5 therefore loses to the dealer since Player 5 's hand is a lower ranked straight (9-8 high). As noted above, it is preferred that a player's loss against the dealer will also constitutes the player's loss against the pot. Player 2 , on the other hand, has beaten the dealer by having a flush, which outranks the dealer's straight in the conventional poker hand hierarchy. The dealer therefore pays Player 2 a number of chips equal to the number of chips which Player 2 has bet on his/her 1-4 markers (a 2-1 payoff). Player 2 , however, loses to Player 3 for the chips in the pot, since Player 3 has obtained a full house (Ks over As) which ranks higher than the hands of the dealer and of Players 2 and 5 . Player 3 therefore receives the 2-1 payoff for his/her 1-4 bets from the dealer and also collects the entire pot from the other players; i.e., he receives all of the chips accumulated in the “pot” area 28 . Player 3 's final screen 24 is shown in FIG. 12 indicating both his final hand and his wins against the dealer and the other players in the pool pot. The final screens 24 for Players 2 and 5 are not shown, but similarly show the player's final hand and “win/lose” status against the dealer and in the pool pot. (The chips placed on the 1-4 markers sequentially during play of the game are not shown directly in the Figures. It will be understood, however, that for each player who completes a game, at the end of the game there will be chips 50 ′ on each of the 1-4 markers, as indicated in phantom in FIG. 12 , which will be equal to the player's bet against the house/dealer. A player who has beaten the dealer will receive the payoff described above based on the chips bet on the 1-4 markers, while the chips on the 1-4 markers of players who have lost to the dealer will be collected by the dealer.
[0033] Normally there will be a definite “high hand” among the players so that, preferable assuming that the high hand has beaten the dealer's hand, the player with the high hand will be the sole winner of the players' pot. In the rare instance where two players have equally high hands (for instance, two equal straights or flushes), the pot can be split between them. It is also contemplated that house or table rules can provide for split pots in other situations or even in every game in which two or more players complete the game (and, preferably, also beat the dealer). Pots may be split into equal shares to each player who beats the dealer, or they may be split into graduated-size shares according to the relative rankings, of the winning hands. In this regard, house or table rules may permit all players who complete the game (i.e., have not folded during the game) and who have also bet into the pot at each round of the hand, to participate in a split of the pot, even if they have not also beaten the dealer. The latter variation is not preferred, however, and should be considered only if the shares are graduated and the shares returned to players who did not beat the dealer are less than the amounts they bet into the pool pot, to discourage players with weak hands from continuing to play in a game in effect just to get some portion of their bet back.
[0034] The hand now being over, the dealer's screen for a period of time shows the configuration illustrated in FIG. 13 , with the dealer's final hand and the final hand status of all of the participating players. The final configurations of all dealer and player screens 22 and 24 are normally maintained until payment of all bets from the current game has been completed and dealing of the next hand is initiated. If there are no issues of play raised by any participant of the game, after the predetermined time the dealer's screen 22 reverts to the configuration shown in FIG. 2 and the players' screens 24 return to the FIG. 3 configuration in preparation for the next game. It is contemplated that the software can include a function to allow the dealer to extend the “hold” of the FIGS. 12 and 13 configurations following a game in the event that any participant in the game raises any issue regarding play of the game, so that all participants, can continue to refer to the results of the game while the issue is considered, whether by the participants, the dealer and/or representatives of the casino or appropriate gaming authorities. If desired, that function may include, after each hand, an automatic short time delay before the next deal can begin, to permit the dealer and the players time to review the play of the game and identify any suspected or actual discrepancies and see if a longer “hold” is needed. Such a time delay should normally be no more than about 1-2 minutes, to avoid undue slowing of the overall play. (However, in practice the time needed to pay bets from the just-completed game usually is sufficient time for any discrepancies to be noticed.)
[0035] The software which runs the game is illustrated schematically in FIGS. 14A and 14B . Specific coding is not shown, since the functions are clearly defined and those skilled in the art will be readily able to write software which accomplishes these functions. It is contemplated that various software codes may be used for the different functions. Regardless of the specific code, however, it will be recognized that software which performs the defined functions in any sequence which results in the games of this invention will be within the scope of the appended claims. As illustrated in FIG. 14A , the game is first activated by the dealer's touching the START GAME command 40 on his/her monitor 22 's touch screen. The software then displays five cards face down on the card area 25 of each player's monitor 24 as described above, as well as in the card area 30 of the dealer's monitor 22 , as indicated at 60 and 62 . The dealer then presses the NEW GAME command 42 and the software defaults to the players' previous bets at 64 . If new players have come to the table, or prior players have left, or any of the continuing players has changed his/her bet, such changes are accommodated by the dealer at 66 and 68 , to enter into the system the new information in areas 36 and 38 on his/her monitor 22 , as needed for proper playing of the new hand. Once the system is in order, the dealer presses the DEAL command 48 and the first two cards are dealt, as indicated at 70 and 72 . The respective card images then change to showing the card faces, as illustrated in FIGS. 5 and 6 . The hand then proceeds as indicated above as the players evaluate their initial two cards and bet accordingly for the next card. The dealer observes whether any players have folded at 74 and if so, updates the dealer's screen and each folder player's screen accordingly at 76 . Thereafter the dealer again activates the DEAL command 48 , next card is dealt at 78 and the hand continues with the players again evaluating their hands and the dealer determining if any players have folded. If not all the cards have yet been dealt, the software process cycles as indicated at 80 and 82 . This loop continues until the final cards have been dealt to whichever players remain in the hand at the end. Once the final card has been dealt, the remaining hands are evaluated by the software at 84 and the winning and losing hands identified at 86 and shown in total on the dealer's screen as in FIG. 13 and for each remaining player, on his or her screen as in FIG. 12 . After a suitable review period as described above the dealer activates the GAME OVER command 52 and ends the hand at 88 . The software then resets itself pending the next hand. Alternatively the GAME OVER command can be activated automatically by the software at the end of the review period, unless the dealer has activated a REVIEW command (button not shown) as discussed above to permit further review of the game. It is contemplated that the software may include a function to present the words “GAME UNDER REVIEW” or equivalent indicia on all monitors in such instance.
[0036] It is also contemplated that preferably a “qualifying hand” will be established by house or table rules in order for a player to win against the dealer/house. For instance, the qualifying hand could be defined as a pair of sevens. If the dealer's hand upon completion of a game does not rank above a pair of sevens, all players that have not folding during the course of the game will win only a single bet against the dealer, rather than winning all four bets (on the 1-4 markers) against the dealer. Alternatively, the win against a non-qualifying dealer's hand for a player completing the game could be defined by rules as return of the player's ante bet placed on the 1 marker, with no winnings from any of the 2-4 marker bets. In either case all of the non-folded players wins the single- or ante-bet from the dealer, regardless of whether a player's hand does or does not beat the dealer's hand. Also, the ante and all 24 marker bets made by the non-folding players are retained by them.
[0037] The software system may also incorporate various functions common to other electronic games and game tables. For instance, for times when there may be no players at the table, the normal dealing and card displays on the monitors may be replaced by screen savers, displays of casino logos, game demos or teasers, or other displays of visual images and/or indicia. Such displays will usually be designed to attract players to the game and table. The system preferably will also have the capability of full recording all hands and the play of those hands during each game, and retaining such records for all or a series of games (usually at least a moving ten-game sequence). In practice, such function is intended to be present as a standard feature with complete recording, since it is commonly required by the governing gaming authorities that all games must be fully recorded and the records retained indefinitely of for a prescribed period for audit purposes, investigation or surveillance if cheating may be suspected, and similar regulatory purposes.
[0038] While it is mentioned above that the players' monitors 24 are for the purpose of the present game dedicated in their touch screen functions primarily to allow the player to communicate folds or similar game-related information to the dealer, it is contemplated that such dedication limits will be part of the software, so that if desired other functions may be present in the software that override or supplement those dedication functions. Such changes would be under control of the casino and not the players. For instance, the software may include functions that allow the touch screens of the monitors to be used for the playing of other games, the selection of various video or other visual images or indicia to be displayed on the monitors, or as general purpose monitors.
[0039] Each game can be played with a regular deal, as in a conventional poker game, so that the cards as dealt can be any five-card combination within a deck of cards from the lowest possible ranking hand (2-3-4-5-7, assuming A is high only) to the highest possible ranking hand (an A-high straight flush). However, it is preferred that biased dealing be used to enhance the game experience for the players. The purpose of a biased deal in the present game is to increase the likelihood that each of the players will be dealt a reasonably good poker hand. This reduces the chance that players will get poor early cards and fold at an early round, leaving only one or two continuing players and substantially reducing the amount of the player pot available. Numerous types of biased deal methods are known and most are likely to be suitable for use in the present game. The specific type of biased deal is not critical. However, a particularly preferred biased deal method for use in the present game is one in which the biasing comprises first selecting as an initial single hand rank a first random number between 0 and the number of possible hands and then utilizing the initial single hand rank with a deviation multiplier to determine a range of possible hand rankings for each of the players in the card game. Each player will have assigned a hand rank within that range. The effect of the biased deal is therefore to concentrate the values of hands dealt to all players around an initial hand value and decrease the proportion of hands of significantly lower or higher rank than the initial hand value which would otherwise have resulted from non-biased dealing of the hand. The players will not know each others' actual hand ranks, but will know that all of the hands will be within that range, and thus each player can play accordingly.
[0040] The process is best illustrated by first considering the number of hands (card combinations) possible in a conventional five-card poker game. There are nine types of hands, which are listed in the Table below in order from lowest value to highest value:
[0000] TABLE Hand Rankings Card Combination Hand Rank Value Range High Card 1–8 (no pair or higher combination) One Pair 9–21 Two Pairs 22–33 Three of a Kind 34–46 Straight 47–56 Flush 57–64 Full House 65–77 Four of a Kind 78–90 Straight Flush 91–100
Within each type of hand, the individual hands are further ranked by the face value of the specific cards, from the deuce (2) as the lowest value card and the ace (A) as the highest. Numerous gaps occur in the ordering within the various types, since some combinations nominally within a type may constitute a different type and thus have a higher value since the highest type prevails when evaluating a poker hand for instance, the lowest ranking five-card hand (hand rank=1) in poker is a 7-high, “high card” hand. While a 6-high hand would seem to be lower in value, the 6-high, five card hand actually comprises a 2-3-4-5-6 straight, a higher value combination. On the same basis, the lowest ranked flush is the 7-high flush, since the 6-high flush is the higher ranked 2-3-4-5-6 straight flush. Other such situations will be obvious to those skilled in the art, such as that a hand containing a pair must not also have a third card of the same value, since that would comprise three-of-a-kind, a higher ranked combination than a pair. When the gaps in sequence in the different hand types are taken into account, the result is that the actual number of hand ranks differs among the different hand types. For instance, there are thirteen four-of-a-kind hands (ranked 78-90), but only eight “high card”hands (ranked 1-8). In all cases of the hand rank range in the Table, however, regardless of the number of entries and gaps in each type, the specific rank numbers increase in the 2-A direction. (Note that while the order numbering of 1-100 is preferred as being common and easily understood, any numbering system that maintains the proper playing order of the hands and properly accounts for the increments between their respective value ranks can be used. In such cases corresponding adjustments may be needed in the formula, deviation multipliers and initial hand rank selection, which adjustments will be readily apparently to those skilled in the art.
[0041] For each game, a deviation multiplier is randomly assigned to each player. Deviation multiplier values are selected from the range of 0.1-4.0, more preferably 0.5-3.5. While use of only integer values is not required, for ease of computation it is common for the multipliers in an individual game to be limited to the integer values 1, 2 and 3. The higher the multiplier value, the wider will be the range of allowable hands for a player. At least one value must be different from the others, and it is preferred that the values assigned be distributed among the players in approximately equal quantities; e.g., for five players a preferred distribution might be 1 , 1 , 2 , 2 , 3 . The distribution to the individual players of these values is at random, so Player A might be assigned 2 , Player B assigned 3 , Player C assigned 1 , and so forth, and each player is told only his/her own value, and does not know the values assigned to the other players. (Any correspondence between an assigned deviation multiplier value for a player and that player's poker skill level is entirely coincidental; the deviation multiplier values are not skill-based as a golf handicap is.) Also an initial hand rank value is randomly selected, being equal to or less than the total number of possible hands. From the Table above it is seen that the total number of possible poker hands is one hundred, so the initial hand rank value is selected within the range of 1-100. The hand value for each player is then determined by, the formula:
[0000] Hand value=Initial Hand Rank Value±( N ×the Player's Deviation Multiplier)
[0000] where N is a number in the range of about 5.0-15.0, preferably 8.0-12.0. While integer values are not required for N, again for ease of computation in a game it is common for N to be designated as the integer 10. The higher the value of N, the wider the range of allowable hands for a player. In an individual-game, N will be held the same for all players. Application of this formula is straight-forward. For example, assume that the initial hand rank value selected is 50, which corresponds to an 8 high straight. If N=10, for Player A the hand value range would then be 30-70, which is equal to 50±(10×2). That range corresponds to all hands from two pair, J-high (lowest) through full house, 7-high, so in the biased deal for that game, Player A would not be dealt a hand outside that range; i.e., Player A could not be dealt a very low (value=0-29) hand nor a very high (value=71-99) hand. The players are aware that biased dealing is in effect, but they do not know what value has been selected for the initial hand rank value nor do they know what deviation values have been assigned to them. Therefore only as play progresses will each player be able to assess how his/her hand appears to compare to each other player. However, since all players enter the game aware that they have a reasonably good chance to win the game, there is a much enhanced tendency for all players to stay in the game through one or more betting rounds than would be the case in an unbiased deal, where it is much more common for very high and very low hands to be dealt and to become evident quickly, thus suppressing the competition in that unbiased game.
[0042] Whether a normal or a biased deal is used, the dollar value of the bets or raises permitted will be determined prior to the game by house or table rules. It is preferred, however, to keep bets and raises (if the latter are allowed) the same or within a narrow range in a hand, in order to encourage most or all of the players to stay in the hand and thus avoid having hands prematurely halted by a sudden overwhelming bet or raise by one player. By thus restricting bets and raises, the game experience is enhanced for all of the players. Thus, in a preferred mode the first player's ante or bet in the first round after the ante establishes the basic bet to the pot and thereafter all players must bet the same amount or raise by not more than a predetermined amount, which is preferably limited to no more than a low multiple of the basic bet. This prevents any player who has an apparently good hand based on early cards to bluff and attempt to “by the pot” by making a large early pot raise and thereby discouraging the other players from continuing. On the other hand, individual players' bets against the dealer may vary or may be determined by the initial player's bet, as predetermined by the house or table rules. Preferably each player's subsequent bet against the dealer (on the 2, 3 and 4 markers) must be the same as the player first bet at the beginning of the game (on the 1 marker). This is intended to protect the house, in that if a player after one or two card rounds senses that he/she is going to have a better hand than the dealer he/she cannot take advantage of the house by then increasing his/her bet substantially on the remaining rounds.
[0043] As mentioned above, the game is primarily intended to be played as an electronic casino game, using a specially configured table with computer monitors built into the table at the dealer's position and at each player's position. All of the monitors are connected to a central (usually dedicated) computer processing unit normally which may also be built into the table. The software which runs on the processing unit and operates the play of the game is controlled from the dealer's monitor which includes a touch screen controller. The players' monitors can also have touch screens to communicate with the processor, but only for the purpose of indicating that a player wishes to bet or fold prior to a deal round. Preferably the players' monitor will be for viewing only and players will announce verbally at the table whether they are betting or folding prior to each deal, and after each player has verbally announced the dealer will enter any folds into the system via his/her touch screen and then activate the deal of the next card, also from the touch screen.
[0044] The biased dealing function is normally incorporated directly into the software which otherwise operates the play of the game, although separate biasing software which runs in parallel with the game-play software is also contemplated. As indicated above, specific software coding to accomplish the deal biasing can be readily determined, installed and operated by those skilled in the art. The biasing function will normally be present as part of steps 72 and 78 in FIGS. 14 A/B, since it controls the specific cards to be dealt to the dealer and the players at each point in the hand. It is also contemplated that two or more different biasing methods may be utilized and included in the software. This would effectively allow the play of the poker games to be varied subtly, with different hands being played with different deal biasing in effect, so that players would need to alter their betting and playing strategies for the different hands. In variations on this, two or more different tables in a casino could be run using different deal biasing, so that players could play under the type of biasing they preferred by choosing which table to play at, or, at a single table, the games could be run under one biased dealing method for a specified period of time—such as one hour—and then switch to running under a difference method for a subsequent time period.
[0045] It will thus be seen that this game allows the players to win either by playing against the dealer or by playing against the other players or both. Not only does this feature of the invention make for a much more profitable game for players, but it also raises the players' interest in the progress of each hand since each player must consider not only the status of the other players' hands but also the dealer's hand in determining whether to bet, call, raise or fold on a particular round.
[0046] It will be evident that there are numerous embodiments of the present invention which, while not expressly set forth above, are clearly within the scope and spirit of the present invention. The scope of the invention is therefore to be determined solely by the appended claims and the embodiments described in the above specification are to be considered exemplary only. | A poker card game and apparatus and software for its play are disclosed, particularly adapted for casino play, in which each player in a given game, using only a single dealt hand, plays simultaneously separately against the dealer (the house) and against the other players. Betting for the two lines of play may be separate or linked, and a player can elect to play only against the dealer or to play both games together. The game is played as a form of five-card stud with betting before each deal. At the end of each game a player's status as to whether he/she beat the dealer, beat the other players or both is determined and displayed, and winners are paid accordingly. Conventional dealing may be used, but it is preferred that a biased deal, which enhances the opportunities for players to be dealt reasonably good poker hands, be used. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a search system for search and retrieval of information from a database and for updating of the database.
2. Discussion of the Background
Conventional database systems generally employ a single general purpose computer to perform all actions associated with the search and retrieval of information from the database. In such systems the computer may also serve other general timesharing tasks for users besides those of accessing the database. This can lead to delayed responses from the system for both the database users and the general users of the system.
Additionally there exist distributed database systems which are generally networks or general purpose computers communicating over a network such as ethernet. Again, these systems suffer the same problems with response time due to sharing of single processors for several tasks and the additional overhead of network communications. They do have advantage in that the database can be distributed between widely separated nodes if required. However, in a centralized environment the distributed database systems do not find application.
Multi-processor system concepts have been discussed for many years. The gains in the last few years of VLSI technology allowing high-speed processors with a high degree of operational capability to be placed in very small packages has enabled the development of such systems. There are commercial systems which employ multiple processors connected in a variety of topologies. One such example is described by Hillis, "The Connection Machine", Scientific American, June, 1987. The "connection machine" described by Hillis is a parallel processing computer system having 65,536 small processors, each having a local memory and a communications network to allow communication between any of the processors. The system is designed for high-speed image processing, modeling of physical problems and other mathematical problems which benefit from parallel processing. The "connection machine" is designed to solve general problems and may be configured dynamically.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a new and improved search system for operation in a centralized environment and which exhibits an improved response time to a search request.
Another object of this invention is to provide a novel search system which is capable of simultaneously processing multiple search requests.
Another object of this invention is to provide a novel search system which enables rapid search of a database, by means of single or multiple keys, with a large number of concurrent searches.
A further object of the present invention is to provide a novel search system which is capable of initiating new search requests while active search is underway.
Yet another object of the present invention is to provide a search system which is capable of adding new records to the database even while searching is underway.
These and other objects are achieved according to the invention by providing a new and improved parallel processing search system including a master processor, plural slave processors connected to the master processor and each other by a data bus for transfer of information therebetween and by control lines for control of the slave processors by the master processor, a shared memory also connected to the data bus, and a disk interface connected to the memory and the control lines, the disk interface including a disk channel for connection to a disk for storage of database records and being controlled by the master processor via the control lines.
According to the invention, the master processor has access to an external host system bus for communication with other processors in a larger host system of which the present parallel processing search system is a component.
Also, the shared memory buffers data from the disk and is accessible by the master processor and the slave processors. The control lines allow the master processor to control the operation of the slave processors and allows the slave processors to signal events to the master processor. The control lines also allow the master processor to control operation of the disk interface and receive event signals from the disk interface.
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 is a schematic block diagram illustrating the parallel processing search system according to the invention in one intended application as a search processor in a Picture Archiving and Communication System (PACS);
FIG. 2 is a schematic block diagram illustrating the architecture of the parallel processing search system according to the invention;
FIG. 3 is a schematic functional diagram illustrating data flow in the search system according to the invention;
FIGS. 4a, 4b and 4c are respectively representations of a database update record format, search pattern record format and database record format employed in the search system of the invention;
FIG. 5 is a state diagram illustrating operation of the master processor of the invention;
FIG. 6 is a state diagram illustrating operation of the slave processors of the invention;
FIG. 7 is a state diagram illustrating in more detail the record processing operation performed by the slave processors of the invention;
FIGS. 8a, 8b and 8c are state transition diagrams illustrating several search algorithms employable by the slave processors of the invention; and
FIGS. 9a and 9b are state transition diagrams of specific examples of searches performed by the slave processors of the invention.
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, it is first noted that the parallel processing search system according to the invention is intended to be part of a larger host system, for instance a Picture Archiving and Communications System (PACS) 10. The PACS 10 contains an image database made up of a combination of high-speed magnetic disks 12 and slower optical disks 14 all controlled by a disk manager 16. The disk manager 16 is linked through a high-speed image network 18 to devices (not shown) which source and sink the image data. Also contained in the PACS, the search system 20 of the invention manages index files which allow the retrieval of image data by demographic information associated with the image data. The search system 20 maintains this information on a dedicated disk 22. Overall control of the archive system is the responsibility of the archive manager 24, which is linked through a command network 26 to other devices (not shown) in the PACS. Requests on this network are processed by the archive manager 24 through communications with the search system 20 and the disk manager 16. For example, a request arrives at the archive manager 24 asking for images of a patient with id number N and specifying the destination for the images. The archive manager 24 builds a search request record from the following components: a key specifier indicating that the search key is the patient id, the patient id itself and the destination specification. The search record is sent to the search system 20.
The search system 20 of the invention is shown in more detail in FIG. 2 to include a master processor 210, plural slave processors 212, a shared memory 214 and a disk interface 216. The system 20 is aimed at applications in which a database must be searched by single or multiple keys, with a large number of concurrent searches. Within the search system 20 the master processor 210 has access to an external system bus 28 (also shown in FIG. 1) for communications with other processors of the host system 10, e.g., PACS, in which the search system 20 is a component. Also, the search system 20 has a disk interface 216 with a disk channel 218 to allow connection to the disk 22 for storage of the database records. A data bus 220 within the system 20 connects the slave processors 212 with the master processor 210 and the shared memory 214. The shared memory 214 is used to buffer data from the disk 22 and is accessible by all the processors 210, 212. Additionally, control lines 222 allow the master processor 210 to control the operation of the slave processors 212 and allow the slave processors 212 to signal events to the master processor 210. These lines 222 also allow the master processor 210 to control the operation of the disk interface 216 and receive event signals from the interface 216.
In operation of the host system 10 in which the parallel processing search system of the invention is a component, such as the PACS shown in FIG. 1, the master processor 210 communicates with the other components of system 10 over the system bus 28.
Data flow into and out of the search system 20 takes place through this channel, under the control of the master processor 210. This data flow is illustrated in FIG. 3. From the external system 10, the master processor 210 receives search requests and database update requests. To the external system 10 the master processor 210 returns data location information in a record which is produced as a result of the search operations. The format of these records is indicated in FIGS. 4a, 4b and 4c discussed below. Within the search processor 212, the flow of data is determined by the type of request received by the master processor 210. Database update records are used to add new information to the database and are channeled from the master processor 210, through the memory 214 and on to the disk interface 216 for writing to the disk 22. The slave processors 212 play no role in data base update activity, but may continue searching concurrently. Search requests result in the assignment of an associated search pattern and key specifier to an available slave processor 212. Once a slave processor is assigned a search and thereby becomes active, it watches the search list data stream to detect data which matches the specified keys. The search list data stream consists of database records read from disk 22, through the disk interface 216, into memory 214. These records are then passed to the slave processor 212 for match testing, i.e., comparing of the data with the specified keys. Whenever there is an active slave processor 212 the search list is cycled continuously until the entire list has been processed. Whenever the slave processor 212 slave detects a record with a match in the key field specified by the search request, the data location information portion of the database record is sent to the master processor 210 for transmission to the external system 10. The master processor 210 takes that information, along with destination information for the search request, and places the information on the host system bus 28.
Referring again to FIGS. 1 and 2, when the master processor receives a search request it assigns the execution of the search request to a free slave processor 212. The assigned slave processor 212 then generates an initial state array and waits for the next record from the database location list whereupon it begins attempting to match the specified key. The index of the first record is saved and the slave processor 212 processes record until the same index is seen again, indicating that the entire database location list has been cycled through the slave and the search is complete. Each time a slave 212 successfully matches a key during the search process, a match record is sent via the master processor 210 to the disk manager 16 over the system bus 28. The disk manager 16 uses the location information to extract the image information from the archive and transfer it over the image network 10 to the destination specified in the original request. Transfer of the image information to the destination completes the transaction.
Referring to FIG. 4a, there is shown the data format of data stored in the disk 22. As shown in FIG. 4a, the database record format includes n fields of key information 230 which may be matched, independently or in logical combinations, against the patterns assigned to slaves, and a field of location information 232 returned when a key field is matched by a slave processor 212. This field 232 specifies the location in the host's image database of the image data corresponding to a matched key. In other words, the field 232 is used to identify where in the host system's database image data corresponding to a database record can be found. This field 232 is returned to the host system 10 by the master processor 210 when a match is signalled by a slave processor 212. The host system 10 may then use the data location information 232 to fetch the desired image data from its image database.
In FIG. 4b is shown the search pattern record format also sent by the external host system 10 to the master processor 210 to request a search. The search pattern record format includes a key specifier field 234, a pattern field 236, and a destination field 238, and is transmitted by the host system 10 via the system bus 28 to the master processor 210. Information in the key specifier field 234 controls which key field the slave processor 212 will use when attempting to match the pattern provided in the pattern field 236. Examples of specific key specifier fields 234 are patient name, ID, birthdate, image type, etc., and depend on the particular application of the host system. The pattern field 236 defines the actual pattern in the specified key field which the slave processor 210 will search for in the database list stream. The destination field 238 specifies the destination in the host system for the data location information returned to the host when a slave processor's search produces a match. The destination information 238 is given to the host system 10, over the external bus 28, along with the database location information 232. These two pieces of information allow the host system 10 to retrieve image data within the host system and send it to the desired destination within the host system. The information in the field 238 may also be sent to the disk 22 via the interface 210 and channel 218.
FIG. 4c shows the database record update format sent by the host system 10 to the master processor 210 when the host system has additional data to be added to the database on the disk 22. As shown in FIG. 4c, the database update record format includes an update flag field 240, n fields of key information 242 and data location information 246. The field 240 provides an update flag to the master processor 210 which signals the master processor 210 to process the record specified as an update to the database on the disk 22. The key information 242 specifies n key fields which may be matched, independently or in logical combinations, against patterns assigned tc the slaves. The field 246 is used to return to the host system 10 location information identifying the location in the host system's database corresponding to a key field matched by a slave processor 212. The field 246 is returned to the host system 10 by the master processor 210 when a match is signalled by a slave processor 212. The host system 10 may then use this information to fetch the desired data from its database.
In the system data flow of the search system of the present invention, patterns to be matched are programmed into slave processors 212 from data received by the master processor 210; database information (for update) is sent to the disk interface 216 by the master processor 210 via the multiport memory 214; database information (for search) is brought in through the disk interface 216 to the memory 214 and sent to each slave processor 212; and match information is sent by the slave processors 212 to master processor 210.
The operation of the master processor 210 is depicted in the state diagram illustrated in FIG. 5. While there are no active requests the processor idles in the WAIT FOR REQUEST state 240. If the processor 210 receives an update request it enters the PROCESS UPDATE REQUEST state 242 in which the update request is acted upon. This involves writing the new database information into the database stored on the disk 22 and updating necessary data structures used by the master processor 210 to reflect the addition of new data. Such data structures include, for example, a directory defining where data is stored on the disk, how many entries are on the disk, etc. New entries are written to the data lists and all affected data structures and parameters are written as well. The slave processors do not participate, but may continue search processing concurrently. Once the update is accomplished the master processor 210 returns to the WAIT FOR REQUEST state 240. If the master processor 210 receives a search request it enters the PROCESS NEW SEARCH REQUEST state 244. In the state 244, the master processor 210 assigns a search pattern from the request to a slave processor 212 and initializes the slave processor 212. The master processor 210 then begins search processing by entering the cycle database records state 246. While in the state 246, the master processor 210 sequentially provides database records to the slave processors 212 for match comparison through control of the memory 214 and disk interface 216. This continues until there are no more search requests active, at which time the master processor 210 returns to the WAIT state 240. During the CYCLE state 246, the master processor 210 may receive and process additional update or search requests. In each case, when the request is processed the master processor 210 returns to the CYCLE state 246 as long as there are active search requests. When the master processor 210 is in the CYCLE state 246 it may also receive match signals from slave processors 212 which have matched their key field against the current database record. This event sends the master processor 210 into the PROCESS MATCH SIGNAL state 248. In this state the master processor 210 formulates a data location record and places it on the host bus 28. If there are more active search requests the master processor 210 then returns to the CYCLE state 246, otherwise it returns to the WAIT state 240.
From the above description, it is seen that the master processor 210 controls operation of the entire search system of the invention including management of database tables, communication with the external host system 10 and operation of the slave processors 212, memory 214 and disk interface 216. In conjunction with its control functions, the master processor 210 interacts with the external host system 10 via registers and/or memory mapped into external systems address space; programs search patterns for each active slave processor in response to requests from the external host system 10; manages transfer of input streams, from database tables or lists, to each slave processor 212; manages updates of the database; and routes match information from slave processors 212 to the host system 10 or the disk interface 216.
Each slave processor 212 may be programmed dynamically with a pattern to be searched in the database. The slave processor 212 sends match information to the external host system 10 via the master processor 210 when the slave processor 212 matches its search pattern. Slave processor 212 awaits pattern programming from the master processor 210. An active slave processor 212 scans the input stream provided by the master processor 210 for the occurrence of its programmed pattern using a search algorithm described hereinafter. The slave processors 212 operate independently, synchronized by beginning of string (BOS) and end of string (EOS) markers, and pass match information to master when each assigned pattern is found.
The operation of a slave processor 212 is depicted in FIG. 6. While a slave processor 212 is not assigned a search pattern, it idles in the WAIT FOR SEARCH PATTERN ASSIGNMENT state 250. When the slave processor 212 receives a search record assignment from the master processor 210 it enters the SETUP SEARCH STATE TABLES state 252. In the state 252, the slave processor 212 takes the search pattern from the master processor 210 and initializes its internal state in preparation for search processing. Once the slave processor 212 has completed its initialization, it enters the WAIT FOR NEXT RECORD IN DATA LIST STREAM 254 state. In the state 254, the slave processor 212 performs initializations which must take place immediately before each record to be processed and then waits for the signal from the master processor 210 indicating the start of the next record. This signal sends the slave processor 212 into the PROCESSOR RECORD state 256. A detailed expansion of this state 256 is shown in FIG. 7.
As shown in FIG. 7, in the state 256, the processor 212 waits for each character of the record. When a character arrives, it is compared against the set of active match states in state 258. If any of the active states have a label which matches the current character, the set of match states is updated in state 260. If the new set of match states contains the final, or accepting, state, the slave processors 212 search pattern has been matched and the match signal is sent to the master processor 210 in state 264, shown in FIG. 6. If the new set is not empty but does not contain a final state, the slave processor 212 moves to the WAIT FOR NEXT DATABASE LIST CHARACTER state 262. Otherwise, if the new set is empty the slave then waits for the next record to process.
As is evident from FIG. 2, the memory 214 is a multiported memory which may be shared by the master processor 210 and the slave processor 212. Memory 214 has a port for access by the disk system 22 via the interface 216 and the channel 218. The memory is partitioned, with segments reserved for each slave processor 212 as well as the master processor 210. In other words, the memory 214 is accessible over its entire memory space by the master processor 210 and has memory space segments allocated to respective slave processors 212. This allows the master processor 210 to communicate with each slave processor 212 through a segment of shared memory at a fixed location. This shared memory permits the exchange of messages between processors, including intercommunication between slave processors 212. The connection to the disk interface 216 provides DMA access for database information stored on the disk 22.
The architecture above-described allows flexibility in database organization. A simple linear list might be scanned by all slave processors 212 simultaneously. Alternatively, the database may be organized into a tree and each slave processor 212 allowed to search only the branches which may lead to a match. The choice of database organization affects the control algorithm required for the master processor.
Next described, in more detail, is the search algorithm typically employed by the slave processors 212 of the invention. Each slave processor 212 includes RAM memory in which is stored the pattern, obtained from field 236 (FIG. 4b), to be searched. Each active slave processor 212 searches the data input stream on the bus 220 for the occurrence of the stored pattern, this data stream having been loaded into and read out of the memory 214 under the control of the master processor 210. The slave processor 212 may match classes of input by using wildcard characters. For example `*` may be used to match any characters and `&` may be used to match any single character.
The slave processors 212 each implement a nondeterministic finite automation (NFA). An NFA may be denoted by a quintuple of the form:
<Q, Σ, δ, qo, F>
where
Q is the set of machine states. This set consists of one state for each character of the pattern, a state for beginning of string, end of string, match and fail. (Machine halts on failure). If the characters in the pattern are labeled P C .sbsb.0 through P C .sbsb.n-i, for a pattern string of length N, the Q={BOS, P C .sbsb.0, P C .sbsb.1, . . . P C .sbsb.N-1, EOS, match, fail}
Σ is the input alphabet, for example the set of ASCll codes.
δ is the state transition function on QXΣ to 2 Q . It is described graphically below in FIG. 3.
qo is the initial state. For Q shown above, qo=BOS.
F is the set of accepting states, i.e., the states in which the slave indicates a match has been found. (For Q above, F={match}).
Examples of the state transition functions of NFA's with set Q (described above) states are shown in FIGS. 8a, 8b and 8c. In FIG. 8a is shown an NFA with no wildcards, wherein C i denotes a character matching a stored search pattern character P C .sbsb.i, ε denotes a transition which does not require an input, BOS designates the beginning of a string of data, and
EOS designates an end of a string of data. FIG. 8b illustrates an NFA with wildcard & (match 0 or 1 of any character) at position P C .sbsb.jx. FIG. 8c illustrates an NFA with wildcard `*` (match 0 or any number of characters) at position P C .sbsb.j. In each of the examples shown in FIGS. 8a, 8b and 8c, the state FAIL is implicit and not shown. Any transition which cannot be made, because input does not match required input, will lead to FAIL unless other states are active. If no states are active, the FAIL state is entered and the machine halts. It should also be understood that a slave processor 212 may implement an NFA which contains combinations of wildcards. Since these machines are nondeterministic there may be several states active simultaneously.
FIGS. 9a and 9b illustrate in more detail specific examples of execution of respective search algorithms by a first slave processor 212, and a second slave processor 212 2 , where the pattern to be matched by processor 212 1 , is "Pet" and the pattern to be matched by processor 2122 is "Pete". Where the input stream seen by both processors 212 1 and 212 2 is "Pet", the following Table summarizes the operation:
TABLE______________________________________ SLAVE 212.sub.1 SLAVE 212.sub.2Time Input STATE MEM. STATE MEM.______________________________________T.sub.1`P` BOS BOS Pet BOS BOS Pete EOST.sub.2`e` P EOS PT.sub.3`t` e eT.sub.4EOS t tT.sub.5 Match FAIL______________________________________T.sub.1 : Each slave processor is initialized to beginning of string. (Search pattern). Both processors match first character of input stream `P`. Their states are advanced to state .sub.--P (→matched `P`).T.sub.2 : Both processors match second character of input stream `e`. Their states are advanced to state -e.T.sub.3 : Both processors match third character of input stream ` .sub.-t`. Their states are advanced to state .sub.-t.T.sub.4 : Slave 212.sub.1 matches end of string and advances automatically to T.sub.5. Slave 212.sub. 2 cannot advance to state -e because the next input stream ##STR1##T.sub.5 : Slave 212.sub.1 is in the match state, indicating it matched the pattern it was watching for. Slave 212.sub.2 is in the FAIL state, indicating it failed to observe its assigned pattern.
Once again, in FIGS. 9a and 9b, as in FIGS. 8a, 8b and 8c, ε denotes that no input is required for state transition, and the FAIL state is implicit. If the set of active states becomes empty, the slave processor will stop processing until the next input record is indicated by the BOS input character.
As above described, the parallel processing search system according to the present invention is designed to perform one component of the task of database access--that of searching for the location of the requested data. The parallel nature of the architecture allows multiple requests to be processed simultaneously. Each slave processor 212 can be searching by different keys and each could, if necessary, search by a different algorithm. A further advantage is that the slave processors 212 could be allowed to handle multiple requests. This would slow down the operation of the processor somewhat but would allow an even larger number of parallel searches to take place. Another advantage of the parallel architecture is that it provides the capability to initiate new requests while searching is active and the capability to add new records into the database while searching is underway. This flexibility results from the distribution of the search task to the slave processors 212, freeing the master processor 210 to handle new requests while it controls the operation of the slave processors 212.
The separation of the data search from the data access also prevents the access of data from the from slowing down the search process and conversely, prevents the processor intensive search process from slowing down access of information from the database as well as the central host operations. Those operations may include communications over networks and other management tasks, or perhaps general computing tasks.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A parallel processing search system for searching and updating a database at the request of a host system, including a master processor connected to a host system bus for transfer of information between said master processor and the host system bus; a data bus connected to the master processor; plural slave processors connected to the data bus for independently processing search respective requests under the control of the master processor; a disk drive interface adapted to be connected to a disk which stores a database; and a buffer memory connected to the data bus and the disk drive for storing the database retrieved from the disk and for sequentially placing data from the database on the data bus for match comparison by the slave processors so that a search of the database can be made by the slave processors under the control of the master processor. The buffer memory is also capable of storing updated data obtained from the host system via the master processor so that an updated database can be transferred to the disk memory via the disk drive interface. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This patent application is a divisional of Ser. No. 12/834,818, filed Jul. 12, 2010, now U.S. Pat. No. 7,869,945, issued on Jan. 11, 2011, which is a continuation of Ser. No. 11/801,874, filed May 11, 2007, now U.S. Pat. No. 7,756,633, issued Jul. 13, 2010, the priority filing dates of which are claimed, and the disclosures of which are incorporated by reference.
FIELD
This application relates in general to ridesharing in a transportation system and, in particular, to a system and method for rideshare security.
BACKGROUND
Interaction with transportation systems is a daily fact of life for most everyone. Whether it is a public bus system or private car, getting from one place to another seems increasingly more difficult and costly. Road congestion, burdensome fuel prices and environmental concerns beg for alternatives. Existing alternatives each have their own pluses and minuses. For example, public transportation is relatively inexpensive and safe, but participants are restricted to certain routes and schedules that are unlikely to meet everyone's needs. Use of a private car personalizes routes and schedules, but is expensive in terms of fuel, pollution, and required road infrastructure.
Rideshare programs have been proposed that attempt to match public riders with private drivers. In a rideshare program, a private driver agrees to provide transportation to a rider traveling in generally the same direction at generally the same time. A significant advantage to these rideshare programs is the more efficient use of resources, including cars, fuel and roads. Participants might be slightly inconvenienced in terms of routes and schedules to accommodate the needs of other riders. There are transaction costs to matching riders with drivers in terms of both time and compensation, which must be worthwhile to all parties to encourage use of the system. Examples of rideshare systems are described in U.S. Pat. No. 4,360,875, issued Nov. 23, 1982 to Behnke and U.S. Pat. No. 6,697,730, issued Feb. 24, 2004 to Dickerson, the disclosure of which are incorporated by reference.
Rideshare programs may also introduce issues for participants not present when they make their own way. For instance, besides destination and time, there may be issues with compatibility and compensation. Participants are prudent to be concerned with their own security when matched with participants previously unknown to them. Monitoring the security of the participants during the trip and the success of the rideshare would also be of benefit. There exists a need to encourage the participation of participants in a rideshare program, to match participants based upon compatibility and to enhance the security of the participants while participating in the rideshare. The present invention provides such methods and systems, among the other advantages described below.
SUMMARY
A rideshare method and system is provided that includes, among other aspects, rideshare transaction matching, participant security, participation incentives and rideshare system financing. Rideshare participant devices are made available to rideshare participants. The rideshare participant devices have both communication capabilities and provide location information. An embodiment of the rideshare system communicates with the rideshare participants to facilitate rideshare transaction matching and to provide participation incentives. The rideshare participant device is also employed by the rideshare system to monitor and track the rideshare transaction while it is in progress.
Participant security in rideshare transactions is provided. The rideshare system monitors the rideshare transaction while in progress and determines the security of the rideshare participants. In an embodiment, one or more of the rideshare participant devices are monitored in near real time. Information obtained from the rideshare participant device is analyzed for anomalies that might indicate a security concern. For example, the location of the participant device during the rideshare transaction can be compared to a trip route and a security alert triggered if that location deviates from the expected trip route by more that a predetermined threshold. The trip route may further be specified by the rideshare system to account for communication connectively advantageous to near real time monitoring. Other concerns, such a route visibility to the public and the availability of emergency services may be utilized in the selection of the trip route.
In another embodiment, rideshare participant devices are available to a plurality of rideshare participant. For example a driver and a passenger each have access to a rideshare participant device. The rideshare system monitors and utilizes the plurality of rideshare participant devices to provide security. The rideshare system may communicate security inquires to rideshare participants via their rideshare participant devices when a security alert is determined. Responses to the security inquiry may be confirmed by the rideshare system against pre-arranged confirmation tokens, such as personal identification numbers or biometric information. The rideshare system may also compare location information obtained from the participant devices to determine anomalous conditions, such as when the location of the rideshare participant devices diverges before the rideshare transaction is expected to conclude.
A further embodiment provides a system and method for monitoring participant security in a rideshare environment. A rideshare participant device is made available to at least one rideshare participant during a rideshare. A security check is triggered while the rideshare is in progress. An action is performed based on the security check. Security information regarding the rideshare participant device is gathered and analyzed for inconsistencies. A security response provider is contacted when the inconsistency is identified.
A still further embodiment provides a method for rideshare security. A rideshare participant device is made available to at least one rideshare participant during a rideshare. A security check is triggered when the rideshare is in progress. An action is performed based on the security check. Security information regarding the rideshare participant is gathered. The security information is analyzed for any inconsistencies by applying the security information against predetermined metrics and an inconsistency is identified when the security information is outside a range of the predetermined metrics. A security response provider is contacted when the inconsistency is identified.
Still other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein are described embodiments by way of illustrating the best mode contemplated for carrying out the invention. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various obvious respects, all without departing from the spirit and the scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing, by way of example, a rideshare transaction utilizing location determining communication systems.
FIG. 2 is a block diagram of an exemplary rideshare system.
FIG. 3 is a block diagram of an exemplary rideshare matching transaction system.
FIG. 4 is a block diagram of an exemplary rideshare participation incentives component.
FIG. 5 is a block diagram of exemplary rideshare revenue business methods.
FIG. 6 is a block diagram of an exemplary rideshare security system.
FIG. 7 is a state diagram illustrating a general scenario for server-based security checks.
FIG. 8 is a state diagram illustrating a general scenario for device based security checks.
FIG. 9 is a state diagram illustrating an exemplary location security monitor.
FIG. 10 is a state diagram illustrating an exemplary tracking signal loss security monitor.
FIG. 11 is a state diagram illustrating an exemplary unexpected participant separation security monitor.
FIG. 12 is a state diagram illustrating an exemplary unexpected stop security monitor.
DETAILED DESCRIPTION
Rideshare System Overview
An overview of a rideshare system 100 is shown in FIG. 1 . A rideshare is broadly defined as a transaction between a driver 102 and a passenger 104 that results in the transportation of the rideshare participants 102 , 104 to a destination 106 along a route 108 . The driver 102 provides transportation using a vehicle such as an automobile 110 . Other forms of transportation may be provided, such as airplanes, trains or vans.
Each participant 102 , 104 has available to him or her a rideshare device 112 , 114 . The rideshare device 112 , 114 has communication capabilities and a location determining capabilities. The rideshare device 112 , 114 communicates with a location broadcast station 120 and a communication broadcast station 130 . Commonly, the location broadcast station 120 is a satellite, such as a global positioning satellite provided by the United States government. Examples of communication broadcast stations 130 include cellular towers, WI-MAX broadcasters, WiFi broadcasters, walkie-talkie and other forms of radio communication. The location broadcast station 120 and the communication broadcast station 130 may be combined into any convenient form, satellite or terrestrial.
The rideshare device 112 , 114 may be any type of presently known or future developed communication device. Communication systems are quickly being combined such that computer devices are providing various combinations of voice, text, e-mail, instant messaging, video, pictures and other forms of communication between devices. For example, the rideshare device 112 , 114 may be a cellular telephone with GPS (global positioning satellite) capabilities. GPS capabilities enable determining the three spatial coordinates of the device and the fourth dimension of time at or near when that determination is made. The location of the device generally refers to the three spatial coordinates of the device at a particular time.
To simplify the following discussion, the rideshare device 112 , 114 will generally be discussed as if it is a cell phone with GPS capabilities, but limitation to this type of device is not intended. The participant device 112 , 114 includes, or has access to, a location system such as GPS or other locating strategies. GPS systems determine location by measuring the time differentials for location signals 126 , 128 coming from GPS satellites 120 orbiting the earth. Similarly, a cellular telephone, or similar device, can be located by triangulating communication signals 132 , 134 originating from the device 112 , 114 received at a plurality of broadcast stations 130 .
A rideshare system 160 interfaces with the rideshare devices 112 , 114 through the communication broadcast station 130 . The rideshare system 160 arranges and administers a rideshare transaction between a driver 102 and a passenger 104 . The rideshare transaction occurs along a route 108 starting at an origin 105 and concluding at a destination 106 . As discussed below, the rideshare system 160 determines a driver location 170 using the location capabilities of the driver device 114 . The driver location 170 may be the origin 105 or any point along the route 108 as the vehicle 110 is in transit. A pickup location 172 is determined from the location capabilities of the passenger device 112 . The application 172 need not be the actual location of the passenger device 112 , for instance a safer nearby pickup location may be specified by the rideshare system 160 . Safety functions provided by the rideshare system 160 include the monitoring of a trip location 174 as the passenger 104 shares the transport 110 with the driver 102 .
The rideshare system 160 includes a number of subsystems shown generally in block form in FIG. 2 . The rideshare system 160 may be used in a number of transportation contexts and locations. For example, the rideshare system 160 may support commuting in different metropolitan areas within the same or different countries. A rideshare support system 210 provides a localization module 212 that may provide directions and instructions translated for, or otherwise tailored to, a particular location. A map module 214 provides transportation maps, for example roadmaps of the transportation coverage area administered by the rideshare system 160 . Navigation systems support 216 provides navigation functions such as driving directions and may be interfaced with location determining systems such as GPS or the location determining functions of the participant devices 112 , 114 .
A rideshare match transaction system 220 generally includes functions for matching participants 102 , 104 in a rideshare transaction. A rideshare security module 230 tracks and monitors the participants 102 , 104 during the rideshare transaction. The various components 210 , 260 of the rideshare system 160 employ a communication system 240 . For example, the rideshare match transaction system 220 may utilize the participant devices 112 , 114 to arrange a rideshare transaction and also to track and monitor participant security via the rideshare security module 230 . The communication system 240 may also interface the components 210 , 260 of the rideshare system 160 via wired or wireless communications systems, such as a wide area network, local area network, or cellular communication network.
Rideshare accounting system 250 provides functions for the monetary and non-monetary administration of the rideshare system, for example, tracking and accounting for: rideshare transactions; financial negotiations for rideshare between participants 102 , 104 ; fees and commissions that may be taken by the rideshare system 160 ; revenues generated by the rideshare revenue business methods 260 ; expense allocations; and, rideshare participation incentives. Rideshare revenue business methods 260 provide profit and financing alternatives for the rideshare system 160 .
Participant Matching
Turning to FIG. 3 , the ride matching transaction system 220 includes a participant match component 330 , a ride match component 350 , a financial negotiations component 360 and a rideshare participation incentives component 370 that in various combinations match rideshare participants 102 , 104 using dimensions beyond just a shared route. The participant match component 330 matches participants 102 , 104 using either or both social and security considerations. The identification of a participant is performed by a participant identification component 332 . The identification may be confirmed by the participant component 332 , for instance, by biometric input, video input or passwords. Background information associated with the identity of the participant can be referenced and utilized by a background checker component 334 .
Participants 102 , 104 can also be matched by a social network component 336 using social network information maintained by either the rideshare matching transaction system 220 or third party social network systems. For example, a driver 102 may wish to only be matched to passengers 104 identified as friends (first degree relationships) or friends of friends (second degree relationships). A participation-scoring component 338 may maintain information documenting the participation of the participants 102 , 104 . The participation information may include such values as the number of successful rideshare transactions that the participant has participated in, feedback scores from other participants that have participated in rideshare transactions with the subject participant or recommendations from other rideshare participants.
The shared interest-scoring component 340 determines and compares either or both biographic or behavioral information. Examples of biographic information might include gender, age, hobby, profession and music preferences. Examples of behavioral information might include smoking or non-smoking preferences. The participant match component 330 may utilize information other than that directly associated with a participant. For example, a vehicle information component 342 may obtain and utilize information pertaining to the characteristics of the vehicle 110 , such as vehicle size, number of available seats, insurance safety ratings and the like. Vehicle maintenance and safety inspections are other examples of information associated with the vehicle 110 that may inform a participant 104 directly, or the participant match component 330 automatically, to arrange a rideshare match transaction.
The participant match component 330 also provides for a preferences component 344 , which may require, or give preference to, certain participants or classes of participants. For example, priority may be given to corporate sponsored users, participants with nearby home or work locations, participants with good participant ratings, or participants with certain group associations.
The ride match component 350 includes systems and methods for the transportation specifics of the rideshare transaction. A route match component 352 determines a route 108 that corresponds to a location 170 , a proposed pickup location 172 and a destination 106 . To coordinate a route 108 that meets the criterion of the ride location 170 , the pickup location 172 and the destination 106 , the route match component 352 may determine a suitable route with a route-planning component 354 . A pickup and drop-off alternatives component 356 may suggest an alternative pickup or drop-off location that complies with route planning objectives, such as choosing routes with consideration for the safety of the participants, as is discussed in more detail below. The ride match component 350 may also undertake the negotiation of elements that the participants may be flexible with, for example negotiating the time of pickup using a time negotiation component 358 .
The rideshare matching transaction system 220 may also include a financial negotiations component 360 , whereby the participants negotiate compensation for the rideshare transaction. For example, a ride auction component 362 may administer bidding between one or more passengers 104 for a seat in a vehicle 110 along a particular route 108 . The rideshare matching transaction system 220 may also take into account rideshare participation incentives administered by a rideshare participation incentives component 370 .
Participation Incentives
A block diagram of the rideshare participation incentives component 370 is shown in FIG. 4 . Participation incentives encourage the use of the rideshare program by a diverse group of participants. These participation incentives may be monetary or non-monetary. For example, participants may be awarded prizes or recognition, as well as, cash and discounts. Tie-in promotions are advantageous with the providers of insurance services, wireless communication plan providers, and navigation systems, to name only a few examples. Participation incentives provided by the rideshare participation incentives component 370 include providing a free or discounted navigation system 402 for vehicle 110 and giving free or discounted insurance 404 against liability occurring while participating in the rideshare program. Free or subsidized wireless communication plans 406 and free or subsidized vehicle cleaning services 408 may also be offered as incentives. A rideshare participation incentive 370 might also include inducements 418 to actively participate in the rideshare system 160 ; for instance, a driver 102 may be given graduated fee credits tied to the percentage of time a driver 102 makes his vehicle 110 available for rideshare transactions.
Examples of monetary participation incentives include cash payments 410 , sharing of revenue 412 collected by the rideshare program, or credit against fees 414 charged by the rideshare program. For many participants, a primary advantage of participating in a rideshare program is the benefit to the environment. Recognition, in the form of carbon credits 413 , is a powerful incentive to those participants. A carbon credit is a value assigned to quantify the savings in carbon emissions caused by the participant's choice to engage in the rideshare transaction. The value of a sale of carbon credits may extend beyond just recognition, as there is a market developing to trade carbon credits for monetary and other consideration, such as offsetting rights to generate carbon from other activities.
Revenue Business Methods
Referring to FIG. 5 , the rideshare system 160 provides rideshare revenue business methods 260 . Revenue may be provided to operate the rideshare system 160 may include monthly fees 510 or per transaction fees 512 . Fees may be adjusted, up or down, based upon the monitoring of supply and demand 514 . For example, when there are more passengers 104 then drivers 102 seeking transportation on a given route 108 , the demand based monitoring component 514 may increase the transaction fee 512 . Similarly, if there are more drivers 102 offering transportation on a route 108 then there are passengers 104 willing to participate, the demand base component 514 may lower transaction fees 512 to encourage additional passengers 104 to participate in a rideshare transaction. As discussed above, or rideshare auctions 516 may be conducted directly between rideshare participants 102 , 104 , setting the price of the rideshare transaction through bidding. The rideshare system 160 may take a percentage of these ride auctions.
The rideshare revenue business methods 260 may also include revenue sources originating beyond the participants of the system. For example, advertisements 518 may be sold to third party advertisers for display on interfaces provided by the participant devices 112 , 114 . Third party organizations may offer sponsorships 520 compensating the rideshare program 160 and permitting the third party organization to obtain the public relations value of supporting a worthy program. Third party organization may also benefit by providing reward programs 522 subsidizing rideshare transactions. Providers of products used in the navigation system 115 may also provide promotional tie-ins, such as giving memberships in the rideshare system 160 with the purchase of a navigation system 524 .
Insurance is a significant issue in any rideshare system and an opportunity for revenue. Systems and methods for insurance integration 526 derive revenue from the integration of insurance coverage with the rideshare system 160 for example; low cost, month-to-month insurance premiums can be collected to provide users with additional insurance coverage that protects them while participating in a rideshare transaction. Supplemental insurance policies may also be offered on a per rideshare transaction basis that insure against liability incurred during the rideshare transaction. These supplemental insurance policies could be charged on a per rideshare transaction basis or on a monthly unlimited rideshare transaction basis. The rideshare system 160 could act as the insurer or share in the revenues generated from these supplemental insurance policies, for instance, by collecting something similar to an agent's a fee.
Rideshare Security
The rideshare security system 230 is further described with reference to FIG. 6 . A security match module 610 provides participant matching functions 612 with a security focus. The security match module 610 may be implemented as an extension of the rideshare matching transaction system 220 . A safety testing function 614 might test for indicators that a driver 102 is intoxicated, for instance by asking the driver 102 to solve a puzzle or demonstrate response time through the driver device 114 . A visual identity 616 or biometric identifier 618 are matching functions that match identities at the time the passenger 104 is picked up by the driver. For example, either or both of the participants 102 , 104 could be sent a picture of the other participant 102 , 104 for viewing on their participant device 112 , 114 when the participants 102 , 104 meet at the pickup location 172 . The identity of either or both of the participants 102 , 104 may be confirmed at the pickup location using biometric information associated with that participant, by communicating 620 with the rideshare system using the participant device 112 , 114 .
A rideshare transaction monitor module 630 sets conditions for and monitors the security of the rideshare participants 102 , 104 while the rideshare transaction is in progress. The transaction monitor module 630 works in conjunction with a rideshare security timer 650 . The rideshare security timer 650 triggers monitors 634 - 640 to assess the safety of the participants 102 , 104 at periodic intervals 652 , randomly 654 or at scheduled times 656 during the rideshare transaction. For example, the rideshare security timer 650 might periodically request from a participant to provide a security response to an active participant monitor 638 . Similarly, a passive participant monitor 636 measures and reports a metric using a participant device 112 , 114 , but without the active participation of the participant 102 , 104 .
Some security functions are monitored in real-time 658 . Real-time monitoring occurs at or near an event and is subject to communication lags and other technical limitations. For example, a location monitor 634 may monitor the location of the vehicle 110 in real-time as the vehicle traverses the route 108 . The location of the vehicle may be determined using the location capabilities of either participant device 112 , 114 or using a navigation system 115 associated with the vehicle 110 . If either of the participant devices 112 , 114 or the navigation system 115 deviates from the route 108 by more that a pre-defined threshold, the rideshare security system might take a security action. Examples of the security scenarios are discussed below.
The rideshare security system 230 may also respond to asynchronous notifications initiated by a participant device 112 , 114 . For example, an emergency button 642 would be communicated 620 to the rideshare security system 230 , which might initiate a security response, such as contacting a security response provider 670 . Other security monitoring, whether initiated by the rideshare transaction monitor module 630 or a participant device 112 , 114 , asynchronous or synchronous, periodic, random, scheduled or monitored in real-time, are possible and contemplated by the present invention.
Examples of Rideshare Security
The following examples of the rideshare security systems and methods are broadly separated into server-based and device-based strategies. A server-based security check is initiated by a server associated with the rideshare system 160 and interacts with either or both of the participant devices 112 , 114 or a navigation device 115 . A device-based security check is initiated by a participant device 112 , 114 and interacts with the server to evaluate the security alert and administer a security response, when appropriate. Security checks may include either or both active participant checks, which anticipate the participation of the participant in the security check, and passive participant checks, which judge information obtained without the active participation of the participant. These categories are defined for the purposes of simplifying the following discussion and are not intended as limitations. Also, while examples of security checks may be discussed individually for clarity, those taught or suggested by the examples may be used in various combinations in the embodiments of the invention.
FIG. 7 is a state diagram illustrating exemplary server-based security checks. A server 702 triggers 710 a security check 712 . The trigger 710 may be periodic, random or scheduled. The security check 712 may include an active participant check 714 , a passive participant check 716 , or both. For instance, an active participant check 714 may include sending a message to a participant device 112 , 114 and requesting a reply message. The reply message may include an indication of the participant's perception of the security situation, and an identity token such as a password or biometric confirmation. If the reply is confirmed 718 , the security state is determined to be OK 720 , which is reported 722 to the security check 712 . If the active participant check 714 fails, a security alarm 730 is raised and reported 732 to the server 702 .
A security check 712 may also request a passive participant check 716 that checks security information against metrics generally without the participation of the participant 102 , 104 . If the metric is confirmed 724 to be within a range determined to be safe, the security state is determined to be OK 720 and is reported to the security check 712 . When the metric is determined to be out of range 726 , a security alarm 730 is raised. The security alarm 730 notifies 732 the server 702 of the unsafe security situation. The server 702 may then take appropriate action, such as performing other security checks to verify the security situation or reporting that security situation to a security response provider 670 , such as the police.
FIG. 8 is a state diagram illustrating exemplary device-based security checks. A device based security check is generally monitored by a participant device 112 , 114 . The security check may be either automated or responsive to something that a participant 102 , 104 initiates. For example, a security parameter 802 is provided by a server 702 or directly programmed into a participant device 112 , 114 . A parameter check 804 monitors the status of information obtained from the participant device 112 , 114 and maintains a status of security OK 806 as long as the information stays within pre-defined boundaries 808 . If the information goes out of bounds, the participant device 112 , 114 may direct the process to either an active participant check 810 or a passive participant check 820 . For example, the active participant check 810 may request a reply from the participant and indicate that the security situation is OK 806 if the reply is confirmed 812 . If the participant replies that there is trouble 814 or no reply 816 is received, then the process moves to a state of security alarm 830 . A passive participant check 820 may check confirming metrics and either confirm 822 that security is OK 806 or the metric indicates a problem 824 , triggering a security alarm 830 . The security alarm 830 may then take further action by notifying a centralized server 832 or taking a direct action 834 , for instance, by notifying a security provider. An emergency button 838 may directly cause entry into the security alarm 830 .
FIGS. 9-12 illustrate exemplary embodiments of security monitoring systems and methods, which can either be implemented as server-based or device-based. Turning to FIG. 9 , a security monitor determines the location of a participant device 112 , 114 compares that location to an expected route 108 and triggers a security alarm when an anomaly is detected. The route 108 may be agreed to by the rideshare participants 102 , 104 , assigned by the transaction monitor 630 or other supporting server. In embodiments that either allow or force the assignment of the route 108 , the transaction monitor 630 may choose a route based in part upon a safety profile of the route. The safety profile may take into account such factors as the exposure of the route to the public, the availability of communication connectivity along the route, and the anticipated law enforcement presence along the route.
Once the route 108 is determined, the location monitor 900 enforces the route assignment 902 by conducting a location check 904 at periodic, random or scheduled intervals. The trip location 174 is determined from either or both of the participant devices 112 , 114 or a navigation system 115 associated with the vehicle 110 . If the trip location 174 is within pre-defined boundaries associated with the route 108 , the security status is considered in-bounds 906 and the security situation is maintained as OK 908 . If the trip location 174 is not within the predefined boundaries associated with the enforced route assignment 902 , the location monitor 900 may trigger an off-route 910 active participant check 912 , or may trigger an off-route 914 passive participant check 916 . A no reply 920 or a trouble reply 922 generates in a security alarm 930 . If the reply is confirmed 913 , the process returns to a security ok state 908 . A passive participant check 916 may seek to verify the security situation, for instance by measuring other security-associated metrics, such as vehicle speed. The vehicle speed may be computed from the location information provided by either the participant devices 112 , 114 or the navigation system 115 and the timestamps associated with that location information. If the metric is confirmed acceptable 917 , the process returns to a security ok state 908 . The security alarm 930 is entered if the metric is outside acceptable parameters 919 .
FIG. 10 illustrates an exemplary monitor 1000 that tracks the participant devices 112 , 114 in near real-time and responds if the signal from either of those devices becomes unavailable. If the tracking signal is lost 1002 , a no reply condition 1004 may move directly to a security alarm state 1010 . The monitor 1000 may also seek to determine if there is a condition that explains the signal loss, such as querying 1018 a communication network 1020 for its status. If there is a problem with the network 1022 , the security state may be set to a security ok state 1024 . The security alarm 1010 is moved to if the network status is confirmed as ok 1026 . The monitor 1000 may also query active participant devices 112 , 114 to determine the status of the lost signal or to determine helpful information, for instance, a starting location for a participant search, which is forwarded to the security alarm 1010 .
FIG. 11 illustrates an exemplary monitor 1100 that tracks the participant devices 112 , 114 in near real-time and responds if the location information derived from those devices indicates that there has been an early and unexplained separation of the participants 102 , 104 . The early participant separation state 1102 notes an anomaly, it may inquire 1104 by moving to an active participant check state 1106 , which sends a message requesting a reply to either or both of the participants 102 , 104 . If the replies 1108 are deemed to be sufficient to indicate there is no security situation, the security state may be reset to OK 1110 . Otherwise, if there is no reply 1112 or a reply indicating that there is a security problem 1114 , then a security alarm state 1116 is moved to. The early participant separation state 1102 may also inquire 1120 using a passive participation check 1122 , which further analyzes the security situation. Security Okay state 1110 indicates that a security situation does not exist 1124 . Security alarm state 1116 indicates a security problem 1126 .
FIG. 12 illustrates an exemplary monitor 1200 that tracks the participant devices 112 , 114 in near real-time and responds if the location information derived from those devices indicates that there has been an early and unexplained stop of either or both participant devices 112 , 114 or the navigation system 115 . If an unexpected stop state 1202 notes an anomaly, it may wait a pre-defined amount of time for the participants 102 , 104 and the vehicle 110 to begin moving again, and to reset 1204 to security OK 1210 if the time limit is not exceeded. If the time limit is exceeded 1206 , the state is moved to an active participant check state 1220 , which sends a message requesting a reply to either or both of the participants 102 , 104 . If the replies are confirmed 1222 and deemed sufficient to indicate there is no security situation, the security state may be reset to OK 1210 . Otherwise, if there is no reply 1224 or a reply indicates that there is a security problem 1226 , and then a security alarm state 1230 is moved to. The unexpected stop state 1202 may also inquire 1240 using a passive participation check 1242 , which for further analyzes the security situation and moves 1244 to a security okay state 1210 if it is satisfied that a security situation does not exist.
The methods and systems of the present invention can encompass embodiments in hardware, firmware, software, or a combination thereof. Hardware includes commercially available or proprietary computer systems having a processor for executing program instructions and memory for storing those instructions.
While the invention has been particularly shown and described as referenced to the embodiments thereof, those skilled in the art will understand that the foregoing and other changes in form and detail may be made therein without departing from the spirit and scope of this disclosure. Further, presently unforeseen or unanticipated alternatives, modifications, variations, or obvious improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims. | A system and method for rideshare security is provided. A rideshare participant device is made available to at least one rideshare participant during a rideshare. A security check is triggered while the rideshare is in progress. An action is performed based on the security check. Security information regarding the rideshare participant device is gathered and analyzed for inconsistencies. A security response provider is contacted when the inconsistency is identified. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a coating color for paper to improve brightness, smoothness, gloss, ink receptivity and the like of the paper. More particularly, this invention relates to a coating color having a low viscosity despite a high solid content, and a method for preparation thereof.
A conventional coating color is prepared by the following steps:
(1) heating a starch slurry containing about 30% by weight of starch such as oxidized starch, aminophosphate esterification starch, hydroxyethyl starch or the like and about 70% by weight of water, over 70° C. for about 20 minutes to impaste within a starch-impasting tank thereby obtaining the impasted starch with a concentration of about 20% to 30% by weight, or enzymatically impasting a starch slurry therein to obtain the enzymatically converted starch with a concentration of about 10% to 35%,
(2) preparing an aqueous pigment-suspension by a mixture of, for example, 70 parts by weight of a pigment of clay with 30 parts by weight of water within a pigment-dispersing tank, and
(3) Mixing the impasted starch slurry with the pigment suspension within a coating-color preparation tank.
The large amount of water necessary to impaste the starch causes a decrease in the solid concentration of the coating color. The removal of excess water in the manufacture of the coated paper is extremely expensive and energy consuming because of necessary drying equipment and the large floor space required for such. The heating of the starch slurry to impaste the starch is also energy consuming. Moreover, these processes are labor consuming.
In order to decrease the large amount of water for impasting the starch, an approach for converting the starch with enzymes in the presence of pigments is disclosed by James P. Casey, "Pulp and Paper, Chemistry & Chemical Technology" Vol. 2, P.1020-1025 (1952). Another approach for converting the starch with enzymes in the presence of the total amount of water to be used in the coating color and adding pigments to the starch after conversion, is also proposed by him in the same article. However, both of those approaches still have the drawback that a large amount of water must be heated and the entire batch of starch and pigments must be cooled before use.
SUMMARY OF THE INVENTION
The paper-coating color and method of this invention which overcomes the above discussed and numerous other drawbacks and deficiencies of the prior art, relates to a paper-coating color having a low viscosity despite a high solid content and a method for preparation of the same comprising: the direct addition of about 1 part to about 50 parts by weight of enzymatically converted powdered or granulated starch to an aqueous suspension containing 100 parts by weight of pigments.
The enzymatically converted starch is prepared by:
(1) adjusting the specific gravity of a starch slurry to a range from about 15 to about 24 degrees Baume,
(2) adding alkali to said starch slurry to adjust to a pH of about 6-7,
(3) adding α-amylase with a concentration ranging from about 0.05% to about 1% by weight to said starch slurry,
(4) heating the mixture to be impasted to a temperature ranging from about 70° C. to about 100° C.,
(5) subjecting the resulting paste to an enzymic conversion at a temperature ranging from about 70° C. to about 100° C. for a period ranging from about 0.5 to about 10 hours,
(6) inactivating said enzyme,
(7) drying said paste, and
(8) passing said dry paste through a sieve to thereby yield powdered or granulated paste.
Thus, the invention described herein makes possible the objectives of:
(a) providing a coating color of a low viscosity despite a high solid content, and a method for preparation of the same,
(b) providing a coating color prepared by direct addition of powdered or granulated dry starch to an aqueous suspension of pigments,
(c) providing a coating color containing enzymatically converted starch which requires neither impasting equipment nor impasting heat energy because the starch is soluble and impasted in a cold aqueous suspension of pigments, and
(d) providing a coating color which decreases the heat energy needed for drying when coated on paper due to the high solid content thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A coating color according to this invention comprises 100 parts by weight of pigments, about 1 part to 50 parts by weight, preferably about 3 parts to 30 parts by weight, of starch which is converted with enzymes in advance, insolubilizers and water.
Some examples of pigments are kaolin, clay, talc, barium sulfate, calcium sulfate, calcium carbonate, satin white, alminium hydroxide, titanium dioxide, calcium sulfite, zinc oxide and the like. One or more of the above pigments are suspended into water to prepare a pigment suspension. A dispersion agent or agents may be used for the preparation of the pigment suspension, some examples of which are sodium polyacrylate, sodium ligninsulphonate, phosphorate, olefineanhydrous maleic acid copolymer, sodium citrate and sodium succinate.
The starch used in this invention has the physical properties of a moisture level of 20% or less by weight; crude protein of 2.0% or less by weight; crude fat of 1.0% or less by weight; crude ash of 1.0% or less by weight; a dextrose equivalent of 20% or less by weight; viscosity of the suspention of said starch with a concentration of 30% by weight is 3,000 c.p. or less, preferably 1,000 c.p. or less. This starch is prepared as follows:
A starch slurry deriving from corn, potatoes, sweet potatoes, wheat, rice, tapioca, sagos, or the like, is adjusted to a specific gravity ranging from about 15 to about 24 degrees Baume followed by the addition of alkali, e.g. calcium hydroxide, to adjust the pH of the starch slurry to about 6-7. As an enzyme α-amylase is then added to the slurry with a concentration ranging from about 0.05% to about 1% by weight. The mixture is heated to a temperature ranging from about 70° C. to about 100° C. to cause impasting, and is subjected to an enzymatic conversion at the same temperature for a period ranging from about 0.5 to about 10 hours. Thereafter, the enzyme is inactivated by, for example, heating the reactant to a temperature ranging from 110° C. to 150° C. The resulting paste containing enzymatically converted starch is dried by means of spray drying or the like to form dry paste, which is passed through a 20 mesh sieve to remove solid mass.
As the insolubilizers, dialdehyde compounds, polyalkylene ureas, polyamide ureas, formaldehyde, N-methylol compounds, soluble condensed N-methylol compounds, epoxy compounds or the like may be used. Some examples of dialdehyde compounds are glyoxal and glutaldehyde. Polyalkylene ureas are formed by a deammonia reaction of urea with diethylenetriamine, triethylenetetramine, tetraethylene pentamine, imino bis-propylamin or the like. Polyamide ureas are formed by a reaction of urea with polyamide; polyamides are formed by condensation of, for example, dicarbonic acid such as adipinic acid, phthalic acid or the like, and polyalkylene polyamine. Some examples of N-methylol compounds are methylol melamines, such as trimethylol melamine and trimethylol melamine dimethyl ether, partially alkilated methylol melamines, methylol ureas, and methylolcyclic ureas such as dimethylol ethylene urea and dimethylol glyoximonourea. The condensed N-methylol compounds are compounds which are formed by condensation of N-methylol compounds without loss of their solubilization. Some examples of epoxy compounds are glycerol polyglycidyl ether, trimethyl propanol polyglycidyl ether, diglycerol polyglycidyl ether and sorbitol polyglycidyl ether.
The coating color according to this invention may further contain synthetic latices, which serve to improve a binding tightness among pigment particles, a binding tightness between pigment particles and paper, and a water resistancy and gloss of the final coated paper. As synthetic latices, diene derivative polymers, acryl derivative polymers, vinyl acetate derivative polymers, diene derivative polymers having a modified functional group, acryl derivative polymers having a modified functional group, vinyl acetate derivative polymers having a modified functional group and the like, and a mixture or mixtures thereof is used. Some examples of diene derivative polymers are styrene-butadiene copolymer and methylmethacrylate-butadiene copolymer. Some examples of acryl derivative polymers are polymers or copolymers of acrylic acid ester and/or metacrylic acid ester. An example of vinyl acetate derivative polymers is ethylene-vinyl acetate copolymer.
The coating color may further contain auxiliary agents such as dispersing agents, leveling agents, foam killers, dyestuffs, lubricating agents, water retention aids, and the like.
The coating color according to this invention is prepared by the direct addition of the aforementioned enzymatically converted dry starch to the pigment suspension, and thus, the coating color is in a high concentration. Despite such a high concentration, the coating color is fluid and its viscosity is low. The high concentration and low viscosity result in the following advantages in the coating process:
(a) Normal flow of the coating color can be retained at the tips of the blades of the coating apparatus,
(b) The tips of these blades can be kept clean,
(c) Neither streak troubles nor roll patterns occur on the resulting coated paper,
(d) The resulting coated paper has an excellent smoothness, gloss, ink receptibity and the like, and
(e) Mottles are reduced on the resulting coated paper.
The following examples of experiments which have been carried out and have given excellent results are given to illustrate this invention.
EXAMPLE 1
A starch slurry, which was taken out of the final process of preparation of corn starch, was adjusted to a Be of 20 followed by the addition of calcium hydroxide to adjust the pH of the slurry to 6-7. α-amylase 10,000 units/g, available from Daiwa Kasei Co., Ltd., was then added with a concentration of about 0.3% by weight on the basis of the starch (anhydride). The mixture was heated at approximately 90° C. to impaste and subjected to an enzymic conversion at the same temperature for 2 hours. Thereafter, the mixture was heated to 125° C. under pressure to inactivate the enzyme. The resulting paste containing enzyme-converted starch was subjected to a spray drying process and passed through a sieve (20 mesh) to obtain powdered starch, the physical properties of which are shown in Table 1.
TABLE 1______________________________________Items Qualities & Properties Measurements______________________________________Moisture Below 10% Brabender Rapid Mois- ture TesterCrude Protein Below 0.5% Kjeldahl Nitrogen × 6.25Crude Fat Below 0.3% Soxhlet ExtractionCrude Fiber Below 0.2% Dilute Acid · Dilute Al- kali-TreatmentCrude Ash Below 0.5% Ashing at 600 ± 50° C. for 5 hrsDextrose Eq. 10 ± 2% Determined as Glucose, on Basis of Solid ComponentspH 6-7 pH of 5% SuspentionHeavy Metal Below 5 ppm Sodium Sulfide Color-(As Pb) imetry MethodArsenic Below 1 ppm Silver Carbamate(As AS.sub.2 O.sub.3) MethodViscosity 40 ± 10 cp 30% Suspention by Brook Field Viscometer at 30° C.Grain Size Over 99.5% JIS size Passed Through 840μAppearance White or Pale Yellow Color, Granules______________________________________
EXAMPLE 2
(a) Preparation of a 70% pigment-suspension
One hundred parts by weight of No. 1 Kaolin (EMC CO., UW-90) as a pigment and 0.2 parts by weight of sodium polyacrylate as a dispersing agent were suspended in water, resulting in the formation of a pigment suspension with a concentration of 70% by weight.
(b) Preparation of a coating color
Twenty parts by weight of the granulated starch which was prepared in Example 1, was directly mixed, by use of a stirrer, to a given amount of the above pigment suspension at an ambient temperature. The mixture was stirred at 550 rpm for 20 minutes to impaste. A certain amount of calcium stearate which is used as a lubricating agent in calender processing, was then added to the mixture. The resulting mixture was aged on additional 30 minutes to yield the desired coating color, the composition of which is as follows:
Kaolin (UW-90): 100 parts by weight
Sodium Polyacrylate: 0.2 parts by weight
Starch (Solid): 20 parts by weight
Calcium Stearate: 1.5 parts by weight
(c) Manufacture of coated paper
The coating color made above was applied to a surface of base paper of a basic weight of 68 g/m 2 using an R.D.C. Laboratory Coating Rod. Upon coating, the coated paper was dried at 105° C. for 3 minutes within a dryer and subjected to a calender treatment three times at 55° C. under a wire pressure of 100 kg/cm using a super calender available from URI ROLL Co. The resulting coated paper was subjected to a moisture adjustment to bring the moisture level to 65% followed by an examination of the qualities and properties. The results are shown in Table 2.
(d) Preparation of control coating color
A certain amount of Amino phosphoric acid esterification starch, available on the market, was dissolved in water at 95° C. for 20 minutes to prepare a paste with a 30% concentration. After cooling, the paste was added to the 70% pigment (kaolin) suspension prepared above, by the same process described in (b) above, resulting in the formation of the desired control coating color. According to the same technique as in the abovementioned, the control coating color was used to make control coated-paper, the qualities and properties of which are shown in Table 2.
EXAMPLE 3
A certain amount of the granulated starch obtained as in Example 1 was dissolved in hot water (50° C.) to form a 30% paste, which was added to the 70% Kaolin suspension as prepared in Example 2. The coating color having the same composition as in Example 2 and coated paper were prepared through the same procedures as in Example 2. The results are shown in Table 2.
EXAMPLE 4
A certain amount of the granulated starch was directly added, using a strrer, to the 70% kaolin suspension as prepared in Example 2. The 70% kaolin suspension was heated to 50° C. in advance. Coating color of the same composition as in Example 2 and coated paper were prepared according to the same technique as in Example 2. The results are shown in Table 2.
TABLE 2______________________________________ Ex- Ex- Ex- am- am- am- ple 2 ple 3 ple 4 Control______________________________________Coating ColorSolid Content (%) 50.2 50.3 50.2 45.2Brook field Viscosity (CPS)Just After Preparation (60rpm) 70 63 63 214024 Hrs After Preparation (60rpm) 78 96 88 2840High Shear Viscosity (4400rpm) 22.0 20 20 56Water Retention Value (sec) 25.1 22.8 21.0 24.5Coated PaperCoated Amount (g/m.sup.2) 19.1 18.2 18.6 18.6IGT Pick Strength (cm/sec) 71 60 55 224______________________________________
As seen from Table 2, the solid content of the coating colors in Examples 2,3 and 4 is higher than that of the control color, but the viscosity of the colors in Examples 2,3 and 4 is, nevertheless, much lower than that of the control color. The colors in these Examples are also excellent in high shear viscosity when compared with the control color. The surface strength (ITG pick strength) of the colors in these Examples is inferior to that of the control color. In addition, it is found that the preparation of the coating color according to Example 2 wherein a direct addition of the starch to the pigment suspension was carried out, is the simplest and cost efficient of the three processes explained in Examples 2,3 and 4.
EXAMPLE 5
As an adhesive, a modified styrene-butadiene copolymer latex was employed in addition to the starch as prepared in Example 1 in order to improve the pick strength of the final coated paper. Twenty parts by weight of the total amount of the starch and the latex was used to 100 parts by weight of kaolin. The starch was directly added to the 70% kaolin suspension, as prepared in Example 2, in a proportion ranging from 75% to 15% by weight of the total amount of the starch and the latex. The latex was then added in a proportion ranging from 25% to 85% by weight of the same. The resulting mixture was adjusted to a pH of 9 by ammonium hydroxide followed by the addition of an adequate amount of diluting water resulting in a coating color with a 50% solid content, the composition of which was as follows:
______________________________________Kaolin (UW-90) 100 parts by weightSodium Polyacrylate 0.2 parts by weightStarch (Solid)Styrene-ButadieneCopolymer Latex 20 parts by weight(Japan SyntheticGum Co.: JSR#0692)Calcium Stearate 1.5 parts by weightAmmonium Hydroxide adequate amount.______________________________________
The above coating color was used to prepare coated paper according to the same technique as in Example 2. A control coating color was prepared through the same procedures as for the control coating color in Example 2 and used to form control coated-paper according to the same technique as in Example 2. The results are shown in Table 3.
TABLE 3__________________________________________________________________________ Example 5 Control 1 2 3 4 5 1 2 3 4 5__________________________________________________________________________Proportion of AdhesivesStarch 75 50 35 25 15 75 50 35 25 15Latex 25 50 65 75 85 25 50 65 75 85Coating ColorSolid Content (%) 50.3 50.3 49.8 50.0 49.7 49.9 49.6 49.7 49.8 49.6Brook Field Viscosity (CPS)Just After Preparation (60rpm) 78 51 45 40 35 1.500 351 300 149 9124 hrs After Preparation (60rpm) 139 63 33 31 34 1,835 704 309 171 100High Shear Viscosity (8,800rpm) 9.5 10.6 9.4 9.0 9.0 27.0 16.0 12.8 9.7 9.5pH 8.8 9.2 8.9 9.0 8.9 8.7 8.6 8.6 8.6 8.8Water Retention Value (sec) 8.6 11.2 4.6 4.5 4.7 23.9 14.4 13.7 12.7 11.1Coated PaperCoated Amount (g/m.sup.2) 18.0 17.7 17.9 18.8 17.6 17.7 18.3 18.5 19.4 17.7Sheet Gloss (%) 74.7 80.3 80.2 78.7 81.6 66.8 69.9 70.3 73.5 74.5Brightness (%) 78.3 78.6 78.0 78.3 78.1 79.4 78.1 77.8 77.8 78.7Opacity (%) 88.2 87.9 87.6 88.0 87.5 88.8 87.4 87.3 87.1 86.9Smoothness (sec) 3.200 3.600 5.700 6.200 7.700 2.700 4.800 5.300 5.600 6.700Air Permeability (sec) 4.400 7.800 15.000 18.000 36.000 7.400 18.000 22.000 26.000 34.000Printability of Coated PaperK & N Ink Receptability (%) 22.0 18.0 15.7 15.8 16.1 18.1 16.5 14.9 14.2 14.3Printed Gloss (%) 73.7 86.3 89.6 89.5 88.2 80.2 90.0 90.3 89.4 91.0Printed Ink Density 1.83 2.25 1.93 1.91 1.95 2.19 1.97 1.99 1.99 2.01ITG Pick Strength (cm/sec) 38 60 95 106 115 49 84 80 107 114RI Pick Strength (Dry) 2 3 3.5 4 5 3 3 3.5 4 5RI Pick Strength (Wet) 3.5 4 4 4 4 3 4 4 4 4__________________________________________________________________________
As seen from Table 3, the solid content of the coating color in Example 5 is almost identical to that of the control color. The viscosity of the coating color in Example 5 is nevertheless extremely low when compared with that of the control color. The high shear viscosity of the color in Example 5 is also improved. The addition of the latex results in a decrease in the water retention of the coating color; this tendency becomes more apparent as the amount of the latex increases. The sheet gloss of the coated paper is superior to that of the control. The K & N ink receptibity, given as an indication of the printability of the coated paper, is also superior to that of the control. The IGT pick strength of the coated paper is almost identical to that of the control when the proportion of the amount of latex is over 50% by weight.
EXAMPLE 6
In this example, an insolubilizer was used in order to improve the water resistancy of the final coated paper.
Using the granulated starch and the 70% kaolin suspension as obtained in Example 2, a coating color was prepared according to the same technique as in Example 5 except for the use of an insolubilizer, a melamine derivative resin (Sumitomo chemical Industry; Sumirettsu Resin #613). The composition of the resulting coating color was as follows:
______________________________________Kaolin (UW-90) 100 parts by weightSodium Polyacrylate 0.2 parts by weightStarch (Solid) 10 parts by weightLatex (JSR#0692) 10 parts by weightCalcium Stearate 1.5 parts by weightMelamine Derivative Resin 5-15% by weight(Insolubilizer) (on basis of starch)Ammonium Hydroxide adequate amount______________________________________
Using the above coating color, a coated paper was prepared according to the same technique as in Example 5. The preparation of the control coating color was also the same as that of in Example 5 except for the use of an insolubilizer, a melamine derivative resin. The experimental results are shown in Table 4.
EXAMPLE 7
The coating color was the same composition as in Example 6, except for the use of an epoxy derivative resin (Nagase and Co., Ltd; Denacall #PC-1000) as an insolubilizer. As an insolubilizer in the control coating color the epoxy derivative resin (Denacoal #PC-1000) was likewise used. The experimental results are shown in Table 4.
Table 4 indicates that the use of those insolubilizers increases the water resistancy of the coated paper (especially, 7 days after coating), which is almost identical to that of the control.
TABLE 4__________________________________________________________________________ Example 6 Example 7 Control 1 2 3 4 5 6 1 2__________________________________________________________________________InsolubilizersMelamine Derivative Resin 5 10 15 0 0 0 10 0(Sumirettsu Resin#613)Epoxy Derivative Resin 0 0 0 5 10 15 0 10(Denacall pc-1000)Coating ColorSolid Content (%) 50.6 50.4 50.7 50.3 50.6 50.7 50.0 49.6Brook field Viscosity (CPS)Just After Preparation (60rpm) 55 48 56 49 50 57 428 44024 hrs After Preparation (60rpm) 66 61 61 59 58 111 836 640HIgh Shear Viscosity (8,800rpm) 10.8 10.0 10.5 10.0 10.5 13.0 18.0 17.4pH 9.0 8.7 8.9 8.9 8.9 8.9 9.0 9.0Water Retention Value (sec) 14.8 16.0 16.3 13.7 18.1 19.8 26.5 24.0Coated PaperCoated Amount (g/m.sup.2) 19.2 18.2 17.8 18.2 18.0 18.5 18.4 18.0Sheet Gloss 79.9 79.1 78.0 80.0 79.5 80.0 67.8 68.0IGT Pick Strength (cm/sec) 73 77 72 74 77 74 83 79Water resistancy(Wet Rub Method) 2 Days After Coating 45.5 39.0 39.5 97.5 95.5 96.0 84.5 95.57 Days After Coating 92.0 95.0 99.0 99.0 99.0 100 100 100(RI Wet Pick Method) 2 Days After Coating 3.3 3.3 3 3.3 3.3 3.7 3 3.77 Days After Coating 4 5 5 3 3 4 5 4__________________________________________________________________________
EXAMPLE 8 AND 9
In these examples, the effects of quantity on adhesives and diluting water needed in preparation of the coating color were examined.
In Example 8, 15 parts by weight of the adhesives, including 35% by weight of the granulated starch as prepared in Example 1 and 65% by weight of the latex as used in Example 5, were added to 100 parts by weight of kaolin. The amount of the granulated starch was directly added to the 70% kaolin suspension in the same manner as in Example 2 and the same procedure as in Example 7, No. 5, were carried out to thereby yield the desired coating color, the solid content of which was 62% by weight in the presence of diluting water and 67.7% by weight in the absence of diluting water. The composition of the coating color is briefly shown below:
______________________________________Kaolin (UW-90) 100 parts by weightSodium Polyacrylate 0.2 parts by weightStarch 15 parts by weightLatexCalcium Stearate 1.5 parts by weightEpoxy Derivative Resin 5% by weight(Denacall#PC-1000) (on basis of starch)Ammonium Hydroxide adequate amount.______________________________________
A control coating color was prepared by adding 30% paste containing amino phosphoric acid esterification starch to the 70% kaolin suspension according to the same technique as in the control of Example 2 and the same procedure as described in the control of Example 7. The solid content of the resulting control color was 61-62% by weight in the absence of diluting water.
In Example 9, 20 parts by weight of the adhesives including 35% by weight of the granulated starch and 65% by weight of the latex, were added to 100 parts by weight of kaolin. The amount of the granulated starch was directly added to the 70% kaolin suspension in the same manner as in Example 2 and the same procedures as in Example 7, No.5, were carried out thereby yielding the desired coating color, the solid content of which was 62% by weight in the presence of diluting water and 67.4% by weight in the absence of diluting water. The composition of the coating color is briefly shown below:
______________________________________Kaolin (UW-90) 100 parts by weightSodium Polyacrylate 0.2 parts by weightStarch 20 parts by weightLatexCalcium Stearate 1.5 parts by weightEpoxy Derivative Resin 5% by weight(Denacall#PC-1000) (on basis of starch)Ammonium Hydroxide adequate amount.______________________________________
A control coating color was prepared in the same manner as in that of Example 8.
The experimental results are shown in Table 5, which indicates that the coating colors of Examples 8 and 9 have an extremely low viscosity, respectively, despite a high solid content and that the water retention and the high shear viscosity are improved. Streak and scratch were not observed in the coating process which was carried out by means of a blade coater. The qualities and printability of the coated paper were almost identical to those of the control.
TABLE 5__________________________________________________________________________ Example 8 Example 9 Control 1 2 3 4 1 2__________________________________________________________________________Amount of Adhesives Used 15 parts 15 parts 20 parts 20 parts 15 parts 20 partsProportionStarch 35 35 35 35 35 35Latex 65 65 65 65 65 65Coating ColorSolid Content (%) 63.1 67.7 62.3 67.4 62.6 61.4Brookfield Viscosity (CPS)Just After Preparation (60rpm) 363 1,576 479 1,508 4,140 4,50024 hrs After Preparation (60rpm) 514 1,970 598 2,120 4.200 4.920HIgh Shear Viscosity (4,400rpm) 55 275 30 170 95 109(8,800rpm) -- -- 28 -- -- --pH 9.1 9.1 9.0 8.9 9.5 9.2Water Retention Value (sec) 19.5 26.1 23.4 27.0 27.2 30.7Coating Condition By Blade Coater ⊚ ⊚ ⊚ ⊚ ⊚ ⊚Coated PaperCoated Amount (g/m.sup.2) 19.6 -- 20.0 -- 17.0 18.3Sheet Gloss (%) 80.9 -- 79.2 -- 76.2 73.9Brightness (%) 79.5 -- 79.1 -- 79.5 78.9Opacity (%) 89.1 -- 88.6 -- 88.5 87.9Smoothness (sec) 3,600 -- 4,300 -- 3,700 4,400Air Permeability (sec) 4,600 -- 10,000 -- 5,000 12,000Wet Rub (4 days After) (%) 98.0 -- 98.0 -- 98.0 98.0Printabilty of Coated PaperK & N Ink Receptibility (%) 21.4 -- 12.0 -- 21.4 11.8Printed Gloss (%) 80.4 -- 89.4 -- 83.5 90.3Printed Ink Density 2.27 -- 2.37 -- 2.36 2.39ITG Pick Strength (cm/sec) 93 -- 106 -- 82 92RI Pick Strength (Dry) 3.2 -- 5 -- 3.2 5RI Pick Strength (Wet) 2 -- 4.1 -- 1 3.9__________________________________________________________________________
EXAMPLES 10
According to the same technique as in the aforementioned examples, a coating color was prepared, the composition of which is shown in the upper part of Table 6. The coating color was applied to a base paper by means of a test plant bar coater at a coating speed of 70 m/min thereby obtaining coated paper with a coated color amount of 11 g/m 2 on its each surface. After drying, the coated paper was subjected to a super calender treatment to improve the smoothness and brightness thereof. The qualities of the coating color and coated paper are shown in the middle part and the lower part of Table 6, respectively. It can be seen in Table 6 that both the Brookfield viscosity and the high shear viscosity are superior to those of the control. It is also found that the sheet gloss of the coated paper is particularly excellent. In addition, the coating process using the bar coater showed no evidence of streak or scratch.
TABLE 6______________________________________ Example 10 Control______________________________________CompositionKaolin (UW-90) 70 70Calcium carbonate 30 30Starch 7* 7**Latex (JSR#0692) 13 13Sumirettsu resin #633 0.42 0.42Calcium Stearate 1.5 15.5Ammonium HydroxidepH 9-10Coating ColorSolid Content 54.5 52.3Brookfield Viscosity (CPS)Just After coating (60rpm) 85 38024 hrs After coating (60rpm) 150 455pH 9.9 9.5High Shear Viscosity (8,800rpm) 20.4 25.6Coating Condition By Bar Coater ⊚ ⊚Coated PaperCoated Amount (g/m.sup.2) 11.6 12.1Brightness (%) 82.5 82.1Opacity (%) 85.0 85.0Sheet Gloss (%) 55.2 50.3Smoothness (mmHg) 23 22Air Permeabilty (mmHg) 11 15Printed Gloss (%) 62.3 65.3K & N ink Receptivity 21.1 22.6IGT Pick Strength (cm/sec) 113 104RI Pick Strength (Dry) 4 4(Wet) 4 4Ink Setting (For 1 minutes) (%) 40.5 39.5______________________________________ Note: *Enzymeconverted starch **Aminophosphate esterification starch
The coated paper was printed under the belowmentioned conditions to evaluate the print properties such as an printing operation conditions, picking occurrence, paper dust production, print conditions and the like:
______________________________________1. Printing Machine Rolandrecoad RZK-3 Type Two Coloring Machine2. Test Board Fuji Photofilm Co., Ltd. GAP-II3. Blanket Kinyo Co., Ltd. Blanket S5300W4. Ink Dainippon Ink Co., Ltd. New Champion Superapex S Type5. Printing Order Indigo to Red6. Damping Solution Industrial Water +5% of EPA+ 0.5% of DH-78(Dainippon Ink Co., ltd.)7. Printing Press 15/100 mm between plate cylinder and blanket cylinder; 15/100 mm between blanket cylinder and press cylinder8. Printing Speed 5,000 Sheets/hr9. The number of 2,000 Sheets. Printed sheets______________________________________
Evaluation of the print properties of the coated paper are shown in Table 7, indicating that the coated paper using the coating color according to this invention is the most excellent in light of the total evaluation.
TABLE 7______________________________________ Printed Papers Reference E- (Commercial valu- Example CoatedItems ation 10 Control Light-Paper)______________________________________OperationConditionFeeder 0 0 0Feeder Pertinency 9 -1 -2 0Damping Solution 0 0 0Ink Amount 0 0 0PickingOccurenceFirst Cylinder 20 -5 -5 -10Second Cylinder 0 -2 -10Paper DustProductionResidue on Feeder -0.5 -0.5 0Residue on Blanket 17 -5 -5 -5Residue on Inkroller 0 0 0PrintConditionThickness of Printed 0 -5 -5InkDot Reproduction 40 0 0 -6Gloss 31 7 -7 0OthersTime Required For 0 0 0Ink SettingDimension Stabillity 14 0 0 0Delivery 0 0 0Total Evaluation 100 81.5 73.5 64______________________________________
The various measurements in the aforementioned examples were carried out according to the following methods:
(1) The viscosity of the coating color was measured at 25° C. and 60 rpm by a Brookfield type viscometer available from Tokyo Keiki Co., LTd.,
(2) The high shear viscosity (10 5 dyne-cm) of the coating color was measured at 8800 rpm and 4400 rpm by a Hercules type high shear viscometer, available from Kumagai Riki Co., Ltd.,
(3) The water retention value of the coating color was measured using No.6 filter paper by the KMnO 4 method,
(4) The sheet gloss was measured at 75° specular gloss on paper by a Murakami type gloss meter,
(5) The brightness was measured using a blue filter by a Murakami type hunter,
(6) The opacity was measured using a green filter by a Murakami type hunter,
(7) The smoothness (sec) was measured by an Oji Laboratory type smoothness examining machine,
(8) The smoothness (mmHg) was measured by a Smoothter, smoothness examining machine,
(9) The air permeability (sec) was measured by an Oji type permeability examining machine,
(10) The air permeability (mmHg) was measured by a smoothter permeability examining machine,
(11) The K & N ink receptibity was measured using K & N ink by a reduction rate of brightness,
(12) The printed gloss was measured at 75° specular on the printed side by a RI printing tester,
(13) The printed ink density was based on a reflection density of the printed side prepared by an RI printing tester; The reflection density was measured by a density meter available from Dainippon Screen Co., Ltd.,
(14) The IGT pick strength was measured by a IGT pick strength meter,
(15) The RI pick strength (dry) was evaluated through visual inspection (5 points indicates the most excellent and 1 point the most inferior) after measurement of pick resistance in printing by means of an RI printing meter,
(16) The RI pick strength (wet) was evaluated through visual inspection (5 points indicates the most excellent and 1 point the most inferior) after measurement of wet pick resistance by means of an RI printing tester,
(17) The water resistancy by the Wet Rub method was measured as follows:
Using a abrasion machine available from Taber Co., Ltd., 10 ml of distilled water were added dropwise to the coated surface of the paper to thereby make the surface damp. The resulting damp surface was rubbed by a rubber wheel of 250 g at 10 to 20 revolutions. The coated color on the rubbed surface of the paper was removed with distilled water. One hundred ml of the distilled water containing the removed color coating was measured at 420 nm by a Hirama type spectrophotometer to calculate the amount of coated color washed out of the coated surface of the paper.
(18) The coating color was coated at 600 m/min using a high speed sheet type blade coater available from Kumagai Riki Co., Ltd. The resulting coated surface was visually inspected to evaluate the coating condition using a blade coater by the following basis:
: Quite Excellent
: Just Excellent
: Good
Δ: Ordinary
×: Inferior, and
(19) The coating color was continuously applied to the surface of the paper using a pilot test bar coater. The resulting coated surface of paper was visually inspected to evaluate the coating condition using a bar coater by the abovementioned base.
It is understood that various other modifications will be apparent to and can readily be made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly it is intended that the scope of the following claims be construed as encompassing all the patentable features which are associated with the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which the invention pertains. | Coating color and method for providing an excellent coating condition and paper quality through steps comprising a direct addition of enzymatically converted powdered or granulated dry starch to an aqueous suspension of pigments. The dry starch is soluble and impasted in the cold aqueous suspension of pigments without impastation heat and/or other equipment. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a 35 U.S.C. 371 national phase entry of International Patent Application number PCT/CA2006/000370 filed Mar. 13, 2006 and amended under Article 19 during the International Phase, which claims priority of U.S. provisional patent application No. 60/660,471 filed Mar. 11, 2005, all of which are hereby incorporated by reference.
TECHNICAL FIELD
The present invention generally relates to the field of three-dimensional scanning of an object's surface geometry, and, more particularly, to a portable three-dimensional scanning apparatus for hand-held operations.
BACKGROUND OF THE INVENTION
Three-dimensional scanning and digitization of the surface geometry of objects is now commonly used in many industries and services and their applications are numerous. A few examples of such applications are: inspection and measurement of shape conformity in industrial production systems, digitization of clay models for industrial design and styling applications, reverse engineering of existing parts with complex geometry, interactive visualization of objects in multimedia applications, three-dimensional documentation of artwork and artifacts, human body scanning for better orthesis adaptation or biometry.
The shape of an object is scanned and digitized using a ranging sensor that measures the distance between the sensor and a set of points on the surface. From these measurements, three dimensional coordinates of points on the target surface are obtained in the sensor reference frame. From a given viewpoint, the ranging sensor can only acquire distance measurements on the visible portion of the surface. To digitize the whole object, the sensor must therefore be moved to a plurality of viewpoints in order to acquire sets of range measurements that cover the entire surface. A model of the object's surface geometry can be built from the whole set of range measurements provided in a global common coordinate system.
Different principles have been developed for range sensors (see F. Blais, “A Review of 20 Years of Range Sensor Development”, in proceedings of SPIE-IS&T Electronic Imaging, SPIE Vol. 5013, 2003, pp. 62-76). Among them, interferometry, time-of-flight and triangulation-based principles are well known principles that are each more or less appropriate depending on the requirements on accuracy, the standoff distance between the sensor and the object, and the required depth of field.
We are especially interested in triangulation-based range sensors that are generally adequate for close range measurements, typically inferior to a few meters. Using this type of apparatus, one must collect two observations of a same feature point on the object from two different viewpoints separated by a baseline distance. From the baseline and two ray directions, the relative position of the observed point can be recovered. The intersection of both rays is solved for using the knowledge of one side length and two angles in the triangle. This is actually the principle of passive stereovision. One can replace a light detector with a light projector issuing a set of rays in known directions. In this case, it is possible to exploit the orientation of the projector and each detected ray reflected on the object's surface for solving a triangle. In both cases, it is possible to calculate the coordinates of each observed feature point relative to the basis of the triangle. Although specialized light detectors can be used, digital CCD or CMOS cameras are typically used.
The usage of a light projector facilitates the detection of reflected points anywhere on the object's surface so as to provide a dense set of measured surface points. Typically, the light source is a laser source projecting a spot, a light plane or many other possible patterns of projection such as a crosshair. This type of projector with coherent light offers good depth of field characteristics but is subject to speckle noise. It is also possible to project non coherent light patterns (e.g. white light) to avoid speckle when a loss in the depth of field is less critical.
To scan an object means to collect points on its surface. The points can be further structured in the form of curves (profiles) or range images. To scan the whole surface of an object, one must displace the sensor. Although it is possible to move the projector independently (see J. Y. Bouguet and P. Perona, “3D Photography Using Shadows in Dual-Space Geometry”, Int. Journal of Computer Vision, vol. 35, No. 2, November-December 1999, pp. 129-149.) the sensor is usually a single assembly comprising the light detector and the projector. The light detector and the projector can be a rigid set or it is also common that the light projector be a scanning mechanism within the sensor device. The sensor can be moved around the object using a mechanical system or hand-held for more versatility. Portable hand-held systems are especially useful for rapid scanning and for objects that must be scanned on site.
Using a hand-held system, the main challenge is to continuously estimate the position and orientation (6 degrees of freedom) of the apparatus in a global coordinate system fixed relative to the object. This can be accomplished using a positioning device (see U.S. Pat. No. 6,508,403) that is coupled to the range scanner. Using a positioning device significantly increases the complexity and cost of the apparatus. It is also cumbersome in some cases or noisy enough to limit the quality of the integrated data.
To avoid the usage of an external positioning device, an alternative consists of using the 3D measurements collected on a rigid object in order to compute the relative position and orientation between the apparatus and the object. It is even possible to hold and displace the object in hand while scanning (see S. Rusinkiewicz, O. Hall-Holt and M. Levoy, “Real-Time 3D Model Acquisition”, in ACM Transactions on Graphics, vol. 21, no. 3, July 2002, pp. 438-446, F. Blais, M. Picard and G. Godin, “Accurate 3D Acquisition of Freely Moving Objects,” in proc. of the Second International Symposium on 3D Data Processing, Visualization and Transmission. Thessaloniki, Greece. Sep. 6-9, 2004. NRC 47141). This idea of integrating the computation of the position directly into the system while exploiting measurement is interesting but these systems depend completely on the geometry of the object and it is not possible to ensure that an accurate estimate of the pose be maintained. For instance, objects whose geometry variation is weak or objects with local symmetries with spherical, cylindrical or planar shapes, lead to non constant quality in positioning.
One can exploit principles of photogrammetry by using fixed points or features that can be re-observed from various viewpoints in the scene. These positioning features can be natural points in the scene but in many cases their density or quality is not sufficient and target positioning features are set in the scene. One may thus collect a set of images and model the 3D set of positioning features in a common global coordinate system. One can further combine this principle using a camera with a 3D surface scanner. The complementarity of photogrammetry and range sensing has been developed (see, for example, the Tritop™ by GOM mbH which is a an optical coordinate measuring machine.) where a white light projector is used with cameras enlighting retro-reflective targets. Using this type of system, a photogrammetric model of the set of retro-reflective targets is measured and built beforehand, using a digital camera. Then, the 3D sensor apparatus is displaced at a set of fixed positions to measure the surface geometry. The range images can be registered to the formerly constructed model of positioning features since the 3D sensor apparatus can detect the retro-reflective targets.
An interesting idea is to integrate within a same system a hand-held scanner projecting a light pattern but also with the capability of self-positioning while simultaneously observing positioning features. Hebert (see P. Hébert, “A Self-Referenced Hand-Held Range Sensor”. in proc. of the 3rd International Conference on 3D Digital Imaging and Modeling (3DIM 2001), 28 May-1 Jun. 2001, Quebec City, Canada, pp. 5-12) proposed to project laser points on the object to be scanned with an external fixed projector to help position the hand-held sensor. Nevertheless, although the system is freely hand-held, it is limited since it does not build a model of the positioning feature points dynamically; there must exist a single viewpoint where all—three—positioning feature points are visible.
SUMMARY OF THE INVENTION
It would thus be of great interest to simultaneously scan and model the object's surface while accumulating a second model of the positioning features in real-time using a single hand-held sensor. Furthermore, by fixing additional physical targets as positioning features on an object, it would be possible to hold the object in one hand while holding the scanner in the second hand without depending on the object's surface geometry for the quality of the calculated sensor positions.
It is therefore an aim of the present invention to provide a 3D laser scanning system that can simultaneously measure the 3D surface geometry and measure a model of a set of positioning features for positioning.
It is further an aim of the present invention to provide a compact apparatus embedding a hand-held sensing device for scanning the surface geometry of an object.
It is still a further aim of the present invention to provide an improved method for 3-D scanning of objects.
Therefore, in accordance with the present invention, there is provided a system for three-dimensional scanning, said system comprising a hand-held sensing device including a set of at least one laser pattern projector, a set of at least two objectives and light detectors, said sensing device providing images from each light detector; and an image processor configured for obtaining at least one set of 2D surface points originating from the reflection of the said projected laser pattern on the object's surface and at least two sets of 2D positioning features originating from the observation of target positioning features; and a 3D surface point calculator for transforming the said sets of 2D surface points into a set of 3D surface points related to the sensor coordinate system; and a 3D positioning feature calculator for transforming the said sets of 2D positioning features into a set of calculated 3D positioning features related to the sensor coordinate system; and a positioning feature matcher for matching the sets of 3D positioning features and 2D positioning features to an accumulated representation of the already observed positioning features and calculating the spatial relationship between the current sensing device and the said accumulated representation of positioning features; and a 3D positioning feature transformer for transforming the sets of 3D positioning features into a set of calculated 3D positioning features related to the global coordinate system; and a 3D reference positioning feature model builder for calculating, updating and accumulating a representation of the already observed 3D positioning features; and a 3D surface point transformer for transforming the said set of 3D surface points into a global coordinate system related to the 3D positioning feature representation.
Also in accordance with the present invention, there is provided an apparatus embedding a hand-held sensing device including a set of at least one laser pattern projector, a set of at least two objectives and light detectors, wherein a subset of said light detectors comprise a light source for illuminating and facilitating the detection of retro-reflective target reference points in the scene, said apparatus being connected to a computer for providing at least one set of 2D surface points originating from the reflection of the projected pattern on the object's surface and at least one set of 2D positioning features originating from the observation of target positioning features.
Further in accordance with the present invention, there is provided a method for obtaining 3D surface points in a global coordinate system using a hand-held device, comprising the steps of obtaining at least one set of 2D surface points originating from the reflection of the laser projected pattern on the object's surface and at least two sets of 2D positioning features originating from the observation of target positioning features; and transforming the said sets of 2D surface points into a set of 3D surface points related to the sensor coordinate system; and transforming the said sets of 2D positioning features into a set of calculated 3D positioning features related to the sensor coordinate system; and matching the sets of 3D positioning features and 2D positioning features to an accumulated representation of the already observed positioning features and calculating the spatial relationship between the current sensing device and the said accumulated representation of positioning features; and transforming the sets of 3D positioning features into a set of calculated 3D positioning features related to the global coordinate system; and calculating, updating and accumulating a representation of the already observed 3D positioning features; and transforming the said set of 3D surface points into a global coordinate system related to the 3D positioning feature representation.
Further, in accordance with the present invention, there is provided a method for obtaining 3D surface points of an object in an object coordinate system using an hand-held device, said method comprising providing a projection pattern on said object; securing a set of positioning features on said object such that said object and, accordingly, said object coordinate system can be moved in space while said positioning features stay still on said object; acquiring a pair of 2D images of said projection pattern on said object and of at least part of said set of positioning features, an acquiring position of said pair of 2D images being defined in a sensing device coordinate system; extracting, from said pair of 2D images, a pair of sets of 2D surface points originating from said projection pattern and a pair of sets of 2D positioning features originating from said at least part of said set of positioning features; calculating a set of 3D surface points in said sensing device coordinate system using said pair of sets of 2D surface points; calculating a set of 3D positioning features in said sensing device coordinate system using said pair of sets of 2D positioning features; computing transformation parameters for characterizing a current spatial relationship between said sensing device coordinate system and said object coordinate system, by matching corresponding features between said set of calculated 3D positioning features in said sensing device coordinate system and a set of reference 3D positioning features in said object coordinate system, said reference 3D positioning features being cumulated from previous observations; transforming said set of calculated 3D surface points in said sensing device coordinate system into a set of transformed 3D surface points in said object coordinate system using said transformation parameters; transforming said set of calculated 3D positioning features in said sensing device coordinate system into a set of transformed 3D positioning features in said object coordinate system using said transformation parameters; and cumulating said set of transformed 3D positioning features to provide and augment said set of reference 3D positioning features.
Also in accordance with the present invention, there is provided a system for acquiring a 3D surface points of an object in an object coordinate system, said system comprising a sensing device having a pattern projector for providing a projection pattern on said object, a pair of cameras for acquiring a pair of 2D images of said projection pattern on said object and of at least part of a set of positioning features, and a sensing device coordinate system, said set of positioning features being secured on said object such that said object and, accordingly, said object coordinate system can be moved in space while said positioning features stay still on said object; an image processor for extracting, from said pair of 2D images, a pair of sets of 2D surface points originating from said projection pattern and a pair of sets of 2D positioning features originating from said at least part of said set of positioning features; a 3D surface point calculator for calculating a set of 3D surface points in said sensing device coordinate system using said pair of sets of 2D surface points; a 3D positioning features calculator for calculating a set of 3D positioning features in said sensing device coordinate system using said pair of sets of 2D positioning features; a positioning features matcher for computing transformation parameters to characterize a current spatial transformation between said sensing device coordinate system and said object coordinate system, by matching corresponding features between said set of calculated 3D positioning features in said sensing device and a set of reference 3D positioning features in said object coordinate system, said set of reference 3D positioning features being obtained from previous observations; a 3D surface point transformer for transforming said set of calculated 3D surface points in said sensing device coordinate system into a set of transformed 3D surface points in said object coordinate system using said transformation parameters; a 3D positioning features transformer for transforming said set of calculated 3D positioning features in said sensing device coordinate system into a set of transformed 3D positioning features in said object coordinate system using said transformation parameters; and a reference positioning features builder for cumulating said set of transformed 3D positioning features to provide and augment said set of reference 3D positioning features.
Also in accordance with the present invention, there is provided an auto-referenced sensing device for scanning an object to provide 3D surface points thereof in an object coordinate system, said sensing device comprising: a sensing device current coordinate system; a pattern projector for providing a projection pattern on said object; a pair of cameras for acquiring a pair of 2D images of said projection pattern and of at least part of a set of positioning features, said positioning features being located such that at least part of said positioning features are in said pair of 2D images at a given time, a spatial relationship between said pair of cameras being known, said pair of 2D images for providing calculated 3D surface points of said object and calculated 3D positioning features in said sensing device current coordinate system, said calculated 3D positioning features for characterizing a spatial transformation between said current sensing device coordinate system and said object coordinate system by matching corresponding features between said set of calculated 3D positioning features in said sensing device current coordinate system and in a set of reference 3D positioning features in said object coordinate system, transformed 3D surface points in said object coordinate system being calculated using said transformation.
A system, apparatus and method for three-dimensional scanning and digitization of the surface geometry of objects are claimed. The system comprises a hand-held apparatus that is auto-referenced. The system is auto-referenced since it does not need any positioning device to provide the 6 degree of freedom transformations that are necessary to integrate 3D measurements in a global coordinate system while the apparatus is manipulated to scan the surface. The system continuously calculates its own position and orientation from observation while scanning the surface geometry of an object. To do so, the system exploits a triangulation principle and integrates an apparatus that captures both surface points originating from the reflection of a projected laser pattern on an object's surface and 2D positioning features originating from the observation of target positioning features. A significant advantage of the described system is its capability to implement a method that makes it possible to simultaneously build and match a 3D representation of the positioning features while accumulating the 3D surface points describing the surface geometry.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, and in which:
FIG. 1 is a block diagram illustrating a system for three-dimensional surface scanning in accordance with the present invention.
FIG. 2 depicts a configuration of an apparatus for three-dimensional surface scanning in accordance with the present invention.
FIG. 3 illustrates a configuration of the apparatus depicted in FIG. 2 along with the object to be measured during acquisition, in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , the 3D surface scanning system is generally shown at 10 .
Sensing Device
The system comprises a sensing device 12 described in more details thereafter in this description. The sensing device 12 collects and transmits a set of images 13 , namely a frame, of the observed scene to an image processor 14 . These images are collected from at least two viewpoints where each of these viewpoints has its own center of projection. The relevant information encompassed in the images results from the laser projection pattern reflected on the object's surface as well as positioning features that are used to calculate the relative position of the sensing device with respect to other frame captures. Since all images in a given frame, are captured simultaneously and contain both positioning and surface measurements, synchronisation of positioning and surface measurement is implicit.
The positioning features are secured on the object such that the object can be moved in space while the positioning features stay still on the object and, accordingly, with respect to the object's coordinate system. It allows the object to be moved in space while its surface is being scanned by the sensing device.
Image Processor
The image processor 14 extracts positioning features and surface points from each image. For each image, a set of 2D surface points 15 and a second set of observed 2D positioning features 21 are output. These points and features are identified in the images based on their intrinsic characteristics. Positioning features are either the trace of isolated laser points or circular retro-reflective targets. The pixels associated with these features are contrasting with respect to the background and may be isolated with simple image processing techniques before estimating their position using centroïd or ellipse fitting (see E. Trucco and A. Verri, “Introductory techniques for 3-D computer vision”, Prentice Hall, 1998, p. 101-108). Using circular targets allows one to extract surface normal orientation information from the equation of the fitted ellipse, therefore facilitating sensing device positioning. The sets of surface points are discriminated from the positioning features since the laser pattern projector produces contrasting curve sections in the images and thus presenting a different 2D shape. The image curve sections are isolated as single blobs and for each of these blobs, the curve segment is analyzed for extracting a set of points on the curve with sub-pixel precision. This is accomplished by convolving a differential operator across the curve section and interpolating the zero-crossing of its response.
For a crosshair laser pattern, one can benefit from the architecture of the apparatus described thereafter. In this configuration with two cameras and a crosshair pattern projector, the cameras are aligned such that one among the two laser planes produces a single straight line in each camera at a constant position. This is the inactive laser plane for a given camera. These inactive laser planes are opposite for both cameras. This configuration, proposed by Hebert (see P. Hébert, “A Self-Referenced Hand-Held Range Sensor”. in proc. of the 3rd International Conference on 3D Digital Imaging and Modeling (3DIM 2001), 28 May-1 Jun. 2001, Quebec City, Canada, pp. 5-12) greatly simplifies the image processing task. It also simplifies the assignation of each set of 2D surface point to a laser plane of the crosshair.
While the sets of surface points 15 follow one path in the system to recover the whole scan of the surface geometry, the sets of observed 2D positioning features 21 follow a second path and are used to recover the relative position of the sensing device with respect to the object's surface. However, these two types of sets are further processed for obtaining 3D information in the sensing device coordinate system.
3D Positioning Features Calculator
Since the sensing device is calibrated, matched positioning features between camera viewpoints are used to estimate their 3D position using the 3D positioning features calculator 22 . The sets of observed 2D positioning features are matched using the epipolar constraint to obtain non ambiguous matches. The epipolar lines are calculated using the fundamental matrix that is calculated from the calibrated projection matrices of the cameras. Then, from the known projection matrices of the cameras, triangulation is applied to calculate a single set of calculated 3D positioning features in the sensing device coordinate system 23 . This set of points will be fed to the positioning features matcher for providing the observation on the current state of the sensing device, and to the 3D positioning features transformer for an eventual update of the reference 3D positioning features in the object coordinate system.
3D Surface Point Calculator
The 3D surface point calculator 16 takes as input the extracted sets of 2D surface points 15 . These points can be associated with a section of the laser projected pattern, for instance one of the two planes for the crosshair pattern. When the association is known, each of the 2D points can be transformed into a 3D point in the sensing device coordinate system by intersecting the corresponding cast ray and the equation of the laser plane. The equation of the ray is obtained from the projection matrix of the associated camera. The laser plane equation is obtained using a pre-calibration procedure (see P. Hébert, “A Self-Referenced Hand-Held Range Sensor”. in proc. of the 3rd International Conference on 3D Digital Imaging and Modeling (3DIM 2001), 28 May-1 Jun. 2001, Quebec City, Canada, pp. 5-12) or exploiting a table look-up after calibrating the sensing device with an accurate translation stage for instance. Both approaches are adequate. In the first case, the procedure is simple and there is no need for sophisticated equipment but it requires a very good estimation of the cameras' intrinsic and extrinsic parameters.
It is also possible to avoid associating each 2D point to a specific structure of the laser pattern. This is particularly interesting for more complex or general patterns. In this case, it is still possible to calculate 3D surface points using the fundamental matrix and exploiting the epipolar constraint to match points. When this can be done without ambiguity, triangulation can be calculated in the same way it is applied by the 3D positioning features calculator 22 .
The 3D surface point calculator 16 thus outputs a set of calculated 3D surface points in the sensing device coordinate system 17 . This can be an unorganized set or preferably, the set is organized such that 3D points associated with connected segments in the images are grouped for estimating 3D curve tangent by differentiation. This information can be exploited by the surface reconstructor for improved quality of the recovered surface model 31 .
Positioning Subsystem
The task of the positioning subsystem, mainly implemented in the positioning features matcher 24 and in the reference positioning features builder 28 , is to provide transformation parameters 25 for each set of calculated 3D surface points 17 . These transformation parameters 25 make it possible to transform calculated 3D surface points 17 into a single, object coordinate system while preserving the structure; the transformation is rigid. This is accomplished by building and maintaining a set of reference 3D positioning features 29 in the object coordinate system. The positioning features can be a set of 3D points, a set of 3D points with associated surface normal or any other surface characteristic. In this preferred embodiment it is assumed that all positioning features are 3D points, represented as column vectors [x,y,z] T containing three components denoting the position of the points along the three coordinate axes.
At the beginning of a scanning session, the set of reference 3D positioning features 29 is empty. As the sensing device 12 provides the first measurements and the system calculates sets of calculated 3D positioning features 23 , the features are copied into the set of reference 3D positioning features 29 using the identity transformation. This set thus becomes the reference set for all subsequent sets of reference 3D positioning features 29 and this first sensing device position defines the object coordinate system into which all 3D surface points are aligned.
After creation of the initial set of reference 3D positioning features 29 , subsequent sets of calculated 3D positioning features 23 are first matched against the reference set 29 . The matching operation is divided into two tasks: i) finding corresponding features between the set of calculated 3D positioning features in the sensing device coordinate system 23 and the set of reference 3D features in the object coordinate system, and ii) computing the transformation parameters 25 of the optimal rigid 3D transformation that best aligns the two sets. Once the parameters have been computed, they are used to transform both calculated 3D positioning features 23 and calculated 3D surface points 17 thus aligning them into the object coordinate system.
The input to the positioning features matcher 24 are the set of reference 3D positioning features 29 , R, the set of calculated 3D positioning features 23 , O, along with two sets of observed 2D positioning features 21 , P 1 and P 2 which were also used by the 3D positioning features calculator 22 , as explained above. Matching these sets is the problem of finding two subsets O m ⊂ O and R m ⊂ R, containing N features each, such that all pairs of points (o i ,r i ) with o i εO m and r i εR m , represent the same physical features. Finding these subsets is accomplished by finding the maximum number of segments of points ( o i o j ; r i r j ), such that
|∥ o i −o j ∥−∥r i −r j ∥|≦ε for all i,jε{ 1, . . . , N}, i≠j, (1)
where ε is a predefined threshold which is set to correspond to the accuracy of the sensing device. This constraint imposes that the difference in distance between a corresponding pair of points in the two sets be negligible.
This matching operation is solved as a combinatorial optimization problem where each segment of points from the set O is progressively matched against each segment of points in the set R. Each matched segment is then expanded by forming an additional segment using the remaining points in each of the two sets. If two segments satisfy the constraint (1), a third segment is formed and so on as long as the constraint is satisfied. Otherwise the pair is discarded and the next one is examined. The solution is the largest set of segments satisfying (1). Other algorithms (see M. Fischler and R. Bolles, (1981) “Random sample consensus: A paradigm for model fitting with applications to image analysis and automated cartography”, Communications of the Assoc. for Computing Machinery, (June 1981), vol. 24, no. 6, pp. 381-395.) can be used for the same purpose.
As long as the number of elements in the set of reference 3D positioning features 29 is relatively low (typically less than fifteen), the computational complexity of the above approach is acceptable for real-time operation. In practice however, the number of reference 3D positioning features 29 can easily reach several hundreds. Since the computational complexity grows exponentially with the number of features, the computation of corresponding features becomes too slow for real-time applications. The problem is solved by noting that the number of positioning features that are visible from any particular viewpoint is small, being limited by the finite field of view of the sensing device.
This means that if the calculated 3D positioning features 23 can be matched against reference 3D positioning features 29 , then the matched features from the reference set are located in a small neighbourhood whose size is determined by the size of the set of calculated 3D positioning features 23 . This also means that the number of points in this neighbourhood should be small as well (typically less than fifteen). To exploit this property for accelerating matching, the above method is modified as follows. Prior to matching, a set of neighbouring features [N i ] is created for each reference feature. After the initial segment of points is matched, it is expanded by adding an additional segment using only points in the neighbourhood set [N i ] of the first matched feature. By doing so, the number of points used for matching remains low regardless of the size of the set of reference 3D positioning features 29 , thus preventing an exponential growth of the computational complexity.
Alternatively, exploiting spatial correlation of sensing device position and orientation can be used to improve matching speed. By assuming that the displacement of the sensing device is small with respect to the size of the set of positioning features, matching can be accomplished by finding the closest reference feature for each observed positioning feature. The same principle can be used in 2D, that is, by finding closest 2D positioning features.
Once matching is done, the two sets need to be aligned by computing the optimal transformation parameters [M T], in the least-squares sense, such that the following cost function is minimized:
∑
i
=
1
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r
i
-
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i
+
T
2
,
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i
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{
1
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The transformation parameters consist of a 3×3 rotation matrix M and a 3×1 translation vector T. Such a transformation can be found using dual quaternions as described in M. W. Walker, L. Shao and R. A. Volz, “Estimating 3-D location parameters using dual number quaternions”, CVGIP: Image Understanding, vol. 54, no. 3, November 1991, pp. 358-367. In order to compute this transformation, at least three common positioning features have to be found. Otherwise both positioning features and surface points are discarded for the current frame.
An alternative method for computing the rigid transformation is to minimize the distance between observed 2D positioning features 21 and the projections of reference 3D positioning features 29 . Using the perspective projection transformation II, the rigid transformation [M T] that is optimal in the least-squares sense is the transform that minimizes:
∑ i = 1 N Π M - 1 ( r i - T ) - p i 2 , for all i , j ∈ { 1 , … , N } , ( 3 )
where p i εP 1 or p i εP 2 are observed 2D features that correspond to the 3D observed feature o i εO m . The rigid transformation [M T] can be found by minimizing the above cost function using an optimization algorithm such as the Levenberg-Marquardt method.
3D Positioning Features Transformer
Once the rigid transformation is computed, the 3D positioning features transformer 26 transforms the set of calculated 3D positioning features from the sensing device coordinate system 23 to the object coordinate system 27 . The transformed 3D positioning features are used to update the set of reference 3D positioning features 29 in two ways. First, if only a subset of observed features has been matched against the set of reference 3D positioning features 29 , the unmatched observed features represent newly observed features that are added to the reference set. The features that have been re-observed and matched can be either discarded (since they are already in the reference set) or used to improve, that is, filter the existing features. For example, all observations of the same feature can be summed together in order to compute the average feature position. By doing so, the variance of the measurement noise is reduced thus improving the accuracy of the positioning system.
3D Surface Point Transformer
The processing steps for the surface points are simple once the positioning features matcher 24 makes the transformation parameters 25 available. The set of calculated 3D surface points in the sensing device coordinate system 17 provided by the 3D surface point calculator 16 are then transformed by the 3D surface point transformer 18 using the same transformation parameters 25 provided by the positioning features matcher 24 , which is the main link of information between the positioning subsystem and the integration of surface points in the object coordinate system. The resulting set of transformed 3D surface points in the object coordinate system 19 is thus naturally aligned in the same coordinate system with the set of reference 3D positioning features 29 . The final set of 3D surface points 19 can be visualized or preferably fed to a surface reconstructor 20 that estimates a continuous non-redundant and possibly filtered surface representation 31 that is displayed, on a user interface display 30 , optionally with the superimposed set of reference 3D positioning features 29 .
Having described the system, a closer view of the sensing device is now detailed. FIG. 2 illustrates a front view of a sensing device 40 that is used in this preferred embodiment of the system. The device comprises two objectives and light detectors 46 that are typically progressive scan digital cameras. The two objectives and light detectors 46 have their centers of projection separated by a distance D 1 52 , namely the baseline, and compose a passive stereo pair of light detectors. The laser pattern projector 42 is preferably positioned at a distance D 3 56 from the baseline of the stereo pair to compose a compact triangular structure leading to two additional active sensors, themselves composed in the first case by the left camera and the laser pattern projector and, in the second case by the right camera and the laser pattern projector. For these two additional active stereo pairs, the baseline D 2 54 is depicted in the figure.
In FIG. 2 , besides the laser pattern projector, the sensing device further comprises light sources for positioning. These are two sets of LEDs 50 distributed around the light detectors 46 . These LEDs illuminate retro-reflective targets that are used as positioning features. The LEDs are preferably positioned as close as possible to the optical axes of the cameras in order to capture a stronger signal from the retro-reflective targets. Interference filters 48 are mounted in front of the objectives. These filters attenuate all wavelengths except for the laser wavelength that is matched to the LEDs' wavelength. This preferred triangular structure is particularly interesting when D 3 56 is such that the triangle is isosceles with two 45 degree angles and a 90 degree angle between the two laser planes of the crosshair 44 . With this particular configuration, the crosshair pattern is oriented such that each plane is aligned with both the center of projection of each camera as well as with the center of the light detectors. This corresponds to the center epipolar line where the main advantage is that one laser plane (the inactive plane) will always be imaged as a straight line at the same position in the image, independently of the observed scene. The relevant 3D information is then extracted from the deformed second plane of light in each of the two images. The whole sensing device is thus composed of two laser profilometers, one passive stereo pair and two modules for simultaneously capturing retro-reflective targets. This preferred configuration is compact.
For a hand-held device, the baseline D 1 will be typically around 200 mm for submillimeter accuracy at a standoff distance of 300 to 400 mm between the sensing device and the object. By scaling D 1 , distances D 2 automatically follow. Although this arrangement is particularly useful for simplifying the discrimination between the 2D positioning features and the projected laser pattern in the images, integrating a stereo pair and eventually one or more additional cameras for a better discrimination and accuracy, makes it possible to process images where a different laser pattern is projected. Grids and circular patterns are relevant examples. Another possibility is to increase or decrease D 3 for more or less accuracy while losing the advantage of simplified image processing. While a linear configuration (i.e. D 3 =0) would not provide all the advantages of the above described configuration, it is still one option.
FIG. 3 illustrates a 3D view of the sensing device while observing an object to be measured 62 . One can see the formerly described compact triangular architecture comprising two cameras with objectives 46 and a crosshair laser pattern projector 42 . The sensing device captures the image of the projected pattern 58 including a set of positioning features 60 .
While illustrated in the block diagrams as groups of discrete components communicating with each other via distinct data signal connections, it will be understood by those skilled in the art that the preferred embodiments are provided by a combination of hardware and software components, with some components being implemented by a given function or operation of a hardware or software system, and many of the data paths illustrated being implemented by data communication within a computer application or operating system. The structure illustrated is thus provided for efficiency of teaching the present preferred embodiment.
One skilled in the art should understand that the positioning features, described herein as retro-reflective targets, could alternatively be provided by light sources, such as LEDs, disposed on the surface of the object to be scanned or elsewhere, or by any other means that provide targets to be detected by the sensing device. Additionally, the light sources provided on the sensing device could be omitted if the positioning features themselves provide the light to be detected by the cameras.
It should be understood that the pattern projector hereinabove described as comprising a laser light source could also use a LED source or any other appropriate light source.
It will be understood that numerous modifications thereto will appear to those skilled in the art. Accordingly, the above description and accompanying drawings should be taken as illustrative of the invention and not in a limiting sense. It will further be understood that it 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 herein before set forth, and as follows in the scope of the appended claims. | A system, apparatus and method for three-dimensional scanning and digitization of the surface geometry of objects are claimed. The system includes a hand-held apparatus that is auto-referenced. The system is auto-referenced since it does not need any positioning device to provide the 6 degree of freedom transformations that are necessary to integrate 3D measurements in a global coordinate system while the apparatus is manipulated to scan the surface. The system continuously calculates its own position and orientation from observation while scanning the surface geometry of an object. To do so, the system exploits a triangulation principle and integrates an apparatus that captures both surface points originating from the reflection of a projected laser pattern on an object's surface and 2D positioning features originating from the observation of target positioning features. | 6 |
This invention relates generally to a machine for producing a parabolic, hyperbolic or spherical surface on a relatively large workpiece, and in particular to a machine which simulates lathe-type techniques in the manufacture of independent panels which are to be assembled into a segmented parabolic reflector for an astronomical telescope.
BACKGROUND OF THE INVENTION
one of the few technological fields where "bigger is better" is that of telescopic instruments used in the exploration of outer space. The resolution of a telescope for light capturing increases in direct proportion to the diameter of its primary mirror or lens. Prior to dedication of the first reflector-type telescope in 1917, astronomers had been limited to using refractive lens-based instruments. After the conversion to reflection, and even until only recently, the reflective mirrors were also produced from glass. The low thermal inertia of the larger glass lenses had a tendency to distort the incoming light because the air immediately adjacent the lens was almost always either hotter or cooler than the lens itself. In subsequent developments, the lens mass was reduced by sandwiching a glass core between thin outer glass plates, but this too had size as well as production limitations.
In the late 1970's, building of larger parabolic reflectors became more practical due to the advent of the computer. The mirror was made of segments like a jigsaw puzzle, which enabled the individual pieces to be made in the form of panels which are thin and light in weight. When assembled, the panels were individually tipped, tilted and pistoned up and down at balljoint-supported corners or sides under very accurate computer control. Under this technique, known as adaptive optics, each panel was kept within a 0.001 micron optical tolerance to the next adjacent panel. This was made possible by development of sensors which were able to detect even the minutest displacements. Constant adjustment, up to a thousand times per second, is made to compensate for the up and down tilt and rotation of the reflector and the attendant effect of gravity resulting from those movements. Wind, is yet another factor requiring frequent segment adjustment. One scientific article has described a computerized model of the effects of wind on such a segmented mirror as resembling "nothing so much as a manta ray thrashing in a turbulent sea".
Computerization has also led to effectively combining the readings from multiple smaller mirrors to achieve the resolution of a much large mirror. One proposed design is said to be able to combine six 3-foot mirrors with one 6-foot mirror to simulate the resolution of a single large 20-foot diameter mirror. While this technique has been known since the 1930's, it has become feasible only recently because of the capabilities of high speed computers.
A relatively recent and innovative panel design employs the use of pure aluminum, machined with a burnishing effect to provide the necessary highly-polished mirror surface. Pure aluminum does not oxidize, nor does it require repolishing (which would in itself destroy the accuracy of the surface). It must, however, be kept clean. The typical environment for such a mirror is in a mountain-top observatory, away from most elements capable of causing contamination of the reflective surface. Producing a concave, parabolic surface by machining may be possible with some difficulty and much expense on a 5-axis CNC (computerized, numerically controlled) milling machine. The tool for CNC machining, would necessarily be one with only minimum point contact because of the compound motions necessary to achieve the accuracy of finish required. Such a point would likely cause only burnishing of a concave aluminum surface without actual metal removal. Obviously, the complexity of the 5-axis machine, its programming and its operation would make a simpler and more easily operated machine desirable.
SUMMARY OF THE INVENTION
A relatively simple 2-axis machine simulating some of the machining techniques of a conventional lathe is employed to create a radially and circularly contoured surface on a workpiece such as a panel designed for use in a segmented, telescope mirror. Each axis is independently controlled, enabling the use of extremely simple computer programming. Contrary to normal lathe practice, however, in order to achieve a perfect optical axis, the large workpiece is rotated or oscillated past a fixed position tool in an arcuate path. Conventional lathe practice on much smaller workpieces results in a compound movement of the tool, resulting in a spiral or helical (rather than arcuate) swath being cut. A helical cut is incapable of providing the essential contour for a telescope reflector.
A principal object of the invention is to provide a relatively simple machine and method for producing a highly-polished, very accurate parabolic surface on a panel of a segmented mirror of a telescope.
A further object is to accomplish the foregoing by means of a 2-axis machine which is relatively inexpensive to program and easy to operate.
Another object is to machine either a concave or convex surface on any large workpiece where an accurate surface finish is required, and to do so at minimal cost and with a relatively high rate of productivity.
Still another object is to provide a unique hinge for maintaining a high degree of accuracy laterally of the hinge while enabling limited axial and rolling motion of the hinge member.
Further objects and advantages will become apparent from the following description, in which reference is made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric depiction of an array of segmented parabolic reflectors which are computerized to coact and simulate tie resolution of a single image of the subject under observation.
FIG. 2 shows a large diameter single parabolic reflector the segments of which can be produced on the disclosed machine.
FIG. 3 is an isometric elevational view of the improved machine taken from an operator's side.
FIG. 4 is an enlarged side elevational view of the machine taken from the right as viewed in FIG. 3, with an appended enlargement of one form of cutting tool.
FIG. 5 is a fragmentary elevational view taken looking from an operator's side in the direction of the arrow 5 of FIG. 4.
FIG. 6 is a fragmentary plan view of the machine looking down in the direction of the arrow 6 of FIG. 5.
FIGS. 7, 8 and 9 are isometric, side and top views respectively of a panel produced by the method and machine of this invention.
FIG. 10 is an Underside view of the platen which supports the panels of FIGS. 7-9 on it upper side during their machining.
FIG. 11 is a schematic elevational view of one of the three air bearings used to support the platen of FIG. 10 on a cushion of air during platen oscillation.
FIG. 12 is a simplified schematic control diagram illustrating computerized position control of the cutting tool with respect to the panel being machined.
FIG. 13 is an isometric view of a unique hinge for the platen.
FIG. 14 is a side elevational view of the hinge of FIG. 13, pivotally supporting one end of the platen of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENT
To illustrate a primary end product use resulting from the machine of the invention, two different types of reflective telescopic mirror arrangements are shown in FIGS. 1 and 2. In both, a plurality of independent segments 10 are produced and assembled into parabolic reflectors 12. The reflectors scan the skies under control of astronomers in conventional fashion, either manually or by computer. Each segment 10 is separately mounted on a plurality of hydraulic screw-driven actuators (not shown) which are individually digitally controlled to maintain an accurate relationship within a 0.001 micron optical tolerance from one segment to the next. As such control is not a necessary aspect of this invention, suffice it to say that these techniques are known in the field of astronomy and will not be described herein except as background for products which can be produced by the machine of this invention. The segments are produced to a very high degree of accuracy by being mounted on the same kind and size of structure during machining as is used in their functional operation when in the final reflector.
An exemplary array of parabolic reflectors 12 is shown in FIG. 1, the array,being capable of combining the outputs of the several collectors into a simulated single image under sophisticated computerized control, in a manner now well understood in that art. In this example, six 6-meter reflectors are placed ten to fifteen meters apart along their baselines 13 and are adapted to receive electromagnetic waves between 1.3 to 0.3 millimeters in length, The FIG. 1 example has been dubbed a "submillimeter array" by the astronomers involved in its development. There is wide recognition in their field that the skies are virtually unexplored at submillimeter wavelengths, i.e., those which can view, quasars and "black holes". Depending on the spacing of the mirrors, the angular resolution of 0.87 millimeter wavelengths will range between 12 and 0.8 arcseconds for ten and fifteen meter spacing respectively. FIG. 2 shows a single reflector 12 and its support structure 15. This collector can be part of a multi-mirror array of mirrors as in FIG. 1 or can be a stand-alone unit of more than double the 6-meter unit illustrated in FIG. 2.
In addition to the obvious weight savings as compared to full-diameter refractive glass lenses, one of the benefits of segmented mirrors is the ability to assemble the segments into much larger mirrors than had been previously attainable. They can be produced in diameters as large as fifteen meters, very much larger than is possible in the construction and use of conventional non-segmented refractive lenses. The thermal inertia of larger glass lenses, i.e., the inability of the glass to change in temperature as quickly as the air directly surrounding the lens, has been a major cause of image distortion with such lenses. This can be easily compensated for in a segmented mirror. Astronomical telescopy is one of the few technologies where the larger the mirror, the greater the image resolution. While the combined effects of a multi-mirror array such as that shown in FIG. 1 can achieve improved results because of their combined images, the need still exists for large diameter single, stand-alone unit. The reflector 12 of FIG. 2 is turret-mounted for tipping, tilting and rotating about a vertical axis. As each positional change is made, compensation must be made for the effects of gravity as well as any environmental changes that occur as a result of the shift. These effects can be wind, air temperature variations due to the repositioning, etc. As required to compensate, a computer will adjust each segment 10 with respect to its next adjacent neighboring segment in response to detectors, (not shown), which are capable of detecting the need to refocus the segments of mirror surface to properly receive the image of the body being viewed.
The segments to-be produced are of pure non-oxidizable aluminum. Once provided with a highly reflective mirror surface, that condition is retained. While any surface is capable of collecting dirt, the reflectors 12 are typically located at high elevations, well above contaminating earth elements. Additionally, any cleaning required can be done without the wearing effects of polishing as is often necessary with glass mirrors. Furthermore, in the event any segment 10 distorts or loses its surface resolution due to any of several factors, a substitute segment can be placed in the reflector with nominal inconvenience, and the affected segment returned to the factory for remachining.
Machine 14 has as its main structural components a base 16, left and right vertical columns 18 and 20 respectively, and a tool-supporting bridge 22. All are fabricated of steel and their respective connective surfaces are accurately machined for assembly by means of conventional fasteners. A thick, stable granite bed 24, 2.4 meters in width by 3 meters in length, is supported on three-point, triangularly-spaced suspension means 26, seen best in FIGS. 4 and 5. The bed 24 is highly polished to a surface resolution of five microns, and its top surface is smooth and substantially non-porous.
A unique hinge 28 (described in detail in FIGS. 13 and 14) is mounted on left column 18 to support the left end of an elongated platen 30 for pivotal or oscillatory movement in the direction of arrow 32. The platen 30 serves to support the segments 10 as they are individually machined by one or a pair of diamond-coated carbide cutting tools 34 mounted on a ram 36. The ram 36 is carried by a saddle 38 which is movable horizontally on roller bearings 37 (FIG. 4) along ways 39 representing an x axis (schematic FIG. 12). Horizontal movement is in response to rotation of a ball screw 40 driven by a servo motor 42 mounted on the left column 18. Saddle 38 supports a second servo motor which drives a similar ball screw 46 to move the ram vertically along ways 45 representing a z axis, (also seen in FIG. 12). The tool 34 is first positioned in a fixed location along the two axes, maintained in that position while the platen oscillates past the tool to perform cutting, and is then repositioned for the next machining pass.
Oscillation may be by any conventional means and is depicted here as a simple flyweighted crank arm 48 which reciprocates a link 50 connected to one side of the platen 30 to move the platen and any workpiece carried thereby past the cutting tool 34. In the example illustrated, the platen 30 is oscillated twenty strokes per minute over 37.5 degrees to machine fifteen and thirty degree panels for the reflector 12. The cutting tool 34 is shown in greater detail in the enlarged dot-dash circle 82 at the left of FIG. 4. For rough cutting, cuts can be made in each both directions of oscillation, and therefore two opposed circular cutting buttons are shown. The button tools are secured to a tool support 51, but each is made to be rotationally adjustable about a horizontal axis to present a different cutting edge to the workpiece if needed. When a final finishing cut is performed, it is done by only a single tool 34 and in only one direction of oscillation. This provides a highly burnished, highly reflective surface, needing no polishing. It is ready for installation in a reflector after the final cut is made. The tool or tools 34 are indexed to new positions along both the x and z axes after each cutting pass. The amount of indexing is dependent on the size of the cutting tool 34. To perform the finish and accuracy required, a button of 2.5 centimeters in diameter is horizontally indexed 0.2 millimeters along the x axis after each cutting pass. The essence is to produce a cut which is that length of the chord or the circular tool 34 which provides a continuous smooth surface on the face of the workpiece.
The platen 30 is shown from the underside in FIG. 10. It carries three triangularly-spaced air bearings 54 which face downwardly for supporting the platen 30 on an air cushion as it moves over the top surface of the granite bed 24. The bearings 54 are positioned on harmonic dead spots of the platen 30. The bearings 54 provide for non-contact floating operation of the platen over bed 24 as it is oscillated in response to the cranking motion. The air bearings are well known in the art, being purchased from AeroDyne Belgium of Westkerke, Belgium. One such bearing is shown schematically in FIG. 11. Air filtered by filter F is communicated to a circumferential groove 56 through conduit 58 and provides the air cushion for the lower surface of the bearing 54 by passage through the wall of a short porous tube 60. The film of air spreads radially outwardly along the granite surface Of the bed 24, performing a self-cleaning function with respect to their respective paths of travel of the bearings 54. The particular air bearings 54 used, Model PD-RA 215, are each capable of supporting a 600 kilogram object at an air pressure of 30 kilograms per square centimeter. The tube 60 has a porosity of five microns, necessitating that the filter F exclude from the air supply any particulate matter above the size of the interstitial openings in the tube from reaching and clogging the bearings. Filter F is a one micron filter, i.e., capable of filtering from the air reaching the filter any particle larger than that size.
The entire operation of the machine described herein is performed in a "clean room", i.e., one which is secured against any outside contamination. Temperature of the clean room is constantly maintained within plus or minus two degrees. The high degree of machining accuracy required to achieve the extreme accuracy of the finish for a parabolic reflector dictates that everything be as near perfect in cleanliness as possible. Any dirt or other contaminant on the bed where the air bearings glide over the surface might result in unacceptable product and has the potential for scoring and thereby,affecting the accuracy of the bed surface and bearings. This is partially compensated for by the self-cleaning capability of air flow exiting from the air bearings 54, but also results from use of conventional vacuum cleaning nozzles, (not shown), which surround the cutting tools 34. An example of an off-the-shelf vacuum cleaning system usable is manufactured by Spencer Industravac of Columbus, Ohio.
The segments 10 are contoured both radially along the length of the platen 30 and circularly, from side to side of the platen 30 defined by an arc about a pivotal axis 62 of the platen (FIGS. 10 and 14). The effect is similar to that of producing a bowl on a wood-turning lathe, but with one significant difference. The tool of a wood-turning lathe has a compound motion which results in a gradual spiral cutting action, either radially inward or outward. In contrast, the tool of the present invention is held absolutely fixed for any given cutting pass, resulting in a true circular cut rather than a spiral cut. It may be said that the machine of this invention tends to simulate the actions of a lathe, but the results are different by virtue of achieving a true circular rather than a spiral or helical cut. To obtain a true surface for a reflector 12 or, as illustrated in this particular design, for a segment of such a reflector, the cut must be circular. If not, the focus of the reflector would result in poor resolution and a diffused image. Because the diameter of the reflector is so large, production in segments can reduce the overall size of the machine to essentially the radius of the reflector, or, in some instances, to the radial length of a segment. However, the machine is not limited to a reflector radius the length of the platen 30, since the pivotal axis of the platen can be moved outward of the left column 18 by straddling the column and mounting a hinge comparable to hinge 28 leftwardly of the column 18.
Let us now consider how individual segments 10 are produced. One such segment is shown in FIG. 5. It is mounted at the outer extremity of the platen 30, indicating that it is a segment which is to be located at the outer periphery of a final reflector 20. The next inwardly located segments would be positioned toward the axis of the platen 30 on its upper, surface. For ease of description, as well as to illustrate that the machine has use for producing contoured products other than segments of a reflective mirror, the segments may also be referred to as "panels" during the machining operation, since it is only the upper flat surfaces of the segments which are machined.
A panel 10 in FIG. 5 is clamped to the panel-supporting surface 84 of the platen 30. The panel in this instance is a precast highly-accurate casting shown in FIGS. 7-9. Bosses 88 are preliminarily machined on the bottom side of the panel and screwholes are provided for fastening ball elements thereto. The ball elements are eventually to be seated in ball sockets of the pistons which later adjust the segments in the final assembled reflector 12. Comparable ball elements are shown schematically in FIG. 5. They are used to support a panel 10 in the same relationship on the platen 30 that the given panel is to occupy in the end product. A socket 68 is attached on the platen surface 64 for each ball and clamping means 70 of any conventional type can straddle each ball and maintain it firmly in the socket during machining. In this manner, machining is achieved exactly as is eventually required for mounting each segment in the reflector. Holes and attaching means, (not shown), are provided at the upper surface 64 of the platen for mounting the sockets 68 and the clamping means 68.
FIG. 12 is a simplified schematic representation of computer control of tool positioning along the x and z axes. Servo motor 42 incrementally indexes the tool 34 horizontally along the x axis as called to do so by a relatively simple program installed in computer 72. The program need only position for the z axis, off which the x axis would slave. The simpler programming is estimated to provide a cost advantage of 5:1 over the programming that would be required to achieve a comparable result on a 5-axis CNC machine. The position is determined by a scanning head 74 traversing a horizontal scale 76 of an exposed incremental linear encoder manufactured by Heidenheim GmbH of Traunheut, Germany. The vertical positioning of tool 34 is via a scanning head 78 along scale 80 manufactured by the same company. Scanning heads 74 and 78 are affixed to and travel with the saddle 38 and ram 36 respectively, in conventional fashion. The increments of movement are determined according to that necessary to produce the accuracy of finish required. The radial and circular contours machined onto the panel surface are determined by the location and angularity of the panel 10 on the platen 30. To minimize the need for excessive machining, the cast panels are only slightly greater in thickness than the end machined product. Thus, only a single rough bi-directional cut and a single unidirectional finish cut are normally required for each panel. The accuracy of the cast segment also determines its eventual end weight in the reflector as well as its overall thickness in relation to other of the segments. In the reflector for which the machine was originally designed, there are only four different sizes and shapes of panels. Certain ones are thirty degrees and others are fifteen degrees. For those that are thirty degrees, twelve panels circumscribe the circular row in the reflector. Twenty-four panels are located in the row of fifteen degree panels.
FIGS. 13 and 14 illustrate the unique hinge 28. The hinge 28 is mounted on a vertical pad 82 machined on the inner side of left column 18. It comprises a ball plate 84, a shaft-supporting plate 86, a pair of removable shaft-capturing caps 88 and a vertical shaft 90 held to the plate 86 by the caps 88. The shaft 90 receives a ball sleeve 92 carried by the platen 30 and forming its pivotal axis 62. The ball sleeve 92, the shaft on which it is mounted and the openings receiving the shaft 90 are all maintained to very high degree of accuracy. However, it will be noticed that a small spacing appears between the platen 30 and the adjacent surfaces of the two caps 88. This allows flotation of the platen vertically whenever air pressure is provided to the air bearings 54.
The key feature of the design of the hinge 28 is its ability to restrain the platen against horizontal movement toward or away from the pad 82 of the column 18 while enabling accurate vertical platen movement to accommodate the application of air pressure to bearings 54. A spherical concave surface 94 is machined into the column 18 at pad 82, and a mating spherical convex surface 96 is provided on the left face of the plate 84. Preferably, the spherical surface 96 and ball plate 84 are integral and are machined from a single piece of nickel stock. The column being steel, the bearing surfaces 94 and 96 are self lubricating in the dry state, and can be kept in very close contact under a spring bias provided by Bellville washers 98. Three shouldered bolts 100 spaced 120 degrees apart about the sphere hold the ball plate 84 and it convex surface 96 snuggly against the concave surface 96.
A space is provided between the left side of ball plate 84 and the facing side of pad 82 to allow freedom of pivoting of the ball plate 84 about the concave bearing surface 94. The center of the ball or sphere is shown by the numeral 102 in FIG. 14. This center coincides with that of the axis 62 of the platen 30. Thus, any lifting, lowering, pitching or rolling of the platen as it is oscillated are all about center 102 and linear movement of the elongated platen is prevented, even though minute vertical movement is permitted along axis 62. As can be seen from FIG. 14, retention bolts 104 and slots 108 allow for vertical adjustment of shaft-supporting plate 88 relative to ball plate 84 before being fixed in final operating position. Plate 88 is also provided with slots 108 to accommodate vertical adjustment. Clearance is provided at slots 108 to allow for expansion and contraction of the Bellville washers as the ball plate 84 tends to want to move about center 102 in the event of slight rotational or rolling movement of the platen.
At start-up and shut-down of operation of the unit, a protocol must be followed to prevent damage to the surface of the granite bed 24 and air bearings 54. Before any crank motion can be applied to the platen 30, sufficient air flow must be present at the air bearing surfaces. If air is not flowing for any reason to all three bearings, or is insufficient at any one of the bearings, flow sensor switches (not shown) will inhibit operation of the crank arm 48. Insufficient air can be caused by any of the usual things, such as pump malfunctioning, clogged filter F, etc. Such flow sensors can be an/off switches which turn on, e.g., at flow of four liters of air/minute. With the sensors connected in series, it becomes essential that air be supplied to each bearing 54 in order to power-up the platen drive. If during operation one of the sensors detects inadequate air flow, damage to the bed 24 can occur unless means is provided to prevent it. This can be accomplished by providing means to maintain the platen above the bed until the crank arm 48 comes to rest. Such a means can consist of pistons beneath the platen which move down to support the platen above the bed promptly upon detecting an interruption in air exiting from the bearings 54. Whatever is provided in this regard should make contact along paths other than the arcuate paths of contact of the three air bearings 54 with the bed. Thus, if any bed surface scoring occurs, it will be outside the areas of air bearing contact with the bed.
Various changes, including but not restricted to producing the panels from other materials or by other surface-reducing techniques and to shapes other than parabolic may be made without departing from the spirit and scope of the claims. | A method and apparatus are provided for the production of panels for a large segmented parabolic telescope reflector, using a simple adaptation of a technique common to a lathe. The reflective surface of each panel is contoured both radially and circularly by oscillating a platen supporting the panel about a fixed axis relative to a tool which is fixed during platen oscillation. The tool is repositionable between oscillations along an x axis to achieve the radial contour and along a z axis to achieve the desired parabolic or spherical contour. Contrary to the normal contouring of such a surface with a 5-axis CNC machine, tool positioning along either axis is independent of tool location along the other axis, simplifying the machine structure as well as its computerized operation. A unique hinge is provided to restrain the platen in a radial direction while allowing floating action of the platen on an air cushion during its oscillation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
This Non-Provisional Utility application is a Continuation-In-Part of, and claims benefit of, co-pending U.S. Non-Provisional patent application Ser. No. 12/263,549, filed on Nov. 3, 2008, which claims benefit of co-pending U.S. Non-Provisional patent application Ser. No. 12/201,207, filed on Aug. 29, 2008, which claims benefit of U.S. Non-Provisional patent application Ser. No. 11/588,541, filed on Oct. 27, 2006, and now issued as U.S. Pat. No. 7,527,017, issued on May 5, 2009, all of which are incorporated herein in its entirety.
FIELD OF THE INVENTION
The present invention relates to travel accessories, and more particularly, to a travel bowl, including a food container and drink holder carried by a removable cup holder insert, for adaptation to a vehicle.
BACKGROUND OF THE INVENTION
Many people have a desire to eat snacks and drink while traveling in a vehicle. It is considered difficult and distracting to snack and drink while driving. Passengers prefer to have a location to hold their snacks and drinks while traveling to avoid leaving crumbs and other undesirable residue in the vehicle. Drink holders are considered a standard feature in modern vehicles, while food storage compartments are lacking.
Snacks are normally stored in the original packaging and positioned in non-optimal places, such as against the seat door pockets, between the seat and the center console, and the like, in order to avoid being spilled. Further, snacks such as fast foods (hamburgers, French fries, and the like) are typically not conducive to the same type of storage or packaging as general consumer grocery products.
Accordingly, there remains in the art a need for a travel bowl for holding and storing snacks and drinks in a vehicle where the holder is inexpensive, lightweight, and optionally includes a seal-able cover for preventing snacks from becoming stale. It is desirable for the travel bowl to be securely stabilized within a vehicle when the vehicle is in motion.
SUMMARY OF THE INVENTION
The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing a travel bowl assembly for use in a vehicle where the travel bowl assembly is portable, gives rise to manufacturing economy, and is easy to maintain and use. Moreover, the overall construction of the travel bowl assembly provides a removable cover for sealing a snack portion of the bowl while allowing the user to simultaneously secure a drink within the apparatus.
In accordance with one embodiment of the present invention, there is provided a travel bowl assembly comprising a container comprising a base and sidewall defining a container receptacle for holding food and/or fluids, the receptacle having an oval shaped bowl including a vertical wall and an oval shaped base wall. The travel bowl assembly further includes a lid that is removably attached to a portion of the oval shaped bowl providing a seal for maintaining food within the bowl receptacle.
Advantageously, the travel bowl includes a cup holder insert in a shape and size that dimensionally corresponds to a shape and size of a recess of a cup holder in a console of a vehicle such that the cup holder insert is securely retained within the recess of the vehicle's cup holder. The cup holder insert, and oval shaped bowl are dimensionally configured to provide a selected storage capacity, and can be integrally molded as one piece or a plurality of interconnecting components. Alternatively, the bowl can be provided in any reasonable shape conducive to the application of the present invention.
In one aspect, the travel bowl member includes a dividing wall disposed within the oval shaped bowl forming a food storage compartment and a drink holder portion.
A bowl lid is provided having a peripheral shape conforming to the food compartment portion of the travel bowl, the lid being removably attached to the shaped bowl by any one of a snap-on feature, a living hinge, a magnet, a clip, a rotating post, a hook and loop, sliding rails, threads, or pressure detents.
In accordance with an alternative embodiment of the present invention, there is provided a travel bowl assembly comprising a cup holder insert including a container receptacle for holding snacks, with an upper portion having threads. The travel bowl assembly further includes a threaded recess (a coupling interface) formed within the base of the bowl for detachably receiving the upper portion of the cup holder insert; thereby sealing snacks within a receptacle formed within the cup holder insert. The coupling interface can be provided within the base of the bowl or extending there from. A leveling feature can be provided extending from the base of the bowl, such that the leveling feature compensates for the extending coupling interface thus supporting the bowl ensuring it remains level.
Preferably, the cup holder insert includes a shape and size that dimensionally corresponds to a shape and size of a recess of a cup holder that is included in any one of a console of a vehicle including a boat, truck, van, transport, airplane, camper, RV, bus, train, ATV, or table, chair, or any other mode or device that includes a cup holder for securely holding a cup therein. The cup holder insert can include a plaint member for adapting the shape and size of the cup holder insert to the shape and size of a vehicle cup holder. The pliant member can be assembled to or removably attached to the cup holder insert. The pliant member can consist of a series of winglets projecting radially from the exterior wall of the pliant member.
In yet another aspect, the cup holder insert and the bowl are either integrally molded as one piece providing the cup holder insert receptacle to be in fluid communication with the bowl receptacle, or the cup holder insert is separately attached to the bowl having a means for detachably receiving formed therein for releasably attaching the cup holder insert to the bowl. The means for detachably engaging may include any one of threads, a bayonet connection, a snap-on feature, a slide means, magnets, pressure detents and the like.
Another aspect of the present invention provides an adapting sleeve, which compensates for a variety of cup holder designs and dimensions, via a plurality of flexible adapter winglets. The winglets can extend from a tubular sleeve having the dimensions consistent with the mating dimensions of the cup holder insert. The cup holder insert can be tapered (or funnel shaped) providing assistance in mating the tubular sleeve to the cup holder insert.
Regarding the embodiments described herein, as well as those covered by the claims, the travel bowl assembly is loaded with food and/or fluid and a lid is removably attached to the travel bowl. The travel bowl assembly is securely inserted within the recess of the cup holder of a vehicle console allowing the oval shaped bowl to extend partially between two front seats of a vehicle. The lid may be opaque or transparent for allowing a user to view the contents stored within the travel bowl. Further, the lid may include an extending grasp for assisting a user in removing the lid from the travel bowl. The cup holder insert, travel bowl and lid may having components fabricated utilizing glass, ceramic, metal, tin, a rigid or resilient material, a light-weight synthetic material or a polymeric material including plastic, rubber, urethane or neoprene material, or any combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary embodiment of a travel bowl assembly, according to the present invention;
FIG. 2 is an exploded assembly view of the exemplary travel bowl assembly originally introduced in FIG. 1 ;
FIG. 3 is a side elevation view of the exemplary travel bowl assembly originally introduced in FIG. 1 ;
FIG. 4 is a top planar view of the exemplary travel bowl assembly originally introduced in FIG. 1 ;
FIG. 5 is a side elevation view of the travel bowl assembly introducing a bowl interior compartment sectioning structure;
FIG. 6 is an isometric view of a bowl member of the travel bowl assembly;
FIG. 7 is a top view of the bowl member of the travel bowl assembly;
FIG. 8 is a bottom view of the bowl member of the travel bowl assembly;
FIG. 9 is a top view of a first exemplary lid member of the travel bowl assembly;
FIG. 10 is a side sectional view of the first exemplary lid member of the travel bowl assembly, the section taken along section 10 - 10 of FIG. 9 ;
FIG. 11 is a top planar view of a cup holder insert member of the travel bowl assembly;
FIG. 12 is a side elevation view of the cup holder insert member of the travel bowl assembly;
FIG. 13 is an isometric view of a pliant cup holder adapting member as assembled to the cup holder insert member of the travel bowl assembly;
FIG. 14 is an elevation view of the pliant cup holder adapting member shown being assembled to the cup holder insert member of the travel bowl assembly;
FIG. 15 is a side elevation assembly view of the cup holder insert member, a cup holder insert extension member, and the bowl member;
FIG. 16 is a sectional elevation view of the travel bowl assembly;
FIG. 17 is a top planar view of the exemplary lid installed on the travel bowl assembly, further illustrating the interaction of the exemplary lid and a drink;
FIG. 18 is a side sectional view of the travel bowl assembly, the section taken along section 18 - 18 of FIG. 17 ;
FIG. 19 is a top planar view of an alternate exemplary lid installed on an alternate embodiment of the travel bowl member, further illustrating the interaction of the alternate exemplary lid and a drink; and
FIG. 20 is a side sectional view of the alternate travel bowl assembly embodiment, the section taken along section 20 - 20 of FIG. 19 ;
FIG. 21 is a side elevation view of yet another alternate travel bowl assembly embodiment;
FIG. 22 is a side elevation view of a bowl body portion of the travel bowl assembly embodiment, originally presented in FIG. 21 ;
FIG. 23 is a side elevation view of a lid and container portion of the travel bowl assembly embodiment, originally presented in FIG. 21 ; and
FIG. 24 is a side sectional view of the alternate travel bowl assembly embodiment, the section taken along a section similar to section 20 - 20 of FIG. 19 ; and
FIG. 25 is a side elevation view illustrating a nesting of a plurality of containers for varying a height of the bowl assembly.
DETAILED DESCRIPTION
Detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular embodiments, features, or elements. Specific structural and functional details, dimensions, or shapes disclosed herein are not limiting but serve as a basis for the claims and for teaching a person of ordinary skill in the art the described and claimed features of embodiments of the present invention.
Referring now to the drawings wherein like elements are represented by like numerals throughout, there is shown in FIG. 1 a perspective view of a travel bowl assembly 100 , according to one embodiment of the present invention. Additional details of the travel bowl assembly 100 and the individual components are provided in FIGS. 2 through 14 presented herein. The travel bowl assembly 100 includes a bowl 102 , a cover 120 , and a cup holder insert 130 . The bowl 102 is defined having a bowl body 104 comprising a snack containing section 112 and a drink holder section 116 separated via a bowl sectioning wall 114 . A mount receptacle 106 is provided on a lower face of a base portion of the bowl body 104 and can extend from the bottom (as shown) or project upwards into the snack containing section 112 or drink holder section 116 regions. A leveling feature 110 can be included providing a planar supporting surface should the design of the mount receptacle 106 extend downward from the base of the bowl body 104 . The leveling feature 110 can be of any reasonable form factor, such as two projecting legs as illustrated, a projecting ridge or wall, and the like, working in conjunction with the mount receptacle 106 for supporting the bowl 102 when placed upon a resting surface 150 . The cover 120 provides a seal to retain freshness of snacks disposed within the snack containing section 112 of the bowl 102 . A snap latch ring 126 can be formed about an upper edge of the bowl body 104 providing a means for sealing a cover securing interface 124 of the cover 120 to the bowl body 104 .
The travel bowl assembly 100 is secured in the vehicle via the cup holder insert 130 . The cup holder insert 130 is formed having a shape and size substantially similar to a shape and size of a common vehicle cup holder. The cup holder insert 130 is provided, preferably being removably attached to the bowl body 104 via a connection interface disposed between an upper edge of the cup holder insert 130 and the mount receptacle 106 . The cup holder insert 130 is defined via a mount container body 132 having a horizontal base and a sidewall extending upwards from the edge of the horizontal base, forming an object storage receptacle 136 . The object storage receptacle 136 provides a means for storing snacks 119 ( FIG. 16 ) or other small items. Mount securing threads 134 are provided along the upper edge of the cup holder insert 130 , wherein the mount securing threads 134 provide a mating connection interface for removably attaching the cup holder insert 130 to the mount receptacle 106 . Alternately, the mount securing threads 134 can be of any known detachably engaging form factor including any one of threads (as shown), a bayonet connection, a snap-on feature, a slide means, magnets, pressure detents, and the like.
A cup holder adapter sleeve 140 can be provided to aid in conforming and securing the cup holder insert 130 to the vehicle cup holder. The cup holder adapter sleeve 140 includes a adapter body 142 having a shape and size similar to the exterior of the mount container body 132 and a plurality of adapter winglet panels 144 extending there from. The adapter winglet panels 144 are preferably thin, pliant ribs extending radially from the exterior surface of the adapter body 142 , providing an adaptive means for ensuring a reliable holding interface between the cup holder insert 130 and the respective cup holder. The preferred shape of the adapter sleeve opening 146 of the adapter body 142 is tubular and tapering having a larger upper opening diameter with a smaller lower opening diameter, ensuring a reliable and repeatable mating between the mount container body 132 and the adapter body 142 . The adapter winglet panels 144 are provided having a thin wall projecting radially from the adapter body 142 with a tapered distal edge. The adapter winglet panels 144 have an initial width at the lower edge, with a span from the central interface edge increasing in the radial direction as the adapter winglet panels 144 as the distal edge progresses towards the upper edge. The cup holder adapter sleeve 140 is fabricated of a pliant material such as nylon.
The bowl 102 is presented in FIGS. 6 through 8 . The bowl 102 is defined having a bowl body 104 , divided into a snack containing section 112 and a drink holder section 116 via the incorporation of a bowl sectioning wall 114 as illustrated in FIGS. 5 through 7 . The bowl sectioning wall 114 extends upwards from the base of the bowl body 104 , formed in an arc spanning between two sections of the bowl's vertical wall. The bowl sectioning wall 114 divides the interior of the bowl 102 into two sections: the snack containing section 112 and the drink holder section 116 . The bowl sectioning wall 114 is formed having a size and shape commonly utilized for a cup holder for containing items such as a drink 118 . The exemplary embodiment presents a mount receptacle 106 , having a mount receptacle coupling threads 108 , disposed on a bottom surface of the bowl body 104 . A pair of leveling features 110 projects from the bottom of the bowl body 104 , projecting the same distance as the mount receptacle 106 , thus providing a stable support of the travel bowl assembly 100 when the cup holder insert 130 is removed and the travel bowl assembly 100 is placed on a planar surface.
The cover 120 can be provided in a variety of form factors with one exemplary embodiment being presented in FIGS. 9 and 10 . The cover 120 includes features such as a cover securing interface 124 for removably securing the cover 120 to a snap latch ring 126 of the bowl 102 and a extending grasp 128 for assisting the user in removing the cover 120 from the bowl 102 . An optional identification 123 can be disposed upon the lid surface. A first form factor presented seals the entire periphery of the entire upper edge of the bowl 102 . Other geometries will be presented later herein.
The cup holder insert 130 is detailed in FIGS. 11 and 12 , with the cup holder adapter sleeve 140 being assembled in FIGS. 13 and 14 . The cup holder insert 130 is formed having a mount container body 132 extending from a peripheral edge of a bottom forming an object storage receptacle 136 . A mount securing threads 134 is formed along the upper edge of the mount container body 132 . Although the mount securing threads 134 is noted as having threads, it is recognized that other releasably attaching interfaces can be utilized for releasably coupling the cup holder insert 130 to the bowl 102 . It is preferred that the mount container body 132 is tapered, having a smaller diameter along the lower portion of the cup holder insert 130 . The diameter of the mount container body 132 would be compatible with generic cup holders. A cup holder adapter sleeve 140 can be included, being slideably assembled to the cup holder insert 130 . The cup holder adapter sleeve 140 includes a plurality of adapter winglet panels 144 projecting radially from an adapter body 142 . The adapter body 142 is shaped to slideably assemble to the cup holder insert 130 , preferably utilizing a tapered shape to help ensure a reliable interface. The cup holder adapter sleeve 140 would be fabricated of a nylon or nylon-like material.
For instances where the bowl 102 needs to be raised from the cup holder insert 130 , a mount extension 160 can be assembled between the cup holder insert 130 and the bowl 102 , as illustrated in FIG. 15 . The mount extension 160 is fabricated having an extension body 162 , with an extension male threading 164 formed along an upper edge and an extension female threading 166 formed along a lower edge. The extension male threading 164 would be removably attached to the mount receptacle 106 and the extension female threading 166 being removably attached to the mount securing threads 134 . The extension body 162 could be hollow, increasing the available storage volume of the object storage receptacle 136 . The spacing can vary via having mount extension 160 with different lengths, utilizing a plurality of mount extension 160 or combination thereon.
Snacks 119 can be stored in the object storage receptacle 136 as illustrated in the sectional view of FIG. 16 . Alternately, snacks 119 can be stored in the snack containing section 112 , being sealed via the cover 120 .
Two (2) alternate bowl configurations are presented in FIGS. 17 through 20 . The extended bowl sectioning wall 115 can be extended, providing an additional coupling region for securing a cover 121 to the bowl body 104 as illustrated in FIGS. 17 and 18 . The cover 121 would include an opening, which provides a clearance for insertion and removal of a drink 118 . By providing a cover securing interface 125 , the user can secure the cover 121 to the bowl 102 and rotate the cover 121 about the drink 118 , thus giving access to snacks stored in the snack containing section 112 . A small notch can be provided along the snap latch ring 126 ( FIG. 2 ) for clearance for the rotation.
Alternately, the extended bowl sectioning wall 115 can be extended as previously shown and a portion of the bowl body 104 adjacent to the easy access drink holder section 117 can be formed shorter as illustrated in FIGS. 19 and 20 . The cover 122 would be formed having a crescent shape, exposing the easy access drink holder section 117 . The lower wall section of the bowl body 104 improves access to the drink 118 .
The present invention utilizes a cup holder insert 130 as the mounting interface for removably securing the travel bowl assembly 100 to a vehicle cup holder. The present invention can be adapted to other applications such as a stroller, crib, child's car seat, bicycle, and the like by providing a variation of the cup holder insert 130 . The mount would have a similar interface for securing the mount to the bowl 102 , while having a form factor suitable for securing the travel bowl assembly 100 to a respective object, such as a loop for securing the mount to a handlebar. The loop can have any specific features allowing the loop to tighten and release from the tubular structure. Other designs, such as a quick release camera mount design, and the like can be utilized.
The mount container body 132 can be sealed via several means, as illustrated in FIGS. 21 through 24 . A travel bowl assembly 200 comprises a bowl 202 , similar to the bowl 102 previously introduced. The bowl 202 includes a bowl body 204 , formed having a bowl base and a vertical wall projecting upwards from a perimeter of said base. A container mount receptacle 206 is disposed upon a lower surface of the bowl base for removably attaching the mount container body 132 . This configuration provides a first means for sealing the container portion of the mount container body 132 . A container lid assembly 230 provides an alternate means for sealing the mount container body 132 , versa vi the utilization of the bottom of the bowl body 204 . The container lid assembly 230 is formed including a container lid 232 and a lid coupling interface 234 formed along a coupling edge of the container lid assembly 230 . The container lid assembly 230 is stored when not in use by removably coupling the container lid assembly 230 to a lid storage coupling interface 236 disposed upon the lower surface of the bowl base. The removable coupling is accomplished via a mechanically coupling provided between the lid coupling interface 234 and the lid storage coupling interface 236 . The lid coupling interface 234 can be of any form factor providing a mechanical interface for mating to the mount securing threads 134 provided along a coupling edge of the mount container body 132 . When the container lid assembly 230 and mount container body 132 are removed from the bowl body 204 , the travel bowl assembly 200 remains level on the resting surface 150 , using the bottom of the container mount receptacle 206 and the lid coupling interface 234 as a supporting structure.
The bowl sectioning wall 114 can be of any shape such as being angled, as illustrated in FIGS. 5 , 16 , 18 , and 20 . Alternately the bowl sectioning wall 214 is presented as having a vertical configuration, as illustrated in FIG. 24 . The sectioning wall 214 aids in securing a drink 118 ( FIG. 19 ) within the drink holder section 116 ( FIG. 20 ). The sectioning wall 214 can be either straight as shown herein, or angled as previously presented. The sectioning wall having a vertical configuration increases manufacturability. A production design would be determined by the product designer.
A plurality of containers 130 , 240 can be included with the travel bowl assembly 200 as illustrated in FIG. 25 . Container 240 comprises the same features as container 130 , including a mount container body 242 and a mount securing threads 244 , while having different heights (H). The containers 130 , 240 are shaped providing the ability for the user to nest the plurality of containers 130 , 240 as illustrated. The various heights (H) provides several advantages, including compatibility in different vehicle cup holders, different storage volumes, and the like. Nesting the plurality of containers increases the potential number of heights.
The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims. | A travel bowl assembly for traveling in a vehicle including a bowl divided into a snack section and a cup holder section. A container extends downward from a bottom of the bowl member, secondarily used as a cup holder insert and assembly support. The cup holder insert can be integrated or removably attached to the bowl. A pliant adapter can be integrated or removably attached to the cup holder insert. The pliant adapter utilizes flexible winglets for compensating between dimensional differences between the cup holder insert and a receiving cup holder. The pliant adapter is formed having a tapered sleeve for sliding the adapter onto a tapered sidewall of the cup holder insert. A cover can be provided, sealing the snack section of the bowl. A lid can be provided, sealing the container. The lid can be fastened to a storage interface disposed on the lower surface of the bowl. | 1 |
TECHNICAL FIELD
The present invention relates to cooling systems for auxiliary power units on airplanes and, more particularly, pertains to the passive cooling of the components and oil of such units and the enclosure ventilation of such units.
BACKGROUND OF THE INVENTION
Large aircraft often use an on-board auxiliary power unit (APU) to provide electrical power and compressed air for systems throughout the airplane. When the aircraft is grounded, the APU provides the main source of power for environmental control systems, hydraulic pumps, electrical systems and main engine starters. During flight, the APU can supply pneumatic and electric power.
Auxiliary power units are generally small gas turbine engines, often mounted in the aft tail section of the aircraft. They require a certain amount of cooling air, and are lubricated by oil that is generally cooled by an oil cooler which also requires cooling air. Active cooling systems are usually employed to provide this cooling air, and are typically comprised of an active fan used to push air through the oil cooler and across auxiliary power unit components. These fans are driven at high speeds by the APU through a complex shaft and gear assembly. The mechanical complexity and high operating speeds of these fans increases the possibility of failure. Active fan cooling systems therefore can significantly reduce the reliability of an auxiliary power unit.
While APU passive cooling systems which eliminate the need for active fan cooling systems are well known, they all generally draw cooling air into the APU compartment, before it is drawn through the air cooled oil cooler. This arrangement causes the cooling air to be heated up in the compartment before it reaches the oil cooler, and therefore, oil cooling is not optimized. U.S. Pat. No. 5,265,408, for example, discloses a method and apparatus for cooling a compartment mounted gas turbine engine comprising a first exhaust eductor within which is mounted an oil cooler, and which incorporates a mixer nozzle to entrain cooling air flow first through the APU compartment and then through the oil cooler. Surge bleed flow from the load compressor is discharged into the exhaust eductor. Ambient air is received into the compartment through a second exterior eductor inlet.
U.S. Pat. No. 5,655,359 similarly discloses an APU passive cooling system wherein cooling air for the oil cooler is drawn from the compartment. An inlet scoop in the engine air intake duct used to divert a portion of the air flow into the APU compartment. This air is used to cool the engine before being drawn through the oil cooler, mounted in a vacuum duct, by a lobed mixer which acts as an aspirator.
U.S. Pat. No. 6,092,360 discloses an APU passive cooling system in which cooling air is drawn into the engine compartment through an opening located in the rear of the aircraft. An eductor mounted before the exhaust duct of the engine, draws compartment air through the oil cooler, which in turn draws atmospheric air in through the aft opening.
Thus, while these patents provide for cooling of an auxiliary power unit without the use of a mechanically driven fan, they all teach systems which draw cooling air for the oil cooler from the APU compartment. A need exists for an auxiliary power unit passive cooling system that can provide enhanced oil cooling capabilities by directing exterior cooling air, through ducts, directly to the oil cooler, and which is nevertheless adaptable enough to be able to provide damage protection from foreign objects and be combined with the engine compressor surge bleed flow to provide improved airflow through the oil cooling heat exchanger.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved cooling system for an auxiliary power unit on an airplane.
It is also an object of the present invention to provide a simpler cooling system for auxiliary power unit engine oil and external components which does not require moving parts and does not include a cooling fan.
It is a further object of the present invention to provide improved cooling of the oil in an auxiliary power unit by providing enhanced cooling airflow through the heat exchanger.
Therefore, in accordance with the present invention there is provided a passive cooling system for an auxiliary power unit installation on an aircraft, comprising an auxiliary power unit housed within a nacelle of the aircraft, the auxiliary power unit comprising at least a compressor portion of a gas turbine engine and an oil cooler contained separately within the nacelle, an engine exhaust opening defined in the aft portion of the nacelle and communicating with the gas turbine engine, at least a first cooling air inlet duct communicating with a second opening defined in the nacelle and with the compressor portion, the oil cooler located within a second duct communicating with the exterior of the nacelle and the engine exhaust opening whereby exterior cooling air, and engine exhaust ejected through the engine exhaust opening entrains cooling air through the second duct to the oil cooler, providing engine oil cooling.
In accordance with the present invention, there is also provided a passive cooling system for an auxiliary power unit installation on an aircraft, comprising: an auxiliary power unit housed within a nacelle of the aircraft, the auxiliary power unit comprising at least a compressor portion of a gas turbine engine and an oil cooler contained separately within said nacelle; an engine exhaust opening defined in the aft portion of said nacelle and communicating with said gas turbine engine via an exhaust eductor assembly; said exhaust eductor assembly being in fluid flow communication with a compressor surge bleed duct; at least a first air inlet duct communicating with a second opening defined in said nacelle and with said compressor portion; and said oil cooler located within a second duct communicating with an opening other than the engine exhaust opening of said nacelle and with said engine exhaust opening, whereby exterior cooling air and engine exhaust ejected through said exhaust eductor assembly, entrain cooling air through said second duct to said oil cooler, providing engine oil cooling.
In accordance with a more specific embodiment of the present invention, the engine air inlet includes a first duct portion, and the second duct is bifurcated from the first duct portion and extends downstream from the first duct portion with a third duct portion also formed downstream of the first duct, the third duct portion communicating with the compressor portion and the oil cooler located within the second duct portion providing direct exterior cooling air to the oil cooler.
In one embodiment, contamination of aircraft environmental control system air is prevented by an air inlet splitter, which isolates the load compressor gas path. Protection against damage from foreign objects, for the powerplant, may be provided by a bypass duct located in-line with the first air inlet duct, and a scavenger discharge duct and outlet which expels harmful foreign objects from the aircraft. The nacelle is provided with a rear exhaust opening, and at least a second opening for the outside air intake. The third air inlet duct portion directs the air from the air intake to the engine compressor portion. The auxiliary power unit comprises a gas turbine engine having both load and core compressors and a compressor surge bleed valve and duct. The oil cooler may comprise an air-to-oil heat exchanger. The engine exhaust ejector creates a depressurization in the nacelle or in the exhaust eductor assembly, which results in the entrainment of cooling air through the heat exchanger and through the nacelle. In at least one embodiment, a dedicated small opening in the exhaust eductor assembly permits nacelle ventilation.
Further features and advantages of the present invention will become fully apparent by referring to the following detailed description, claims, and the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional schematic illustration of a first embodiment of the APU passive cooling system in accordance with the present invention.
FIG. 2 a is a cross sectional schematic illustration of a second embodiment of the APU passive cooling system in accordance with the present invention.
FIG. 2 b is a cross sectional schematic illustration of the second embodiment of the APU passive cooling system shown in FIG. 2 a.
FIG. 3 is a cross sectional schematic illustration of a third embodiment of the APU passive cooling system in accordance with the present invention.
FIGS. 4 a to 4 d are cross sectional schematic illustrations of a fourth embodiment of the APU passive cooling system in accordance with the present invention.
FIG. 5 is a perspective view of an engine having a main air inlet duct and exhaust eductor assembly in accordance with the present invention.
FIG. 6 is a vertical cross-sectional view of an exhaust eductor assembly used in accordance with the present invention.
FIG. 7 is a perspective view of the cooling air flow inner shroud of the exhaust eductor assembly shown in FIG. 6 .
FIG. 8 is a side perspective view of the exhaust eductor assembly shown in FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIG. 1 embodies an APU installation 10 comprising the elements of the present invention that will be described. The APU installation 10 is principally comprised of a gas turbine power plant 12 and an oil cooler 14 , both within an auxiliary power unit nacelle 16 . This nacelle is defined for the purposes of the present invention, as any dedicated enclosed compartment or enclosure, generally although not essentially located within the aircraft tailcone. The nacelle 16 shown in these embodiments as an aft compartment in the aircraft, has an exterior skin surface 18 . Compartment access doors 42 allow external access to the auxiliary power unit when the aircraft is on the ground, for such purposes as engine maintenance.
In the embodiment shown in FIG. 1, the exterior surface 18 of the APU nacelle 16 comprises principally two openings, the rear exhaust opening 20 and the main air inlet opening 22 . The main air inlet opening 22 in the aircraft exterior skin 18 allows air to be drawn from outside the aircraft by the power plant compressors. The gas turbine engine power plant 12 is comprised of two compressors, a load compressor 34 and a core compressor 36 . The load compressor 34 provides the aircraft environmental control system (ECS) air, while the core compressor 36 provides the powerplant with air for combustion. Inlet air is directed by a first air inlet duct 24 from the air inlet opening 22 to the power plant compressors. The oil cooler 14 , shown to be normal to the direction of airflow but is not necessarily limited to this orientation, is located in a second duct 27 . A bifurcation 26 in the first air inlet duct 24 is provided to directly supply cooling air to the oil cooler 14 , in the form of an air-to-oil heat exchanger, through the second duct 27 . This allows air to be directly fed to the oil cooler 14 through a duct, providing improved cooling airflow. After passing through the oil cooler, the cooling air enters the APU compartment 16 to provide cooling to the APU components.
An exhaust ejector 38 of the powerplant 12 , causes a depressurization of the APU compartment 16 . The exhaust ejector 38 achieves this by reducing the diameter of the power plant exhaust passage, causing an increase in the velocity of the exhaust gases. This causes the depressurization upstream in the APU compartment 16 , resulting in entrainment of the cooling air through the heat exchanger and the APU compartment, thereby cooling the engine oil and the powerplant components within the APU compartment.
Within the first air inlet duct 24 is located an air inlet splitter 28 . The splitter 28 in the engine air inlet duct 24 extends down into the engine intake plenum 30 . The air splitter 28 and the bifurcation 26 in the first air inlet duct are positioned such that the bifurcation 26 in the inlet duct is downstream of the leading edge 32 of the splitter 28 . When the power plant is run with the access doors 42 open, the resulting ambient pressure in the APU compartment 16 equalizes with the outside air pressure, which causes a flow reversal within the heat exchanger as the power plant creates a depression within the first air inlet duct 24 . In this operating mode, a reversal of airflow occurs, as the air is entrained from the compartment, through the heat exchanger and the second duct 27 , and gets ingested into the engine. The splitter 28 , consequently, prevents contamination of the airflow of the load compressor 34 in the event of a leak in the heat exchanger 14 when the powerplant is operated with the compartment access doors 42 open. Therefore, any oil leaked from the heat exchanger is forced down the core compressor and burned by the engine, rather than contaminating the aircraft environmental control system air.
FIGS. 2 a and 2 b illustrate an alternate embodiment of the passive cooling system. Referring to the embodiment illustrated in FIG. 2 a , a heat exchanger air inlet duct 59 directs cooling air from a bifurcation 58 in the main engine air inlet duct 24 to the heat exchanger 14 , and a heat exchanger discharge duct 52 directs cooling air downstream of the heat exchanger 14 directly to an exhaust eductor assembly 57 . The exhaust eductor, or exhaust ejector plenum, while it is generally an annular plenum adapted to receive exiting APU cooling air which is drawn through the eductor and into the engine exhaust by the depressurization caused by the engine exhaust ejector 38 , could alternately be any similar device of varying shape which performs the equivalent function. APU component cooling air is admitted into the APU compartment through a small second bifurcation 54 in the heat exchanger air inlet duct 59 . The component cooling air then exits the APU compartment 16 through another small bifurcation 56 in the exhaust eductor assembly 57 . The surge bleed duct 48 is combined with the heat exchanger discharge duct 52 downstream of both the surge bleed valve 50 and the heat exchanger 14 . This combined heat exchanger and surge bleed duct design, while preventing contaminating oil from the heat exchanger 14 from entering the aircraft bleed system or the ECS air, provides further enhanced airflow through the heat exchanger when the surge bleed valve 50 is open.
In the embodiments shown in FIGS. 2 a and 2 b , the oil cooler is located further forward with respect to the engine, nearer the gearbox casing of the power plant and close to the oil pumps of the engine. This eliminates the need for long oil lines. The surge bleed valve 50 is closed when the APU supplies bleed air to the aircraft. However, when the APU only supplies electric power, the surge bleed valve 50 is opened, and the junction between the surge bleed duct 48 and the heat exchanger discharge duct 52 is designed to enhance air flow through the heat exchanger using the additional kinetic energy of the surge bleed flow, thereby improving oil cooling. As in the embodiment of FIG. 1, the exhaust ejector 38 , here within the exhaust eductor assembly 57 , causes the entrainment of cooling air flow through the heat exchanger and out through the engine exhaust duct.
FIG. 2 b illustrates a similar embodiment as FIG. 2 a , having, however, a dedicated heat exchanger opening 44 in the exterior surface 18 of the nacelle compartment 16 . This provides outside air via the alternate heat exchanger inlet duct 46 to the heat exchanger 14 . In this embodiment, the compartment cooling air inlet 54 is shown to be located in the first air inlet duct 24 rather than the heat exchanger inlet duct 59 . Nevertheless, either location for the compartment air inlet 54 is possible. The embodiment shown in FIG. 2 b , however, provides independent air cooling sources for the oil cooler and the engine components within the APU compartment. The advantage of this embodiment over that shown in FIG. 1 is that more efficient cooling of the engine components is achieved because cooling air does not first get warmed by first going through the heat exchanger before it reaches the APU components.
FIG. 3 shows a further embodiment of the present invention. This embodiment additionally includes a duct providing foreign object damage protection for the engine. The power plant compressors draw air from the outside through a main air inlet opening 22 in the aircraft skin exterior surface 18 . The engine air inlet duct 24 directs the air to the engine compressors. According to the embodiment shown in FIG. 2 b , a small bifurcation 54 in the inlet duct is provided to supply cooling air to the APU compartment. The exhaust ejector 38 within the exhaust eductor assembly 57 creates a depressurization of the APU compartment resulting in airflow through the bifurcation opening 54 in the air inlet duct. Cooling air exits the APU compartment through a second bifurcation 56 in the exhaust eductor assembly 57 .
An in-line bypass duct 60 is adjoined to the first air inlet duct 24 , in order to direct cooling air to the heat exchanger 14 , located in the mouth of the eductor assembly 57 parallel to the direction of airflow in the bypass duct. The airflow in the bypass duct 60 is sustained by the eductor induced flow through the oil cooling heat exchanger. One advantage this embodiment permits is the use of a smaller oil cooler. A scavenge discharge duct 62 is used as a collector to discharge overboard any foreign objects collected by the bypass duct 60 . The bypass and scavenge ducts are designed such that separated liquid and solid particles will drain or be drawn by gravity out through the scavenge duct exit 64 . The scavenge duct 62 and scavenge exit 64 are sized such that flow reversal is minimized during aircraft static and low speed conditions which cause flow reversal in the scavenge duct. The air bypass and the scavenge ducts 60 and 64 respectively, provide a level of foreign object damage protection for the powerplant.
FIGS. 4 a to 4 d show another embodiment of the present invention wherein the oil cooler 14 is located within the exhaust eductor assembly 57 and the dedicated heat exchanger inlet duct 46 feeds air directly from the aircraft exterior to the oil cooler. Dedicated heat exchanger opening 44 in the exterior surface 18 of the aircraft's nacelle compartment 16 permits exterior air to be fed through the inlet duct 46 to the oil cooler 14 located perpendicular to the inlet air flow in the annular exhaust eductor assembly 57 . The engine exhaust ejector 38 within the eductor assembly 57 draws the cooling air through the heat exchanger inlet duct 46 and the oil cooler 14 , and out into the main engine exhaust duct 40 .
The variations of the fourth embodiment of the present invention shown in FIGS. 4 a to 4 d , involve alternate locations of the compartment cooling air inlet and exits. FIG. 4 a shows an embodiment wherein the compartment cooling air inlet 54 is a bifurcation in the main engine air inlet duct 24 . This permits air to enter the nacelle compartment 16 to provide cooling to the externals of the APU. This cooling air then exits the compartment through a bifurcation in the heat exchanger inlet duct 46 for the compartment cooling air exit 68 . The embodiment shown in FIG. 4 b uses a compartment cooling air inlet 70 in the heat exchanger inlet duct 46 . The compartment cooling air then exits the nacelle compartment through a small bifurcation 56 in the exhaust eductor assembly 57 , similar to the embodiments of FIGS. 2 and 3. The embodiments of FIGS. 4 c and 4 d both have a separate compartment cooling air inlet 72 in the exterior surface 18 of the nacelle compartment 16 . The engine exhaust ejector 38 pulls cooling air from the exterior of the aircraft via the air inlet 72 , through the compartment 16 , and out through either the air exit bifurcation 56 in the exhaust eductor 57 , as shown in FIG. 4 c , or the air exit bifurcation 68 in the heat exchanger inlet duct 46 , as shown in FIG. 4 d.
FIG. 5 shows an embodiment of the APU installation 10 , comprising the gas turbine power plant 12 , the oil cooler 14 and the exhaust eductor assembly 57 .
The assembly shown in FIG. 6 consists of a construction of sheet metal components either welded or riveted together. The assembly is of modular design and is supported by the engine exhaust casing 81 . The exhaust eductor assembly comprises a primary nozzle 82 located immediately downstream of the engine exhaust gas path. The gas path of the primary nozzle 82 is bounded by the primary nozzle shroud 83 and exhaust plug 84 . The primary nozzle is circumscribed by the surge bleed nozzle 85 , which is bounded by the cooling air plenum inner shroud 86 and the primary nozzle shroud 83 . The cooling air mixing plane is located downstream of the primary nozzle 82 .
Mixing lobes 87 are introduced to improve the mixing efficiency, thereby resulting in improved cooling mass flow. The number of lobes within the eductor assembly inner shroud may vary depending on exhaust duct diameter and cooling air flow requirements. Similarly, the geometrical shape of the mixing lobes 87 may vary based on pumping requirements and acoustics. These mixing lobes 87 can be either welded or mechanically fastened to the cooling air plenum inner shroud 86 .
The eductor assembly incorporates a primary surge bleed plenum 88 in which the surge bleed flow is redistributed circumferentially before exiting through a series of openings on the surge bleed flow plenum inner shroud 89 and entering the secondary surge bleed plenum 90 . In this plenum, the surge bleed flow is realigned axially and then ejected back into the main engine gas path through the surge bleed nozzle 85 . The primary surge bleed plenum 88 is fed, during specific engine operating conditions, by the surge bleed duct 48 . This surge bleed flow is controlled by the modulating surge bleed valve 50 located in the surge bleed duct 48 . Flow from the surge bleed duct 48 enters the primary surge bleed plenum 88 , at the junction 93 of the two components, in a radial direction and impinges directly on the diaphragm 94 , which divides the primary surge bleed plenum 88 and the cooling air plenum 95 . This diaphragm 94 has a conical shape and acts as a natural splitter to redistribute the surge bleed flow uniformly around the circumference of the surge bleed plenum inner shroud 89 .
The cooling air plenum 95 located on the aft side of the diaphragm 94 is bounded by the cooling air plenum outer shroud 96 and inner shroud 86 . Openings 97 are provided on the outer shroud for the cooling air to enter the cooling air plenum 95 . The air cooled heat exchanger 14 is located upstream of these openings. Both the surge bleed flow and the cooling air flow plenums 88 and 95 respectively are sealed to prevent any leakage.
A mechanical interface 98 is provided on the downstream end of the eductor assembly for connecting to the aircraft exhaust duct 40 . Opening 56 is provided on the cooling air plenum outer shroud in order to accept ventilation air exiting from the engine compartment. The cutouts 80 on the cooling air flow inner shroud 86 , as seen in FIG. 7, are provided in line with each mixing lobe 87 .
The layout of the eductor assembly as described in detail above offers several additional advantages. The engine exhaust velocity can be easily altered by changing a simple axisymmetric part, namely, the primary nozzle shroud 83 , in order to improve the amount of secondary air flow used for cooling purposes. This can be easily done without requiring modification of any of the more complex and more expensive parts of the eductor assembly. Also, a large exhaust plug 84 is required in order to control the air flow in the primary nozzle 82 and the air flow into the primary passages of the mixing lobes 87 . The resulting large volume of space inside the exhaust plug 84 can then be used for acoustic treatment, for example, by introducing inside the plug low frequency cavities extending from the engine exhaust casing 81 interface to the cooling air flow mixing plane.
Therefore, in summary, the eductor assembly and passive cooling system of the present invention, provides engine oil cooling and engine enclosure cooling without requiring the use of any rotating parts and permits the reinfection of surge bleed flow into the main engine exhaust gas path thereby providing additional pumping capability to the cooling air. The eductor assembly is additionally capable of redistributing the surge bleed flow circumferentially within the surge bleed plenum, providing a method for controlling the pumping capability of the eductor assembly by the introduction of a simple axisymmetric primary nozzle shroud into the main exhaust gas path, and providing a method to control the noise generated by the engine in the eductor assembly by the introduction of a large exhaust plug with internal acoustic chambers.
The embodiments of the invention described above are intended to be exemplary only. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims. | A passive cooling system for an auxiliary power unit (APU) installation on an aircraft is provided. The system is for an auxiliary power unit having at least a compressor portion of a gas turbine engine and an oil cooler contained separately within a nacelle. The system includes the auxiliary power unit housed within the nacelle of the aircraft, an engine exhaust opening defined in the aft portion of the nacelle and communicating with the gas turbine engine, at least a first air inlet duct communicating with a second opening defined in said nacelle and with said compressor portion and the oil cooler is located within a second duct communicating with an opening other than the engine exhaust opening of said nacelle and with the engine exhaust opening. Exterior cooling air and engine exhaust ejected through said engine exhaust opening entrain cooling air through said second duct to said oil cooler, and thus provide engine oil cooling. An exhaust eductor is also provided. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a Divisional Application of U.S. patent application Ser. No. 12/063,559, filed on Apr. 16, 2009, which is a 371 filing of International Patent Application No. PCT/FR2006/001946, filed on Aug. 11, 2006, which claims priority to French Application No. 0508535, filed on Aug. 12, 2005, the contents of all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] In general, this present invention concerns the methods that make use of a fluid in a supercritical state and, in particular, the field of chromatography and extraction in the supercritical phase.
SUMMARY OF THE INVENTION
[0003] More precisely, according to a first of its aspects, the invention concerns a chromatography or extraction method that includes:
a separating operation in a column or extractor, with the said column or the said extractor receiving a product and being fed into an eluent that includes a supercritical fluid, routed via a first pumping operation, and a modifier, routed via at least one second pumping operation, an operation to collect at least one fraction downstream of the column or extractor, an operation for recycling the supercritical fluid mixed with a residual quantity of modifier following after the collecting operation and preceding the first pumping operation, with the said first pumping operation being used to pumps at least the said supercritical fluid mixed with a residual quantity of modifier, and a condensing operation, following on from the collecting operation and preceding the first pumping operation.
[0008] Such a chromatography or extraction method, in which the supercritical fluid is recycled, is known to those skilled in the art.
[0009] Recycling of the supercritical fluid is preferable in order to reduce the cost of implementing the method and the necessary actions, particularly when high flows are employed.
[0010] For example, at a flow of carbon dioxide (CO 2 ), used as a supercritical fluid, of 80 ml/min, about 115 kg of CO 2 is lost every 24 hours if it is not recycled. This loss represents a considerable cost.
[0011] In a conventional chromatography or extraction method in the supercritical phase, the addition of a modifier is often necessary in order to increase the polarity of the supercritical fluid.
[0012] In chromatography and extraction, the modifier level at the input to the chromatography column or the extractor is an important parameter that affects the performance of the method.
[0013] When the supercritical fluid is not recycled, this modifier level is easily kept constant in that it depends on the flow in the pump supplying the modifier, as well as on the flow in the pump supplying the supercritical fluid, with these two flows themselves being kept constant.
[0014] On the other hand, when the supercritical fluid is recycled following the collecting operation, a certain quantity of modifier can also be so. The result is a variation of the modifier level at the input to the column or extractor, which is harmful to the method.
[0015] In chromatography, for example, a variation of the modifier level at the input to the column affects the retention time, the resolution, and sometimes the selectivity of the eluted products and therefore the stability of the method.
[0016] This also applies to the extraction, in which the modifier level affects the extraction time and the concentration of extracted product.
[0017] One is familiar with French patent FR 2 601 883, which concerns a method and a device for separation with the aid of a supercritical fluid, in which the supercritical fluid is recycled.
[0018] After the separating operation and before it is recycled, the supercritical fluid, in the gaseous or semi-gaseous phase and containing a residual quantity of modifier, is brought into contact with the modifier in the liquid phase in a conventional gas/liquid contactor.
[0019] The composition of the phase with the lowest density (gaseous or semi-gaseous) is adjusted by varying the pressure and the temperature so as to obtain the desired supercritical-fluid/modifier mixture at the output from contactor.
[0020] This method is limited however, due to the thermodynamic balances to be observed in the contactor, at mixtures containing at most 10% by weight of modifier.
[0021] Moreover, this method is complex to implement. In fact it leads to a requirement for a certain number of elements in, and in relation to the contactor, such as a system for filling and monitoring the level of modifier, a coating, a sintered material and a droplet-separating device.
[0022] In this context, the aim of this present invention is to propose a chromatography or extraction method in which the supercritical fluid is recycled, and free of the limitations of the prior art.
[0023] To this end, the method of the invention, which also conforms to the generic definition provided in the foregoing preamble, is essentially characterised in that it also includes:
downstream of the collecting operation and upstream of the separating operation, an operation for determining at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid, and if necessary an operation for correcting the flow in the first pumping operation and the flow in the second pumping operation, in order to limit variation, during execution of the method, of the modifier level in the eluent at the input to the column or extractor, and in a direction that is suitable for meeting a first setpoint, determined beforehand, of total flow corresponding to the sum of the flows of the first pumping operation and the second pumping operation.
[0026] The invention therefore has the advantage of proposing controlling of the modifier level at the input to the column or extractor. As a consequence, the method of the invention is more stable than the methods of the prior art that use a modifier and recycle the supercritical fluid without regulation of the modifier level. By the stability of the method is meant the maintenance of all of its parameters (temperatures, pressures, flows, levels, etc.) at constant values. In particular, the method of the invention ensures minimal variation of the modifier level at the input to the column or extractor.
[0027] In addition, in the method of the invention, there exists no limitation of the modifier level in the eluent. The user can choose to make up an eluent containing between 0 and 100% of modifier.
[0028] In general, an eluent constitutes the mobile phase of a chromatography or extraction. According to the invention, the mobile phase is based on a fluid chosen from any fluid that is compatible with an application in chromatography or extraction in the supercritical phase. Hereinafter, such a fluid will be referred to as a supercritical fluid, even if, in certain pressure and temperature conditions, the fluid is not in a supercritical state in the strict sense of the term. The supercritical state corresponds to a pressure value (P) that is greater than the critical pressure (Pc), and to a temperature value (T) that is greater than the critical temperature (Tc). Also in the supercritical state is included the subcritical state for which P>Pc and T<Tc. We speak of a supercritical or subcritical fluid with reference to a fluid of which the density and therefore the solvent power undergo wide variation with the pressure and the temperature when it is pure.
[0029] By simplification, we refer to the supercritical or subcritical state as the state that the fluid would assume is it were in the quoted pressure and temperature conditions only, even if, in these conditions, it is mixed with another solvent and the state of the mixture is not necessarily supercritical or subcritical.
[0030] We finally speak of a recycled supercritical fluid even if the fluid in the temperature and pressure conditions is not in a supercritical state in the strict sense of the term, but in a state that can be gaseous (with the temperature being greater than the liquid-vapour equilibrium temperature for the pure fluid at a working pressure less than the critical pressure) or liquid (with the temperature being less than liquid-vapour equilibrium temperature for the pure fluid at a working pressure less than the critical pressure).
[0031] The eluent can also include a liquid solvent or a mixture of liquid solvents, which constitutes a modifier. The modifier can be an organic solvent. This is added in order to modify the polarity of the supercritical fluid.
[0032] By a magnitude associated with the modifier level is meant any magnitude from which the value of the modifier level can be obtained, directly or indirectly. Thus, this magnitude can be the modifier level itself.
[0033] In a first preferred embodiment of the invention, the operation for determining at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid takes place upstream of the first and second pumping operations and includes:
an operation for measuring, at one measuring point at least, the density of the recycled supercritical fluid mixed with a residual quantity of modifier, and an operation for evaluating the level of modifier mixed with the recycled supercritical fluid, with the modifier level being evaluated, from the measured density, by means of a calibration-density=f (modifier level) graph established beforehand at the pressure and the temperature existing at the measuring point and around the latter, and the correction operation consists of modifying the flow in the first pumping operation and the flow in the second pumping operation in order to meet the first setpoint and a second setpoint, set beforehand, for the modifier level in the eluent.
[0037] In this first embodiment, the first pumping operation and the second pumping operation preferably take place in parallel with each other. The second pumping operation can also take place upstream of the first pumping operation.
[0038] According to a second preferred embodiment of the invention, the operation for determining a magnitude associated with the modifier level in the eluent consists of measuring the density of the eluent upstream of the first pumping operation and downstream of the second pumping operation, and the correction operation consists of modifying the flow in the first pumping operation and the flow in the second pumping operation in a direction that is suitable for meeting the first setpoint and a third setpoint, set beforehand, for the density of the eluent.
[0039] Preferably, the operation for determining at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid is effected downstream or upstream of the condensing operation.
[0040] Advantageously, the method of the invention can also include at least one operation for regulating the pressure followed by at least one operation for regulating the temperature, downstream of the separating operation and upstream of the collecting operation.
[0041] The invention also concerns a chromatography or extraction installation that includes:
a separating device such as one or more chromatography columns or an extractor, which receives a product and feeds into an eluent that includes a supercritical fluid, routed via a first pump, and a modifier, routed via at least one second pump, a device for collecting at least one fraction of the product separated in the separating device, a path for recycling the supercritical fluid mixed with a residual quantity of modifier, downstream of the collection device and upstream of the first pump, with the said first pump pumping at least the said supercritical fluid mixed with a residual quantity of modifier, and a condenser placed downstream of the collection device and upstream of the first pump,
[0046] with the said installation being characterised in that it also includes a measuring and correcting device, placed in the recycling path or downstream of the first pump, and upstream of the separating device, which measures at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid and that, if necessary, performs correction of the flow in the first pump and of the flow in the second pump in order to limit the variations, while running the installation, of the said levels at the input to the separating device, and in a direction that is suitable for meeting a first setpoint, determined beforehand, of total flow corresponding to the sum of the flows in the first pump and in the second pump.
[0047] According to a first preferred embodiment of the invention, the measuring and correcting device is positioned at a measuring point located upstream of the first and second pumps and measures the density of the recycled supercritical fluid, mixed with a residual quantity of modifier, from which it evaluates the level of modifier mixed with the recycled supercritical fluid by means of a pre-established density=f (modifier level) calibration curve at the pressure and the temperature existing at the measuring point and around the latter; and the said measuring and correcting device modifies the flow in the first pump and the flow in the second pump in order to attain the first setpoint and a second setpoint, set beforehand, of modifier level in the eluent.
[0048] In this first embodiment, the first pump and the second pump are preferably mounted in parallel with each other. The second pump can also be positioned upstream of the first pump.
[0049] According to a second preferred embodiment of the invention, the measuring and correcting device measures the density of the eluent upstream of the first pump and downstream of the second pump, and the correction consists of modifying the flow in the first pump and the flow in the second pump in a direction that is suitable for meeting the first setpoint and a third setpoint, set beforehand, for the density of the eluent. The measuring and correcting device can be located downstream or upstream of the condenser.
[0050] According to one particular embodiment, the installation according to the invention also includes a device to regulate the pressure, a pressure-reducer for example, followed by a device to regulate the temperature of the eluent, by heating it for example, downstream of the separating device and upstream of the collection device.
[0051] The invention is advantageously implemented with carbon dioxide as the supercritical fluid.
[0052] As the modifier, it is preferable to use an organic solvent liquid, like an alcohol for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] Other characteristics and advantages of the invention will emerge more clearly from the detailed description provided below, purely as a guide and in no way limiting, with reference to the appended drawings in which:
[0054] FIG. 1 is a diagram of one embodiment of the method of the invention,
[0055] FIG. 2 represents a density=f (modifier level) calibration curve that can be used in accordance with the invention, and
[0056] FIGS. 3 and 4 each represents a diagram of an installation according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] According to one particular embodiment of the invention, the chromatography or extraction method includes the operations represented in FIG. 1 .
[0058] Conventionally, a separating operation 1 takes place in a chromatography column or in an extractor.
[0059] The column or the extractor are supplied with an eluent that includes a supercritical fluid and a modifier.
[0060] The product P is inserted into the chromatography column, by injection for example.
[0061] A first pumping operation 2 brings the supercritical fluid, which has been subjected beforehand to a condensing operation 6 , to the column or to the extractor.
[0062] A second pumping operation 3 brings the modifier to the column or to the extractor.
[0063] Thus, a supercritical-fluid/modifier mixture constituting the eluent is formed for the separating operation 1 . At this stage, the eluent is preferably in a supercritical state.
[0064] An operation 11 for regulating the temperature of the eluent can be effected before the separating operation 1 . For example, the eluent is heated in a heat exchanger.
[0065] An operation 4 for collecting at least one fraction of the product P is effected downstream of the column or extractor.
[0066] An operation 9 for regulating the pressure and an operation 10 for regulating the temperature of the eluent are preferably effected following the separating operation 1 and prior to the collecting operation 4 .
[0067] The operation 9 for regulating the pressure consists, for example, of reducing pressure in the eluent enriched with at least one fraction of the product P, to a pressure that is less than the critical pressure of the supercritical fluid. If the supercritical fluid CO 2 , the pressure reduction therefore occurs at a pressure that is less than 74 bars, and typically between 30 and 65 bars.
[0068] After the pressure reduction, the supercritical fluid is in liquid and gaseous form. The liquid part is in the majority, and depends on the pressure at which pressure reduction takes place.
[0069] This liquid part can be converted to a gas by heating during the operation 10 for regulating the temperature.
[0070] This conversion results in a drop in the density of the supercritical fluid and therefore in the solubility of the solute constituting the fraction of product P in this fluid. The solubility of the solute diluted in the modifier becomes almost zero, which allows separation of the solute, solid or liquid, of the supercritical fluid brought to the gaseous state, by means of gas-solid or gas-liquid separators.
[0071] An operation 5 for recycling the supercritical fluid brought to the gaseous state and mixed with a residual quantity of modifier follows on from the collecting operation 4 and precedes the first pumping operation 2 .
[0072] There exist two causes for the presence of a residual quantity of modifier in the supercritical fluid brought to the gaseous state following the collecting operation 4 .
[0073] Firstly, the modifier has a vapour tension that results in a certain solubility in the supercritical fluid brought to the gaseous state. The percentage of modifier that is recycled depends on the solubility of the modifier in the supercritical fluid brought to the gaseous state, and this solubility is a function of the pressure and temperature of the supercritical fluid brought to the gaseous state in the separators.
[0074] Secondly, the percentage of modifier that is recycled depends on the effectiveness of trapping in the separators.
[0075] The condensing operation 6 follows on from the collecting operation 4 and precedes the first pumping operation 2 . It takes place advantageously during the recycling operation 5 . The pressure and the temperature of the supercritical fluid mixture brought to the gaseous-modifier state, obtained by the corresponding regulating operations 9 , 10 , are constant during the collecting and recycling operations 4 , 5 and up to the condensing operation 6 , during which the temperature is lowered.
[0076] In addition, the method of the invention includes, downstream of the collecting operation 4 and upstream of the separating operation 1 , an operation 7 for determining at least one magnitude associated with the modifier level mixed with the supercritical fluid recycled and brought to the gaseous or liquid state.
[0077] Preferably, in order to facilitate the implementation of the method, the operation 7 is effected upstream of the first pumping operation 2 . The fact of measuring the density at the input to the pump facilitates the operation since, at this stage of the method, it is possible, whatever the operating conditions of flow, column type and size, temperature, etc., to maintain a constant pressure and temperature during execution of the method and from one method to the next.
[0078] If necessary, an operation 8 for correcting the flow in the first pumping operation 2 and the flow in the second pumping operation 3 is effected in order to limit the variations, during execution of the method, of the modifier level in the eluent at the input to the column or the extractor. The flows are corrected in a direction that is suitable for meeting a first setpoint, determined beforehand, of the total flow corresponding to the sum of the flows of the first pumping operation 2 and of the second pumping operation 3 .
[0079] More particularly, FIG. 1 represents an advantageous version of the invention. According to this version, the operation 7 for determining at least one magnitude associated with the level of modifier mixed with the supercritical fluid brought to the liquid state takes place upstream of the first and second pumping operations 2 , 3 . It includes an operation, at one measuring point at least, for measuring the density of the supercritical fluid recycled and brought to the liquid state, mixed with a residual quantity of modifier, and an operation for evaluating the level of modifier mixed with the supercritical fluid, with the modifier level being evaluated, from the measured density, by means of a density=f (modifier level) calibration curve established beforehand at the pressure and the temperature existing at the measuring point and around the latter. Such a calibration curve is represented in FIG. 2 .
[0080] The correction operation 8 consists, in this case, of modifying the flow in the first pumping operation 2 , and the flow in the second pumping operation 3 , in order to satisfy the first setpoint and a second setpoint, set beforehand, of modifier level in the eluent.
[0081] The density of the supercritical fluid, mixed with a residual quantity of modifier, is the sum of the densities of the constituents, namely the supercritical fluid and modifier, weighted by their percentage, with an offset in the case where the mixture of the constituents has a final volume other than the sum of the initial volumes of the constituents.
[0082] In FIG. 2 , the term “density” refers to the mass per volume. Moreover, the CO 2 is given by way of an example of a supercritical fluid.
[0083] In order to draw a calibration curve as represented in FIG. 2 , the density of the supercritical fluid mixed with a residual quantity of modifier, shown on the ordinate, is measured for different modifier levels, shown on the abscissa. The different supercritical fluid-modifier mixtures are created by the first and second pumping operations, at a given temperature and pressure.
[0084] The variation in the density of the supercritical fluid mixed with a residual quantity of modifier as a function of the modifier level depends on the difference in density of the pure constituents in the set conditions of pressure and temperature. The greater this difference, the greater too is the variation in the density of the mixture as a function of its composition, and the greater is the precision in determining the modifier level.
[0085] Therefore, it is preferable to establish conditions of temperature and pressure at which the difference in density of the pure constituents is greatest.
[0086] The precision in determining modifier level also depends on the precision of the test gear for measuring the density.
[0087] The density=f (modifier level) curve is linear, except in the case mentioned previously in which the supercritical-modifier fluid mixture has a final volume that is different from the sum of the initial volumes of supercritical fluid and modifier.
[0088] In the configuration of the invention represented in FIG. 1 , the first pumping operation 2 and the second pumping operation 3 take place in parallel with each other.
[0089] Nevertheless, a configuration in which the second pumping operation takes place upstream of the first pumping operation also forms part of the invention.
[0090] It is preferable to measure the density in order to determine the level of modifier mixed with the supercritical fluid, in that this measurement is relatively easy to implement and has good precision, but other physical magnitudes can also be used to obtain the value of the level of modifier mixed with the supercritical fluid. It is possible, for example, to measure the thermal conductivity of the mixture, or indeed to perform a measurement of the absorption of this melange in the ultraviolet range.
[0091] According to another advantageous version of the invention, the operation for determining a magnitude associated with the level of modifier mixed with the supercritical fluid recycled and brought to the liquid state, consists of measuring the density of the mixture, which is then the eluent, upstream of the first pumping operation and downstream of the second pumping operation. In this case, the correction operation consists of modifying the flow in the first pumping operation and the flow in the second pumping operation in a direction that is suitable for meeting the first setpoint and a third setpoint, set beforehand, for the density of the eluent.
[0092] As before, it is possible to replace the measurement and the density setpoint of the eluent with a measurement and a setpoint of thermal conductivity or absorption in the ultraviolet.
[0093] In this configuration, one is not seeking to determine the residual modifier level in the supercritical fluid recycled and brought to the liquid or gaseous state, but to aim for a density setpoint at the input to the pump. For this, a regulation loop is created.
[0094] The density setpoint is determined, for example, by measuring the density corresponding to the modifier level in the eluent in the absence of recycling, by adjusting the flows of the pumping operations to as to ascertain the wanted modifier level and the total flow, in fixed operating conditions.
[0095] The regulation loop consists of adjusting the flows of the pumping operations in the direction that is suitable to satisfy two setpoints, namely density and total flow. A single pair of values of the flows in the first and second pumping operation satisfy both a density setpoint and to a total-flow setpoint.
[0096] Advantageously, the operation 7 for determining at least one magnitude associated with the level of modifier mixed with the supercritical fluid is effected downstream of the condensing operation 6 . In fact, in order to measure the density, the supercritical fluid is preferably brought to the liquid state by cooling it to below the liquid-vapour equilibrium temperature, at the recycling pressure that is less than the critical pressure. Thus, the measurements are more precise than measurements in a gaseous phase.
[0097] Nevertheless, this operation for determining at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid can be performed upstream of the condensing operation 6 . In this case, the density is measured in the supercritical fluid brought to the gaseous state.
[0098] One way of measuring the density is, for example, the use of a mass flowmeter based on the Coriolis principle, which can be used to obtain the flow and the density, or of an appliance dedicated to the specific measurement of the density of a fluid or of a mixture of fluids at a given pressure and temperature.
[0099] The measured density can be corrected to take account of the temperature.
[0100] The supercritical fluid is preferably carbon dioxide, but can be any fluid that is compatible with chromatography and/or extraction in the supercritical phase, such as an alkane, a chloro-fluoroalkane or xenon.
[0101] The modifier is preferably an alcohol, like methanol, ethanol or isopropanol for example, but can also be any organic solvent, such as acetonitrile, methyltertbutylether or MTBE, or ethyl acetate. It can be a mixture of at least two of these compounds.
[0102] FIGS. 3 and 4 each schematically represent an installation according to the invention, which can be used to implement the method of the invention. We have chosen in particular to illustrate the chromatography installations.
[0103] The same elements making up the installation are each indicated by the same reference in these two figures.
[0104] FIG. 3 illustrates a first configuration according to the invention. This installation includes a separating device that includes at least one chromatography column 12 .
[0105] This column 12 receives a mixture that includes a product P introduced by injection and an eluent that includes a supercritical fluid, such as the CO 2 , and a modifier. The supercritical fluid, held in recipient A, is routed via a first pump 13 and the modifier, held in recipient B, is routed via at least one second pump 14 .
[0106] At the output from the column 12 , a detector 20 is used to detect the fraction or fractions of the product, (P) that come out of the column with the eluent.
[0107] These fractions are collected in a collection device 15 that includes at least one solid-gas or liquid-gas separator according to which the solute constituting the fraction of product (P) is solid or liquid. Several separators can be connected in series.
[0108] In the case of an eluent that is free of modifier and that is therefore a pure supercritical pure, its recycling would simply require arranging for the trapping of all the solute in the separator or separators.
[0109] In the case of the invention, the eluent includes modifier at between 0 and 100% by weight, preferably between 0.1% and 70%, or preferably between 0.5% and 35%. At the output from the column 12 , there is a mixture of eluent and solute, making a mixture of three constituents—supercritical fluid, modifier and solute.
[0110] This mixture is put through a device to regulate the pressure, and a device to regulate the temperature. Thus, in a first stage, the mixture passes through a pressure-reducer 19 in order to reduce the pressure of the eluent. This results in a mixture of supercritical fluid brought to the liquid state, supercritical fluid brought to the gaseous state, modifier, and solute.
[0111] This last mixture is then heated in the device to regulate the temperature, in order to convert the supercritical fluid part brought to the liquid state into supercritical fluid brought to the gaseous state. One is therefore in the presence of two phases, namely a liquid phase containing the modifier in which the solute is soluble, and a gaseous phase of supercritical fluid brought to the gaseous state in which we find a certain modifier level and traces of solute.
[0112] A first separator is used to separate the liquid phase from the gaseous phase and to collect the soluble solute in the modifier.
[0113] The use of a second separator in series with the first allows all of the solute to be trapped.
[0114] A path 16 for recycling the supercritical fluid brought to the gaseous and then the liquid state mixed with a residual quantity of modifier is positioned between the collection device 15 and the first pump 13 . The first pump 13 pumps at least the supercritical fluid brought to the liquid state and mixed with a residual quantity of modifier.
[0115] The pumped mixture first passes via a condenser 17 placed downstream of the collection device 15 and upstream of the first pump 13 . The condenser 17 is preferably placed in the recycling path 17 .
[0116] The installation according to the invention also includes a measuring and correcting device 18 , placed in the recycling path 16 or downstream of the first pump 13 and upstream of the chromatography column 12 . The measurements are facilitated in the case where the device 18 is located in the recycling path 16 , upstream of the first pump 13 .
[0117] This device 18 measures at least one magnitude associated with the level of modifier mixed with the recycled supercritical fluid and, if necessary, performs correction of the flow in the first pump 13 and of the flow in the second pump 14 in order to limit the variations, while running the installation, of this level at the input to the chromatography column 12 .
[0118] The correction is effected in a direction that is suitable for meeting a first setpoint, determined beforehand, of total flow. The total flow corresponds to the sum of the flows in the first pump 13 and in the second pump 14 . Preferably, the measuring and correcting device 18 is placed downstream of the condenser 17 .
[0119] Nevertheless, the measuring and correcting device can also be placed upstream of the condenser.
[0120] In the first particular configuration represented in FIG. 3 , the measuring and correcting device 18 is placed at a measuring point located upstream of the first and second pumps 13 , 14 , and more precisely the first pump 13 and the second pump 14 are mounted in parallel with each other.
[0121] According to a second particular configuration (not shown) of the invention, the second pump is positioned upstream of the first pump, and the measuring and correcting device is positioned at a measuring point located upstream of the second pump.
[0122] In this case, the installation has the advantage of requiring only a high-pressure pump, which is the first pump 13 . The second pump 14 , in series with and upstream of the first pump 13 , can be just a low-pressure pump. For example, the first pump has a feed pressure of between 30 and 300 bars, preferably between 100 and 300 bars, and the second pump, for example, has a feed pressure of between 1 and 100 bars, preferably of the order of 50 bars.
[0123] At the measuring point, in these two configurations, the measuring and correcting device 18 measures a first magnitude associated with the modifier level mixed with the supercritical fluid recycled and brought to the liquid state, which is preferably the density of the mixture. From this measured density, the device 18 evaluates a second magnitude associated with the level of modifier mixed with the supercritical fluid recycled and brought to the liquid state, which is the modifier level, by means of a calibration curve such as that represented in FIG. 2 .
[0124] The measuring and correcting device 18 modifies the flow in the first pump 13 and the flow in the second pump 14 in order to attain the first setpoint and a second setpoint, set beforehand, of modifier level in the supercritical-fluid/modifier mixture.
[0125] The setpoints are set by the user as a function of the process that he wishes to execute with the installation according to the invention.
[0126] The recycled supercritical fluid contains traces of modifier due to the solubility of the latter in the supercritical fluid brought to the gaseous state.
[0127] The first pump 13 pumps supercritical fluid brought to the liquid state and containing modifier, and the flow of supercritical fluid is less than its initial value, meaning than the value set at the start-up of the installation. It is therefore necessary to increase the flow in the first pump 13 in order to adjust the flow of supercritical fluid to its initial value by compensating for the presence of the modifier.
[0128] For example, at the start-up of the installation, the flow of supercritical fluid is set to a value of 80 g/min, and the flow of modifier to a value of 20 g/min. The first total-flow setpoint is therefore 100 g/min, and the user fixes the second setpoint of modifier level at 20%.
[0129] The residual level of modifier in the recycled supercritical fluid is 5% for example. In this case, if the flow is not corrected in the first pump 13 , then the actual flow of supercritical fluid will be 95% of 80 g/min, which is 76 g/min.
[0130] It is then necessary to adjust the flow in the first pump 13 so as to satisfy the relation Q. x 0.95=80 g/min, where Q is the value of the corrected flow in the first pump 13 . Here, Q is about 84.2 g/min. The flow in the first pump 13 is therefore increased by 4.2 g/min.
[0131] The flow in the second pump 14 is reduced so as to maintain a modifier level of 20% in the eluent, and a total flow of 100 g/min. The corrected flow in the second pump 14 is 100-84.2 or 15.8 g/min, which represents a reduction in the initial flow of 84.2×0.05 g/min which is about 4.2 g/min.
[0132] According to a third particular configuration of the invention, as represented in FIG. 4 , the measuring and correcting device 18 measures the density of the eluent upstream of the first pump 13 and downstream of the second pump 14 . In other words, this third configuration differs from the previous two in that the second pump 14 is installed upstream of the device 18 .
[0133] In this third configuration, the correction consists of modifying the flow in the first pump and the flow in the second pump in a direction that is suitable for meeting the first setpoint and a third setpoint, set beforehand, for the density of the eluent.
[0134] This third setpoint can be determined by the user by calculation, given that the density of the supercritical-modifier fluid mixture is equal to the sum of the respective densities of the supercritical fluid and modifier, weighted by their respective percentages, but a more precise measurement is preferred, by measuring in the installation in operation without recycling.
[0135] For regulating the flows of the two pumps 13 , 14 , each of these pumps is connected to a flowmeter.
[0136] For example, an eluent is composed of CO 2 , as the supercritical fluid, and ethanol as the modifier. For a pressure of 50 bars and a temperature of 0° C., the density of the CO 2 is 950 kg/m 3 , and that of the ethanol is 789 kg/m 3 . For precision in the measurement of the density of ±0.1 kg/m 3 , it is possible to adjust the composition of the CO 2 -ethanol eluent with a precision of ±0.05%.
[0137] The precision increases as the respective densities of the supercritical fluid and modifier differ from reach other. For example, in the case where the supercritical fluid is CO 2 , the alcohols are very suitable as modifiers, in that they are of low density, and the chlorated solvents are also suitable in that they are high density.
[0138] Naturally however, the chromatography column 12 can be replaced by several chromatography columns or, in the case of one method of extraction, by an extractor in which we find the product P.
[0139] This column 12 can be one that contains a stationary phase like that used in chromatography in the gaseous phase, or a column containing a stationary phase like that used in chromatography in the liquid phase, such as high-performance liquid chromatography (HPLC), or indeed any other column compatible with the separation to be effected.
[0140] Likewise, the extractor used in the invention can have a liquid or solid stationary phase. | A chromatography or supercritical extraction method is disclosed, in which the eluent comprises a mixture of a fluid and a modifier and in which the fluid is recycled. One exemplary method comprises an operation consisting in determining at least one quantity linked to the level of modifier that is mixed with the recycled fluid and, if necessary, a correction operation in order to limit variations in the level of modifier in the eluent at the inlet of the column or the extractor. The disclosure also relates to a chromatography or extraction installation. | 1 |
REFERENCES CITED [REFERENCED BY]
“Not Applicable”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
“Not Applicable”
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
“Not Applicable”
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
“Not Applicable”
REFERENCE TO A “MICROFICHE APPENDIX”
“Not Applicable”
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of mailboxes, in the category of receptacles in general mailboxes, however more particular in the security mail box arena. Mailboxes generally are of two types, the urban mailbox and the rural mailbox; both types are contained within this patent application
2. Description of Related Art
The proximity of the rural mailboxes to the edge of the road allows the mail carrier to deposit mail in the rural mailbox without getting out of their vehicle since the door to such typical rural mailbox face the roadside.
Unfortunately, the fact that the single door to the typical rural mailbox faces the road means that the homeowner has to step out into the street to send or retrieve mail. This could create hazardous conditions for the homeowner, which could involve roadside/curbside accidents.
The design of the Safe “T” box, Multi Safe “T” Box, and Residential Safe “T” Box is designed to secure homeowners' mail, which also has safety in mind, and make uniformity in single family neighborhoods. The basic design allow for modifications to the Safe “T” Box allows for expanding the unit, for homeowners with multiply occupants in one home to have private mail units. The Safe “T” Box mailbox has a secure door positioned in the middle of the mailbox for easier excess then some of the standard bottom open security mailboxes used today, for those with disabilities, making the Safe “T” Mailbox easy for all homeowners' to access.
The Safe “T” Box with modifications allows city residents to have mail and small packages deposited safely and secured in the mailbox then what is currently used on the market today.
The aspects of each design are shown within the accompanying drawings.
BRIEF SUMMARY OF THE INVENTION
By virtue of this Design, the homeowner doesn't ever have to go around to the front of the mailbox, or step into the street anymore to send or retrieve mail again. The unit has a security lock panel in the rear that mail is secure for pick-up at the end of the day.
The unit is fully functional, easy to install, and durable, which makes the Safe “T” Box, Residential Box, and Multi-Safe “T” Box more effective than the current mailboxes being used today. Most current mailboxes don't have a way to secure the mail and this allows vandals to steal homeowners' personal information, using that information in Identity theft crimes.
The stand along unit is made from some sort of fabricated material, designed to be secure and safe for homeowner. The unit is completely enclosed, made from some sort of fabricated material, held together with some type of heavy duty clear glue and screws. The unit can be enclosed if the consumer wishes with bricks or remain as designed, a stand-alone unit, able to withstand the weather, keeping the U.S. Mail, newspapers/advertisements, not delivered by U.S. Postal Service secured from thieves.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 depicts, front views of Safe “T” Box showing top of mailbox item ( 1 ), which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, smooth exterior mailbox panel item ( 3 ), newspaper/advertisement door item ( 4 ), incoming and outgoing mail door are attached as one piece with a cosmetic seam line item ( 5 ), address placeholder item ( 6 ) for numbered address, flag holder item ( 7 ), homeowners nameplate item ( 8 ), one design element item ( 9 ) could be used on front of Safe “T” Box by homeowner, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, vertical handle item ( 11 ) for newspaper/advertisement door, horizontal handle item ( 12 ) for pull down door, front elongated chamber item ( 13 ) that houses chambers for outgoing, incoming and newspaper/advertisement panels.
FIG. 2 depicts, Safe “T” Box on an angle, showing top of mailbox item ( 1 ), which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, smooth exterior mailbox panel item ( 3 ), newspaper/advertisement door item ( 4 ), incoming and outgoing mail door are attached as one piece with a cosmetic seam line item ( 5 ), address placeholder item ( 6 ) shown with front and side address place holders for numbered address, flag holder item ( 7 ), homeowners nameplate item ( 8 ), one design element item ( 9 ) could be used on front of Safe “T” Box by homeowner, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, vertical handle item ( 11 ) for newspaper/advertisement door, horizontal handle item ( 12 ) for pull down door, front elongated chamber item ( 13 ) that houses chambers for outgoing, incoming and newspaper/advertisement.
FIG. 3 depicts, how Safe “T” Box mailbox is used to create Multi Safe “T” Box mailbox, interlocking hinge attachment item ( 41 ) shows closed interlocking hinge that mount to the side of the Safe “T” Box mailbox allowing for expansion of unit for each family to have a secure and private mail unit in front of multi-dwellings occupied homes, newspaper/advertisement door item ( 4 ), incoming and outgoing mail door are attached as one piece with a cosmetic seam line item ( 5 ), address placeholder item ( 6 ) for numbered address, flag holder item ( 7 ), homeowners nameplate item ( 8 ), one design element item ( 9 ) could be used on front of Safe “T” Box by homeowner, reflectors item ( 10 ) to reflect side of mailbox at night, vertical handle item ( 11 ) for newspaper/advertisement door, horizontal handle item ( 12 ) for pull down door, front elongated chamber item ( 13 ) that houses chambers for outgoing, incoming and newspaper/advertisement.
FIG. 4 depicts, back view of the Safe “T” Box, showing top of mailbox item ( 1 ) which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, smooth exterior mailbox panel item ( 3 ), address placeholder item ( 6 ) for numbered address, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, vertical handle item ( 11 ) attaches to door in opening and closing, upper elongated housing chamber item ( 14 ) housing rear outgoing mail swing door item ( 15 ), rear non-functioning panel item ( 16 ), rear newspaper/advertisement swing door item ( 17 ), rear elongated housing chamber item ( 19 ) housing chambers for security door panel, security key entry lock item ( 18 ) key entry lock for securing door when not in use, awning cover item ( 19 a ) to protect lock mechanism from elements, divided grooved sleeve glider item ( 19 b ) used inside of mailbox for sliding door as a stabilizer track gilding rim, sliding door item ( 20 ) slides open and close when mail is retrieved, non-movable door item ( 21 ) door has no function.
FIG. 5 depicts, elongated housing chamber item ( 19 ) housing chambers for security key entry lock item ( 18 ) lock for securing door when not in use, awning cover item ( 19 a ) to protect lock mechanism from elements, divided grooved sleeve glider item ( 19 b ) used inside of mailbox as a stabilizer track gilding rim for sliding door sliding door item ( 20 ) slides open and close when mail is retrieved, vertical handle item ( 11 ) attaches to door for opening and closing, non-movable door item ( 21 ) door has no function, stabilizer bars item ( 30 ) positioned on the inside the non-movable door for added strength, the stabilizer bars are attached to inside wall of the Safe “T” Box with some sort of screws or some sort of heavy duty glue, stabilizer bars are shown extracted from non-moveable door to better show side view of stabilizer bars, stabilizer track gliding rim item ( 19 b ) is shown extracted from non-moveable door to better show view of track gliding rim.
FIG. 6 depicts, top of mailbox item ( 1 ) which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, interlocking panel are shaped from 1 inch down to ½ inch which create interlocking connections for interlocking panels items ( 2 a ) base of unit that sits upon ground, interlocking panel are shaped from 1 inch down to ½ inch which create interlock connections, smooth exterior mailbox panel item ( 3 ), address placeholder item ( 6 ) for numbered address, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, reflectors item ( 10 ) to reflect side of mailbox at night, interlocking panels item ( 23 ) interlocking panel are shaped from 1 inch down to ½ inch which create interlock connections, screw with interlocking screw chamber item ( 33 ) to secure interlocking panels.
FIG. 7 depicts, top of mailbox item ( 1 ) which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, interlocking panels are shaped from 1 inch down to ½ inch which create interlocking connections for interlocking panels items ( 2 a ) base of unit that sits upon ground, interlocking panel are shaped from 1 inch down to ½ inch which create interlocking connections, address placeholder item ( 6 ) for numbered address shown with top mount, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, division of interlocking panels item ( 2 ) top panel, ( 2 a ) base of front and back smooth exterior mailbox panels item ( 3 ) and item ( 23 ) side panels, shown where some sort of heavy duty clear glue will be placed to secure mailbox, screw with interlocking screw chamber item ( 33 ) to secure interlocking panels.
FIG. 8 depicts, internal view of Safe “T” Box, showing top of mailbox item ( 1 ) which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, interlocking panels items ( 2 a ) base of unit that sits upon ground, interlocking panel are shaped from 1 inch down to ½ inch which create interlocking connections, address placeholder item ( 6 ) for address numbers, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, vertical handle item ( 11 ) attaches to door to open and close, plastic covers seals item ( 22 a ) plastic seal that go over internal poles, interlocking panels item ( 23 ) interlocking panel is shaped from 1 inch down to ½ inch which create interlocking connections, mailbox chute item ( 24 ) which mail travels into awaiting mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guide mail into basket, internal poles item ( 26 ) that hold basket, hooks item ( 27 ) attach to internal poles, spring coils item ( 28 ) attach to hooks on internal poles, “O” rings item ( 29 ) attach to end basket and spring coils, basket item ( 31 ) holds mail secure for pick-up by homeowner, screw with interlocking screw chamber item ( 33 ) to secure interlocking panels, outgoing mail holding chamber item ( 42 ) chamber for outgoing mail, incoming mail chamber item ( 43 ) chamber for incoming mail that has mailbox chute attached, newspaper/advertisement chamber item ( 44 ) chamber for newspaper/advertisement once deposited rests upon for pick-up.
FIG. 9 depicts, internal side view of Safe “T” Box, showing top of mailbox item ( 1 ) which interlocks with panel items ( 2 ) as one piece with cosmetic seam line, interlocking panels items ( 2 a ) base of unit that sits upon ground, interlocking panel are shaped from 1 inch down to ½ inch which create interlocking connections, horizontal handle item ( 12 ) attaches to door to pull down and close, incoming mail and outgoing mail door are attached as one piece with a cosmetic seam line item ( 5 ), address placeholder item ( 6 ) for address numbers, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, mailbox reflectors item ( 10 ) to reflect side of mailbox at night, plastic covers seals item ( 22 a ) plastic seal that goes over internal poles, interlocking panels ( 23 ) interlocking panel are shaped from 1 inch down to ½ inch which create interlocking connection, mailbox chute item ( 24 ) which mail travels into awaiting mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guide mail into basket, internal poles item ( 26 ) that hold basket and extend 12 inches into the ground, hooks item ( 27 ) attach to internal poles, spring coils item ( 28 ) attach to hooks on internal poles, “O” rings item ( 29 ) attach to end basket and spring coils, basket item ( 31 ) holds mail secure for pick-up by homeowner, bumper board item ( 32 ) mail hits back of bumper board and falls into awaiting basket, screw with interlocking screw chamber item ( 33 ) to secure interlocking panels, 45-degree angled stationary arm housing item ( 34 ), for 45-degree angled retractable movable arm item ( 35 ) to retracts into when door is closed.
FIG. 10 depicts, front elongated housing chamber item ( 13 ) of Safe “T” Box with newspaper/advertisement door item ( 4 ) with vertical handle item ( 11 ) for swing door to open and close, incoming mail and outgoing mail door are attached as one piece with a cosmetic seam line item ( 5 ), with horizontal handle item ( 12 ) to pull door open and close.
FIG. 11 depicts, front elongated housing chamber item ( 13 ) of Safe “T” Box with newspaper/advertisement door item ( 4 ) with vertical handle item ( 11 ) to swing door open and close, incoming and outgoing mail door attached as one piece with a cosmetic seam line item ( 5 ) shown with door open, mailbox chute item ( 24 ) which mail travels into mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guides mail into basket item ( 34 ), 45-degree angled stationary arm stationary arm, 45-degree angled retractable movable arm item ( 35 ) that retracts when door is closed, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, magnets item ( 38 ), ( 39 ) keeps door closed when not in use, outgoing mail holding chamber item ( 42 ) chamber for outgoing mail to rest in for pick-up.
FIG. 12 depicts, front elongated housing chamber item ( 13 ) of Safe “T” Box with newspaper/advertisement door item ( 4 ) shown with door open, incoming mail and outgoing mail door attached as one piece with a cosmetic seam line item ( 5 ) with door open, mailbox chute item ( 24 ) which mail travels into mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guides mail into basket, 45-degree angled stationary arm housing item ( 34 ), 45-degree angled retractable movable arm item ( 35 ) that retracts when door is closed, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, stabilizer swing door pole item ( 37 ) enable door to swing open and close, magnets item ( 38 ), ( 39 ) keeps door closed when not in use, outgoing mail holding chamber item ( 42 ) chamber for outgoing mail to rest in for pick-up, newspaper/advertisement chamber item ( 44 ) chamber for newspaper/advertisement and other items to rest in for pick-up.
FIG. 13 depicts, rear elongated housing chamber item ( 14 ) of Safe “T” Box from back view, showing outgoing mail door item ( 15 ) that has a swing door shown open, rear non-functioning panel item ( 16 ) non-functioning panel is the back of the bumper board item ( 32 ), newspaper/advertisement door item ( 17 ) with swing door open, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, stabilizer swing door pole item ( 37 ) enables door to swing open and close, magnets item ( 38 ), ( 39 ) keeps door closed when not in use, outgoing mail holding chamber item ( 42 ) chamber for outgoing mail to rest in for pick-up, newspaper/advertisement chamber item ( 44 ) chamber for newspaper/advertisement and other items to rest in for pick-up.
FIG. 14 depicts, some internal parts of the Safe “T” Box used to create the residential Safe “T” Box, incoming mail and outgoing mail door attached as one piece with a cosmetic seam line item ( 5 ) door open, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, horizontal handle item ( 12 ) attaches to pull down door, mailbox chute item ( 24 ) which mail travels into awaiting mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guide mail into basket, cross stitched weaved basket item ( 31 ) for incoming mail once deposited by the United Stated Postal Worker for pick-up, 45-degree angled stationary arm housing item ( 34 ), 45-degree angled retractable movable arm item ( 35 ) that retracts when door is closed, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, holding basket item ( 40 ) that supports the weight of basket, incoming mail holding chamber item ( 43 ) chamber for incoming mail to rest in for pick-up.
FIG. 15 depicts, some internal parts of the Safe “T” Box used to create the residential Safe “T” Box, incoming mail and outgoing mail door attached as one piece with a cosmetic seam line item ( 5 ) door open, flag holder item ( 7 ) signals postal worker outgoing mail awaiting pick-up, horizontal handle item ( 12 ) attaches to pull down door, mailbox chute item ( 24 ) which mail travels into awaiting mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guide mail into basket, 45-degree angled stationary arm housing item ( 34 ), 45-degree angled retractable movable arm item ( 35 ) that retracts when door is closed, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, holding basket item ( 40 ) that supports the weight of basket, incoming mail holding chamber item ( 43 ) chamber for incoming mail to rest in for pick-up.
FIG. 16 depicts, internal base unit item ( 22 ) that attaches to the inside base of the mailbox, shown with 4 plastic covers seals item ( 22 a ) that slip over internal PVC poles item ( 26 ) that insert through the mailbox and into the ground.
FIG. 17 depicts, front elongated housing chamber item ( 13 ) of Safe “T” Box mailbox without cover showing newspaper/advertisement door item ( 4 ) door open, incoming mail and outgoing mail door attached as one piece with a cosmetic seam line item ( 5 ) with door open, non-functioning panel item ( 16 ) that has no function and is the back of the incoming mail chamber, mailbox chute item ( 24 ) which mail travels into mailbox for pick-up, mailbox chute guardrail item ( 25 ) which guides mail into basket, bumper board item ( 32 ) mail hits bumper board and falls into basket, 45-degree angled stationary arm housing item ( 34 ), 45-degree angled retractable movable arm item ( 35 ) that retracts when door is closed, thin rubber trim item ( 36 ) attached around the edge of each door to protect mail from getting wet, stabilizer swing door pole item ( 37 ) enables door to swing open and close, magnets item ( 38 ), ( 39 ) keeps door closed when not in use, outgoing mail holding chamber item ( 42 ) chamber for outgoing mail to rest in for pick-up, incoming mail chamber item ( 43 ) to secure mail for pick-up, newspaper/advertisement chamber item ( 44 ) chamber for newspaper/advertisement and other items to rest in for pick-up.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 depicts a mailbox that could be constructed from CPVC or some sort of fabricated material can be safer for the consumer and functional for securing homeowners mail. The unit will be about 60 inches in height, about 26 inches wide and 26 inches in length.
Top of mailbox 1 26 inches wide by 26 inches in length, 1 interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections to give the illusion that 1 and 2 are separate sections, for a combined length of 8 inches in height, 1 is ½ inch thick, 2 inches in height, has about a 15-degree raised top with about a 15-degree angled curved sides for rain or snow to runoff mailbox, 2 is 6 inches in height, 1-inch thick, corner portion of 2 is trimmed down from 1 inch to ½ inch thick, which interlocks with interlocking panel 23 ( FIG. 6 ), which is trimmed down ½ inch to interlock with interlocking panel 2 a ( FIG. 6 ), seams are glued with some sort of heavy duty clear glue and screwed 33 ( FIG. 6 ), with some sort of threaded post with screws, about 1 inch long, to secure interlocking panels together. Exterior mailbox panel 3 comprises of 4 interlocking panels 2 top panel which interlocks with 2 a ( FIG. 6 ), shows interlocking base panel for front and back panel from interior view, 3 smooth exterior front and rear panel ( FIG. 4 ), 23 ( FIG. 6 ), side panel, Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material.
Mounted in the front upper chamber of the mailbox is the elongated housing chamber 13 housing is 25 inches long by 25 inches wide, 13 inches high, with ½ inch cosmetic seam line on top and bottom of elongated housing chamber, constructed from some sort of fabricated material as one piece, consisting of a pull down retractable door 5 18-inch wide and 13 inches in height, thickness of the pull down door 5 is ½ inch thick, for incoming and outgoing mail ( FIG. 11 ), with horizontal handle 12 handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close.
Also, mounted in the front upper chamber of the mailbox is the elongated housing chamber 13 is the newspaper/advertisement door 4 is a swing door, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S. Postal Service and closes when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close.
Address placeholder 6 housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material.
Conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment.
Homeowners nameplate 8 nameplate is 20 inches long by 2 inches high, nameplate has about a ¼-inch border, made from some sort of fabricated material, holding up to about 18 1-inch letters for the homeowners' name, sticky backed letters currently used on market today, base of nameplate has two holes which allow up to two additional families' name to be added to front of the Safe “T” Box mailbox, additional name plate are attached with “S” hooks to expand nameplate when necessary.
Design element 9 size of design element is about 11×17, allowing homeowner to personalize front panel of mailbox, designs range from sports, gardening, automobiles, the arts, etc., designs are made on computer, from peel away adhesive backed plastic artist print paper that is whether resistant, pressed and rubbed into position in front of mailbox.
Mail reflectors 10 reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night.
FIG. 2 depicts Safe “T” Box on angle, showing 1 interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections in front of mailbox to give the illusion that 1 and 2 are separate sections, exterior mailbox panel 3 smooth exterior panels, made from some sort of plastic or fabricated material, comprised of 4 separate interlocking panels, 50 inches in height, 26 inches wide that interlock together to make sealed enclosure, 2 top panel which interlocks with 2 a ( FIG. 6 ), 2 a shows interlocking base panel for front and back panel from interior view, 3 smooth exterior view of front and 3 rear panel ( FIG. 4 ), 23 side panel ( FIG. 6 ), showing trimmed down interior interlocking panel with exterior smooth side of exterior panel.
Newspaper/advertisement door 4 swinging door, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to retrieve newspaper/advertisement or other items not delivered via U.S. Postal Service and close when not in use, outgoing mail door and incoming mail door 5 pull down retractable door 5 18-inch wide and 13 inches in height, thickness of the pull down door 5 is ½ inch thick.
Address placeholder 6 housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, shown from front and side view of mailbox, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material, conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment, homeowners nameplate 8 nameplate is 20 inches long by 2 inches high, nameplate has about a ¼-inch border, holding up to about 18 1-inch letters for the homeowners' name, sticky backed letters currently used on market today, base of nameplate has two holes which allow up to two additional families' name to be added to front of the Safe “T” Box mailbox, additional name plate are attached with “S” hooks to expand nameplate when necessary, design element 9 size of design element is about 11×17, allowing homeowner to personalize front panel of mailbox, designs range from sports, gardening, automobiles, the arts, etc., designs are made on computer, from peel away adhesive backed plastic artist print paper that is whether resistant, pressed and rubbed into position in front of mailbox, mailbox reflectors 10 reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close, horizontal handle 12 handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close.
Front elongated housing chamber 13 housing is 25 inches long by 25 inches wide, 13 inches high, with ½ inch cosmetic seam line on top and bottom of elongated housing chamber, constructed from some sort of fabricated material as one piece to house outgoing, incoming mail compartments and newspaper/advertisement compartment.
FIG. 3 depicts original mailbox showing top for mailbox 1 26 inches wide by 26 inches in length, 1 interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections to give the illusion that 1 and 2 are separate sections, for a combined length of 8 inches in height, 1 is ½ inch thick, 2 inches in height, has about a 15-degree raised top with about a 15-degree angled curved sides for rain or snow to runoff mailbox, 2 is 6 inches in height, 1-inch thick, corner portion of 2 is trimmed down from 1 inch to ½ inch thick, which interlocks with interlocking panel 23 ( FIG. 6 ), which is trimmed down ½ inch to interlock with interlocking panel 2 a ( FIG. 6 ), seams are glued with some sort of heavy duty clear glue and screwed 33 ( FIG. 6 ), with some sort of threaded post with screws, about 1 inch long, to secure interlocking panels together. Exterior mailbox panel 3 comprises of 4 interlocking panels 2 top panel which interlocks with 2 a ( FIG. 6 ), shows interlocking base panel for front and back panel from interior view, 3 smooth exterior front and rear panel ( FIG. 4 ), 23 ( FIG. 6 ), side panel, Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material.
Mounted in the front upper chamber of the mailbox is the elongated housing chamber 13 housing is 25 inches long by 25 inches wide, 13 inches high, with ½ inch cosmetic seam line on top and bottom of elongated housing chamber, constructed from some sort of fabricated material as one piece, consisting of a pull down retractable door 5 18-inch wide and 13 inches in height, thickness of the pull down door 5 is ½ inch thick, for incoming and outgoing mail ( FIG. 11 ), with horizontal handle 12 handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close.
Newspaper/advertisement door 4 swing door, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S.
Postal Service and closes when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close.
Address placeholder 6 housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material.
Conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment.
Homeowners nameplate 8 nameplate is 20 inches long by 2 inches high, nameplate has about a ¼-inch border, made from some sort of fabricated material, holding up to about 18 1-inch letters for the homeowners' name, sticky backed letters currently used on market today, base of nameplate has two holes which allow up to two additional families' name to be added to front of the Safe “T” Box mailbox, additional name plate are attached with “S” hooks to expand nameplate when necessary.
Design element 9 size of design element is about 11×17, allowing homeowner to personalize front panel of mailbox, designs range from sports, gardening, automobiles, the arts, etc., designs are made on computer, from peel away adhesive backed plastic artist print paper that is whether resistant, pressed and rubbed into position in front of mailbox.
Mail reflectors 10 reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night.
Interlocking hinge attachment 41 to create multi-Safe “T” Box mailboxes, interlocking hinge attachment 41 mounts to sides of the mailbox, made from some sort of fabricated material, interlocking hinges are 1 inches wide by 1 inches high, ½ inch thick, one near the top, one near the bottom, each interlocking hinge is glued with some sort of heavy duty clear glue, attached with some sort of screw, allowing for attachment of more then one mailbox at a time.
FIG. 4 depicts back view of Safe “T” Box, showing 1 interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections to give the illusion that 1 and 2 are separate sections, Exterior mailbox panel 3 comprises of 4 interlocking panels 2 top panel which interlocks with 2 a ( FIG. 6 ), shows interlocking base panel for front and back panel from interior view, 3 smooth exterior front and rear panel ( FIG. 4 ), 23 ( FIG. 6 ), side panel, Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material.
Address placeholder 6 back view of housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, shown from front and side view if mailbox, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material, conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment.
Rear upper elongated chamber 14 that attaches to front elongated housing chamber 13 in the rear of the mailbox, which front elongated housing chamber 13 is 25 inches long by 25 inches wide, 13 inches high which extends through upper chamber of mailbox to rear upper elongated chamber 14 and attaches to one another to make one continuous chamber, with ½ inch cosmetic seam line on top and bottom of rear upper elongated housing chamber, constructed from some sort of fabricated material as one piece.
Rear outgoing mail door 15 swinging door, 8 inches wide, 13 inches in height, ½ inch thick, that swings opens to retrieve newspaper/advertisement or other items not delivered via U.S. Postal Service and close when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, handle is attached to inside door 15 with screws for the swinging door to pull open and close, stabilizer swing door pole 37 ( FIG. 17 ), about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 42 ( FIG. 17 ), for door to swing open and close, rear non-functioning panel 16 that is 9 inches wide by 13 inches high, ½ thick, non-functioning door panel is part of incoming mail chamber 43 ( FIG. 17 ).
Rear newspaper/advertisement door 17 swinging door, 8 inches wide, 13 inches in height, ½ inch thick, that swings opens to retrieve newspaper/advertisement or other items not delivered via U.S. Postal Service and close when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, handle is attached to inside door 17 with screws for the swinging door to pull open and close, stabilizer swing door pole 37 ( FIG. 17 ), about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 44 ( FIG. 17 ), for door to swing open and close.
Rear elongated housing chamber 19 housing is 20 inches long by 24 inches wide, 19 inches high, with ½ inch cosmetic seam line on top and bottom of elongated housing chamber.
Security lock 18 standard market key entry security lock that is currently used on homeowners' front door will be used for Safe “T” Box mailboxes.
Awning cover 19 a ½ inch angle awning, ½ inch wide, 24 inches long, to protect lock mechanism from rusting due to rain and snow runoff.
Stabilizer track gilding rim seam 19 b depicts divided grooved sleeve, 24 inches long, attaches top and bottom of rear elongated housing chamber 19 made from some sort of fabricated material, attached to interior with some sort of heavy duty glue and screws, stabilizer track gilding rim has a thin ¼ inch high groove divided seam line between the 1 inch wide internal seam to ensure even gliding of door 20 sliding door 20 is 10 inches wide by 18 inches high, ½ inches thick, made from some sort of fabricated material, sliding door fits into stabilizer track gilding rim seam 19 b to ensure even gliding of door 20 vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside sliding door 20 with screws for the door to slide open or close, non-movable door 21 which is 10 inches wide by 18 inches high, ½ inches thick, non-functioning door fits into top stabilizer track gilding rim seam 19 b for housing stability of non-movable door.
FIG. 5 depicts Rear elongated housing chamber 19 housing is 20 inches long by 24 inches wide, 19 inches high, with ½ inch cosmetic seam line on top and bottom of elongated housing chamber.
Security lock 18 standard market key entry security lock that is currently used on homeowners' front door will be used for Safe “T” Box mailboxes, awning cover 19 a is a ½ inch angle awning, ½ inch wide, 24 inches long, to protect lock mechanism from rusting due to rain and snow runoff, stabilizer track gilding rim seam 19 b depicts divided grooved sleeve, 24 inches long, attaches top and bottom of rear elongated housing chamber 19 made from some sort of fabricated material, attached to interior with some sort of heavy duty glue and screws, stabilizer track gilding rim has a thin ¼ inch high groove divided seam line between the 1 inch wide internal seam to ensure even gliding of door 20 sliding door 20 that is 10 inches wide by 18 inches high, ½ inches thick, made from some sort of fabricated material, sliding door fits into stabilizer track gilding rim seam 19 b to ensure even gliding of door 20 vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside sliding door 20 with screws for the door to slide open or close.
Internal view of non-movable door 21 with stabilizer bars 30 non-movable bars, 22 inches high, ½ inches wide, ½ inches thick, attached to inside of mailbox for added reinforcement of non-moveable door 21 made from some sort of plastic, metal or fabricated material, attached with some sort of screws, stabilizer bars 30 are extracted from rear middle elongated housing chamber 19 to show detailed side view of stabilizer bars 30 stabilizer track gilding rim 19 b is extracted to show detailed view of stabilizer track gilding rim 19 b which has a thin ¼ inch high grooved divided seam line to ensure even gliding of door 21 when door is open and closed to retrieval the mail.
FIG. 6 depicts top of mailbox 1 26 inches wide by 26 inches long, interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections for a combined length of 8 inches, 1 is ½ inch thick, 2 inches in height, has about a 15-degree raised top with about a 15-degree angled curved sides for rain or snow to runoff mailbox, 2 is 6 inches in height, 1-inch thick, corner portion of 2 is trimmed down from 1 inch to ½ inch thick, which interlocks with interlocking panel 23 which is trimmed down ½ inch to interlock with interlocking panel 2 a seams are glued with some sort of heavy duty clear glue, and screwed 33 will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels 2 ( FIG. 6 ), 2 a ( FIG. 6 ), 3 ( FIG. 1 ), 23 ( FIG. 6 ), together, screwed with interlocking screw chamber 33 screws will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels which creates mailbox enclosure.
Address placeholder 6 back view of housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, shown from front and side view if mailbox, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material, conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment, mail reflectors 10 reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night.
FIG. 7 depicts separation view of Safe “T” Box, showing 1 interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections in front of mailbox to giving the illusion that 1 and 2 are separate sections, address placeholder 6 back view of housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, shown from front and side view if mailbox, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material, conventional flag holder 7 mounted on the side of the mailbox, standard market item used today with screw attachment.
Separation of interlocking panels consisting of four interlocking panels that create enclosed mailbox, 2 top panel 3 smooth front exterior panel ( FIG. 1 ), that attaches to interior of 2 a ( FIG. 6 ), rear exterior panel 3 ( FIG. 4 ), that attaches to interior of 2 a base panel, 23 side panel ( FIG. 6 ), Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material, interior interlocking panels, seams are glued with some sort of heavy duty clear glue in seam where interlocking panels are trimmed down from 1 inch to ½ inch thick, screwed with interlocking screw chamber 33 screws will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels.
FIG. 8 depicts mailbox 1 26 inches wide by 26 inches long, interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections for a combined length of 8 inches, 1 is ½ inch thick, 2 inches in height, has about a 15-degree raised top with about a 15-degree angled curved sides for rain or snow to runoff mailbox, 2 is 6 inches in height, 1-inch thick, corner portion of 2 is trimmed down from 1 inch to ½ inch thick, which interlocks with interlocking panel 23 which is trimmed down ½ inch to interlock with interlocking panel 2 a seams are glued with some sort of heavy duty clear glue.
Address placeholder 6 back view of housing for address is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material.
Flag holder 7 standard market item used today with screw attachment, mailbox reflectors 10 circle reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night, plastic covers seals 22 a four ½ inch circular plastic cover seals that slip over internal PVC poles 26 glued in place with some sort of heavy duty clear glue.
Incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate chute 24 angled mailbox chute 24 opening has 1-inch in length flat surface, ½ inch thick, opening space for mail deposited through chute is about 9 inches long, 12 inches high where slide is installed ( FIG. 17 ), mail chute is on about a 32-degree angle, angled 12 inches long for mail to slide down slide into mailbox, attached to mailbox chute 24 are sidewalls guard 25 about 6 inches long, ¼ inch thick, controlling mail flow into basket 31 the other section of the incoming mail chamber is for the bumper board 32 ( FIG. 9 ), bumper board 32 attaches to incoming mail chamber base is about 14½ inches inside the incoming mail chamber, bumper board is 10 inches wide, ½ inch thick, glued to the rear section of the base and inside sidewall of interior of incoming mail chamber ( FIG. 17 ).
Internal poles 26 PVC poles total lengths are 42 inches, ½ inch hollow internal PVC poles, PVC pole height is 30 inches inside internal of mailbox, and internal PVC poles extend 12 inches out of mailbox into the ground.
Hooks 27 hooks are ½ inch in length and height, with about ¼ inch half “U” shaped end attach to 26 and spring coils 28 about 12 inches long with curved hooked on each end, made from plastic, metal or some sort of fabricated material, that attach to 27 and 29 to support basket 31 “O” rings 29 are ½ inch circular rings attached to corners of basket 31 made from some sort of plastic, metal or fabricated material to support the weight of basket, “O” rings could be used or left off of basket where spring coils 28 could directly be attached to each corner of basket giving equal support of basket, the basket 31 is 18 inches wide, 18 inches deep, made from some form of plastic, metal or fabricated material, finished basket could be made into a solid, diagonal or cross-stitched weaved pattern.
33 will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels 2 top panel 3 with smooth front exterior panel ( FIG. 1 ), that attaches to interior of 2 a ( FIG. 6 ), rear exterior panel 3 ( FIG. 4 ), that attaches to interior of 2 a base panel, 23 side panel ( FIG. 6 ), Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material, interior interlocking panels, that create enclosure of mailbox.
Outgoing mail holding chamber 42 outgoing mail holding chamber is 7 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for outgoing mail to rest upon for pick-up, incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate mailbox chute 24 and bumper board 32 ( FIG. 9 ), newspaper/advertisement chamber 44 newspaper/advertisement chamber that is 7 inches wide, 12 inches height, 25 inches in length, ½ inch thick, chamber for newspaper/advertisement or other items not being delivered by U.S. Postal Service is received for pick-up.
FIG. 9 depicts mailbox 1 is 26 inches wide by 26 inches long, interlocks with panel 2 as one piece with ¼ inch cosmetic seam line between the two sections for a combined length of 8 inches, 1 is ½ inch thick, 2 inches in height, has about a 15-degree raised top with about a 15-degree angled curved sides for rain or snow to runoff mailbox, 2 is 6 inches in height, 1-inch thick, corner portion of 2 is trimmed down from 1 inch to ½ inch thick, which interlocks with interlocking panel 23 which is trimmed down ½ inch to interlock with interlocking panel 2 a seams are glued with some sort of heavy duty clear glue.
Outgoing, incoming mail door 5 that is 18-inch wide and 13 inches in height, thickness of the pull down door 5 is ½ inch thick, for incoming and outgoing mail, with horizontal handle 12 ( FIG. 1 ), handle is 9 inches long, made from some sort of plastic, metal or fabricated material, handle is attached to inside door 5 with screws for pull down door to open or close.
Address placeholder 6 back view of housing for address placeholder is 6 inches long, 1½ inches high, ¼ inch thick, consisting of 5 numeral place holders for address, numbers for address are 1 inch high, sticky backed numbers currently used on market today, address placeholder will have some sort of circular base attachments that will fit into pre-drilled circular holes for address placeholder to mount on top ( FIG. 7 ), address placeholder is made from plastic, metal or some sort of fabricated material, flag holder 7 standard market item used today with screw attachment, mailbox reflectors 10 reflectors about 4 inches in height, either circle or square with sticky backing, reflectors come in different colors and attached to side of mailbox, homeowner can see side of mailbox at night when they approach driveway at night, plastic covers seals 22 a four ½ inch circular plastic cover seals that slip over internal PVC poles 26 glued in place with some sort of heavy duty clear glue.
Interlocking panels 23 1 inch thick interlocking panel, 50 inches tall, 26 inches wide, ends are trimmed from 1 inch to ½ inch thick, which creates interlocking chamber that connects to interlocking panels, 2 top panel 3 smooth front exterior panel ( FIG. 1 ), that attaches to interior of 2 a ( FIG. 6 ), rear exterior panel 3 ( FIG. 4 ), that attaches to interior of 2 a base panel, 23 side panel ( FIG. 6 ), Exterior panels are 50 inches in height, 26 inches wide, smooth on exterior side of mailbox, trimmed on interior side to create interlocking components, made from some sort of fabricated material, interior interlocking panels, seams are glued with some sort of heavy duty clear glue in seam where interlocking panels are trimmed down from 1 inch to ½ inch thick, screwed with interlocking screw chamber 33 screws will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels.
Incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate mail chute 24 mailbox chute 24 10 inches wide, 12 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip, ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, open space area for mail being deposited through chute is about 9 inches long, 12 inches high where slide is installed ( FIG. 17 ), mail chute is on about a 32-degree angle, is angled 12 inches long for mail to slide down slide into mailbox, sidewalls guard 25 about 6 inches long, ¼ inch thick, controlling mail flow into awaiting basket 31 the basket 31 is 18 inches wide, 18 inches deep, made from some form of plastic, metal or fabricated material, finished basket could be made into a solid, diagonal or cross-stitched basket weave pattern.
Internal poles 26 PVC poles total lengths are 42 inches, ½ inch hollow internal poles, PVC pole height is 30 inches inside internal of mailbox, and internal PVC poles extend 12 inches out of mailbox into the ground.
Hooks 27 are ½ inch in length and height, with about ¼ inch half “U” shaped end attach to 26 and spring coils 28 about 12 inches long with curved hooked on each end, made from plastic, metal or some sort of fabricated material, that attach to 27 and 29 to support basket 31 “O” rings 29 are ½ inch circular rings attached to corners of basket 31 made from some sort of plastic, metal or fabricated material to support the weight of basket, “O” rings could be used or left off of basket where spring coils could be directly attached to each corner of basket equal support of basket, the basket 31 18 inches wide, 18 inches deep, made from some form of plastic, metal or fabricated material, finished basket could be made into a solid, diagonal or cross-stitched weaved pattern.
Bumper board 32 attaches to incoming mail chamber base about 14½ inches inside the incoming mail chamber, 10 inches wide, ½ inch thick, glued to the inside sidewalls and base of the interior of incoming mail chamber 43 ( FIG. 17 ).
33 will be some sort of threaded post with screws, about 1 inch long, to secure interlocking panels connects to interlocking panels, 2 top panel 3 smooth front exterior panel ( FIG. 1 ), that attaches to interior of 2 a ( FIG. 6 ), rear exterior panel 3 ( FIG. 4 ), that attaches to interior of 2 a base panel, 23 side panel ( FIG. 6 ), glued with some sort of heavy duty clear glued together.
45-degree angled stationary arm housing 34 ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12½ inches long, shaped on a 45 degree angle. 45-degree angled retractable movable arm 35 ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue.
Thin rubber trim 36 rubber seam that is about ⅛ inch wide, length is determined by door being trimmed, glued with some sort of heavy duty glue.
FIG. 10 depicts side view of front of the elongated housing chamber 13 of mailbox, housing is 25 inches long by 25 inches wide, 14 inches high, consisting of a pull down retractable door 5 18-inch wide and 13 inches in height, is ½ inch thick, for incoming and outgoing mail, with horizontal handle 12 handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close. Also, mounted in the front of the elongated housing chamber 13 is the newspaper/advertisement door 4 swing door, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S. Postal Service and closes when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close.
FIG. 11 depicts side view of the elongated housing chamber 13 housing is 25 inches long by 25 inches wide, 14 inches high, consisting of a pull down retractable door 5 shown open, 18-inch wide and 13 inches in height, is ½ inch thick, for incoming and outgoing mail, with horizontal handle 12 ( FIG. 10 ), handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close, also mounted in the elongated housing chamber 13 is the newspaper/advertisement door 4 shown closed, has swing door, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S. Postal Service and closes when not in use, vertical handle 11 handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close.
Mailbox chute 24 that is 10 inches wide, 13 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip area ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, open space area for mail being deposited through chute is about 9 inches long, mailbox chute guardrail 25 about 6 inches long, ¼ inch thick sides, controlling mail flow into basket.
45-degree angled stationary arm housing 34 ( FIG. 12 ), ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12½ inches long, shaped on a 45 degree angle.
45-degree angled retractable movable arm 35 ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue.
Thin rubber trim 36 rubber seam that is about ⅛ inch wide, length is determined by door being trimmed, glued with some sort of heavy duty glue, magnets 38 and 39 current standard market magnets used today, about ¼ length that attaches to door 4 and 5 outgoing mail holding chamber 42 outgoing mail holding chamber that is 7 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for outgoing mail to rest upon for pick-up, incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate mailbox chute 24 and bumper board 32 ( FIG. 9 ).
FIG. 12 depicts side view of front elongated housing chamber 13 housing is 25 inches long by 25 inches wide, 14 inches high, consisting of a pull down retractable door 5 18-inch wide and 13 inches in height, is ½ inch thick, for incoming and outgoing mail, with horizontal handle 12 ( FIG. 10 ), handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close, also mounted in the front elongated housing chamber 13 is the newspaper/advertisement door 4 with swing door open, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S. Postal Service and closes when not in use, vertical handle 11 ( FIG. 10 ), handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close.
Mailbox chute 24 that is 10 inches wide, 12 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip, ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, open space area for mail being deposited through chute is about 9 inches long, mailbox chute guardrail 25 about 6 inches long, ¼ inch thick sides, controlling mail flow into basket.
45-degree angled stationary arm housing 34 that is a ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12½ inches long, shaped on a 45 degree angle.
45-degree angled retractable movable arm 35 that is a ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue.
Thin rubber trim 36 rubber seam that is about ⅛ inch wide, length is determined by door being trimmed, glued with some sort of heavy duty glue, stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chambers 44 for swinging door 4 to open and close, magnets 38 and 39 current standard market magnets used today, about ¼ length that attaches to door 4 and 5 outgoing mail holding chamber 42 outgoing mail holding chamber that is 7 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for outgoing mail to rest upon for pick-up, incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate mailbox chute 24 and bumper board 32 ( FIG. 9 ).
Newspaper/advertisement chamber 44 newspaper/advertisement chamber is 7 inches wide, 12 inches height, 25 inches, chamber for newspaper/advertisement to rest upon for pick-up by homeowner.
FIG. 13 depicts back view of rear upper elongated chamber 14 that attaches to front elongated housing chamber 13 in the rear of the mailbox, which front elongated housing chamber 13 is 25 inches long by 25 inches wide, 13 inches high which extends through upper chamber of mailbox to rear upper elongated chamber 14 and attaches to one another to make one continuous chamber, with ½ inch cosmetic seam line on top and bottom of rear upper elongated housing chamber, constructed from some sort of fabricated material as one piece.
Rear outgoing mail door 15 swinging door, 8 inches wide, 13 inches in height, ½ inch thick, that swings opens to retrieve newspaper/advertisement or other items not delivered via U.S. Postal Service and close when not in use, rear non-functioning panel 16 that is 9 inches wide by 13 inches high, ½ thick, non-functioning door panel is part of incoming mail chamber 43 ( FIG. 17 ), rear newspaper/advertisement door 17 swinging door, 8 inches wide, 13 inches in height, ½ inch thick, that swings opens to retrieve newspaper/advertisement or other items not delivered via U.S. Postal Service and close when not in use.
Thin rubber trim 36 rubber seam that is about ⅛ inch wide, length is determined by items being trimmed, glued with some sort of heavy duty glue, stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 42 for swing door 15 to open and close, stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 44 for swing door 17 to swing open and close, magnets 38 and 39 current standard market magnets used today, about ¼ length that attaches to door 15 and 17 outgoing mail holding chamber 42 outgoing mail holding chamber, 7 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for outgoing mail to rest upon for pick-up, newspaper/advertisement chamber 44 newspaper/advertisement chamber that is 7 inches wide, 12 inches height, 25 inches, chamber for outgoing mail to rest upon for pick-up.
FIG. 14 depicts how some of internal parts 5 12 24 25 31 34 35 36 40 and 43 are used to create the city design of Safe “T” Box mailbox, made from some sort of fabricated material, outgoing mail door and incoming mail door 5 pull down retractable door 5 that is 10 inches wide by 10 inches high, ½ inch thick, horizontal handle 12 handle is 5 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close, mailbox chute 24 that is 10 inches wide, 10 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip area ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, mailbox chute guardrail 25 about 4 inch length, ¼ inch thick sides, controlling mail flow into basket, basket 31 that is 18 inches wide, 18 inches deep, made from some form of plastic, metal or fabricated material, finished basket could be made into a solid, diagonal or cross-stitched basket weave pattern, 45-degree angled stationary arm housing 34 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 7½ inches long, shaped on a 45 degree angle, 45-degree angled retractable movable arm 35 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 7 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue, holding rubber seals 36 made from some sort of thin rubber material that attaches around edge of doors 5 to protect mail from getting wet when doors not in use, basket 40 that is 18¼ inches wide, 18¼ inches deep, basket support is made from plastic, metal or some sort of fabricated material that supports the basket, incoming mail chamber 43 incoming mail chamber 43 incoming mail chamber, internal chamber for incoming mail is 10 inches wide, 10 inches in height, 12 inches long, ½ inch thick.
FIG. 15 depicts how some of internal parts 5 12 24 25 34 35 36 40 and 43 are used to create the city design of Safe “T” Box mailbox, made from some sort of fabricated material, outgoing mail door and incoming mail door 5 pull down retractable door 5 10 inches wide by 10 inches high, ½ inch thick, horizontal handle 12 handle is 5 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 5 with screws for pull down door to open or close, mailbox chute 24 that is 10 inches wide, 10 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip, ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, mailbox chute guardrail 25 about 4 inch length, ¼ inch thick sides, controlling mail flow into basket, basket 31 ( FIG. 14 ), 18 inches wide, 18 inches deep, made from some form of plastic, metal or fabricated material, finished basket could be made into a solid, diagonal or cross-stitched basket weave pattern.
45-degree angled stationary arm housing 34 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 7½ inches long, shaped on a 45 degree angle.
45-degree angled retractable movable arm 35 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 7 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue.
Thin rubber trim 36 made from some sort of thin rubber material that attaches around edge of doors 5 to protect mail from getting wet when doors not in use, incoming mail chamber 43 internal chamber for incoming mail is 10 inches wide, 10 inches in height, 12 inches long, ½ inch thick.
FIG. 16 depicts internal base unit 22 square base, ½ inch thick, square, approximately 25¾ inches wide by 25¾ inches wide, attaches to the base of the mailbox, made from some sort of fabricated material, glued around edges with some sort of heavy duty glue, four ½ inch circular cut out holes are made in 22 for insertion of internal poles 26 ( FIG. 8 ), that extend through the mailbox into the ground, plastic covers seals 22 a four ½ inch circular plastic cover seals that slip over internal PVC poles 26 glued in place with some sort of heavy duty clear glue.
FIG. 17 showing view of front elongated housing chamber 13 without top cover, detailing views of inside chambers for housing that is 25 inches long by 25 inches wide, 13 inches high, consisting of a pull down retractable door 5 18-inch wide and 13 inches in height, is ½ inch thick, for incoming and outgoing mail, with horizontal handle 12 ( FIG. 10 ), handle is 9 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door with screws for pull down door to open or close, also mounted in the front elongated housing chamber 13 is the newspaper/advertisement door 4 with swing door open, 8 inches wide, 13 inches high, ½ inch thick, that swings opens to insert newspaper/advertisement or other items not delivered via U.S. Postal Service and closes when not in use, vertical handle 11 ( FIG. 10 ), handle is 7 inches long, made from some sort of plastic, metal or fabricated material, attached to inside door 4 with screws for the swinging door to pull open or close, rear non-functioning panel 16 that is 9 inches wide by 13 inches high, ½ thick, non-functioning door panel is part of incoming mail chamber 43 .
Mailbox chute 24 that is 10 inches wide, 12 inches high, ½ inch thick, mail chute opening has 1-inch length flat lip, ½ inch thick before mailbox chute, mail chute is on about a 32-degree angle, 12 inches long for mail to slide down chute into mailbox, open space area for mail being deposited through chute is about 9 inches long, mailbox chute guardrail 25 about 6 inches long, ¼ inch thick sides, controlling mail flow into basket, bumper board 32 attaches to incoming mail chamber base 14½ inches inside the incoming mail chamber, 10 inches wide, ½ inch thick, glued to the inside sidewall of interior of incoming mail chamber 43 .
45-degree angled stationary arm housing 34 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12½ inches long, shaped on a 45 degree angle.
45-degree angled retractable movable arm 35 which is ½ inch hollow chamber, made from plastic, metal or some sort of fabricated material, 12 inches long, shaped on a 45 degree angle, attached to 5 with some sort of heavy duty clear glue.
Thin rubber trim 36 rubber seam that is about ⅛ inch wide, length is determined by door being trimmed, glued with some sort of heavy duty glue, stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 44 for swinging door 4 to open and close.
Stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the upper interior portion of 2 about 1 inch down into the chamber 44 for swing door 4 to open and close.
Stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the rear upper interior portion of 2 about 1 inch down into the chamber 42 for swing door 15 to swing open and close ( FIG. 13 ).
Stabilizer swing door pole 37 about ½ hollow circular pole, 16 inches long, extends 1 inch into the rear upper interior portion of 2 about 1 inch down into the chamber 44 for swing door 17 to swing open and close ( FIG. 13 ).
Magnets 38 and 39 , current standard market magnets used today, about ¼ length that attaches to door 4 and 5 outgoing mail holding chamber 42 outgoing mail holding chamber that is 7 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for outgoing mail to rest upon for pick-up, incoming mail chamber internal chamber for incoming mail is 10 inches wide, 12 inches in height, 25 inches long, ½ inch thick, chamber for incoming mail is divided into two sections to accommodate mailbox chute 24 and bumper board 32 .
Newspaper/advertisement chamber 44 newspaper/advertisement chamber that is 7 inches wide, 12 inches height, 25 inches, chamber for newspaper/advertisement to rest upon for pick-up by homeowner. | A security mailbox system known as Safe “T” Box being a fully enclosed square mailbox that can be designed from PVC or some fabricated material, the Safe T Box is easy to install, environmentally friendly and will provide long service life. The mailbox includes chambers for incoming and outgoing mail being delivered via the U.S. Postal Service, it also has a chamber for newspapers/advertisements not delivered via U.S. Postal Service. The incoming mail chamber is designed for mail to go down a mail chute into a basket for pick-up through back of the locked mailbox. Outgoing mail can be placed from the back for pick-up from the front by postal worker. The mailbox is attached to the ground though internal poles extending from the bottom of the mailbox into the ground and cemented. | 0 |
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/944,726 as filed on Jun. 18, 2007; which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Domestic cats often enjoy perching or resting near windows, on windowsills, and/or on cat shelves attached to windowsills. This allows them to be able to look out the window as they rest. It also gives them a feeling of being outside. Many perches are attached to the windowsill itself, hook under a closed window, or in between the window and windowsill for attachment. Often these animal perches are covered with a type of soft fabric like sheepskin, fleece, a soft blanket or other soft material cats particularly like. Some of these shelves also incorporate soft foam under the fabric or the use of foam-backed fabric to further soften the usually rigid shelf. This makes the shelf feel more bedlike to the animal.
[0003] There are a number of animal window perches available on the marketplace today. One of the more popular shelves is of a simple design incorporating pressed wood for the shelf and round metal wire for the shelf support. Generally, there is a rectangular piece of flat wood. There is usually a foam pad on the wood surface as well as a fitted fabric covering over the foam. Often the covering is a foam-backed fabric. This padded protection is laid or fitted on top of the wood board in its final assembly. There are two metal wire brackets shaped in a “U” which fit under the shelf on the right and left side for the shelf's horizontal support. It is intended for this shelf that the wood platform be screwed down to the windowsill using 1, 2, 3 or more screws on the back of the shelf towards the window. The “U” shaped metal is bent at 90-degree angles with approximate equal distance between the bends. On one leg of the “U”, the metal is bent tightly back against itself to create a slot effect. There are generally 2 brackets included per shelf. The brackets are attached on the left and right underside of the shelf with the “slotted” part of the bracket to the shelf's underside using supplied thumbscrews with large fender style washers screwed into predrilled holes on the underside of the wood shelf. This slotted “U” metal design allows for this bracket to slide in and out on the underside of the shelf for a universal fit on various windowsill designs and dimensions. There are often small suction cups mounted to the end of the angled round metal brackets where they come in contact with the supporting wall under the windowsill.
[0004] The disadvantages of these shelves are that not all of these window shelves/perches are easily adjustable and some are not adjustable at all making it difficult for the consumer to fashion it to their specific window application. It is often true that some of these shelves will only fit specific window and windowsill sizes as they generally come in only one size big enough to fit a domestic cat. There are smaller pet shelves, which are often too small or cramped for most ordinary domestic cats. Some shelves or perches also are much too rigid and/or uncomfortable for pets, often needing additional padding or support. Other disadvantages of these types of shelves is the need for some sort of fastener(s) to set the shelf up, often screws or the use of sticky backed hook and loop (Velcro). Usually there is some sort of defacing to the surface where the shelf rests or attaches to the attaching surface such as the windowsill or wall. Also when the soft fabric covering is applied to the shelf, often the fabric must be tucked under the shelf on the window side prior to attaching the shelf to the sill making it difficult to remove the covering for cleaning. Another disadvantage is that the shelf platform is generally made of a wood or pressed wood product making it difficult to clean cat urine or feces, lice, mites or fleas from the wood, additionally the smell from cat urine and feces is very hard to remove once it comes in contact with the wood or wood product. If cleaning products are used to remove the smell they often leave a toxic residue and/or smell for a long time making the shelf unsuitable for pets. Quite often when the wood becomes to bad to use, the shelf is discarded creating undue early waste for landfills. Another disadvantage of these shelves is that special tools are often required for their setup, use, or take down such as a drill, hammer, or screwdriver as well as certain types of fasteners like screws, hooks, nails or Velcro. Also there are usually limited locations for the use of these shelves because of their need to be attached to something like a windowsill, between a window and its sill or under a window. Furthermore, when the shelf is attached under a windowsill, the window become unusable for ventilation since the shelf is held in place by the window being closed down on the shelf. Another disadvantage to this type of shelf is that window coverings such as curtains or blinds may need to be redesigned because the shelf tends to be at a height above the sill making the window dimensions different after the installation of the shelf.
SUMMARY OF THE INVENTION
[0005] Systems and methods for an animal shelf are disclosed herein. A cat shelf includes a shelf having a first and a second suction cup. A first support wire coupled to the shelf at a first end and to a third suction cup at a second end and a second support wire coupled to the shelf at a first end and to a fourth suction cup at a second end. Wherein when the shelf is attached to a surface using the first and second suction cups and the first support wire and second support wires are extended upwardly and attached to the surface a domestic animal can be supported by the shelf.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
[0007] FIG. 1 is a perspective of the shelf in one embodiment attached to a glass window;
[0008] FIG. 2 is a view of the shelf without the fabric hammock to depict the parts of the frame;
[0009] FIG. 3 is an exploded view of one side and back of the shelf frame to show a bushing inside the “T” fitting where the suction cup #52 fits;
[0010] FIG. 4 is a view of the fabric hammock showing the looped and hemmed edges;
[0011] FIG. 5 is a view of the suction cups used in the invention; and
[0012] FIG. 6 is an end view of the shelf to show the shelf support cable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] In accordance to the described pet shelves or perches, window or wall shelves in general for pet animals, a window shelf made large enough for the domestic cat with a soft hammock like seat is provided herein. It is the object of this invention to provide a portable, lightweight, waterproof, moveable shelf for an animal to rest, sit, perch or view, in a window or wall location. It is also the object of this invention to be easy to setup or taken down, removable or moveable, without the use of tools, be set at any particular height or angle to the window or smooth non-porous surface it is attached to. It is also the object for this invention to be easily collapsible in its entirety, piece-by-piece for storage or shipping. Further it is the object for this invention to be washable entirely without undo deterioration of it parts and components. It is also the object of this invention to be used so as not to cause destruction to its attaching surface, in effect the use of screws, nails, glue, adhesive tape or the like for its use. Further it is the object of this invention to have a multipurpose use both indoors and/or outdoors as well as not being limited to specific locations for its use.
[0014] In its preferred embodiment the Kitty Cot is a flat panel rectangular shelf. The frame is made of plastic pipe or similar tube stock including metals, consisting of four lengths of pipe and four couplings or fittings, two of the fittings being 90-degree couplings and two fittings being “T” couplings. Two lengths of pipe are generally shorter and two are generally slightly longer to create the rectangular shape of the frame, though in some embodiments the frame can be a square. The lengths of pipe are joined together with the use of the described fittings or couplings. There is a single piece of rectangular, breathable, waterproof, plastic coated fabric that is hemmed on all four edges to fit inside of the frame acting as a sling-like hammock. The fabric panel is hemmed on all four sides in an open loop fashion to accept the four pieces of pipe, which make up the frame. There is a front and back to the shelf. The front of the shelf has a 90-degree fitting on the each end of the front pipe, while the back of the shelf has a “T” fitting on each end of the pipe. The two shorter sidepieces of pipe are inserted into the couplings of the front and back pipe assemblies to complete the rectangular frame. Inserted in the open ends of the “T” fittings is a short piece of pipe acting as a bushing to accept a large diameter suction cup that has a molded stud to fit into this short piece of pipe. There are two cables attached to the front pipe of the shelf by means of a crimped loop in the cable, which slides over the front pipe during assembly. The two cables are positioned on the left and right side of the front pipe just outside of the fabric hammock. On the other end of each cable is another small crimped loop; an attached “S” hook, connecting to a large suction cup, which has a molded closed loop on the back of the suction cup. These support cables hold the shelf level to the vertical surface the shelf is attached to by means of applying the suction cups to the vertical surface above the shelf. The shelf is positioned into place on the surface it is being attached to. The shelf is pushed in place from the front with slight pressure to engage the suction cups located on the back of the shelf. Holding the shelf at a level or perpendicular angle to the attaching surface, the front cables are then positioned above the shelf whereby engaging the suction cups to the vertical surface above the shelf.
[0015] A shelf 10 in accordance with one embodiment is shown attached to a window 12 in FIG. 1 . With this embodiment, the shelf is generally comprised of a frame 14 as shown in FIG. 2 and a fabric hammock 20 as shown in FIG. 4 . The frame 14 is generally rectangular or square and has a defined front and back and two sides as shown in FIG. 1 . The frame 14 is generally made of a lightweight round pipe stock such as plastic or metal. There is a defined opening inside of the frame 14 to accept a fabric hammock 20 as seen in FIG. 4 . The fabric hammock 20 is generally made of a lightweight, durable, washable, waterproof, plastic coated material designed for indoor as well as outdoor use, to provide a comfortable resting place for a domestic cat. The resting area is attached to the frame 14 , which creates a sling hammock 20 and is generally lower in the center as it sags slightly, which gives the cat a feeling of being lower and/or more comfortable. Other types of fabric can be used to make the fabric hammock 20 as well as an additional piece of soft fabric to lie over the fabric hammock 20 such as sheepskin, fleece or a soft blanket which cats particularly enjoy resting on.
[0016] The shelf can be secured to a window or any surface by any suitable means but in its preferred embodiment the shelf is attached to a window or non-porous surface with the use of suction cups 52 , 50 as shown in FIGS. 1 , 2 , 5 , and 6 . The frame 14 consists generally of ten parts. There are two end pieces of pipe 28 as well as two front and back pieces of pipe 42 as shown in FIG. 2 . To connect these pipes together to make a frame 14 there are two 90-degree fittings 18 on the front right and left side of the frame 14 , and two “T” fittings 30 on the back right and left of the frame as shown in FIG. 1 . In the assembly of the shelf 10 , the end pipes 28 are inserted into the sewn hem on the short side of the fabric hammock 20 . The front and back pipes 42 are then inserted into the sewn hem on the long side of the fabric hammock 20 . In its preferred embodiment the two support cables 15 as shown in FIG. 6 have a defined larger crimped 22 loop, which slides over the front pipe 42 on the left and right side prior to attaching the front pipe-fittings 18 . The front pipe fittings 18 are now attached to the front left and right sides of the front pipe 42 , then connected to the front left and right side pipes 28 as shown in FIGS. 1 and 2 . The rear pipe 42 is connected to the center hole of the “T” fitting 30 then connected to the right and left side pipes 28 . There are two short pieces of pipe 75 as shown in FIG. 3 inserted into the end or back of the open holes of the “T” fittings 30 to act as a bushing for the acceptance of the suction cups 50 as shown in FIG. 5 . The suction cups 50 are inserted into the end of the “T” fittings 30 as seen in FIG. 6 . On the other unattached ends of the support cables 15 are small crimped 22 loops. Attached to these loops is a closed “S” hook 33 , which is also attached to a closed loop suction cup 52 . This method of attaching the suction cups 50 , 52 to the invention allows for ease of changing or replacing the suction cups.
[0017] The advantages of this shelf is that it is lightweight, made of durable plastic pipe or metal for the frame as well as a durable plastic coated fabric for the hammock. It is easy to assemble and/or disassemble, making it compact for shipping or storage. There is no need for special tools to assemble, setup, take down or disassemble the shelf. The shelf is easy to put up and/or in place hence the use of suction cups on the shelf for its attachment. There is no defacing of the surfaces it attaches to since there is no need for screws, nails, hooks, glue, fasteners, hook and loop (Velcro), etc. for its use and attachment. The shelf can be put at any height or angle to the attaching surface. The shelf can attach to slider windows, double hung windows, sliding glass doors picture windows. The windows or doors can be useable for ventilation with the shelf attached to the glass free or clear of the opening features of said components. Replacement parts are easily replaced due to the common pipe tube and fittings used in the invention, additionally there is no need for fasteners or glues to assemble the shelf. The fabric hammock is easily cleaned without disassembling the shelf because it is open webbed and plastic coated. The hammock is also easily replaceable because the frame can be disassembled. The fabric hammock is sling-like with the sides higher than the center making the animal more comfortable than a normal flat cushioned board other shelves use. The shelf can be made in different sizes for different window and/or wall fits. Two or more shelves can be set on a flat vertical surface to create a step effect for the pet as well as allow for more than one pet to perch on the same wall or window. The shelf can be used indoors as well as outdoors without undue deterioration due to its waterproof qualities. The invention has a wide variety of uses and/or applications beyond the use as a pet shelf. No wood products are used in the invention making it more desirable since cat feces or urine will not penetrate the plastic as easily as wood. The plastic frame is recyclable.
[0018] In alternate embodiments the shelf could be used for, but is not limited to: outdoor or indoor pool shelf for toys and supplies; sauna or hot tub shelf for supplies, reading materials, drinks or chemicals; plant shelf for indoor and/or outdoor use; watering shelf for plants; shower shelf for soaps and shower supplies; sink shelf for washing fruits and vegetables; towel rack or holder; shelf for boats to hold maps, beverages or supplies; shelf for motor homes to hold supplies; spice rack for the kitchen; soap rack for the laundry room; shelf to ripen fruit on; office shelf for office supplies; photo shelf to hold pictures; clothing shelf to hold clothes; shoe rack; clothes drying shelf, window food dehydrator; outdoors drink holder; bookshelf; magazine shelf, sunshade for plants; cut flower shelf; and/or a sun-visor shelf.
[0019] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. | A portable, lightweight, collapsible pet shelf for the attachment above a windowsill, to attach on a window or other smooth surface, generally comprised of a square or rectangular frame open in the middle to accept a soft fabric-like material suitable for a pet such as a domestic cat. The middle fabric is suitable for the animal to rest, view or sleep. The shelf is generally to be above ground level, often placed on or near a window for the pets viewing pleasure. The use of suction cups attached to the frame as well as on the ends of the front support cables or support arms, which attach to a surface above the shelf, to create a level shelf for the pet. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 12/114,919, filed May 5, 2008, which claims the benefit of U.S. Provisional Application No. 60/973,093, filed on Sep. 17, 2007, both of which applications are incorporated herein expressly by reference.
BACKGROUND
A wide variety of roofing materials has been developed over the years to provide lasting protection of a building. While most of the available alternatives have provided adequate protection of buildings, a common characteristic with most available materials is that they are impervious to precipitation, the intent being to prevent precipitation from penetrating the roofing surface and impacting the underlying structure. However, one consequence from a stormwater management perspective has been a steady increase in impervious surfaces associated with the footprint of most new developments. The introduction of impervious surfaces translates into increased volumes of stormwater runoff and increased rates at which this runoff leaves a given site. In predeveloped conditions (i.e., before a structure and roof), there are typically trees, grasses, shrubs, and other natural ground covers that allow for infiltration, evapotranspiration, and a generally slow rate of surface runoff from precipitation. New structures and the impervious rooftops change the hydrology of a site considerably by creating a fast and efficient path for precipitation to leave the structure and, ultimately, the property.
This widespread change of land cover and associated change in surface runoff hydrology has led to similarly widespread problems with stormwater management throughout the country and world. In watersheds drained by open channels, the increased rate and volume of stormwater runoff can cause flooding and erosion in downstream ditches, streams, and rivers. In man-made systems, the change in hydrology can cause overloaded conveyance systems, property damage, and other related consequences. As a result, many jurisdictions in the United States and worldwide have developed stormwater regulations that, among other things, set regulatory limitations on the rate at which stormwater runoff can leave a site. Typical approaches to achieving these regulations include providing stormwater detention or retention systems to capture and temporarily store stormwater runoff and release it at a slower rate or infiltrate it into surrounding soils.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
While development inevitably leads to a change in land cover, the embodiments of a roofing composition disclosed herein seek to minimize the impact of traditional impervious roofing systems on downstream hydrology. Rather than accepting the notion that rooftops are impervious surfaces and then trying to manage the increased rate of stormwater runoff by capturing the roof runoff and detaining or retaining it after it leaves the rooftop, the roofing composition will help slow the rate at which stormwater runoff is able to leave the roof surface by temporarily storing the precipitation on the rooftop within a porous storage layer incorporated into the roofing composition. To this end, embodiments of the roofing composition provide a roofing material and system that is still impervious to weather at its base, but includes a storage layer above the base layer comprised of natural or synthetic materials other than growing media (i.e., green roofs) that will allow for the temporary holding and gradual and controlled delayed release of the majority of precipitation that falls onto the roof surface. The storage layer may be designed to inhibit biological growth (e.g., plant or bacterial), or may allow for incidental biological growth, but unlike green roof systems, the storage layer is specifically designed as a manufactured precipitation storage media and not a plant growth media. To this end, the storage media is preferably made from an inert non-growing material. Additionally or alternatively, the storage media may comprise a biocide, herbicide, algaecide, or bactericide to prevent the growth of plant, animal and other living matter.
A further embodiment provides a roofing composition and unit that can be easily manufactured, stockpiled, distributed, and installed on typical roofs.
A further embodiment provides a roofing composition and unit that is standard in its purpose but variable and customizable in thickness, porosity, and hydraulic conductivity such that it can meet the unique precipitation, stormwater regulatory, and roof slope properties of a given site.
A further embodiment provides a roofing composition and unit that is applicable to both new and existing structures (e.g., incorporated as part of a standard re-shingling effort).
A further embodiment provides a lightweight roofing composition and unit of sufficient strength, stiffness, and impact resistance to withstand the variety of outdoor conditions encountered, including hail, freeze/thaw, snow load, high winds, and foot traffic.
A further embodiment provides a roofing composition and unit that maximizes the use of post consumer and/or post industrial materials.
A further embodiment provides a roofing composition and unit with equal or superior product longevity over typical roofing materials.
A further embodiment provides a roofing composition and unit that is variable and customizable in appearance, such that it may be tailored to appear similar to typical asphalt shingle roofing, slate roofing, or other roofing materials as desired.
A further embodiment provides a roofing composition and unit that is resistant to pests, bacteria, and fungus.
A further embodiment provides a roofing composition and unit with equal or greater solvent, detergent, and other chemical resistance than typical metal, PVC, or asphalt roofing products.
A further embodiment provides a roofing composition and unit with a Class C or higher fire rating.
A further embodiment provides a roofing composition and unit that conserves the use of industrial and energy resources, and produces less waste in the creation and installation of the material compared to other common roofing materials.
A further embodiment provides a roofing composition and unit that maximizes the content of recyclable materials.
These and other embodiments of the roofing composition disclosed herein provide interception and temporary storage (detention) of precipitation and stormwater runoff on the roof surface. This application discloses a means to reduce on-site or off-site stormwater detention and retention needs by providing for deliberate detention of precipitation and stormwater runoff on the rooftop before it is released to the site stormwater drainage system. The rooftop stormwater detention provides a reduced release of stormwater runoff compared to traditional roofing systems, allowing for reduced or elimination of the need for other stormwater flow control facilities to manage the runoff from the rooftop. Embodiments of the roofing composition could also be customized with simple changes to material dimensions and composition to meet varying regulatory requirements and precipitation patterns. Embodiments of the roofing composition provide an improved means to meet any regulatory requirements for stormwater detention, and provide improved environmental protection by partially simulating the hydrologic characteristics of an undisturbed (pervious) surface that typically existed historically prior to the disturbance and development of the building site. In addition to the stormwater detention and environmental benefit, other benefits include improved service life of the roofing material, improved insulation, and the potential for reduced gutter clogging and maintenance.
Embodiments of the roofing composition include a multi-layered system that will provide the same protection of the underlying roof surface (typically plywood) that traditional roofing materials provide, but will also allow for increased storage and detention of precipitation and stormwater runoff.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a diagrammatical illustration of a first embodiment of a roofing composition in accordance with the present invention;
FIG. 2 is a diagrammatical illustration of a roof including the roofing composition made in accordance with the present invention;
FIG. 3 is a diagrammatical illustration of a roof including the roofing composition made in accordance with the present invention;
FIG. 4 is a diagrammatical illustration of a roof including the roofing composition made in accordance with the present invention;
FIG. 5 is a diagrammatical illustration of a cross-sectional view of a roofing composition in accordance with the present invention;
FIG. 6 is a diagrammatical illustration of a cross-sectional view of an alternative embodiment of a drainage layer in accordance with the present invention; and
FIG. 7 is a diagrammatical illustration of a cross-sectional view of an alternative embodiment of a drainage layer in accordance with the present invention.
DETAILED DESCRIPTION
The present invention is related to roofing compositions. The roofing composition includes a plurality of layers. Embodiments of the roofing composition can be provided as individual units or shingles or the roofing composition can be constructed from larger sheets placed individually on the roof. Any one or more of the disclosed layers can be fabricated from such a large sheet of material. Embodiments of the roofing compositions are related to the field of roofing materials, and are designed to respond to demands in stormwater management. Embodiments of the roofing compositions provide a roofing system possessing characteristics desired in standard roofing materials including durability, impermeability, weather resistance, fire resistance, and aesthetic appeal. However, the embodiments of the roofing composition also include a water-holding storage layer which will reduce the rate of stormwater runoff from a roof surface. This provides important stormwater management functions that are lacking in most current roofing approaches. For example, conventional green roofs (i.e., where soil and plant material are used to cover a building) provide some stormwater management benefits. However, unlike the conventional green roofs, embodiments of the roofing compositions disclosed herein provide a system that is more suited to mass manufacturing and ease of installation, which are desirable characteristics for roofing installations. Embodiments of the roofing composition also do not rely on soil and living plant material. Roofing compositions disclosed herein can use manufactured materials that will provide precise and customizable stormwater detention capabilities desired for a given setting. Embodiments of the roofing composition can be fabricated as individual roofing shingles, much like the conventional shingle design, but the embodiments disclosed herein incorporate a stormwater storage layer that will provide additional benefits.
Referring to FIG. 1 , a representative roofing composition 100 in accordance with one embodiment is illustrated. Roofing compositions in accordance with embodiments of the invention include at least a storage layer and a base layer. “Layer” as used herein in plural or singular form may designate completely separate and distinct materials, or “layer” may designate a zone or area of a material that performs or behaves differently than another zone or area of the same material or may designate a zone or area having a different structure and/or composition than another zone or area of the same material. While the following description is with reference to particular embodiments of the roofing composition, the invention is not thereby limited to any one particular embodiment.
In FIG. 1 , the lowermost layer 102 is a base layer 102 . The base layer 102 includes a water-impermeable underlayment material made of, for example, asphalt impregnated felt, high density polyethylene, recycled rubber, metal, or other impermeable synthetic or naturally-occurring material. The base layer 102 extends, at least, the length, height, and depth of the remaining layers, but is further extended beyond the remaining layers for generally more than twice the depth of the remaining layers. The base layer 102 is placed on the roofing support structure, such as, but not limited to, plywood. The base layer 102 is a durable, impermeable layer that will serve as the base and waterproofing system to be attached to the roof surface. This layer can be constructed of metal, synthetic materials, or other durable and impervious materials.
One or more layers disclosed herein can be installed singly as a unit or shingle. In another embodiment one or more layers could be installed in large sheets or panels (as opposed to individual shingles) over large portions of the roof surface. Depending on the other layers described below, the base layer may be flat, or may include ridges on the upper facing side of the layer to serve as drainage channels. Most sections would likely be rigid, but there will be some need for moderately flexible materials to fit contoured roof segments. The base layer may be attached to the support structure through a variety of methods including mechanical fastening, chemical adhesives and bonding agents, heat-sealing, hook and eye, VELCRO, or other methods.
If a drainage layer 104 is used, the drainage layer 104 is placed over the base layer 102 . The drainage layer 104 is provided with means to direct water transversely within the drainage layer 104 . More specifically, when water enters the drainage layer 104 , water is allowed to run transversely through the drainage layer 104 according to the slope of the roof on which the roofing composition 100 is located. To this end, the drainage layer 104 can include voids, channels, tunnels, pores, or any other water-channeling structure to allow for the flow of water through the height, depth, and length of the drainage layer 104 and for directing water downslope beneath the drainage layer 104 . The drainage layer 104 serves as the drainage section that will convey detained runoff along the base of the unit. This layer can be constructed of metal, synthetic materials, or other durable materials. Depending on the other system layers, the drainage layer may include various geometric designs to serve as drainage pathways that convey water from the storage layer to discharge at the terminus of the roofing system. The drainage layer may also be configured such that precipitation is retained in the drainage layer and allowed to evaporate back into the atmosphere rather than drain from the roofing system. The drainage layer 104 could be adhered to the base layer 102 through a variety of methods including mechanical fastening, chemical adhesives and bonding agents, heat-sealing, hook and eye, VELCRO, or other methods. As mentioned for the base layer 102 , another embodiment of the drainage layer 104 could include large sheets or panels (as opposed to shingles) installed over large portions of the roof surface.
If a separation layer is used, the separation layer 106 is placed over the drainage layer 104 . The separation layer 106 supports the storage layer 108 to keep the storage layer 108 from encroaching on the drainage pathways in the drainage layer 104 . The separation layer 106 could be constructed of geosynthetic materials or other durable materials. The separation layer 106 should be highly permeable to allow water stored in the storage layer 108 to flow freely to the drainage pathways in the drainage layer 104 . As mentioned for the other layers, another embodiment of the separation layer 106 could include large sheets or panels (as opposed to shingles) installed over large portions of the roof surface.
The storage layer 108 is placed over the separation layer 106 , if present. Alternatively, the storage layer 108 may be placed directly on the drainage layer 104 , if present. If the separation layer 106 and the drainage layer 104 are not included, the storage layer 108 may be placed directly on the base layer 102 . The storage layer 108 includes inert non-growing storage means or media for absorbing and temporarily detaining precipitation for gradual release. In one embodiment, the storage layer has the capacity to detain at least 0.3175 centimeters (0.125 inches) of precipitation when fully saturated and in one embodiment has a water permeability (hydraulic conductivity) of 0.00001 to 0.1 centimeters per second. Individual embodiments will be tailored to match the environmental conditions and design needs of different applications. In another embodiment, the storage layer has a hydraulic conductivity of 0.00001 to 0.0001 centimeters per second. In another embodiment, the storage layer has a hydraulic conductivity of 0.0001 to 0.001 centimeters per second. In another embodiment, the storage layer has a hydraulic conductivity of 0.001 to 0.01 centimeters per second. In another embodiment, the storage layer has a hydraulic conductivity of 0.01 to 0.1 centimeters per second. Methods for determining hydraulic conductivity vary depending on test material and permeability, but are generally based on Darcy's Law and should follow applicable standard test methods such as ASTM D5856 or ASTM D2434. The storage layer 108 includes an inert non-growing storage media that has temporary water storage characteristics. The preferred materials for the storage media would be determined through field and/or laboratory testing but may include a honeycombed style material, open-cell foam material, a semi-rigid sponge material, a woven fibrous material, layers of synthetic fabric layers of varying permeability, or other materials with desired water storing and hydraulic conductivity characteristics. The preferred materials would also vary depending on climate, stormwater detention objectives, aesthetics, and other site-specific needs. The layer may also provide varying degrees of storage through the depth of the material. In one embodiment, the storage layer may have two or more zones having a different hydraulic conductivity, wherein the zones are arranged such that water can be conveyed through the storage layer at variable design rates. For example, a higher hydraulic conductivity near the surface to promote absorption of precipitation, a slower hydraulic conductivity in the middle to promote storage, and a higher hydraulic conductivity near the base to promote drainage of runoff from the roof material. As mentioned for the other layers, another embodiment of the storage layer 108 could include large sheets or panels (as opposed to shingles) installed over large portions of the roof surface.
If a surface layer is used, the surface layer 110 is placed over the storage layer 108 . The surface layer is capable of allowing for the passage of precipitation through its thickness for passage into the storage layer 108 . In one particular embodiment as illustrated in FIG. 1 , the surface layer 110 may include a tab 112 running the entire length of the surface layer 110 and extending in the depth dimension beyond the remaining layers for a small amount to overlap the seams created by placing a first roofing composition adjacent to a second roofing composition. The surface layer 110 could have several embodiments but likely would include a highly permeable but durable membrane. The surface layer 110 would generally be durable, UV resistant, and weather (wind, storm, and frost) resistant. The materials could also vary according to the desired aesthetic appearance—for example, to mimic the appearance of traditional asphalt shingles, slate shingles, wood shingles, etc. The surface layer 110 should resist penetration by leaves, needles, or other materials typically deposited on rooftops, but would also promote the rapid absorption and pass-through of precipitation through the surface layer 110 to the storage layer 108 below. The surface layer 110 should have sufficient strength and surface texture to allow safe walking on the roof surface. The surface layer 110 may be permanently fastened or bonded to the storage layer 108 , or may be independent such that it can be installed after the other layers are installed. The surface layer 110 can be of variable color and texture (for appearance), and in one embodiment can be removed for cleaning or replacement without removing the entire system. As mentioned for the other layers, another embodiment of the surface layer 110 could include large sheets or panels (as opposed to shingles) installed over large portions of the roof surface.
In other embodiments, there may be a need for an additional drainage layer to improve flow routing through the system, as well as a wrapping or packaging layer to securely enclose the storage layer 108 . Other perimeter layers may also be needed to secure the system, prevent damage, improve appearance, or otherwise maximize the performance measures.
FIG. 2 is a diagrammatical illustration showing a cross-sectional view of a roof structure 201 having a plurality of roofing compositions 200 in accordance with one embodiment. The roof includes multiple individual roofing composition units or shingles 200 . In place of individual surface layers for each unit or shingle 200 , this embodiment uses a large sheet surface layer 210 to cover multiple shingles 200 . This construction method is not limited solely to the surface layer. Any layer disclosed herein can be applied in large sheets covering more than one shingle. Also visible in FIG. 2 are the base layers 202 overlapping the entire depth of adjacent shingles. The base layers extend from a lower edge of a roofing composition to the roofing composition adjacent and behind the roofing composition and even further beyond the second roofing composition.
FIG. 3 is a diagrammatical illustration showing a cross-sectional view of a roof structure 301 having a plurality of roofing composition units or shingles 300 utilizing the roofing composition shingles of FIG. 1 , that include a surface layer with a tab 112 . FIG. 3 illustrates roofing composition shingles 300 where each individual shingle or unit 300 has its own attached surface layer 310 with a tab 312 .
By way of contrast to the construction method of FIG. 2 , FIG. 3 illustrates a plurality of roofing compositions 300 that include a surface layer 310 and a tab 312 that extends over the seam created by placing more than one roofing composition next to each other.
FIG. 4 is an illustration of a roof structure 401 with a plurality of roofing compositions 400 with individual surface layers for each roofing composition 400 , utilizing the roofing composition shingles of FIG. 3 , for example.
FIG. 5 illustrates a representative cross section of drainage layer 104 a , wherein the drainage layer 104 a includes a repeating pattern of supports that create voids and/or channels in the drainage layer 104 a . The channels are preferably arranged so that when placed on a roof, the channels direct the flow of water from a higher elevation to a lower elevation. However, there may be cross channels that also allow water to flow in a direction perpendicular to the downstream flow of water.
Referring to FIG. 6 , an alternative embodiment of a drainage layer 104 b is illustrated. The drainage layer cross-sectional view illustrates that the supports are fabricated in a saw-tooth configuration. Cross channels may also be provided to allow water to flow in a direction perpendicular to the downstream flow of water.
Referring to FIG. 7 , an alternative embodiment of a drainage layer 104 c is illustrated. A cross-sectional view of the drainage layer illustrates a wave or sinusoidal configuration of the drainage channels.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A roofing composition is formed as a shingle or from one or more separate sheets. The roofing composition includes a storage layer with an inert non-growing storage medium to absorb and detain precipitation for gradual release. The roofing composition reduces hydraulic discharge rates to avoid overloading downstream drainage systems. | 4 |
[0001] This application claims the benefit of prior filed, co-pending Ser. No. 60/656,047, filed Feb. 24, 2005, entitled ELECTRONIC SPEED CONTROL PROGRAMMING.
FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for programming an electronic speed control and, more particularly, to a method and apparatus for programming an electronic speed control through an RX receive control port.
BACKGROUND OF THE INVENTION
[0003] Radio controlled models, such as airplanes, helicopters, boats and cars, are known in the art. Battery-powered RC models include a battery, a direct current (DC) motor, a radio receiver, and an electronic speed control. Electronic speed controls for DC motors typically include a microprocessor with a memory or firmware. Most electronic speed controls are preprogrammed at the manufacturer for a particular application and with a fixed set of instructions or functions. These electronic speed controls typically have no means for reprogramming the memory. Other electronic speed controls may include programmable memory such as EEPROM or flash memory and a dedicated programming port to enable updating of the software functions or to correct programming errors.
SUMMARY OF THE INVENTION
[0004] The present invention provides a method and apparatus for reprogramming an electronic speed control (“ESC”) through the receive (“RX”) port of an electric radio controlled model vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a functional block diagram of a radio controlled model control circuit.
[0006] FIG. 2 is a functional block diagram of an electronic speed control circuit interfaced with a programmer.
[0007] FIG. 3 is a circuit diagram of the ESC programmer interface.
[0008] FIG. 4 is a circuit diagram of another embodiment of the ESC programmer interface.
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , a block diagram of a radio controlled model control circuit is generally indicated by reference numeral 10 . RC model control circuit 10 includes an electronic speed controller (ESC) 12 , a power supply such as a battery 14 , a DC motor 16 a radio receiver circuit 18 and an antenna 20 . Radio receiver 18 is connected to the electronic speed controller 12 through line 22 and connector 24 . In a typical application, the components of the radio controlled model control circuit 10 are mounted in a radio controlled model such as an airplane, for example. The antenna 20 and receiver 18 receive control commands from a transmitter (not shown) under the control of a user, and transmit the commands to the electronic speed controller 12 via line 22 through a three-pin connector 24 . Electronic speed controller 12 includes a microprocessor, program memory and associated electronic components (not shown). In response to commands received from the receiver 18 , the electronic speed controller 12 applies power from battery 14 to DC motor 16 . Electronic speed controller 12 controls the timing and duration of voltage pulses applied to the DC motor 16 as necessary in response to the commands sent from the transmitter.
[0010] Referring to FIG. 2 , a programmer adapter 26 may be connected to the electronic speed controller 12 using the same connector 24 and an adapter cable 28 to reprogram the electronic speed controller 12 , discussed in detail hereinbelow. Programmer 26 may connect to a USB or serial port, for example, on a personal computer 30 via cable 32 .
[0011] In greater detail referring to FIGS. 2 and 3 , programmer 26 includes a bidirectional signal line 34 connected to a send buffer 36 and a receive buffer 38 . A directional signal line 40 is connected to each of the buffers 36 and 38 to enable or disable the respective buffer. Power on lines 42 and 44 and ground on line 46 may be provided through the USB cable 32 from the USB port on the personal computer 30 , or may be supplied by the battery 14 connected to ESC 12 , for example.
[0012] The electronic speed controller 12 includes a microprocessor 47 , and an ESC interface 48 . The ESC interface 48 includes a buffer circuit similar to the buffer circuit for the programmer 26 . A receive buffer 50 and a send buffer 52 are connected to a bidirectional signal line 54 from programmer 26 and a signal line 56 from the microprocessor 47 . A direction signal line 58 is connected to each of the buffers 50 and 52 to enable or disable the respective buffer.
[0013] To reprogram the firmware in the ESC 12 , the battery 14 may be disconnected from the ESC 12 . The programmer 26 is connected to a USB or serial port of computer 30 with cable 32 . Cable 28 is then connected to connector 24 of the ESC 12 .
[0014] When power is applied to the ESC 12 on line 44 , the ESC 12 determines the function of the port 24 , i.e., whether it is connected to the receiver 18 or connected to the programmer 26 . If the signal on line 54 is an activation signal such as a consistent high voltage, then the ESC 12 is connected to the programmer 26 and will enter a programming mode. The consistent high level is generated by the pull-up resistor 60 on line 42 and connected to line 54 . If a high voltage signal is not detected by the ESC 12 on line 54 , then the ESC 12 is connected to the receiver 18 and will use the port 24 as a normal, unidirectional RX port by setting the direction line 58 on the ESC 12 low. The power 44 and ground 46 lines through the RX port 24 are used to power the ESC 12 and set a consistent ground level.
[0015] Once the ESC 12 enters the programming mode, the signal line 54 is treated as a single wire bidirectional bus. The PC 30 initiates all communications with the ESC 12 through the programmer 26 . Either the ESC 12 or the programmer 26 may put data on line 54 by actively pulling it to ground to indicate a low signal or by going into a high-Z state and allowing the pull-up resistor 60 on line 42 to pull the line 54 to a high signal level. Because there is no common clock signal between the ESC 12 and the PC 30 , data is input on line 54 and read from line 54 in a predetermined sequence. The PC 30 is responsible for negotiations and control of the ESC 12 .
[0016] Communication over the bus 54 is accomplished using data packets. All packets begin with a synchronization start field, followed by a packet identifier. The packet identifier indicates the type of packet such as a token, data or handshake, for example. An address field specifies the function, via its address, that is either the source or destination of a data packet, followed by the endpoint field. A data field includes an integral number of bytes depending on the packet identifier. A cyclic redundancy check or checksum field is used to ensure that the data is transmitted and received correctly.
[0017] When power is detected by the ESC 12 on line 54 , the ESC 12 sends out a start or connect byte of data on line 54 and waits for a response from PC 30 . If a response is not received within a predetermined amount of time, such as 10 milliseconds for example, the ESC 12 sends another byte of data on line 54 . This continues until the PC 30 responds or a maximum number of retries is exceeded, for example.
[0018] More particularly, when the programmer 26 is initially connected to the ESC 12 through RX port 24 , the PC 30 waits to receive the start or connect byte from the ESC 12 . Once the start or connect byte is received, the PC 30 sends a 16-byte data packet to the ESC 12 .
[0019] Typically, the first data packet includes instructions to reprogram or update the communication software on the ESC 12 , for example. Once the task is completed, the ESC 12 sends an acknowledgment along with a checksum. If the checksum is incorrect, the PC 30 ignores the response from the ESC 12 and sends the same data packet again.
[0020] Once the communication software in the ESC 12 is updated, if necessary, the motor controller software may be updated. Some of the commands that may be sent from the PC 30 to the ESC 12 include Erase Flash to erase the contents of the flash memory beginning at a specified memory address and Program Flash to program the flash memory with program data beginning at a specified memory address, for example.
[0021] Using the RX port 24 and programmer 26 interface, program parameters or settings stored in the firmware on the ESC 12 may be modified using software loaded on the personal computer 30 . Parameters such as the cutoff voltage, cutoff type, brake type, throttle type, soft start, motor settings, current, pulse frequency and rotation direction may be modified or adjusted, for example.
[0022] User upgradeable firmware on the ESC 12 allows the user to incorporate product improvements into existing controllers without returning the controller to the manufacturer or purchasing another controller. The user may add new functionality to the controller for a specific application or may reconfigure the controller for another application and use such as changing from airplane firmware to helicopter or race car firmware, for example. Additionally, bug fixes and upgrades may be easily, quickly and inexpensively distributed to end users.
[0023] Referring to FIG. 4 , another embodiment of an ESC programmer interface circuit is illustrated. In both the programmer 80 and ESC 82 , a MOS FET transistor 84 and 86 , respectively, each with an open drain output 88 and 90 , respectively, is used to drive an RX signal line 92 . Components corresponding in function to components designated in FIGS. 1-3 are designated with the same reference numerals with the addition of the “a” notation. As described hereinabove for line 54 , line 92 is a bidirectional bus for communication between the ESC 12 and the PC 30 .
[0024] It should be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto except insofar as such limitations are included in the following claims. | A method and apparatus for programming an electronic speed controller for a radio controlled model including a programmer for interfacing a personal computer to the RX port of the electronic speed controller. The electronic speed controller software may be updated, modified or replaced through the RX port. | 7 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to a copy protected document and more particularly to a copy protected document which when replicated by photocopying or any scanning-type copying device will indicate that the document is a copy.
[0002] Secured documents and negotiable instruments are easily copied or reproduced for counterfeiting purposes with the use of a black and white or color copier. Additionally, with the introduction of desk top publishing software and in combination with hardware such a personal computers and scanners, it is relatively easy to reproduce high quality copies of documents. The sophistication of these copying methods is such that is it very difficult to distinguish original documents from the reproductions. Numerous attempts have been made at trying to prevent copies from being made of original documents. Many techniques have been developed to prevent reproduction of security documents such as checks, bank notes, paper currency, stock certificates, passports, and licenses. One technique is to hide a warning message within the document that reappears upon a reproduced document. This hidden message is invisible or nearly invisible to an observer of the original document. However, upon a copy being made of the original document, the copy will visibly show thereon a warning message, such as the words VOID, COPY, UNAUTHORIZED, or DUPLICATE. An example of this technique is the use of the combination of a single tone warning phrase and a single tone background pattern. Tone is used to mean the visual effect produced by solid ink coverage or by half-tone dots, bars, marks, or lines which cover a portion of the printed area of a document. These warning phrases or patterns typically have a frequency that is measured in dots, lines, or marks per inch. Half-tone dots, bars, marks, or lines may be more or less uniformly distributed over an area to produce the visual effect.
[0003] Other examples include using a background and a warning phrase, which are each made up of half-tone elements of two pairs of element sizes. For example, the background may be made with about 50% of 130 lines per inch and 0.005 inch diameter elements such as dots, and the balance of the 130 lines per inch having 0.006 inch diameter dots. The warning message may consist of about 50% of the elements being 65 lines per inch with 0.010 inch diameter dots and the remainder of the 65 lines per inch having 0.012 inch diameter dots.
[0004] These methods have been, for the most part, successful in protecting documents from being copied. It has been found that the copying protection of these documents may be avoided by the simple adjusting of the settings for sharpness and darkness on a copier. Additionally, some documents have had their copying protection defeated by copying the document at different angles. By adjusting the angle at which the copy is placed on a copier, it is possible to produce a copy in which the warning is not visible. Therefore, it is desirable and advantageous to provide a copy protected document which is not susceptible to overriding its copy protected status by copying the document at different angles.
SUMMARY OF THE INVENTION
[0005] In one form of the present invention, a copy protected document comprises a document having a surface for receiving printed images, a first image which indicates that a copy of the document has been made, the first image comprising a series of concentric circles radiating out from a central point, and a second image which hides the first image.
[0006] In another form of the present invention, a copy protected document comprises a document having a surface for receiving printed images, a series of first images which each indicate that a copy of the document has been made, each of the first images comprising a series of concentric circles radiating out from a central point, and a second image which hides the series of first images.
[0007] In yet another form of the present invention, a method of making a copy protected document which has a surface for receiving printed images is disclosed. The method comprises the steps of printing a first image on the surface of the document, the first image comprising a series of concentric circles radiating out from a central point and which indicates that a copy of the document has been made, and printing a second image which hides the first image.
[0008] In light of the foregoing comments, it will be recognized that a principal object of the present invention is to provide an improved copy protected document which protects against counterfeit copies being made of the original document.
[0009] Another object of the present invention is to provide a copy protected document which is of simple construction and design and which can be easily employed with highly reliable results.
[0010] A further object of the present invention is to provide a copy protected document which has a hidden image or message printed thereon which is invisible until copied and will appear independent of the angle at which the document is copied.
[0011] A still further object of the present invention is to provide a copy protected document which prevents against copying by adjusting the settings on a copier or against copying by using a desk top publishing system.
[0012] These and other objects and advantages of the present invention will become apparent after considering the following detailed specification in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is an illustration of a preferred embodiment of a copy protected document constructed according to the present invention;
[0014] [0014]FIG. 2 is an illustration of a copy of the copy protected document shown in FIG. 1 which is obtained after being copied by use of a copier; and
[0015] [0015]FIG. 3 is an illustration of a pattern which is used to be hidden within the copy protected document constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring now to the drawings, wherein like numbers refer to like items, number 10 identifies a preferred embodiment of a copy protected document 10 constructed according to the present invention. With reference now to FIG. 1, the copy protected document 10 is shown as a blank check 12 which does not have any printed information on it yet, such as customer information, bank name, or check number. The check 12 is rectangular in shape and has printed thereon a subdued printed design or pattern 14 , such as a basket weave type pattern, which consists of various dots, lines, or combination of dots and lines. The printed pattern 14 may be printed by using various well-known methods, such as intaglio, gravure, or rotogravure. Embedded or hidden within the pattern 14 is an image (not shown) which when copied will appear on the copy of the check 12 . The check 12 is shown as would be seen by an observer. Although a check 12 is shown in FIG. 1, it should be appreciated that other security type documents or other printed documents which need protection from copying could be used.
[0017] Referring now to FIG. 2, a photocopy 16 of the check 12 is illustrated. The photocopy 16 is the result of an attempt to copy the check 12 by use of, for example, a copier machine. The photocopy 16 shows an image 18 , such as the words VOID, which was not visible on the original document or check 12 . Additionally, a portion of the pattern 14 is still visible on the photocopy 16 in the area where the image 18 does not show or interfere. Due to the appearance of the image 18 . the ability to counterfeit or copy the original check 12 is eliminated.
[0018] [0018]FIG. 3 shows a pattern 40 that is used to form the image 18 . The pattern 40 is formed by constructing each letter or character, such as the letter V 42 , the letter O 44 , the letter I 46 , and the letter D 48 , from concentric circular lines 50 that radiate out from a central point 52 . The design of the circular lines 50 is a rule weight of 0.1 point. The circular lines 50 increase in size at a rate of 0.02 inches per circle. The density of a screen is approximately 15% that these circles can be hid. When photocopied at any angle, the image 18 will be distinguishable.
[0019] The process of creating the circular lines 50 is accomplished using graphic arts or typesetting electronic software. Each character, such as the letter V 42 , of the image 18 is treated as a separate logo or piece of artwork. Using “outline and fill” commands, the area of each character 42 , 44 , 46 , or 48 , is filled with the concentric circular lines 50 that radiate from the central point 52 . The pattern 14 or background or second image consists of dots, lines, or a combination of dots and lines, and the density of these elements is adjusted so that the complete information including the hidden image 18 has the same visual appearance when viewed by the unaided eye. However, when photocopied, the circular lines 50 create an interference on the copier or scanner. The reproduction process magnifies this interference which causes the pattern 18 to be prominent on the copy 16 . Because the circular lines 50 encompass all angles, it does not matter at what angle the document is copied and the image 18 will appear on the copy 16 .
[0020] The basic method of the present invention teaches the inclusion of circular lines radiating outwardly which are embodied and integrally formed into art, pictures, or other forms of images in an original document. The circular grid lines are formed so as to differentiate from the linear grids employed by the scanning mechanisms of the machines used to replicate these black and white or colored documents. After the original documents has been created any attempt at imitation or reproduction by use of a scanning type copier will result in the generation of interference patterns which are readily discernible from the original document. The copied document is not an exact duplicate of the original document because a hidden image or message will now appear on the copied document. In this manner, duplication or counterfeiting of documents is prevented and any attempt at trying to manipulate the angle at which the document is copied will also result in the hidden message appearing.
[0021] As can be appreciated, it should be noted that other words or images may be incorporated within the copy protected document of the present invention. Any word, image, object, symbol, or device which is hidden until a copy is made is suitable for preventing copying of an original document. For example, although the word VOID has been used, it is also possible and contemplated to use other words, such as COPY, DUPLICATE, or COUNTERFEIT, as long as it is evident that the document is a copy of the original.
[0022] From all that has been said, it will be clear that there has thus been shown and described herein a copy protected document which fulfills the various objects and advantages sought therefor. It will become apparent to those skilled in the art, however, that many changes, modifications, variations, and other uses and applications of the subject copy protected document are possible and contemplated. All changes, modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow. | A copy protected document is disclosed which comprises a document having a surface for receiving printed images, a first image which indicates that a copy of the document has been made, the first image comprising a series of concentric circles radiating out from a central point, and a second image which hides the first image. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims benefit of U.S. Provisional Patent Application Serial No. 60/407,077, filed Aug. 30, 2003, the disclosure of which is incorporate herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the synthesis of N-vinylformamide, and particularly, to the synthesis of N-vinylformamide using cyclic anhydride reagents.
[0003] N-vinylformamide (NVF) is a monomer with potentially useful properties in that it free-radically polymerizes to produce water-soluble poly(N-vinylformamide) (PNVF) and also undergoes controlled radical polymerization using RAFT methodology. Badesso, R. J.; Nordquist, A. F.; Pinschmidt, Jr. R. K.; and Sagl, D. J. “Hydrophilic polymers: performance with Environmental Acceptance”, Glass, E.; Ed.; America Chemical Society, Washington, D.C., 1995, p489. PNVF is probably the most practical precursor for preparation of poly(vinylamine). Because vinyl amine is unstable and hence cannot be maintained, PNVF is likely the best route to the generation of polyvinyl amine, a useful and less toxic alternative to polyacrylamide and other cationic, water-soluble polymers PNVF is easily hydrolyzed under basic or acidic conditions to form poly(vinylamine).
[0004] There are three known commercial routes to NVF. For example, BASF, at its Ludwigshafen, Germany site, reacts acetaldehyde with HCN, then formamide, forming the cyanoethyl formamide (FAN). FAN is then “cracked” to NVF plus HCN, where the latter is recycled. The BASF Ludwigshafen, Germany site is one of the few sites in the world skilled in HCN chemistry. As this highly toxic chemical cannot be transported, the process is most likely restricted to Ludwigshafen.
[0005] Mitsubishi developed a process whereby acetaldehyde is reacted with formamide to form hydroxyethyl formamide (HEF) using either acid or base catalysis. HEF is then reacted with methanol to form methoxyethyl formamide (MEF) using an acid catalyst with the loss of water. HEF is finally cracked to methanol and NVF, and the NVF purified. It has been reported that the NVF material synthesized by this method, exhibited lower than desired purity.
[0006] Air Products developed an alternative route to NVF wherein HEF is reacted with additional formamide (over a solid acid catalyst) to form the ethylidene bisformamide (BIS) plus water. BIS is then cracked (pyrolyzed) to form NVF plus formamide (wherein the latter is recycled). The NVF is then vacuum distilled. It is quite important in the operation of this process to minimize the hydrolysis of formamide (creating ammonia that fouls the catalyst) during BIS formation. Obviously the presence of water during this reaction creates problems.
[0007] It is very desirable to develop alternative routes to the synthesis of N-vinylformamide.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention provides a process to produce N-vinylformamide including the steps of: reacting hydroxyethyl formamide with a reactant including at least one cyclic anhydride group to form an ester, and dissociating (or cracking) the ester to synthesize N-vinylformamide and a compound including at least one diacid group. The ester can be dissociated using heat. The reactant including at least one cyclic anhydride group can, for example, be succinic anhydride, maleic anhydride, phthalic anhydride, a polymer including at least one cyclic anhydride group, or a solid support to which at least one cyclic anhydride group is covalently tethered. Preferably, the cyclic anhydride is regenerated from the diacid formed in the synthesis of the ester. The anhydride can, for example, be regenerated by heating the diacid to dehydrate the diacid or by passing the diacid over a dehydration catalyst. Homogeneous or heterogeneous dehydration catalysts can be use (for example, zeolite, resins acids, vanadium oxide, phosphoric oxide or any other dehydration catalyst as known to those skilled in the art). The conditions required to dehydrate diacid groups are preferably different from the conditions used to dissociate the ester. For example, in the case that heat is used to dehydrate the diacid, the temperature required for dehydration can be higher than the temperature used to dissociate the ester.
[0009] As used herein, the term “polymer” refers to a compound having multiple repeat units (or monomer units) and includes the term “oligomer,” which is a polymer that has only a few repeat units. The term polymer also includes copolymers which is a polymer including two or more dissimilar repeat units (including terpolymers—comprising three dissimilar repeat units—etc.).
[0010] Although the reaction can be carried out without the use of solvent, a solvent can be added. Suitable solvents include aprotic or aromatic solvents. Preferably, such solvents do not interfere with the reactions of the present invention. NVF can be used as a solvent in the process. Examples of other suitable solvents include, but are not limited to, toluene, xylene, acetonitrile, ether, dimethyl sulfoxide and/or acetaldehyde. Suitable solvents also include isoparafin-like solvents, including, but not limited to, the products sold by Exxon Corporation under the name ISOPAR®, which are generally non-toxic in nature.
[0011] In one embodiment a solvent (for example, NVF) is used in which NVF is soluble and in which a polymer including at least one cyclic anhydride group is at least partially soluble. However, the polymer including at least one ester group formed in the synthesis and the polymer including at least one diacid group formed in the synthesis have no or limited solubility in the solvent.
[0012] Generally, polymers used in the process of the present invention preferably include or incorporate a plurality of cyclic anhydride groups. For example, a copolymer of methyl vinylether and maleic anhydride can be used. The methyl vinylether/maleic anhydride copolymer can, for example, have a weight average molecular weight in the range of approximately 190,000 to 3,000,000. The polymer can also be a reaction product of an alpha olefin or a mixture of alpha olefins with maleic anhydride. In one embodiment, the alpha olefin is a C-18 alpha olefin and the co polymer has a molecular weight of at least 20,000. The polymer can also be a methyl vinylether/maleic anhydride/decadiene copolymer. Another suitable polymer for use in the present invention is a copolymer of styrene and maleic anhydride. The styrene/maleic anhydride copolymer can, for example, have a weight average molecular weight of at least 2000.
[0013] In one embodiment the polymer is a solid in the reaction. For example, the polymer can be a porous crosslinked solid. Preferably, the porous polymer has a relatively high surface area.
[0014] In one embodiment in which the reactant including at least one cyclic anhydride group is a solid support to which at least one cyclic anhydride group is covalently tethered, the solid support is silica.
[0015] In another embodiment, acetaldehyde, formamide and the reactant including at least one cyclic anhydride group are mixed in a single reaction vessel, wherein hydroxyethyl formamide is formed in the reaction vessel to react with the reactant including at least one cyclic anhydride group.
[0016] In another aspect, the present invention provides a process to produce N-vinylformamide including the step of: mixing acetaldehyde, formamide and a source of anhydride in a single reaction vessel. The anhydride reacts with hydroxyethyl formamide formed in the reaction vessel to form an ester as described above. The ester is dissociated (or cracked) as described above to synthesize N-vinylformamide and a compound including at least one diacid group. In one embodiment, the source of anhydride is a reactant including at least one cyclic anhydride group. The reactant including at least one cyclic anhydride group can, for example, be succinic anhydride, maleic anhydride, phthalic anhydride, a polymer including at least on cyclic anhydride group, or a solid support to which at least one cyclic anhydride group is covalently tethered. In one embodiment, the acetaldehyde to formamide mole ratio can, for example, be at least two. However, lower acetaldehyde to formamide mole ratios can be used. An acid or base catalyst can be used in the reaction to make hydroxyethyl formamide.
[0017] The process of the present invention can be carried out continuously or batchwise. Suitable reactors include, but are not limited to, tubular reactors and stirred tank reactors.
[0018] In still another aspect, the present invention provides a reagent including at least on cyclic anhydride group covalently tethered to a solid support. The solid support can, for example, be silica. Preferably, a plurality of cyclic anhydride groups are tethered to the solid support.
[0019] The present invention, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 illustrates the sequential synthesis of NVF via first synthesizing HEF, reacting HEF with acetic anhydride and cracking the resulting ester to form NVF.
[0021] [0021]FIG. 2 illustrates a one pot synthesis of NVF of the present invention wherein acetaldehyde, formamide and acetic anhydride are mixed.
[0022] [0022]FIG. 3A illustrates an embodiment of a synthetic route to NVF of the present invention wherein a cyclic anhydride is reacted with HEF to form an HEF-adduct, which is subsequently cracked to form NVF.
[0023] [0023]FIG. 3B illustrates a sequential synthesis under the general synthetic route of FIG. 3A.
[0024] [0024]FIG. 3C illustrates a one-pot synthesis under the general synthetic route of FIG. 3A.
[0025] [0025]FIG. 4 illustrates an embodiment of a synthetic route of the present invention in which a poly(styrene-co-maleic anhydride) copolymer is reacted with HEF.
[0026] [0026]FIG. 5A illustrates a cyclic anhydride covalently tethered to a solid support for use in the synthetic methods of the present invention.
[0027] [0027]FIG. 5B illustrates one embodiment of a synthetic route to the synthesis of a silica supported cyclic anhydride.
DETAILED DESCRIPTION OF THE INVENTION
[0028] [0028]FIG. 1 illustrates a sequential synthesis of NVF developed at Air Product wherein HEF is first synthesized via the reaction of acetaldehyde and formamide. See Parris, G. E. and Armor, J. N, Applied Catalysis, Vol. 78, pp 65-78 (1991). HEF is then reacted with acetic anhydride to form an HEF adduct The resulting HEF adduct/ester is subjected to heat (cracked) to form NVF.
[0029] The present inventors have discovered that NVF can also be formed via a single reaction mixture including acetaldehyde, formamide and an anhydride such as acetic anhydride as illustrated in FIG. 2. The resulting HEF adduct is cracked to form NVF, The one-pot or single reactor synthesis of the present invention can, for example, provide cost savings by reducing unit operation costs. As expected from studies of the sequential synthetic route, the reaction rate increased in the one-pot synthesis with increasing temperature. As monitored by IR, for example, the anhydride peak was found to disappear in 42 hours at room temperature (approximately 22° C.), in 23 hours at 50° C., and in 7.5 hours at 100° C., in the sequential synthesis. IR analysis of a one-pot synthesis according to FIG. 2 also demonstrated disappearance of the anhydride peak over time. The temperature of the reaction of the present invention is generally approximately 0° C. to 150° C., preferably approximately 20° C. to 100° C., and more preferably approximately 30 to 80° C. In the studies of the present invention, a reaction temperature in the range of approximately 30° C. to approximately 80° C. was used. Either an acid catalyst or a base catalyst can be used. If an acid catalyst is used, only a catalytic amount of acid is preferably added to the reaction mixture (for example, 0.001-0.2 times the stoichiometry to HEF). Example of suitable acid catalysts include, but are not limited to, sulfuric acid, paratoluenesulfonic acid, methane sulfonic acid, amberlyst or any other acidic ion exchange resin. If a base catalyst is used, a nearly stoichiometric amount of base can be required (for example, 0.2 to 5 times the stoichiometry to HEF). Suitable homogeneous catalyst for use in the present invention include, but are not limited to, triethylamine, pyridine and caustic catalysts. In general, any basic ion exchange catalyst such as Amberlite, Lewatit, Puralit is also suitable. Basic zeolites can also be suitable in certain cases.
[0030] In each of the synthetic routes of FIGS. 1 and 2, however, two moles of acetic acid are produced during the synthesis of one mole of NVF. One mole of acetic acid is produced in the synthesis of the HEF adduct, and another mole of acetic acid is produced during cracking of the HEF adduct. Acids such as acetic acid destabilize NVF. Moreover, the removal of such acids via, for example, distillation is difficult as the relative volatilities of the acid and NVF are similar.
[0031] In another aspect of the present invention as illustrated, for example, in FIGS. 3A through 3C, an alternative route to the synthesis of NVF is provided in which a cyclic anhydride is reacted with HEF. In the synthetic route of the present invention, HEF is reacted with a cyclic anhydride to form the corresponding ester (HEF adduct). The ester is then cracked to NVF plus the corresponding diacid under very mild conditions (for example, temperatures less than 25° C.). The temperature of cracking is generally approximately 0° C. to 250° C., preferably approximately 20° C. to 200° C., and more preferably approximately 60 to 180° C.
[0032] While one can form NVF from a simple, non-cyclic anhydride (for example, acetic anhydride as illustrated in FIGS. 1 and 2), this reaction produces a very soluble acid byproduct which ultimately destabilizes the NVF as described above. Once again, the removal or separation of the resultant acids using non-cyclic anhydrides is very difficult. In the synthetic route of the present invention, relatively heavy cyclic anhydrides (many of which are commercially available or readily synthesized from commercially available reagents) are reacted with HEF to produce the corresponding HEF adduct and a diacid. No byproduct is produced. The diacid generated during the cracking step is generally less soluble than, for example, acetic acid formed in the synthetic route of FIGS. 1 and 2. Indeed, in several embodiment of the present invention in which a solubilized source of cyclic anhydride is used, the diacid may precipitate as a solid as it is formed. Examples of cyclic anhydrides suitable for use in the synthetic processes of the present invention include maleic anhydride, succinic anhydride and phthalic anhydride (the structures of which are set forth in FIG. 3A).
[0033] The diacid formed in the synthesis of the present invention can be recycled and dehydrated to reform the anhydride. This recycling dehydration step can generally occur at a temperature higher than the temperature used to crack the HEF adduct and results in the formation of water. The temperature of the dehydration is generally approximately 100° C. to 450° C., preferably approximately 120° C. to 300° C., and more preferably approximately 150 to 250° C. A dehydration catalyst can also be used to lower the temperature of dehydration, but is preferably not present in the cracking step to avoid the undesirable formation of water when NVF is formed. Suitable dehydration catalysts include homogeneous and heterogeneous catalysts (for example, zeolite, resins, acids, vanadium oxide, phosphoric oxide and any other dehydration catalyst as known to those skilled in the art). Unlike several current synthetic routes to NVF, the water produced in the recycling step of the present invention is formed “offline” and will not result in hydrolysis of the formamide precursor or the NVF product. Moreover, the synthetic route of the present invention requires less stringent conditions than current synthetic routes and hence can provide a product of increased purity. NVF of increased purity, for example, allows for generation of higher molecular weight poly(NVF)).
[0034] Various “substituted” cyclic anhydrides can be used in the synthetic route of the present invention to further decrease any adverse effects upon the NVF product of the diacid produced in the synthesis of the present invention. Generally, the use of such substituted cyclic anhydrides preferably reduces the solubility of the resulting diacid in the process solvent and/or facilitates the separation of that diacid from the NVF product. For example, in one embodiment a polymeric material including cyclic anhydride groups can be reacted with HEF. In the embodiment of FIG. 4, for example, a copolymer of styrene and maleic anhydride was used as the source of cyclic anhydride. In this embodiment, the cracking reaction produced liquid NVF and generally insoluble or reduced solubility polymer including diacid groups.
[0035] Polymers including cyclic anhydride groups for use in the present invention can be soluble in a solvent in which the reaction is carried out. As HEF is a solid at room temperature, the adduct of HEF and the anhydrides used in the present invention may in some cases also be a solid. Thus, the use of a solvent/co-solvent may be required. As any solvent used in the processes of the present invention is typically ultimately required to be separated from the NVF product, it is advantageous to use NVF as a process solvent in the reactions of the present invention. In using NVF as the process solvent, a recycle stream can be taken from an intermediate point in the process to provide the needed solvent. In the case that a soluble polymer including cyclic anhydride groups are used, the resulting polymer containing diacid groups preferably readily precipitates from solution (for example, upon formation or upon addition of a co-solvent or other additive) and/or is preferably readily otherwise separable from the NVF product. Separation of the polymer including diacid groups from NVF is typically readily achieved given the substantial difference in molecular weight between NVF and the polymer including diacid groups.
[0036] Because of the great difference in the volatilities of the diacid and NVF, it is possible, for example, to separate the monomer by a short residence time flash stripping leading to an enhanced quality of monomer. Melt crystallization can also be used to separate the monomer from a third solvent used to remove the diacid. Conditions of cracking (temperature and vacuum) can also be adjusted to flash the monomer as soon as it is formed. If the solid ester is heated at, for example, 150° C. and 2 mm Hg, NVF will naturally be formed in a gaseous state and can be condensed as pure NVF in another vessel.
[0037] Additionally, polymers including cyclic anhydride groups that are insoluble in the process solvent (for example, solid polymers) can also be used in the present invention. As reactions of HEF with such insoluble polymers will occur only at the surface of the polymer, the surface area of such polymer is preferably relatively high. Such polymers can, for example, be synthesized as porous polymeric beads in a manner similar to the synthesis of, for example, polymeric ionic exchange beads as known in the art. In one embodiment, for example, divinyl benzene can be used as a crosslinker in a copolymer of divinyl benzene, styrene and maleic anhydride to produce a high surface area, porous polymer bead including cyclic anhydride groups for use in the reactions of the present invention. Preferably, the surface area is maximized. A surface area of, for example, at least 10 m 2 /g is preferred. As the resulting diacid is covalently bound to the solid polymer, the detrimental effect of the diacid groups upon the NVF product is not substantial.
[0038] As illustrated in, for example, FIG. 5A, in another embodiment of the present invention, cyclic anhydride reagents for use the present invention can be immobilized upon a solid support (for example, a polymeric bead or a silica support). FIG. 5B illustrates one embodiment of immobilization of a cyclic anhydride group on silica. Supports other than silica (for example, glass, alumina and activated carbon can also be used to immobilize the cyclic anhydride reagents of the present invention.
[0039] The cyclic anhydrides of the present invention can be reacted in either a sequential synthesis or a one-pot synthesis to form NVF as described above. In the generalized formula of a cyclic anhydride suitable for use in the present invention, R 1 and R 2 can independently be chosen from a very broad range of substituents. It is believed that electron withdrawing groups (for example, NO 2 , halo group (for example, Cl, F or Br) and —CN) may result in a faster reaction time. In the case that a polymer including or incorporating cyclic anhydride groups is used, R 1 and R 2 can, for example, be styrene or vinyl repeat groups. Virtually any vinyl monomer (for example, vinyl ether) is suitable for use in synthesizing polymers suitable for use in the present invention. Maleic anhydride typically copolymerizes in an alternative fashion. Thus R 1 and R 2 can be the same in the case of copolymerization of maleic anhydride. Styrene is an attractive comonomer as formation of crosslinked porous beads is readily achieved using styrene as a comonomer.
[0040] A number of polymeric anhydrides suitable for use in the present invention are commercially available. For example, a methyl vinylether/maleic anhydride copolymer is available from ISP Chemicals under the name GANTREZ® in the molecular weight range of 190,000 to 3,000,000. The polymer has the general formula:
[0041] A methyl vinylether/maleic anhydride decadiene crosslinked polymer is also available from ISP Chemicals under the name STABILEZE®.
[0042] A copolymer of a C-18 alpha olefin with maleic anhydride have the following formula:
[0043] is available from Chevron Phillips under the produce name PA-18 Polyanhydride Resin.
[0044] Styrene maleic anhydride copolymers having the general formula:
[0045] are available, for example, from Sartomer of Exton, Pa.
[0046] Experimental Examples
[0047] In the studies of the present invention, some of the quantities were varied between experiments but the quantities set forth in the examples below are representative values and scales. No attempt was made to optimize any of the reactions studied.
[0048] (1) One-Pot Reaction of Acetaldehyde, Formamide and Acetic Anhydride
[0049] i) No solvent: Acetaldehyde [21 ml; 0.377 mol], formamide [5 ml; 0.126 mol; containing 0.5 mol % K 2 CO 3 ] and acetic anhydride [6 ml; 0.062 mol] were added to a flask and stirred at approximately 10° C. for 2 h. The reaction was allowed to warm to room temperature over 1 h and then heated to 70° C. IR monitoring was done throughout, demonstrating disappearance of the anhydride peaks and indicating the synthesis of the HEF adduct.
[0050] ii) With solvent: The same method as i) was followed but in addition, 40 ml of isooctane was added at the start of the reaction. Two layers were present throughout the reaction. IR monitoring was done throughout, demonstrating disappearance of the anhydride peaks and indicating the synthesis of the HEF adduct.
[0051] (2) Production of NVF Using Poly(Styrene-Co-Maleic Anhydride)
[0052] Sequential addition: Acetaldehyde [5.66 ml; 0.10 mol] was dissolved in dioxane [20 ml] at 10° C. Formamide [01 ml; 0.025 mol; containing 0.5 mol % K 2 CO 3 ] was added dropwise, and the reaction was stirred at 10-15° C. for 2 h. Poly(styrene-co-maleic anhydride) [68 wt % styrene; Mn˜1700] [8.29 g] was dissolved in dioxane [50 ml] and the solution added to the reaction. IR monitoring was done throughout the reaction. Anhydride peaks substantially reduced but did not completely disappear in IR over the time the reaction was carried out. Synthesis of NVF was confirmed by NMR.
[0053] (3) Preparation of Tethered Anhydride
[0054] i) As illustrated in Scheme 1 below, Allylsuccinic anhydride [0.67 g; 0.005 mol], (3-mercaptopropyl-trimethoxysilane [2.8 g; 0.014 mol] and AIBN [50 mg] were dissolved in chloroform [60 ml] and refluxed overnight. Solid product was filtered off, and the solvent was removed from the filtrate to leave a yellow oil.
[0055] ii) The product from i) was added to a stirred suspension of silica gel [8 g; surface area ˜500 m 2 /g] in toluene [200 ml] and stirring was continued at room temperature for approximately 20 h. The silica (i.e. tethered anhydride) was then filtered off and washed with toluene.
[0056] (4) Reaction of tethered anhydride
[0057] HEF and the tethered anhydride were reacted at 80° C. in dioxane. The silica support was then filtered from the reaction mixture. The remaining reaction components were then heated at 100° C. for approximately 6 hours.
[0058] The foregoing description and accompanying drawings set forth the preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. | A process to produce N-vinylformamide includes the steps of: reacting hydroxyethyl formamide with a reactant including at least one cyclic anhydride group to form an ester, and dissociating (or cracking) the ester to synthesize N-vinylformamide and a compound including at least one diacid group. The ester can be dissociated using heat. The reactant including at least one cyclic anhydride group can, for example, be succinic anhydride, maleic anhydride, phthalic anhydride, a polymer including at least one cyclic anhydride group, or a solid support to which at least one cyclic anhydride group is covalently tethered. Preferably, the cyclic anhydride is regenerated from the diacid formed in the synthesis of the ester by heating the diacid to dehydrate the diacid. The temperature required to dehydrate diacid groups is preferably higher than the temperature use to dissociate the ester. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to toy devices, and more specifically, to a toy device which can be twisted into a plurality of configurations.
2. Prior Art
It has long been recognized that certain devices which enable the user to manually move the device have gained wide acceptance. Perhaps one of the earliest forms of such devices are "worry beads" which have been popular for hundreds of years in many middle eastern countries. While it is not certain what the reasons are for such beads to have remained popular, it is believed that it is related to the fact that the movement of the beads require some degree of manual dexterity. Other devices of this type include a "touch stone". A touch stone is generally a uniquely shaped stone which is slid across the fingers of the hand and provides the user with a pleasant feeling.
While devices of these types have only achieved limited success in the United States, it is believed that a device that could be twisted into a plurality of configurations would satisfy the user's needs for manual dexterity. On the other hand, there are a number of devices which can be twisted and flexed, but for a variety of reasons, have not gained wide acceptance. One of these devices is disclosed in U.S. Pat. No. 3,662,486. In that patent, a series of units are disclosed each having the shape of a polyhedron. Each polyhedron is equipped with connecting means such that individual polyhedrons may be connected to each other in order to form an elongated string or series. In one embodiment, they are joined together so as to form a closed loop which is capable of being turned up to 360° inside of itself. While the device set forth in the U.S. Pat. No. 3,662,486 does not allow one to manually rotate the device, each of the pieces is of rather complex geometry adding to the cost of such device. Furthermore, the number of geometric configurations which can be formed are substantially limited by the manner in which the polyhedrons are joined together. Other similar type devices are disclosed in U.S. Pat. Nos. 1,853,436; 2,208,149; and 3,977,683. In these patents, rod-like members are joined together at the ends thereof in order to form a variety of geometric configurations. However, the device shown in such patents are likewise specifically limited in terms of the geometric patterns which can be obtained, and do not provide the twisting action achieved by the device of the present invention. The present invention, therefore, represents an advancement in the art of moveable toy-like devices, and contains none of the aforementioned shortcomings associated with prior art devices. In addition, the method of joining each of the various members together of the present invention enables a wide variety of geometric configurations to be achieved while maintaining a generally closed loop configuration. The present invention thus provides a device which satisfies the need for manual dexterity, but does so in a manner which permits the device to be constructed of low cost components in a simple and straight forward manner.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to twistable devices, and more specifically, to a device which while functioning primarily as a toy, can also be used to illustrate a wide variety of geometric patterns, as well as an aid where manual dexterity can be improved by the twisting action of the hands. In the present invention, a series of joining members are joined together such that each member is axially rotatable with respect to adjacent members. As each of the members are twisted, a plurality of geometric configurations can be made. Further, by providing the device with uniquely designed joining means, the device of the present invention can be made with low cost materials.
In one embodiment, the device of the present invention is comprised of a series of shaped tubes which are joined together so as to form a closed loop. The tubes are joined together by a cord which passes through each of the tubes. As the tubes are twisted, they are caused to axially rotate in such a manner that while a closed loop configuration is maintained, a plurality of configurations are achieved.
In other embodiments, the shapes of the joining members are changed and/or the means of joining the adjacent members together. In all such embodiments, however, the joining members are axially rotatable with respect to adjacent members, and enable the device to provide the user with a pleasing form of manual movement.
It is therefore one object of the present invention to provide a toy-like device which can be twisted into a plurality of configurations.
It is yet another object of the present invention to provide a device which enables various members to be joined together in a rotatable manner so as to maintain a general closed loop configuration.
It is yet another object of the present invention to produce a rotatable toy-like device in a simple and straight forward manner.
The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objective and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings in which a presently preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, the the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a first embodiment of the novel device of the present invention.
FIG. 2 is a perspective view showing a different configuration of the first embodiment of the present invention.
FIG. 3 is a perspective view showing the twisting characteristics of the first embodiment of the present invention.
FIG. 4 is yet another perspective view showing the twisting characteristics of the first embodiment of the present invention.
FIG. 5 is a cross-sectional view showing how the members are joined together.
FIG. 6 is a cross-sectional view showing another embodiment of how the members can be joined together.
FIG. 7 is a perspective view of a second embodiment of the present invention.
FIG. 8 is a perspective view of a third embodiment of the present invention.
FIG. 9 is a perspective view of a fourth embodiment of the present invention.
FIG. 10 is a perspective view of a fifth embodiment of the present invention and illustrates yet another manner in which the various members can be joined together.
FIG. 11 is a perspective view showing a sixth embodiment of the present invention.
FIG. 12 is a perspective view of the sixth embodiment of the present invention which has been twisted into a different configuration.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, the first embodiment of the present invention is clearly shown. In this embodiment, the device 10 is comprised of a series of joining members 12 which are rotatably joined together so as to form first and second closed loops. In the first embodiment of the present invention, two types of sections are used to form each joining member 12. These sections are indicated as sections 14 and 16. Section 14 forms a general right angle or L-shape bend and is comprised of a first sub-section 22 and a second sub-section 23. Section 16, in turn, has a generally T-shape configuration and is formed of intersecting sub-sections 24 and 25. In the first embodiment of the present invention, the device 10 is comprised of a series of ten interconnected members. These members are each identified as elements 30, 32, 34, 36, 38, 40, 42, 44, 46 and 48, respectively. More specifically, the first embodiment is comprised of eight right angle bend sections 14 and two T-shape sections 16. The result of interconnecting the various members 12 together is a configuration having two joined loops which can be twisted as hereinafter described.
As discussed hereinabove, one improvement of the present invention over the prior art is the fact that the joining members 12 of the present invention are joined to adjacent members so as to be axially rotatable. It has been found that this axial rotation provides the user with a pleasing form of manual movement. In addition, in the preferred embodiment, the members 12 are made of a plastic tubing such as is commonly used in the construction industry. Preferably, members 12 are made of polyvinyl chloride or other similar plastic tubing material. This type of tubing material not only enables the axial rotation to take place, but also has a smooth finish which provides the user with a pleasant feel.
Referring now to FIG. 2, one can see that the various members 12 have been axially rotated so as to form what is referred to herein as a "chair" configuration. One can see that members 42 and 44, as well as members 32 and 34, have been sufficiently twisted so as to form sections which are parallel with respect to each other at opposite ends of the device 10.
Referring now to FIGS. 3 and 4, one can see the twisting action illustrated by phantom lines of the various members 12 so as to achieve a plurality of geometric configurations. In the preferred embodiment, this is achieved by making each of the various members 12 axially rotatable with respect to adjacent members. This rotation, however, is such that as between two adjacent members, each member is axially rotatable a little more than 180° with respect to the adjacent member. After traveling a little more than 180° in one direction, the continued rotation of a member 12 will cause it to return to its initial starting point by traveling along the same path in the opposite direction. By such action, the entire device 10 can be twisted in a 360° manner.
One problem with the prior art devices was that the means which were used to join the various sections together were such that axial rotation was precluded. The present invention enables the axial rotation to take place by disposing an elastic cord 54 or other similar member as shown in FIG. 5 which runs internally through the closed loop configuration through each of the members 12 and which also forms a closed loop. Cord 54 helps maintain the integrity of device 10 and whatever configuration into which the device 10 is twisted. In the preferred embodiment, a sleeve 50 is disposed between and circumferentially surrounded by adjacent members 12, and is positioned between ledge members 52 formed within each member 12. The sleeve member 50 helps maintain the integrity of the device 10 as it is being twisted, and further encourages the twisting action to take place.
Referring now to FIG. 6, a second embodiment of the means for joining the various members 12 together is illustrated. In this embodiment, a first end 62 of a member 12 is equipped with an outwardly extending rim member 56. An inwardly extending ledge member 58 is disposed on the second end 64 of each member 12. The rim member 56 is caused to flex inwardly as end 62 is pushed into end 64. Rim member 56 rides up on the ledge 58 and snaps outwardly so as to engage ledge 58. In this manner, an interlocking configuration is achieved between adjacent members 12 which enables the necessary axial rotation to take place. To encourage the necessary sliding and locking action, each member 12, adjacent end 62 thereof, may include a slot 60 which enables end 62 of the member 12 to be flexed inwardly. In this manner the necessary interlocking action between rim 56 and ledge 58 is further encouraged to take place. Of course, it is understood, that yet other configurations for joining the members 12 together are within the scope of this invention.
The twisting characteristics of the first embodiment of the device 10 will now be described. Assuming that members 12 are joined together as illustrated in either FIG. 5 or 6, and that the device 10 has the configuration shown in FIG. 1. Ten members, 38 through 48, inclusive, are thus joined together to form a two loop configuration. Assume further that members 42 and 44 are grasped by one hand, and that members 32 and 34 are grasped by the other hand. An opposed, rotational twisting force is then applied to members 32 and 34 and to members 42 and 44 respectively. The result is the configuration shown in FIG. 2, i.e. the chair configuration. Assume further that the same twisting force is again applied in the same opposed direction to members 32, 34 and members 42, 44. Eventually, the configuration illustrated in FIG. 3 will be achieved. Note in this configuration, that the device 10 has been twisted into what is referred to herein as a generally U-shape. Continued application of the twisting force as described above will cause the device 10 to go through the configuration illustrated in FIG. 4 and will ultimately return to the initial configuration illustrated in FIG. 1. The ability to continually rotate the members 12 so as to achieve the various configurations, is achieved by each adjacent member being axially rotatable through an angle of somewhat more than 180° before rotating back in the opposite direction. The ability to rotate the members 12 such that continued rotation causes the device 10 to go through various configurations and then repeat these configurations as the twisting action is continued is also achieved by coupling the various members 12 together such that axial rotation of one member 12 causes some axial movement between all the members 12.
Referring now to FIG. 7, the second embodiment of the device 10 of the present invention is illustrated. In the second embodiment, the members 12 are comprised of a series of general right angle or L-shape bends which are joined together in either of the manners hereinabove discussed. In this configuration, while only a single closed loop is formed, a plurality of geometric configurations can still be achieved by rotatably twisting the various members 12 into a predetermined configuration. Again, each of the adjacent members 12 is axially rotatable so as to achieve this twisting ability.
Referring now to FIG. 8, yet a third embodiment of the present invention is shown. In the third embodiment, the various members 12 are selected such that as between sub-sections 22a and 23a, an acute angle is formed. Even in this configuration, however, the members 12 are axially rotatable through an angle of somewhat more than 180° such that the device 10 can be twisted in a 360° manner so as to achieve a plurality of geometric configurations.
Referring now to FIG. 9, the fourth embodiment of the present invention is shown. In this embodiment, sub-sections 22b and 23b are joined together so as to form an obtuse angle thereinbetween. Again, the rotation of each member 12 is the same as hereinabove discussed, thus permitting the device 10 to achieve a plurality of configurations.
Referring now to FIG. 10, a fifth embodiment of the present invention is illustrated. In the fifth embodiment, the means for joining the members 12 together comprise a threaded member 78 which has a flange section 80 integrally attached thereto. The flange section 80 is attached to one member 12 by glue or other means. The threaded member 78 is then screwed into an adjacent member 12a. The result of such configuration is what appears to be a "plumber's nightmare". The twisting action is still maintained, however, inasmuch as adjacent members are rotatable by approximately 180° and then return along the same path. As two adjacent members 12 and 12a shown in FIG. 10 are rotated in one direction, the threaded member 78 would be caused to be screwed into and then out of member 12a such that continued attachment between adjacent members is maintained. Thus, in the fifth embodiment of the present invention, the twisting and rotational aspects of the device 10 are maintained.
Referring now to FIGS. 11 and 12, the sixth embodiment of the present invention is illustrated. In the sixth embodiment, a series of six blocks or cubes 84 each having six sides are joined together so as to form a specific configuration. Disposed within adjacent blocks is a sleeve 86 through which an elastic member 88 passes. As discussed hereinabove, a wide range of other means for joining the various blocks 84 together are within the scope of the present invention. In the sixth embodiment, six blocks, blocks 92, 94, 96, 98 and 100 are joined together as hereinabove described. Referring now to FIG. 12, one can see that the blocks 84 have been rotated such that block 92 is now disposed atop block 94 while block 90 is disposed atop block 96. This is achieved by axially rotating the various block members with respect to each other made possible by sleeve member 86. The elastic member 88 helps maintain the device 10 in any specific configuration.
As discussed hereinabove, in embodiments 1 through 5, the members 12 are formed of rod-like members formed of rigid plastic tubing. In the sixth embodiment of the present invention, members 84 have a polygonal configuration and may be made from plastic material such as polyvinylchloride, acrylates, etc. However, the underlying feature with respect to all such embodiment is that between all adjacent members, each member is axially rotatable with respect thereto. This enables the device 10 of the present invention to be axially rotated into a plurality of uniquely shaped configurations.
Although this invention has been disclosed and described with reference to particular embodiments, the principles involved are susceptible to yet other applications which will be apparent to persons skilled in the art. For example, various handle members can be attached to one or more of the members 12 so as to enable two or more persons to twist the device 10. This invention, therefore, is not intended to be limited to the particular embodiments herein disclosed. | A novelty toy device for forming a variety of geometric configurations. The device is constructed of a series of uniquely shaped members which form at least one closed loop. The members are joined together such that each member is axially rotatable with respect to adjacent members, thereby enabling the members to be twisted into a variety of shapes. | 8 |
TECHNICAL FIELD
The present disclosure relates in general to information handling systems, and more particularly to grounding an antenna cable used in an information handling system and providing mechanical strain relief to an antenna cable.
BACKGROUND
As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option available to users is information handling systems. An information handling system generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes thereby allowing users to take advantage of the value of the information. Because technology and information handling needs and requirements vary between different users or applications, information handling systems may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in information handling systems allow for information handling systems to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, information handling systems may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
An information handling system may comprise a radio-frequency transceiver for wireless communication to and from the information handling system via mobile telephony (e.g., 2G, 3G, 4G, Long-Term Evolution, etc.), Wireless Fidelity (Wi-Fi), Bluetooth, and/or other radio-frequency communication technologies. Effective communication via radio-frequency transmissions typically requires the use of one or more antennas coupled to the radio-frequency transceiver.
Existing approaches to placing and coupling antennas to radio-frequency transceivers in information handling systems have numerous disadvantages. For example, antennas are often coupled to transceivers via coaxial cables. In existing approaches, often the return path of an antenna coaxial cable is relatively weak, relying on a small mechanical interface of a U.FL/IPEX coaxial connector to a wireless transceiver. Such weak antenna cable grounding may increase susceptibility to electromagnetic noise within the antenna and antenna cable.
In addition, in existing approaches, an antenna may often be coupled to a coaxial cable laced along the axis of the hinge of a notebook computer, and is grounded by exposing portions of the ground sheath of the coaxial cable and soldering such portions to a grounded portion of the chassis of the information handling system. Such soldering adds a process step to manufacture of an information handling system, as soldering to provide sufficient electrical coupling of the ground sheath of the coaxial cable to a ground voltage may be costly.
SUMMARY
In accordance with the teachings of the present disclosure, the disadvantages and problems associated with grounding of antenna cables in information handling systems may be reduced or eliminated.
In accordance with embodiments of the present disclosure, an information handling system may include a first member, a second member hingedly coupled to the first member via a hinge, a coaxial cable, and a grounding jacket. The coaxial cable may have a ground sheath and a signal wire internal to the ground sheath, wherein an axis of the signal wire is substantially parallel to a rotational axis of the hinge and wherein the coaxial cable comprises an exposed portion in which the ground sheath is exposed externally to the coaxial cable. The grounding jacket may be mechanically coupled to the first member and the second member, wherein the grounding jacket may be configured to mechanically support the coaxial cable and electrically couple to an electrically conductive portion of at least one of the first member and the second member and to the ground sheath at the exposed portion in order to create an electrically conductive path between the ground sheath and the electrically conductive portion via the grounding jacket.
In accordance with these and other embodiments of the present disclosure, an information handling system may include a circuit board, an information handling resource mechanically and electrically coupled to the circuit board, coaxial cable, and a bracket. The coaxial cable may comprise a first connector configured to mate with a corresponding second connector of the information handling resource. The bracket may be configured to mechanically couple to the circuit board, such that when mechanically coupled to the circuit board, the bracket is further configured to apply a first force to the first connector to maintain connectivity between the first connector and the second connector.
In accordance with these and other embodiments of the present disclosure, an information handling system may include a circuit board, an information handling resource mechanically and electrically coupled to the circuit board; coaxial cable, and a bracket. The coaxial cable may include a first connector configured to mate with a corresponding second connector of the information handling resource, further wherein the coaxial cable comprises an exposed portion in which a ground sheath of the coaxial cable is exposed externally to the coaxial cable. The bracket may be configured to mechanically couple to the circuit board, such that when mechanically coupled to the circuit board, the bracket is further configured to apply a force to maintain electrical coupling between a ground plane of the circuit board and the ground sheath at the exposed portion.
Technical advantages of the present disclosure may be readily apparent to one skilled in the art from the figures, description and claims included herein. The objects and advantages of the embodiments will be realized and achieved at least by the elements, features, and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are examples and explanatory and are not restrictive of the claims set forth in this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 illustrates a functional block diagram of selected components of an example information handling system, in accordance with embodiments of the present disclosure;
FIG. 2 illustrates an exterior view of an example information handling system, in accordance with embodiments of the present disclosure;
FIGS. 3A, 3B, and 3C illustrate different perspective views of an example antenna cable carrier of a keyboard assembly of an information handling system, in accordance with embodiments of the present disclosure;
FIG. 4 illustrates an isolated view of an example grounding jacket, in accordance with embodiments of the present disclosure;
FIGS. 5A and 5B illustrate different views of a portion of a circuit board for coupling an antenna cable to a wireless network interface, in accordance with embodiments of the present disclosure; and
FIG. 6 illustrates an example cable, in accordance with embodiments of the present disclosure.
DETAILED DESCRIPTION
Preferred embodiments and their advantages are best understood by reference to FIGS. 1 through 6 , wherein like numbers are used to indicate like and corresponding parts.
For the purposes of this disclosure, an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, entertainment, or other purposes. For example, an information handling system may be a personal computer, a personal digital assistant (PDA), a consumer electronic device, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The information handling system may include memory, one or more processing resources such as a central processing unit (“CPU”) or hardware or software control logic. Additional components of the information handling system may include one or more storage devices, one or more communications ports for communicating with external devices as well as various input/output (“I/O”) devices, such as a keyboard, a mouse, and a video display. The information handling system may also include one or more buses operable to transmit communication between the various hardware components.
For the purposes of this disclosure, computer-readable media may include any instrumentality or aggregation of instrumentalities that may retain data and/or instructions for a period of time. Computer-readable media may include, without limitation, storage media such as a direct access storage device (e.g., a hard disk drive or floppy disk), a sequential access storage device (e.g., a tape disk drive), compact disk, CD-ROM, DVD, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), and/or flash memory; as well as communications media such as wires, optical fibers, microwaves, radio waves, and other electromagnetic and/or optical carriers; and/or any combination of the foregoing. For the purposes of this disclosure, information handling resources may broadly refer to any component system, device or apparatus of an information handling system, including without limitation processors, service processors, basic input/output systems (BIOSs), buses, memories, I/O devices and/or interfaces, storage resources, network interfaces, motherboards, and/or any other components and/or elements of an information handling system.
For the purposes of this disclosure, the terms “wireless transmissions” and “wireless communication” may be used to refer to all types of electromagnetic communications which do not require a wire, cable, or other types of conduits. Examples of wireless transmissions which may be used include, but are not limited to, short-range wireless communication technologies (e.g., proximity card, Radio-Frequency Identification (RFID), Near Field Communication (NFC), Bluetooth, ISO 14443, ISO 15693, or other suitable standard), personal area networks (PAN) (e.g., Bluetooth), local area networks (LAN), wide area networks (WAN), narrowband personal communications services (PCS), mobile telephony technologies, broadband PCS, circuit-switched cellular, cellular digital packet data (CDPD), radio frequencies, such as the 800 MHz, 900 MHz, 1.9 GHz and 2.4 GHz bands, infra-red and laser.
FIG. 1 illustrates a functional block diagram of selected components of an example information handling system 100 , in accordance with embodiments of the present disclosure. In some embodiments, information handling system 100 may be a personal computer (e.g., a desktop computer or a portable computer). In other embodiments, information handling system 100 may comprise a mobile device (e.g., smart phone, a tablet computing device, a handheld computing device, a personal digital assistant, or any other device that may be readily transported on a person of a user of such mobile device).
As depicted in FIG. 1 , information handling system 100 may include a processor 103 , a memory 104 communicatively coupled to processor 103 , a storage resource 110 communicatively coupled to processor 103 , a wireless network interface 106 communicatively coupled to processor 103 , a user interface 114 communicatively coupled to processor 103 , and an antenna 108 coupled to wireless network interface 106 via an antenna cable 112 .
Processor 103 may include any system, device, or apparatus configured to interpret and/or execute program instructions and/or process data, and may include, without limitation, a microprocessor, microcontroller, digital signal processor (DSP), application specific integrated circuit (ASIC), or any other digital or analog circuitry configured to interpret and/or execute program instructions and/or process data. In some embodiments, processor 103 may interpret and/or execute program instructions and/or process data stored in memory 104 , storage resource 110 , and/or another component of information handling system 100 .
Memory 104 may be communicatively coupled to processor 103 and may include any system, device, or apparatus configured to retain program instructions and/or data for a period of time (e.g., computer-readable media). Memory 104 may include random access memory (RAM), electrically erasable programmable read-only memory (EEPROM), a PCMCIA card, flash memory, magnetic storage, opto-magnetic storage, or any suitable selection and/or array of volatile or non-volatile memory that retains data after power to its associated information handling system 100 is turned off.
Wireless network interface 106 may include any suitable system, apparatus, or device operable to serve as an interface between its associated information handling system 100 and a network, such that information handling system 100 may communicate signals to and from wireless network interface 106 via wireless transmissions (e.g., mobile telephony, Wi-Fi, Bluetooth, mobile broadband telephony). Accordingly, wireless network interface 106 may include a radio-frequency transceiver and/or other components configured to communicate to and from wireless network interface 106 via wireless transmissions.
Antenna 108 may comprise any system, device, or apparatus configured to convert electric power into radio waves, and vice versa. As shown in FIG. 1 , antenna 108 may be coupled to wireless network interface 106 via a cable 112 . In some embodiments, cable 112 may comprise a coaxial cable. Turning briefly to FIG. 6 , in embodiments in which cable 112 is a coaxial cable, cable 112 may comprise a signal wire 602 of conductive material (e.g., copper, aluminum) for carrying an electrical or electronic signal which is surrounded by a layer of insulative material 604 which is in turn surrounded by a ground sheath 606 of conductive material (e.g., copper, aluminum) which may serve as an electrical return path for the electrical or electronic signal communicated via the signal wire. Ground sheath 606 itself may also be surrounded by an electrical insulator 608 . Each end of cable 112 may be terminated by a connector for coupling cable 112 to antenna 108 and wireless network interface 106 . For example, in some embodiments cable 112 may be terminated at one end with a U.FL connector (also known as an IPEX, IPAX, IPX, AMC, MHF, or UMCC connector) for electrically and mechanically coupling cable 112 to wireless network interface 106 .
In some embodiments, antenna 108 may itself comprise a coaxial cable, and in such embodiments, antenna 108 and cable 112 may comprise the same coaxial cable.
Storage resource 110 may include a system, device, or apparatus configured to store data. Storage resource 110 may include one or more hard disk drives, magnetic tape libraries, optical disk drives, magneto-optical disk drives, solid state storage drives, compact disk drives, compact disk arrays, disk array controllers, and/or any other systems, apparatuses or devices configured to store data. In certain embodiments, storage resource 110 may include one or more storage enclosures configured to hold and/or power one or more of such devices. In the embodiments represented by FIG. 1 , storage resource 110 may reside within information handling system 100 . However, in other embodiments, storage resource 110 may reside external to information handling system 100 (e.g., may be coupled to information handling system 100 via a network).
User interface 114 may comprise any instrumentality or aggregation of instrumentalities by which a user may interact with information handling system 100 . For example, user interface 114 may permit a user to input data and/or instructions into information handling system 100 (e.g., via a keypad, keyboard, touch screen, microphone, camera, and/or other data input device), and/or otherwise manipulate information handling system 100 and its associated components. User interface 114 may also permit information handling system 100 to communicate data to a user (e.g., via a display device, speaker, and/or other data output device). As shown in FIG. 1 , user interface 114 may include one or more of a display 116 , microphone 118 , camera 120 , and speaker 124 .
Display 116 may comprise any suitable system, device, or apparatus configured to display human-perceptible graphical data and/or alphanumeric data to a user. For example, in some embodiments, display 116 may comprise a liquid crystal display.
Microphone 118 may comprise any system, device, or apparatus configured to convert sound incident at microphone 118 to an electrical signal that may be processed by processor 103 . In some embodiments, microphone 118 may include a capacitive microphone (e.g., an electrostatic microphone, a condenser microphone, an electret microphone, a microelectromechanical systems (MEMs) microphone, etc.) wherein such sound is converted to an electrical signal using a diaphragm or membrane having an electrical capacitance that varies as based on sonic vibrations received at the diaphragm or membrane.
Camera 120 may comprise any system, device, or apparatus configured to record images (moving or still) into one or more electrical signals that may be processed by processor 103 .
Speaker 124 may comprise any system, device, or apparatus configured to produce sound in response to electrical audio signal input.
In addition to processor 103 , memory 104 , wireless network interface 106 , antenna 108 , storage resource 110 , and user interface 114 , information handling system 100 may include one or more other information handling resources. Such an information handling resource may include any component system, device or apparatus of an information handling system, including without limitation, a processor, bus, memory, I/O device and/or interface, storage resource (e.g., hard disk drives), network interface, electro-mechanical device (e.g., fan), display, power supply, and/or any portion thereof. An information handling resource may comprise any suitable package or form factor, including without limitation an integrated circuit package or a printed circuit board having mounted thereon one or more integrated circuits.
FIG. 2 illustrates an exterior view of example information handling system 100 , in accordance with embodiments of the present disclosure. Although FIG. 2 depicts information handling system 100 as a laptop or notebook computer, information handling system 100 may comprise any type of information handling system (e.g., a mobile device sized and shaped to be readily transported and carried on a person of a user of information handling system 100 , a desktop computer, a tower computer, a server, etc.), and methods and systems disclosed, described, and claimed herein may not be limited to application to a laptop or notebook computer.
As depicted in FIG. 2 , information handling system 100 may include a display assembly 202 and a keyboard assembly 204 hingedly coupled via one or more hinges 206 . Each of display assembly 202 and keyboard assembly 204 may be integral parts of a chassis or case for information handling system 100 . Each of display assembly 202 and keyboard assembly 204 may have an enclosure made from one or more suitable materials, including without limitation plastic, steel, and/or aluminum. Although information handling system 100 is shown in FIG. 2 as having certain components (e.g., display assembly 202 , keyboard assembly 204 , and hinge 206 ), information handling system 100 may include any other suitable components which may not have been depicted in FIG. 2 for the purposes of clarity and exposition. In operation, information handling system 100 may be translated between a closed position (e.g., a position of display assembly 202 relative to keyboard assembly 204 such that display assembly 202 substantially overlays keyboard assembly 204 , or vice versa) and an open position (e.g., a position of display assembly 202 relative to keyboard assembly 204 such that display assembly 202 does not substantially overlay keyboard assembly 204 , or vice versa, such as when the angle formed by display assembly 202 and keyboard assembly 204 at hinge 206 is substantially non zero).
FIGS. 3A and 3B illustrate different views of an antenna cable carrier 300 of keyboard assembly 204 with some portions of keyboard assembly 204 cut away, in accordance with embodiments of the present disclosure. For the purposes of exposition, antenna cable carrier 300 is shown as an integral part of keyboard assembly 204 . In other embodiments, antenna cable carrier 300 could be integral to display assembly 202 , or a hinge assembly for coupling display assembly 202 to keyboard assembly 204 .
As shown in FIGS. 3A and 3B , antenna cable carrier 300 may be configured to carry one or more antenna cables 112 (e.g., cables 112 a , 112 b ) such that the axial length of such antenna cables 112 runs substantially perpendicular to the axial length of hinge 206 . In the embodiments represented by FIGS. 3A and 3B , one or more cables 112 may comprise a coaxial cable. Also as shown in FIGS. 3A and 3B , antenna cable carrier 300 may include a grounding jacket 302 for grounding a ground sheath (e.g., ground sheath 606 as shown in FIG. 6 ) of one or more cables 112 to portions of display assembly 202 and/or keyboard assembly 204 , as described in greater detail below.
In addition to antenna cables, antenna cable carrier 300 may be configured to carry a ground wire 312 , as shown in FIG. 3C . For example, as shown in FIG. 3C , wire 312 may comprise an insulated wire electrically coupled to a ground potential. A portion of the antenna cable 112 (e.g., insulation 608 as shown in FIG. 6 ) may be exposed to expose the ground sheath (e.g., ground sheath 606 as shown in FIG. 6 ) thereof, and a corresponding portion of ground wire 312 may be exposed, such that these exposed portions may be electrically coupled directly to one another or via a tap 314 of conductive material between the two.
FIG. 4 illustrates an isolated view of an example grounding jacket 302 , in accordance with embodiments of the present disclosure. Grounding jacket 302 may be constructed from any suitable electrically conductive material (e.g., copper, aluminum). Referring to FIGS. 3A, 3B, and 4 , grounding jacket 302 may include a web 313 , grounding clips 304 and 306 , fingers 308 , flanges 314 , and openings 310 . Grounding clips 304 and 306 may comprise U-shaped or hook-shaped projections from web 313 configured to mechanically hold cables 112 in place, as well as electrically couple to exposed portions of the respective ground sheaths (e.g., ground sheath 606 as shown in FIG. 6 ) of cables 112 . One or more flanges 314 may extend perpendicularly from web 313 , and may include openings 310 for fastening (e.g., via a screw or other suitable fastener) grounding jacket 302 to antenna cable carrier 300 . Also extending from the same edge of web 313 as flanges 314 may be fingers 308 . Fingers may be configured to electrically couple to an electrically conductive portion of display assembly 202 (e.g., metal integral to display assembly 202 ) which is coupled to a ground voltage.
In operation, grounding jacket 302 may be placed within antenna cable carrier 300 so as to create a spring force to maintain electrical contact between grounding clips 304 , 306 and exposed portions of the respective grounding sheaths (e.g., ground sheath 606 as shown in FIG. 6 ) of cables 112 . In addition, grounding jacket 302 may be placed within antenna cable carrier 300 such that fingers 308 create a spring force against an electrically conductive portion of display assembly 202 which is coupled to a ground voltage. As a result, grounding jacket 302 may ground a grounding sheath (e.g., ground sheath 606 as shown in FIG. 6 ) of a cable 108 substantially along the length of the cable 108 without the use of solder.
FIGS. 5A and 5B illustrate different views of a portion of a circuit board 502 for coupling one or more antenna cables 112 to wireless network interface 106 , in accordance with embodiments of the present disclosure. FIG. 5A depicts a top-down plan view, while FIG. 5B depicts a side elevation view.
Circuit board 502 may include any suitable system, device, or apparatus operable to mechanically support and electrically couple electronic components (e.g., packaged integrated circuits) making up an information handling system. For example, circuit board 502 may be used as part of a motherboard for information handling system 100 . As used herein, the term “circuit board” includes printed circuit boards (PCBs), printed wiring boards (PWBs), etched wiring boards, and/or any other board or similar physical structure operable to mechanically support and electrically couple electronic components. Circuit board 502 may include a plurality of pads and traces. Pads may comprise a conductive material and may be formed on a surface of circuit board 502 . Further, each pad may be operable to receive a pin of an electronic component (e.g., a packaged integrated circuit or other information handling resource) and provide electrical connectivity between the pin and one or more traces. Traces may comprise a conductive material and may be formed on a surface of circuit board 502 , or in a layer of circuit board not visible from the surface thereof. Further, each trace may be operable to provide conductive pathways between electronic components mounted to pads.
A circuit board 502 is not limited to having components on just one side thereof. Traces and pads may be formed on either side of circuit board 502 . In addition, circuit board 502 may comprise a plurality of conductive layers separated and supported by layers of insulating material laminated together, and traces may be disposed on and/or in any of such conductive layers. Connectivity between conductive elements disposed on and/or in various layers of circuit board 502 may be provided by conductive vias.
The various pads, traces, and vias may comprise silver, copper, aluminum, lead, nickel, other metals, metal alloys, and/or any other conductive material that may readily conduct electrical current.
As shown in FIGS. 5A and 5B , wireless network interface 106 may be mechanically mounted and electrically coupled to circuit board 502 . Although not explicitly shown, multiple pins of wireless network interface 106 may electrically couple to corresponding pads of circuit board 502 . Wireless network interface 106 may also include a one or more connectors 518 for mating with respective corresponding connectors 516 , wherein such connectors 516 each terminate a respective antenna cable 112 (e.g., cables 112 a and 112 b ), thus coupling wireless network interface 106 to antenna cables 112 (which may in turn be coupled to corresponding antennas 108 ). One or more of connectors 516 and 518 may comprise a U.FL connector (also known as an IPEX, IPAX, IPX, AMC, MHF, or UMCC connector).
To provide for mechanical strain relief and grounding of antenna cables 112 , a bracket 504 may be utilized. Bracket 504 may comprise an electrically conductive material (e.g., copper or aluminum). Bracket 504 may include a connector portion 508 , an intermediate portion 510 , a ground plane portion 506 , and a fastener hole 512 .
Fastener hole 512 may be configured to receive a screw or other fastener for mechanically attaching bracket 504 to circuit board 502 via a corresponding hole or other receptacle of circuit board 502 . In some embodiments, such hole or other receptacle of circuit board 502 may be configured such that when a screw or other fastener is inserted into such hole or other receptacle, such screw or other fastener is electrically coupled to a ground plane of circuit board 502 .
Prior to attachment of bracket 504 to circuit board 502 , a portion of each cable 112 may be stripped to expose the ground sheath (e.g., ground sheath 606 as shown in FIG. 6 ) of cable 112 at such portion. When bracket 504 is mechanically coupled to circuit board 502 , ground plane portion 506 may apply pressure to cables 112 such that the exposed ground sheaths (e.g., ground sheath 606 as shown in FIG. 6 ) of cables 112 are electrically coupled to a ground plane 520 of circuit board 502 . For example, in some embodiments, circuit board 502 may have traces 524 coupled to a ground plane 520 by vias 522 , such that exposed ground sheaths (e.g., ground sheath 606 as shown in FIG. 6 ) of cables 112 are coupled to ground plane 520 by way of ground plane portion 506 applying pressure to press exposed ground sheaths against traces 524 .
Intermediate portion 510 and connector portion 508 may be configured such that when bracket 504 is attached to circuit board 502 , connector portion 508 applies a downward force on connectors 516 , further securing connectors 516 to corresponding connectors 518 .
Although the present disclosure has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereto without departing from the spirit and the scope of the disclosure as defined by the appended claims. For example, although the present disclosure contemplates a hinge coupling a keyboard assembly to a display assembly, some embodiments may include a hinge coupling any two mechanical members to each other. | An information handling system may include a first member, a second member hingedly coupled to the first member via a hinge, a coaxial cable, and a grounding jacket. The coaxial cable may have a ground sheath and a signal wire internal to the ground sheath, wherein an axis of the signal wire is substantially parallel to a rotational axis of the hinge and wherein the coaxial cable comprises an exposed portion in which the ground sheath is exposed externally to the coaxial cable. The grounding jacket may be mechanically coupled to the first member and the second member, wherein the grounding jacket may be configured to mechanically support the coaxial cable and electrically couple to an electrically conductive portion of at least one of the first member and the second member and to the ground sheath at the exposed portion in order to create an electrically conductive path between the ground sheath and the electrically conductive portion via the grounding jacket. | 7 |
TECHNICAL FIELD
The present invention generally relates to the management and disposal of hazardous materials. More particularly, the present invention relates to a method and apparatus for high-capacity treatment of stocks of pentaborane using hydrolysis and, when appropriate alcoholysis.
BACKGROUND OF THE INVENTION
Pentaborane, a boron hydride, is a propellant that has been used as a rocket fuel additive for air-breathing engines. Accordingly, pentaborane has found utility in rockets, missiles and military jet aircraft. Because of its extremely toxic and pyrophoric nature, it is widely recognized that pentaborane must be handled with extreme caution.
Pentaborane, which may be represented by the chemical formulation "B 5 H 9 " (or "B 5 H 11 " in its unstable state), is an extremely dangerous material. It is typically a colorless liquid or gas that is highly toxic to humans by ingestion, skin contact or inhalation. For example, ingestion or inhalation of even a very small amount of pentaborane, on the order of five parts per million (5 ppm), is likely fatal and at least sufficient to cause severe distress to humans. The toxicity of pentaborane is comparable to that of chemical warfare nerve agents. Moreover, pentaborane is highly pyrophoric in air. Accordingly, there is not only a danger to anyone that must handle pentaborane, there is also an extreme danger of fire or explosion in handling pentaborane. Pentaborane is understandably listed as an "extremely hazardous substance" under Section 302 of the Superfund Amendments and Reauthorization Act ("SARA").
Yet further, while pentaborane is traditionally provided in a liquid state, liquid pentaborane evaporates rapidly and becomes gaseous at ambient, room temperature. Pentaborane is therefore oftentimes stored in cylinders or containers that secure the material and prevent its introduction to air. The cylinders are oftentimes stored in relatively cool environments such as underground facilities or bunkers. The containers are oftentimes of significant size. For example, it is not unusual to store pure pentaborane in a three hundred pound (300 lb.) container. With the pentaborane stored therein, the container and material may weigh as much as eight-hundred pounds (800 lbs.).
Pentaborane containers may sometimes be stored for significant periods of time, perhaps resulting in deterioration of the cylinder. In such an event, the cylinder must be emptied and purged of the pentaborane. Moreover, it has become desirable to dispose of certain quantities of pentaborane. Once again, in order to effect such disposal, the cylinders must be emptied and purged of the pentaborane. Given that pentaborane is colorless, flammable and extremely toxic even in very small amounts, such disposal is difficult.
A variety of attempts have been made in the past to dispose of pure pentaborane stocks. Due to the extremely difficult nature of handling the material, it has sometimes been found necessary to detonate a cylinder containing pentaborane rather than attempt to vent the pentaborane and treat it chemically. An example of one such effort that resulted from a failed cylinder is described in detail in a document entitled "Pentaborane Release Environmental Laboratories Hanover County Va, National Response Team Briefing, March 1982." This reference describes the difficulty experienced with a failed cylinder and the need to destroy the container. Other articles have been written detailing the dangerous nature of pentaborane and handling this material. See, for example, Silverman, J. J., et al., Post Traumatic Stress Disorder From Pentaborane Intoxication, JAMA 254 (18), 2603-2608 (1985).
Yet another article resulting from the Hanover County Pentaborane Release was published in "Fire Engineering" authored by the Hanover County, Virginia Fire Department Chief. This article detailed the dangerous nature of both the pentaborane and the destruction of the cylinder. As described therein, one major concern of the workers charged with the responsibility of disposing of the cylinder was the need to transport the failed cylinder from the location of the accident to another location where the cylinder could be destroyed. Of course, such transportation involves inherent risks to the general public as well as those directly involved in transporting the cylinder. The movement of such a hazardous material understandably involves and concerns a variety of state and federal environmental regulatory persons, depending on the particular circumstances. Even if the pentaborane container is in good condition, the catastrophic consequences of an in-transit accident render shipment of the cylinder difficult, costly and effectively unfeasible.
Thus, as shown by circumstances and instances of human exposure to pentaborane, there exists a need in the art to provide a systematic method and apparatus by which to dispose of pentaborane in a safe and efficient manner. Further, it would be preferable that any such method and apparatus be capable of handling and treating the pentaborane cylinder or other container on site, at the location where the cylinder or container is found. Moreover, because pentaborane is so toxic to humans, the preferred method and apparatus could be operated remotely without an operator being proximate to the cylinder or container. Such a remotely operated method and apparatus would preferably permit the operator to sense or detect the presence of any pentaborane, analyze the contents of the cylinder and any part of the apparatus for pentaborane and its treatment, and monitor the apparatus from a safe distance.
SUMMARY OF THE INVENTION
The present invention fills the above-described need in the prior art by providing a method and apparatus for neutralizing and destroying or disposing of pentaborane in a safe and efficient manner. The apparatus of the present invention is transportable from one location to another such that a pentaborane cylinder or container, failed or not, may be processed and the pentaborane treated on site. Yet further, the present invention is operable from a remote location so as to protect the operator and any other persons necessary to the handling and treatment processes. In fact, worker interface with a pentaborane cylinder is minimized to placement of the cylinder into an airtight chamber and connection of the cylinder to the apparatus of the invention.
Generally described, the present invention comprises a method and apparatus for removing the elemental hydrogen from a stock of pentaborane, oxidizing the hydrogen, and removing the residual boron as boric acid or treating the residual boron with inorganic hydroxides that are precipitated out of solution as non-toxic materials. Thus, it is to be understood that the present invention is intended to safely detoxify liquid and gas phase pentaborane through hydrolytic and alcoholytic processes.
Described more particularly, the method of the present invention includes extracting pentaborane from a container to be purged, mixing the pentaborane with a hydrolysis reagent so as to produce hydrogen gas, venting the hydrogen gas to a flare, oxidizing the hydrogen gas, and removing or treating the residual boron. The present invention may include various other steps such as measuring the temperature at various points in the apparatus (or at various points during practice of the method) and reagent composition levels as it circulates within the system. The method of the present invention may further include a relatively small gas-phase reaction process depending on the amount of pentaborane present, if any, in the evolved gases leaving the reagent vessels for oxidation.
Also described somewhat more particularly, the apparatus of the present invention includes means for extracting a quantity of pentaborane to be neutralized and destroyed from a container, an emulsifier for mixing the pentaborane with a hydrolysis reagent so as to induce the hydrolysis reaction, directing the reagent and pentaborane through a tortuous path wherein the reaction results in the creation of hydrogen gas and dissolved boron, means for oxidizing the hydrogen gas and means for removing or treating the residual dissolved boron. The apparatus of the present invention may further include sampling devices such as temperature sensors, pressure sensors or oxidation reduction potential (ORP) sensors for measuring the quantity of pentaborane present, if any, in the collected hydrogen gas contained in the reagent vessels and the various other operations of the system. The apparatus of the present invention may further include a scrubber that, prior to oxidation of the hydrogen gas, removes any unwanted or undesirable substance from the hydrogen gas. Yet further, the apparatus of the present invention may include a liquid-phase alcoholytic reaction process in the event of residual pentaborane. Such a system of alcoholysis is similar to the primary method (hydrolysis) and apparatus. This reaction process, if utilized, operates to isolate and remove residual pentaborane found in the gases being vented for oxidation.
Thus, it is an object of the present invention to provide a method and apparatus for neutralizing and destroying a container of pentaborane.
It is a further object of the present invention to provide a method and apparatus for remotely neutralizing and destroying a container of pentaborane.
It is a further object of the present invention to provide a method and apparatus for neutralizing and destroying pentaborane that is safe and efficient.
It is a further object of the present invention to provide a method and apparatus for neutralizing and destroying pentaborane that can be transported to a job site so as to minimize or eliminate the need to transport the pentaborane container to another location for treatment.
It is a further object of the present invention to provide a method and apparatus for neutralizing and destroying pentaborane in a environmentally friendly and safe manner.
It is a still further object of the present invention to provide a method and apparatus for neutralizing and destroying pentaborane that provides for the elemental hydrogen to be oxidized and residual boron to be removed or treated in a conventional manner.
These and yet other objects, features and advantages of the present invention will become apparent from reading the following specification, taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in more detail to the drawing, in which like numerals indicate like parts throughout any additional views, FIG. 1 shows an apparatus 10 constructed in accordance with the present invention.
Referring thereto, FIG. 1 shows a cylinder 20 containing pentaborane to be purged. As is known to those of ordinary skill in the art, the cylinder 20 provides an access opening 22 that is traditionally maintained by a liquid phase valve (not shown). As is further known to those of ordinary skill in the art, the cylinder 20 also provides vapor phase valve opening 23. The cylinder also provides a dip tube 25 in conjunction with the liquid phase valve opening 22. The cylinder valve openings 22 and 23 are of sufficient size to receive a section of process piping. For example, opening 22 receives a section of process piping 26 that communicates with the dip tube 25 that extends substantially near the base of the cylinder 20. It is to be appreciated that an airtight seal must be maintained at the location of the openings 22 and 23 to insure that the pentaborane contained in the cylinder 20 is not introduced to the air. In this regard, it is anticipated that an operator of this apparatus will place the cylinder 20 into an airtight chamber and connect process piping 26 to cylinder valve opening 22. It is likewise contemplated that an operator will connect a process piping 40 to cylinder valve opening 23, as described in greater detail below.
A supply of nitrogen, a padding agent, is provided in tanks 30, 31, 32 and 33. The nitrogen is typically stored under pressure in such tanks 30-33 and thus, by opening of one of the respective valves 30a, 31a, 32a or 33a, nitrogen is expelled from one of said tanks. In such an event, nitrogen may be supplied from tank 30 to a supply line 35, to a valve 38 and into process piping 40. By virtue thereof, nitrogen may be introduced to the cylinder 20. It is to be understood that such introduction of nitrogen to the cylinder 20 causes the pentaborane contained therein to be forced into the dip tube 25 and farther into that section of process piping 26 secured on this cylinder opening 22 as shown in FIG. 1. It is to be further understood that the entire system can be purged of air by circulating nitrogen from tanks 30-33 therethrough. The details of such an operation are known in the art and need not be disclosed in further detail herein.
It will be appreciated by those of ordinary skill in the art that a section of process piping section 41 also communicates with nitrogen supply line 35 as shown in the drawing. Further thereto, it will be appreciated that by manipulating valve 38 to direct the flow of nitrogen into line 41, and further into process piping section 26, nitrogen may be introduced to the cylinder 20 through piping section 26 and the dip tube 25.
As shown, another section of process piping, 42, communicates with process piping section 26. Both piping sections 40 and 42 lead to a metering pump assembly 50 including two metering pumps 51 and 52. Those of ordinary skill in the art will appreciate that these pumps 51 and 52 could also be metering or ball valves. Metering pump 51 communicates with either piping sections 40 or 42 through piping section 55. Metering pump 52 communicates with either piping sections 40 or 42 through piping section 56. A bypass line 57 is also provided. The metering pumps 51 and 52 are provided to receive pentaborane being forced out of cylinder 20 and pump a predetermined amount to an emulsifier 100 described in greater detail below. It is to be understood that only one metering pump, 51 or 52, is necessary at one time. Thus, a second pump is provided for redundancy reasons, but may not be necessary to the operation of the apparatus at a given point in time.
The apparatus 10 further includes two tanks 70 and 80. Tank 70 communicates with a metering pump 72 by means of process piping 74. Tank 80 communicates with a pump 82 by means of process piping 84. The tanks 70 and 80 may contain either kerosene or alcohol or a mixture thereof. By operation of metering pump 72, a predetermined quantity of kerosene or alcohol may be delivered to process piping 42 through piping section 76. Kerosene or alcohol may likewise be delivered to section 40 from tank 80 through piping section 86 by operation of pump 82. As described above, both sections 40 and 42 communicate with the cylinder 20. As described in greater detail below, the cylinder 20 may be rinsed with a kerosene/alcohol mixture as the process nears conclusion. Metering pumps 51 or 52 supply pentaborane to the emulsifier 100 by a feed line 102. The emulsifier 100 serves to hydrolize and violently mix a hydrolysis reagent and the pentaborane being forced out of cylinder 20. This process may preferably be accomplished as described herein.
The apparatus 10 includes three tanks 105, 107 and 109. Tank 105 contains water. Tank 107 contains alcohol. Tank 109 contains a caustic, such as sodium hydroxide. By means of process piping sections 106, 108 and 110, and respective valves 105a, 107a and 109a, and further by means of two pumps 112 and 114, the tanks 105, 107 and 109 are in fluid communication with two reagent vessels 115 and 120. It is to be understood that while the two vessels 115 and 120 are essentially identical, vessel 115 serves as the primary reagent vessel. More specifically, a section of process piping section 122 communicates with process piping section 124, which in turn deposit fluids from tanks 105, 107 or 109 into vessel 115. Alternatively, process piping section 122 communicates with piping section 125 which, in turn, may deposit fluids from said tanks into vessel 120. The reagent vessels 115 and 120 are in direct communication one with the other by means of piping section 127. Line 127 includes two valves 128 and 129 that control recirculation of the fluid into one of the reagent vessels 115 or 120 as described below.
Each vessel 115 and 120 is provided with exit lines 130 and 131, respectively. Lines 130 and 131 communicate with a recirculation line, 132, fitted with a valve 134 and another valve 135. By manipulation of the valves 134 or 135, fluid in either reagent vessel 115 or 120 may be drawn to process piping section 138, recirculated by opeartion of pump 147 or 148, and analyzed at station 140. It is to be understood that the sampling station 140 may include electronic transmission devices to alert a remote operator of the results of any analysis. The details of such remote sampling devices and techniques are known in the art and need not be described further herein. Exit line 130 is in communication with valve 139. Exit line 131 is in communication with valve 141. Fluid in either line 130 or 131 may thus be delivered to process piping section 143 for eventual delivery to the emulsifier 100. Section 143 first engages pressure relief line 145. Piping section 143 also communicates with pumps 147 and 148 which are provided in parallel for redundancy to deliver reagent from either vessel 115 or 120 to supply line 150 and on to the emulsifier 100.
A pair of surge tanks 160 and 170 are provided with the emulsifier 100. Surge tank 160 communicates with the emulsifier 100 (and supply line 150) by process piping section 162. Surge tank 170 communicates with the emulsifier 100 by process piping section 172. These surge tanks 160 and 170 are thus provided on either side of the emulsifier 100. A rupture disk 164 and 174 is provided in respective sections 162 and 172 that is intended to fail in the event of an unacceptable pressure build-up at the emulsifier 100.
Thus, it is to be understood that reagent composition may be a mixture of water, alcohol and caustic. The preferred mixture is pure water. The raw materials for that composition are contained in tanks 105, 107 and 109. The composition is introduced to the reagent vessels 115 and 120 by operation of either pump 112 or 114 or both. The composition of the mixture is monitored at sampling station 140 and the reagent composition is delivered to the emulsifier 100 by operation of either pump 147 or 148.
At the emulsifier 100, a steady flow of nitrogen gas is provided to the insertion point 99 by lines 35, 187 and 188 as they communicate with the nitrogen tanks 30-33. The insertion point 99 designates that position at which the flow of pentaborane in piping section 102 is introduced to the reagent composition in line 150. The insertion point 99 may be found at an ejector, at a needle valve opening or at the emulsifier 100. As shown, the insertion point 99 is just upstream of the emulsifier 100. It is to be understood that this steady flow of nitrogen maintains an opening at the ejector needle insertion point 99. Such a construction is known in the art. Those of ordinary skill in the art will appreciate that liquid flow through the emulsifier 100 is maintained by positive pressure from the centrifugal pump 147 or 148. As the pentaborane enters the injection point 99, it encounters a rapidly moving stream of hydrolysis reagent from piping 150. The pentaborane and reagent violently mix inside the emulsifier 100. The mixture is then delivered into a length of tubing 200 referred to as the "tortuous path." Hydrogen gas evolves inside the tubing 200 from the pentaborane diassociation. Gas evolution leads to a buildup of pressure inside the tubing 200. Moreover, the chemical reaction between the pentaborane and the reagent is exothermic, which causes the tubing 200 to heat. Such heat is removed by a recirculating closed-loop cooler 210. The cooler directs cool water to a jacket 212 surrounding the tortuous path tubing 200, which flows in a direction counter to that of the process fluid within the tortuous path 200. Heated water is cooled by an electrically powered fan 215 blowing air over cooling cools represented at 216. Heat rejection of the method and apparatus is estimated at approximately 100,000 Btu's/hour. If desired, static mixers 217 may be incorporated into tubing 200 in order to insure continued mixing of the reagent and the pentaborane. Further, temperature sensors 218 may be provided to permit an operator to remotely monitor the temperature during this reaction in the tortuous path 200.
Evolved gases and process fluid exit the tortuous path 200 under pressure in process piping section 220 for delivery to a reagent tank 115 or 120. The gases and fluids are delivered to either reagent vessel 115 or 120 by means of piping section 127 and valves 128 or 129. It is to be understood that each reagent vessel may be provided with a mechanical mixer. As shown in the drawing, vessel 115 and 120 are fitted with top-loaded mechanical mixers 225 and 230 that promote continued agitation of the reagent tanks. Of course, any suitable device for promoting such agitation is acceptable. Specifically, hydrogen gas is vented from tank 115 through exit line 233. Further, hydrogen gas is vented from tank 120 through line 235. Both lines 233 and 235 communicate with a section of piping 238. In the event that any moisture is present in the hydrogen gas, a vapor trap 240 is provided in line 238 to capture any such moisture and return it to tank 120 by means of a line 237.
A second sampling station 250 is provided in line 238. Gases vented past this point are subject to a gas composition measurement. Depending on the quantity of pentaborane present in the gas, the gas is directed either to a scrubber assembly 280 and a flare assembly for oxidation 290, or to a small, liquid phase reaction loop 300 similar to the primary process line described above. The scrubber assembly 280 preferably comprises a dry scrubber 282 in communication with a valve 284 by means of a process piping section 285.
In the event the gases tested at sampling station 250 are found to contain only small amounts of pentaborane, the valve 284 directs the gas to the scrubber 282 where residual pentaborane is removed therefrom. The scrubber is preferably a dry scrubber. However, an ammonia-based liquid scrubber (over a solid phase reaction media) may be utilized. The purified hydrogen gases are then delivered to a flame assembly 290 which is supported by a supply of propane maintained in a tank 292 that fuels a flame 294. The hydrogen gas is delivered from the scrubber 282 through a supply line 295 to the flame 294 for oxidation. After passing through the scrubber, hydrogen and possibly nitrogen should be the only gases proceeding to the flare where such gases are thermally oxidized into water vapor.
In the event that the gases sampled at sampling station 250 do contain significant amounts of pentaborane, the valve 284 directs such gases into process piping 302, by which such gases are delivered to an ejector 305. By operation of a pump 310, a reagent which may contain alcohol and water is delivered from a small reagent tank 315 to the ejector 305. The ejector 305 mixes and hydrolizes the mixture of said reagent and the mixture is delivered to a second, smaller tortuous path tubing 320 in which the reaction of any residual pentaborane with the reagent occurs to produce hydrogen gas. The gas and process fluid is delivered from the tubing 320 to a process piping section 323 to the smaller reagent vessel 315. In the vessel, the hydrogen gas bubbles to the top and is vented through line 325, where it is redirected to the scrubber 282, and burned as described above. Any residual boron in vessel 315 is treated and disposed of in a conventional manner.
As hydrolysis occurs during interaction of the reagents with the pentaborane, water and alcohol are consumed. These fundamental raw materials are replaced and otherwise maintained in accordance with conventional methods. These constituents essentially leave the system in the form of hydrogen, oxygen and hydroxyl (OH) groups or recombine in various configurations. As these components are consumed, the reagent composition changes and thus interacts with incoming pentaborane differently than with the original reagent mixture. Reactions may therefore proceed more slowly or may accelerate, depending upon the specific interactions which are favored thermodynamically. Because the constantly changing reagent combination leads to unpredictable behavior when reacting with incoming pentaborane, it is desirable to maintain the reagent components within a known, specific range. Using information obtained from the analytical and sampling station 140, reagent composition is monitored continuously. Once out of limit concentrations are observed, deficiencies are noted and specific chemicals (water, alcohol or sodium hydroxyde) are added from tanks 105, 107 or 109 as needed to bring the solution in the reagent vessels 115 and 120 back to within acceptable ranges.
In the event that the reagent composition is maintained in the primary on-line reagent vessel 115, reagent feed is diverted from the primary on-line vessel 115 to the secondary vessel containing fresh reagent 120. Once reagent from the secondary tank 120 is circulated through the system, the primary tank may be drained to a waste water treatment subsystem. Following treatment, recycled raw reagent is routed back to the reagent feed vessels (115 or 120) where it is brought into specification by the addition of necessary reagent elements.
After the majority of pentaborane in cylinder 20 has been forcibly removed by the introduction of nitrogen from one of the tanks 30-33 thereto, the cylinder 20 is turned upside down so that any remaining pentaborane is drained therefrom and processed in accordance with the foregoing description. Once the cylinder 20 has been inverted to remove such residual liquid pentaborane, it is again placed in an upright position for rinsing.
Rinsing is accomplished using a kerosene and alcohol mix in a separate water mix. A kerosene and alcohol mixture is slowly introduced into the now-empty cylinder 20 through its liquid phase valve. The alcohol portion of the mixture is contained in tank 70. The kerosene portion of the mixture is contained in tank 80. Utilizing pumps 82 and 72, the mix is fed slowly into the cylinder 20, interspersed with resting intervals to allow undissolved reactive solids to fully react and enter solution. When approximately twenty-five gallons of rinse mixture has been placed into the cylinder 20, it is again allowed to rest for a period of approximately six (6) hours. After this waiting period, the kerosene and alcohol mix solution is removed from the target cylinder 20 by the application of nitrogen under pressure to the vapor phase valve opening 23. In this manner, spent mixture solution is removed from the target cylinder 20 by application of nitrogen from the tanks 30-33 under pressure to the vapor phase valve opening 23 of the cylinder 20 so as to force such spent mix out of the liquid phase valve opening 23. When the cylinder 20 liquid level drops below the dip tube end, the cylinder 20 is once again inverted and residual rinse mixture is removed out the vapor phase valve opening 23. Spent rinse mixture is routed to its holding tank where it remains until used for another cylinder rinse cycle.
The kerosene and alcohol rinse is followed by a water rinse after the cylinder has once again been placed in an upright position. The water rinse cycle follows the same pattern as the earlier kerosene and alcohol rinse except that a minimum of five hundred gallons (500 gal.) of water is flushed through the cylinder 20 before the process is considered complete.
Water remaining inside the target cylinder 20 is removed using the same procedure as for the kerosene and alcohol mix. Flushed rinse water and residual rinse water are captured in a holding tank for subsequent treatment or reuse on the next cylinder. Whether such water is to be considered available for subsequent treatment is determined by analytical testing.
Thus, in practice of the present invention, a target cylinder 20 is placed into an airtight chamber and connected to process piping 25 and 40. Any air in the apparatus is removed and replaced with nitrogen expended from the tanks 30-33. Actuated valves are opened to allow the pentaborane in the cylinder 20 to flow from the cylinder into the process piping. Nitrogen from tanks 30-33 is forced into the cylinder through the dip tube 25 to the metering pump 51 or 52 as shown in FIG. 1. The metering pumps 51 and 52, which may also comprise metering valves, feed pentaborane into the vacuum feed line 102 at approximately ten pounds per hour. Reagent is pumped into the system from vessel 115 by means of pump 147 or 148 and contacts the pentaborane at the injection point 99. This mixture travels to the emulsifier 100. The pentaborane and reagent liquor passes through the emulsifier 100 where they are violently mixed together so as to start the hydrolysis. The mixture is then delivered to the tortuous path 200, where the exothermic reaction continues. The hydrolysis reaction now occurs wherein the elemental hydrogen is split from the boron. Heat given off during the hydrolysis is removed by a liquid cool jacket surrounding the piping.
The process liquor leaves the tortuous path 200, which may be enhanced by static mixers, and enters the primary reagent vessel 115. The reagent therein is continuously circulated by means of a pump 147 or 148. Moreover, the contents of the reagent vessel 115 (and the secondary reagent vessel 120) are continuously stirred by the vertical mixers 230 and 225. Hydrogen gas and residual boron in solution and any residual pentaborane are delivered to the reagent vessel 115 through line 220. Hydrogen gas and any residual vapors are vented from vessel 115 through line 233 to the vapor trap 240. Subsequent thereto, the vapors are analyzed for chemical constituents. In the event that no pentaborane is detected, the hydrogen gas and any residual vapor are vented to a dry scrubber 282 and flare 294. In the event that pentaborane is noted, the hydrogen gas and vapors may be directed to the alcoholysis subsytem 300 whereby any such residual pentaborane is broken down into its fundamental elements of hydrogen and boron. The hydrogen gas is vented back to the scrubber 282 and flare 294 through line 325. The hydrogen is oxidized at the flare 294, thus producing water vapor. The residual boron may remain in the reagent vessel 115 or 120 as boric acid, in which event its presence is simply monitored and accounted for through the introduction of additional reagent constituent elements, water and alcohol. If desired, the boron may also be precipitated out in a known manner through the use of inorganic hydroxides.
The present invention further contemplates a waste water treatment system whereby the boric acid may be processed and disposed. Such systems are known in the art and need not be disclosed in greater detail herein. Once the cylinder 20 is empty, it may be mechanically inverted (without hands-on worker participation) and any residual pentaborane liquid is removed through the vapor phase valve opening 23. Final clean-out of the cylinder 20 is accomplished using the organic solvent or a water-based reagent mixture that simultaneously dissolves and reacts with any residual solids that may be found inside the cylinder. The final clean-out system is thus a separate circuit from the primary pentaborane treatment processing system and will not contaminate the aqueous reagent stream. The entire process can be monitored and accomplished remotely. The sampling stations 140 and 250 are preferably fitted with necessary and known pH sensors and ORP sensors are provided to give operators the necessary information to respond to operate the apparatus within safe parameters.
While this invention has been described in detail with particular reference to preferred embodiments thereof, it will be understood that variations and modifications can be effected within the spirit and scope of the invention as described hereinabove and as described in the appended claims. | A method and apparatus for neutralizing pentaborane. A high-capacity pentaborane processing system is disclosed that may be employed at a variety of sites where pentaborane may be stored. Remote monitoring and worker interface with the pentaboraneis limited to placement of a target cylinder into an airtight chamber and connection of process piping to each cylinder valve. Hydrolysis of the pentaborane is achieved in the system by rapid and extensive physical mixing of the pentaborane with water, which yields gaseous elemental hydrogen and residual boric acid. Sodium hydroxide may be provided to neutralize boric acid and form borax, which may be later precipitated out of the waste stream. Continuous monitoring through various pH and ORP sensors give operators information needed to maintain correct chemical balance throughout the reaction process. A cylinder or other container filled with pentaborane may be connected to an airtight system. A padding element may be used to extract the pentaborane from the container and deliver it to a metering pump or valve. The pump then delivers the pentaborane to an injection point where the pentaborane is introduced to a reagent, which may be water or some other suitable reagent. A reaction ensues, whereby the elemental hydrogen is isolated from the pentaborane. The elemental hydrogen is vented and oxidized. Residual boron is maintained in solution as boric acid and can be processed into borax. A secondary alcoholytic reaction may be utilized to further destroy any gas-phase pentaborane. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to a line of sight guidance system, and in particular, to a guidance system for a beam rider projectile. While the invention is discussed in particular detail with respect to its missile control application, those skilled in the art will recognize the wider applicability of the inventive concepts disclosed hereinafter. In particular, the invention relates to a method for providing an encoded beam pattern in which the apparent central axis of the beam along a target aim point is shifted to a second axis so that a receiver in the beam is provided with a lead angle component. The lead angle component preferably is based on target tracking rate, wherein the second axis is made to lead the target aim point.
This invention deals with improvements in guidance systems, and in particular, to a guidance system similar to that disclosed in the U.S. Pat. to Esker et al, U.S. Pat. No. 4,014,482, issued Mar. 29, 1977, with which the invention disclosed hereinafter finds application. Details of the guidance system and a missile employed with that system not specifically set forth herein are intended to be incorporated by reference to the Esker et al patent and to the U.S. Patent to Tucker, U.S. Pat. No. 3,868,883, issued Mar. 4, 1975, incorporated by reference in Esker et al, U.S. Pat. No. 4,014,482.
The guidance system disclosed in Esker et al, U.S. Pat. No. 4,014,482, includes a beam projector at a launch site, and a beam receiver and signal decoder carried by the missile. The beam projector employes a laser diode source, laser pulse driver circuits, beam encoder, optic means for projecting the encoded beam, and electronic circuits for controlling the optic means operation. The beam encoder utilizes a reticle having a plurality of spokes formed in it, an opto-interupter for sensing reticle center rotation rate, and drive motor control electronics. The reticle has a center mounted for rotation orbitally about the generated beam so that at least a portion of the reticle intersects the beam in all positions of the reticle. The laser diode source is pulsed at two different rates, those rates being coordinated with the angular position of the reticle center. The laser beam is encoded by rotating the center of the reticle about an axis of the optical system in conjunction with the variation of the pulse repetition rate of the laser source to produce a spatial modulation of the radiated beam. Since the speed of rotation of the reticle center remains constant in U.S. Pat. No. 4,014,482, the missile attempts to align itself with the projected beam axis, where the spatial frequency modulation is a minimum.
While the invention described in Esker et al works well for a stationary beam, the accuracy of the system has been found less than optimized when the beam platform or beam itself is moving and in certain other operating conditions. As indicated above, the guidance system of this invention is designed for use with a number of projectile types. Some launching and projectile types offer more disturbance or recoil to the operator of the projectile system during launch than others. This invention permits the operator greater accuracy by maintaining the beam axis stable during the disturbance, permitting the missile to fly the shifted beam axis rather than the operator's instaneous line of sight aim. Improvement in system accuracy is significant at relatively short operating ranges. Likewise, use of the system described in Esker et al with targets moving at relatively high rates of speed can result in target misses because the actual projectile position often lags behind the moving target line of sight and the collimated center of the projected beam.
The operational performance of the guidance system disclosed in Esker et al can be improved appreciably, particularly with respect to moving targets by providing lead angle information to the missile receiver. Lead angle information is obtained by varying the rate of orbital rotation of the reticle about the optical system axis. That is to say, during each revolution of the reticle center about the optical system axis, the rotational rate of the reticle center is increased and decreased cyclicly to provide lead angle information to a projectile in the beam. The basic technique consists of frequency modulating the rotational rate of the reticle. The frequency modulation amplitude is made to equal the magnitude of the desired angular change in the projected spatially coded axis, and the frequency modulation phase is made to equal the direction in which the spatially coded axis shift is desired. The effect that this beam information has on the missile borne receiver is such that the receiver interprets the image of the reticle pattern as if the receiver were displaced from its unmodulated position in a direction from beam center as indicated by the modulation phase. Since the missile control devices operate to direct the missile toward axis center, or minimum frequency modulation, the missile follows the coded axis shift.
In use, the invention gives stabilization to the coded axis when the beam and the beam projector platform are unstabilized, furnishes spatially coded axis lead angle with respect to the beam center to compensate a missile borne guidance control loop containing a position error when in a moving beam, and supplies a manual or an electronic bore sight alignment between the coded beam axis and a gunner's sight when small angular displacement errors exist.
One of the objects of this invention is to provide improved means for controlling the flight of a projectile.
Another object of this invention is to provide a line of sight guidance system with a lead angle component.
Another object of this invention is to provide a guidance system having improved accuracy for guiding a projectile towards the target.
Another object of this invention is to provide a line of sight guidance system which is relatively inexpensive, light weight, portable and which requires little or no special skill or training in its operation.
Another object of this invention is to provide a means for adjusting the orbital speed of rotation of the reticle center about an optical axis along which a beam is projected based on the rate of change of beam projector motion.
Another object of this invention is to provide a guidance system for a beam rider projectile compatible with a wide range of projectile types.
Other objects of this invention will be apparent to those skilled in the art in light of the following description and accompanying drawings.
SUMMARY OF THE INVENTION
In accordance with this invention, generally stated, a guidance system for a beam rider projectile is provided with a control axis along which the projectile aligns itself, the direction and magnitude of the control axis angle between or with respect to the beam axis center being determined by projected beam axis movement rate and projectile range. The guidance system includes a beam projector at a launch site, and a beam receiver and signal decoder carried by an object to be guided, preferably a missile or similar projectile. The beam projector is adapted to generate a coded control beam along a central optic system axis and includes a reticle having a center mounted for orbital rotation with respect to the optical system axis. The speed of reticle orbital rotation is varied so that the receiver, positioned in the beam, receives a frequency modulation minimum beam information signal at a position displaced from the optic system axis. The missile, which is adapted to align itself with the projected beam spatial modulation center, follows the beam minimum spatial frequency modulation signal. Consequently, the projectile's commanded position is made to lead the moving target line of sight a distance equal to the projectile's position lag with resulting improved guidance system accuracy.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a view in perspective showing the relative in flight positions of a launch site and beam projector or missile director, a missile, a target and the lead angle induced in the control axis for the missile;
FIG. 2 is a view in perspective of one illustrative embodiment of missile director of this invention;
FIG. 3 is a view in perspective of an encoder assembly utilized in conjunction with the missile director of FIG. 2;
FIG. 4 is a block diagrammatic view illustrating the operation of the missile director shown in FIG. 2;
FIG. 5 is a diagrammatic view illustrating reticle center rotation for FM frequency modulation coding of the beam utilized in conjunction with the missile director of FIG. 2;
FIG. 6 is a diagrammatic representation of a cross section of the beam projected through the reticle of the missile director of FIG. 2;
FIG. 7a is a graph illustrating the laser output frequency of the missile director of FIG. 2;
FIG. 7b is a diagrammatic representation comparing the instantaneous reticle velocity in a cross section of the beam generated by the missile director of this invention at a point in the beam;
FIG. 7c is a graphic representation illustrating the pulse width of a signal received at a point in the beam, individual pulses of the pulse plurality shown being, in practice, a group of twenty kilohertz or twenty-eight kilohertz, thirty five nanoseconds pulses, the particular frequency being determined by the position of the reticle center;
FIG. 7d is a graphic representation illustrating the frequency modulation amplitude and phase of a signal received at a point P in the beam; and
FIG. 8 is a diagrammatic representation useful for explanation purposes in describing the spatial frequency modulation of the beam utilized with the missile director of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, reference numeral 1 indicates a guidance system for directing a projectile, for example, a missile 2, along a centerline axis 3 of a beam 4, the beam 4 illuminating both the missile 2 and a target 5. The beam 4 is generated by a missile director 6 associated with a launch device 7.
The launch device 7 and missile 2 may comprise any variety of a suitable projectile and launcher vehicles. As indicated above, the missile and launcher described in the Tucker, U.S. Pat. No. 3,868,883, is particularly well adapted for use with this invention, provided the missile is modified as described in Esker et al, U.S. Pat. No. 4,014,482.
The launch device 7 includes a tube 10, preferably of a recoiless weapon type. The director 6 includes a housing 11 having a face guard (not shown), an eye piece 12, and a sighting scope 13 associated with it. Also contained within the housing 11 are a laser diode source of radiation 14 and its associated driver and control circuits, a beam encoder means 15 and its associated circuits, and a zoom lens optical system 80 and its associated drive circuits. The housing 11 is intended to be removably mounted to the launch device 7 by any convenient method. Launch device 7 conventionally is disposable, although in certain applications, the device may be utilized repeatedly. It may be observed, in FIG. 2, that the laser source 14 is aligned with the encoder 15 and the optical system 80. The beam projected by the director 6 physically passes through an electronic package area 16, which is arranged physically so that no interference with the beam occurs. Other embodiments of our invention may reposition the package area 16.
The beam encoder means 15 is shown with greater detail in FIG. 3. As there illustrated, a DC motor 18 has an output shaft 17 attached to a first gear 20 of a gear train 70. The encoder means 15 is substantially similar to that disclosed in Esker et al, U.S. Pat. No. 4,014,482, and details of the encoder means not described here may be found in that patent.
In general, the gear 20 of the gear train 70 is coupled to an encoder gear 21 by a conventional gear tooth arrangement, the gear teeth being diagrammatically shown in FIG. 3. The encoder gear 21 is mounted for rotation along a shaft 22. The shaft 22 also is mechanically coupled to an opto-interrupter means 23. The opto-interrupter means 23 generates a signal corresponding to the angular position of a center 19 of a reticle 24. A rotating motion for the reticle center 19 is produced by the gear train 70 and the center 19 of reticle 24 rotates about an axis offset from the centerline axis 3 of a bore 27 passing through a spindle 26. The bore 27 is sized to permit the laser beam radiation to pass through the spindle 26.
The reticle 24 is a flat disc with alternating opaque and transparent, equal size spokes 38 and 39, respectively. As indicated above, the center 19 of the reticle 24 is mounted so that it is offset from the axis 3 of the optical system. The beam generated by the director 6 will illuminate only a small circular section of the reticle 24 at any particular instant in the operation of the guidance system 1. The remainder of the optical system is used to radiate the laser source 14 energy so as to project an image of the illuminated portion of the reticle 24 into space along the axis 3 of the optical system. In order to encode usable information on the radiated beam, the reticle 24 is moved so as to interrupt the energy radiation at points within the radiated beam. As is known in the art, in particular the Esker et al U.S. Pat. No. 4,014,482, a section of the reticle, which represents the extremity of the projected beam is shown as a solid line circle in FIG. 5, and again in FIG. 6. The reticle 24 is shown in FIG. 5 with the alternating opaque and transparent spokes 38 and 39, respectively, drawn diagrammatically. The center 19 of reticle 24 follows the dash arrow path 40 during one rotational cycle. A point on the reticle 24 in FIG. 5 will move from the location shown at the bottom of the reticle 24 at a time T 1 to a location shown on the dash reticle 24 at a time T 2 . At time T 2 , the position of the reticle 24 in the beam will have spokes oriented as shown by the dash spoke outlines in FIG. 5. As is known in the art, frequency modulation coding of the beam occurs because of the shape of the spoke images and the instantaneous velocity of the spoke image across a detector aperture. In FIG. 6, one spoke of the reticle 24 is shown. If the instantaneous velocity of the center of the reticle 24 is straight down as indicated, for example, in FIG. 5, then the instantaneous velocity of all points on the spoke image also will be straight down with the same velocity magnitude. Consequently, a receiver 9 of the missile 2 in the beam, looking back at the encoder 15, will receive energy when a transparent spoke 39 of the reticle 24 passes through the beam, and will not receive energy when an opaque spoke 38 of the reticle 24 passes through the beam. For the reticle center position shown in FIG. 6 and when the receiver 9 is displaced horizontally toward the V 3 side of the beam center, as illustratively shown by a point P, the receiver will see a long signal on and long signal off periods, while a receiver 9 displaced toward the V 1 side of the beam will see short signal on and short signal off periods. A frequency disciminator, tuned to the frequency detected at the beam center, will produce a frequency modulated output signal with frequency deviation proportional to the displacement of the receiver 9 from the center of the beam. The rate of the reticle center rotation is shown in FIG. 5 to be equal to the reticle rotation rate to permit simplification of the operational explanation.
The description as set out above furnishes a frequency modulation proportional to the receiver 9 displacement from the optical axis. By sinusoidally accelerating the reticle center 19 orbit at the same frequency as the rotation rate, the centerline axis of the beam as defined by the minimum spatial modulation in the beam will shift to a new axis 100, shown in FIG. 1. Again referring to FIG. 6, if the speed of reticle center 19 rotation is varied, it will appear, to a receiver at the point P in the beam, that the receiver in fact has been repositioned either toward the V 3 or toward the V 1 part of the beam, depending upon the phase of the reticle center 19 orbit sinusoidal acceleration and the magnitude of the change in reticle center speed. This variation in reticle center rotation rate shifts the reference axis for the receiver 9 and provides the lead angle component to the guidance system.
FIGS. 7a through 7d illustratively show the beam coding/decoding operation. As explained in the Esker U.S. Pat. No. 4,014,482, the laser diode for generating the beam is electronically pulsed at different rates during the rotation of the reticle 24 center 19. As the reticle center 19 is rotated through the full rotational cycle, the image projected corresponds to that shown in FIG. 7b. A receiver and decoder carried by the missile 2 in the beam at the point P will see an error signal whose frequency deviation amplitude ρ (rho), will be proportional to the displacement of point P from the apparent beam center, while the error signal phase β (beta) will be proportional to the direction of the displacement error.
In the specific encoder means 15 utilized in the preferred embodiment of this invention, the reticle 24 also rotates about its center on a shaft 37, as best observed in FIG. 3. That is to say, both the center 19 of the reticle 24 and the reticle 24 itself are rotated during operation of the guided system 1 of this invention. As will be appreciated by those skilled in the art, reticle 24 rotation about its center and reticle center 19 rotation about the axis 3 need not occur at the same rate. Rotation of the reticle or the reticle center 19 about the axis 3 of the optical system, for the purposes of this specification, is denominated as movement orbital or orbitally. The terms orbital and orbitally are intended to encompass the variety of possible movements of the reticle center 19 rotation rate in addition to the sinusoidal rotation changes described. Rotating the reticle about its center and rotating the reticle center about the optical axis at different rates results in spatial modulation characteristics containing noise components, which result from mechanical and optical inaccuracies in the mechanisms comprising the encoder means 15, which can be shifted to frequencies outside the missile control range of frequencies processed by the decoder carried by the missile 2. In addition, the slope of the frequency deviation versus missile position in the beam can be increased to improve the resolution to the position error data.
FIG. 8 is a graphic representation which illustrates the encoding function of the missile director 6 and which defines the various parameters employed with the encoder means 15. Only a portion of the spokes of the reticle are shown for clarity in FIG. 8. The circular short dash line with the radius ρmx (rho) mx represents the portion of the reticle that is radiated by the source output, and also represents the reticle image projected in the beam. The long dash circle with the radius r o is the path followed by the reticle center about the optical axis. For convenience, a representative missile position point P, is shown displaced a distance ρ from the center, with ρ at an angle β (beta) from a reference axis of the beam. The reticle center 19 rotates about the beam center or optical axis at rate ω i , and the reticle spokes rotate about the reticle center at a rate ω r . The instantaneous angular position of the reticle center is given by the equation θ=ω i t. The modulation seen at the missile point P is related to the passage of the reticle spoke images, which is seen to be the difference between the rate of spoke rotation, ω r , and the rate of change of the angle θ k . The frequency is given by dividing this rate by the angle between adjacent leading edge reticle spokes 2θ c , or: ##EQU1##
An expression for θ k can be derived using the law of sines: ##EQU2## which can be reduced to: ##EQU3## which is the standard FM form f=f o +Δf, with, where: NB is the number of spokes on the reticle and Δf equals: ##EQU4## The demodulation process which takes place in the receiver/decoder uses a phase lock loop to extract the missile displacement, ρ, which appears as the modulation deviation and the missile displacement angle, β, which appears as the phase of the modulation referenced to the reticle image in the beam.
When the beam lead modulation is added to the encoder rotational rate, the resulting expression for the receiver frequencies can be set as follows: ##EQU5## The relationship between ω r and ω i is a constant and ω i can be expressed as follows: ##EQU6##
The phase position of the encoder rotor thus becomes: ##EQU7## Then, by substitution, the previous equation for θ k becomes: ##EQU8## and ##EQU9## Then: ##EQU10##
This expression contains the reticle center acceleration magnitude, 2/ω io 2 , and phase, γ.
The synchronous detectors and the filters of the missile 2 remove all but the steady state component of this expression.
A functional block diagram of the missile director 6 is shown in FIG. 4. A dash line 140 separates the conventional components of the director 6, shown on the right side of the dash line 140, from those components added in order to provide beam lead capability and to control the speed of rotation of the reticle center, shown on the left side of the line 140. Information concerning the operation and purpose of the conventional portion of FIG. 4 is contained in the above disclosed U.S. Patent to Esker, U.S. Pat. No. 4,014,482. It is here noted that the source for the radiated beam 4 is a laser diode 42 and that a pulse repetition rate generator 47 is synchronized with the encoder reticle 24 and reticle center 19 movement so that it produces either of two predetermined pulse repetition rates during the rotation cycle of the reticle center 19 to provide the reticle image rotation reference signal modulation.
The opto-interrupter 23 provides an output signal which feeds both the pulse repetition rate generator 47, a phase lock loop 48, and a multivibrator 77. The output from the phase lock loop 48 forms an input to a motor drive means 49, the drive means 49 being operatively connected to the encoder drive motor 18. Means for generating a 30 hertz drive command input, generally indicated by the reference numeral 50, also is connected to the motor drive means 49. The drive means 49 powers the drive motor 18, which, as indicated above, is operatively connected to the reticle 24 through a gear train 70, shown in phantom lines in FIG. 4. The remaining components of the encoder 15 on the right side of the line 140 in FIG. 4, while important for encoder 15 operation, form no part of this invention and are not described in detail. Again, reference may be made to Esker, U.S. Pat. No. 4,014,482, for additional information. As indicated above, preferably the lead angle provided to the projected beam is a function of the slew or tracking movement rate of the director 6. Movement of the director is monitored by a pair of rate gyros 81 and 84 which generate signal representations of director movement about a Z axis and a Y axis respectively of a conventional Cartesian coordinate system. The Z and Y axes are perpendicular to the optical axis.
The Z axis rate gyro 81 has an output 82 forming an input to a multiplier 83. The Y axis rate gyro 84 has an output 85 forming an input to a multiplier 86. A range program means 87 generates a voltage function dependent upon time of launch of the projectile 2, the range program output function being initiated by a suitable start pulse at an input 88. The start pulse may be initiated, for example, by a missile first motion signal means 52. Output from the range program means 87 forms an input to the multipliers 83 and 86 respectively.
The respective outputs of the multipliers 83 and 86 form inputs to respective squaring means 89 and 90. The outputs of the squaring means 89 and 90 are combined at a summing means 91. The sum of the square output from the summing means 91 is an input to a square root means 92 which determines the magnitude of the tracking vector. That is to say, the square root means 92 provides the lead angle magnitude. An output 93 of the square root means 92 forms a first input to a variable gain amplifier 94, and controls the gain of that amplifier.
An arc tangent function generator 95 receives the Z and Y axes inputs from the rate gyros 81 and 84 and their multipliers 83 and 86 along inputs 96 and 97, respectively. The notation "other Z inputs" and "other Y inputs" indicated in FIG. 4 are shown for information purposes only, and may comprise bore sight corrections for the director 6. That is to say, it is possible to electrically compensate for various mechanical errors in the director 6 by electrical inputs to the arc target function generator 95. Such compensation, however, does not form a part of the invention disclosed herein.
An output 101 of the arc tangent generator 95 is a second input to the multivibrator 77 and provides the variable delay pulse width control. An output 102 of the multivibrator 77 forms an input to a divide by N counter 103 which controls the acceleration phase and thereby the direction of the lead angle. The counter 103 has an output forming an input to a band pass filter 104. The output of the band pass filter 104 is a second input to the variable gain amplifier 94. The variable gain amplifier 94 has an output 105 which forms an input to the phase lock loop 48.
Operation of the system shown in FIG. 4 is relatively simple to understand. As indicated, the basic speed control loop for the encoder drive motor 18 is controlled by the opto-interrupter 23, the phase lock loop 48, the motor drive means 49 and the encoder drive motor 18. An oscillator (not shown) in the phase lock loop 48 effectively matches the 30 hz command of the command means 50. Any difference in frequency develops an error voltage which drives encoder motor 18. The opto-interrupter 23 senses the change in speed and sends the new speed N 1 back to the phase lock loop 48 to increase or decrease the oscillator frequency. The acceleration control loop for reticle center 19 rotation is formed by providing a multiple of the 30 hz command 50 frequency along an output 107 to the counter 103. A multiple of one hundred is used in this embodiment. Counter 103 serves as a phase shifting network for the acceleration command 30 hz signal. The signal is filtered in band pass filter 104, adjusted in amplitude in amplifier 94 and used to modulate the oscillator in the phase lock loop 48. The motor speed of the drive motor 18 follows the error introduced due to the phase lock loop output differing from the 30 hz command. The counter 103 determines the start of the frequency acceleration modulation cycle and thereby determines the phase or direction of the coded axis shift. Control of the phase shift rests with the output of the arc tangent function generator 95, and the reticle center position reference signal, N 2 from the opto-interrupter 23, which provides the reference pulse start time for pulse width phase delay multivibrator 77.
The counter 103 is made to start its count by the time-out pulse output of the variable pulse-width multivibrator 77. As indicated, the start of the multivibrator pulse is established by the encoder rotor position obtained from the opto-interrupter feedback mechanism 23. The arc tangent function generator 95 output 101 is used to control the period of the monostable multivibrator 77. The counter 103 output is a square wave having a frequency at the reticle center mean rotational rate. The square wave is converted to a sign wave by the band pass filter 104.
The output of the band pass filter 104 is a constant amplitude voltage alternating at the speed of the reticle center mean rotation rate. This output is fed to the variable gain amplifier 94. The amplifier 94 gain is controlled by the magnitude of the Y and Z axes signals from the square root means 92. As indicated, that magnitude signal is the square root of the sum of squares of the magnitudes of the Y and Z axes body rates, angle errors and/or position controls obtained from the squaring means 89 and 90. The output of the variable gain amplifier 94 forms an input to the phase lock loop 48 to provide the speed variation for the encoder drive motor 18. The encoder drive motor 18 in turn varies the speed of the reticle center 19 rotation about the centerline axis of the beam at a cyclic rate equal to the reticle center rotational rate. The cyclic variation of the reticle center 19 speed has the same effect as making the missile 2 think its position in the beam has changed. The missile 2 consequently attempts to realign itself toward what the missile believes is beam center and thereby follows the coded axis shift. The operation of the remaining components of the guidance system is similar to that described in Esker U.S. Pat. No. 4,014,482.
It is thus apparent that the guidance system provided meets all the ends and objects as herein set forth above.
Numerous variations, within the scope of the appended claims, will be apparent to those skilled in the art in light of the foregoing description and accompanying drawings. Thus, the guidance system of this invention is compatible with a number of applications, in addition to the particular weapons system disclosed. Other applications include use of the techniques disclosed herein in infrared missile seekers which use pursuit guidance against aircraft type targets. The turning rate of the missile can be used effectively to advance the indicated target position so as to reduce the amount by which the missile is lagging the moving target. The design of the reticle may vary in other applications. While preferably the reticle center rotates about the optical axis, and the reticle rotates about its center, only the reticle center need be rotated. Various other forms of enclosures and reticle center drive means may be employed for the missile director 6, if desired. It will be understood that certain features and subcombinations of the invention are of utility and may be employed without reference to other features and subcombinations. Although various input and outputs were diagrammatically illustrated as single conductors, those skilled in the art will recognize that the use of a single conductor designation in a diagrammatic illustration merely facilitates the description of the system disclosed, and those single conductors may be multiple connectors in actual embodiments of this invention. With the information disclosed in the drawings and described hereinabove, those skilled in the art will be able to construct physical circuits from the block diagram shown. If additional circuit design information is desired, it may obtained, for example, from Phase Lock Techniques, Floyd M. Gardner, John Wiley & Sons, 1966; Op Amps Replaced Transformer in Phase Detector Circuit, Agaugi, Electronics, 1969; and Characteristics and Applications of Modular Analog Multipliers, E. Zuch, Electronics Instrumentation Digest, April, 1969. These variations are merely illustrative. | A line of sight guidance system in which the radiated output of a pulsed laser is spatially modulated to produce a beam radiated from an optical projector along a first axis, including a missile or projectile carrying a beam receiver and signal decoder which receives and decodes information in the beam to enable the missile to seek beam center, is provided with apparatus for generating a lead angle axis reference for the missile. The basic technique comprises FM modulating the rotational rate of an orbitally driven projected beam chopping spoked reticle. The FM modulation amplitude is chosen to equal the magnitude of the desired angular change of the projected spatially coded axis, while the FM modulation phase is made to equal the direction in which the projected spatially coded axis is shifted. The receiver at the missile interprets the image of the recticle pattern as if the receiver where displaced from the unmodualted first axis position in a direction from beam center as indicated by the modulation phase. Since the missile is controlled to the beam axis center, it follows the coded axis shift. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of U.S. patent application Ser. No. 12/954,727 filed Nov. 26, 2010, which is a continuation of U.S. patent application Ser. No. 11/346,280 filed Feb. 3, 2006, in which all are hereby incorporated by reference.
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by any one of the patent document or patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD
[0003] The present specification relates to a mapping application, in particular, a mapping application for visually representing location information.
BACKGROUND
[0004] Mapping software is widely used to provide a user with a visual location on a map that corresponds to a street address. MapQuest and Google each offer free access to their mapping software over the internet. In addition to using the mapping software to plot various addresses, it is also known to integrate the mapping software into other applications. One example of this is a real estate application in which multiple identifiers are plotted on a map of a particular city. In this case, each identifier visually represents a property that is for sale or for rent. By selecting an identifier, additional information about the property may be displayed, including contact information for the real estate agent associated with that property.
[0005] There are many applications that may be suitable for integration with mapping software. In each case, however, the plotted item is limited to being a building, a tourist attraction or a restaurant, for example. It is therefore desirable to plot the location of a movable item whose location may change over time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The specification will be better understood with reference to the following Figures in which:
[0007] FIG. 1 is a functional block diagram of a communication system for a portable electronic device according to an embodiment;
[0008] FIG. 2 is a functional block diagram of certain components the portable electronic device of FIG. 1 ; and
[0009] FIG. 3 is a front view of a display of the portable electronic device of FIG. 2 .
DETAILED DESCRIPTION
[0010] Referring to FIG. 1 , a functional block diagram of a communication system 10 and a portable electronic device 12 is generally shown. The portable electronic device 12 and the communication system 10 are operable to effect communications over a radio communications channel therebetween.
[0011] For the purpose of illustration, the communication system 10 is functionally represented in FIG. 1 and includes a base station 14 . Base station 14 defines a coverage area, or cell 16 within which communications between the base station 14 and the portable electronic device 12 can be effected. It will be appreciated that the portable electronic device 12 is movable within cell 16 and can be moved to coverage areas defined by other cells, including those that are not illustrated in the present example.
[0012] The base station 14 is part of a wireless network and infrastructure 18 that provides a link to the portable electronic device 12 . The wireless network and infrastructure 18 includes additional base stations (not shown) that provide the other cells referred to above. Data is delivered to the portable electronic device 12 via wireless transmission from base station 14 . Similarly, data is sent from the portable electronic device 12 via wireless transmission to the base stations 14 .
[0013] Wireless networks and infrastructures include, for example, data-centric wireless networks, voice-centric wireless networks, or dual-mode wireless networks. For the purpose of the present exemplary embodiment, the wireless network and infrastructure 18 includes a dual-mode wireless network that supports both voice and data communications over the same physical base stations.
[0014] The communication system 10 further includes a relay device 20 that is connected to the wireless network and infrastructure 18 and to a server 22 . It will be understood that the functions provided by the relay device 20 and the server 22 can be embodied in the same device. The server 22 is also connected to an administration server 24 , as shown. The administration server 24 provides administrative services to and control over the server 22 .
[0015] The server 22 is also functionally coupled through a connector 26 to a backup/restore database 28 . Other connectors and databases can be provided, for example, for synchronization purposes. The connector 26 receives commands from the server 22 . It will be understood that the connector 26 is a functional component and can be provided by way of an application on the server 22 . The backup/restore database 28 is used for storing data records, including, for example, copies of Short Message Service (SMS) or Personal Identification Number (PIN) messages sent from the portable electronic device 12 .
[0016] Referring now to FIG. 2 , a block diagram of certain components within the portable electronic device 12 is shown. In the present embodiment, the portable electronic device 12 is based on the computing environment and functionality of a wireless personal digital assistant (PDA). It will be understood, however, that the portable electronic device 12 is not limited to a wireless personal digital assistant. Other portable electronic devices are possible, such as cellular telephones, smart telephones, and laptop computers. Referring again to the present embodiment, the portable electronic device 12 is based on a microcomputer including a processor 30 connected to a read-only-memory (ROM) 32 that contains a plurality of applications executable by the processor 30 that enables the portable electronic device 12 to perform certain functions including, for example, PIN message functions, SMS message functions and cellular telephone functions. The processor 30 is also connected to a random access memory unit (RAM) 34 and a persistent storage device 36 which are responsible for various non-volatile storage functions of the portable electronic device 12 . The processor 30 receives input from various input devices including a keypad 38 . The processor 30 outputs to various output devices including an LCD display 40 . A microphone 44 and phone speaker 42 are connected to the processor 30 for cellular telephone functions. The processor 30 is also connected to a modem and radio device 46 . The modem and radio device 46 is used to connect to wireless networks using an antenna 48 . The modem and radio device 46 transmits and receives voice and data communications to and from the portable electronic device 12 through the antenna 48 .
[0017] The portable electronic device 12 is operable to effect two way communication of voice and data. Thus, the portable electronic device 12 transmits and receives voice and data communications over the wireless network and infrastructure 18 via wireless communications with the base station 14 over a radio communications channel.
[0018] Referring to FIG. 3 , display screen 40 of portable electronic device 12 of a first user, is generally shown. A map 52 appears on the display 40 . Avatars 54 , 56 , 58 and 60 , which are located at various positions on the map 52 , are also shown on the display 40 . Each avatar 54 , 56 , 58 , 60 is a visual identifier that represents a different portable electronic device user.
[0019] The map 52 is generated using a mapping software application, which uses mapping software to provide worldwide map data. The worldwide map data may be provided by NAVTEQ, Tele Atlas or another provider.
[0020] The position at which each avatar 54 , 56 , 58 , 60 is plotted on the map 52 corresponds to the global location coordinates of each user's portable electronic device at a particular time. The location coordinates are determined locally in each portable electronic device using Global Positioning System (GPS) technology that is integrated into each portable electronic device. The location coordinates may alternatively be determined locally based on signal strength from cell towers, for example, or any other suitable type of positioning technology. Further, it will be appreciated by those skilled in the art that if a user's portable electronic device does not support GPS technology, the user may manually input location information into the portable electronic device.
[0021] Once the location coordinates have been determined locally, the coordinates are sent to the portable electronic device 12 of the first user, whose display 40 is shown in FIG. 3 . The coordinates may be sent following a request from the first user or at regular intervals without a request from the first user. Alternatively, the coordinates may be sent every time there is a change in the coordinates.
[0022] The status of each user is also visually represented on the display 40 . As shown, avatar 54 is grayed out and includes a picture of a bee 62 to indicate that the user associated with this avatar 54 is busy; avatar 56 is grayed out and includes a picture of a do not disturb sign 64 to indicate that the user is not available; avatar 58 includes a picture of a callout 66 to indicate that the user is typing a message and avatar 60 is available. The status of each user is determined locally using algorithms on the portable electronic device. Determining the status of a portable electronic device user is well known in the art. For example, a user's status may be determined to be unavailable if the user does not respond to active notifications, which include emails, calendar events and instant messages, for a predetermined period of time.
[0023] Similar to the location coordinates, the status may be sent to the first user following a request from the first user, at regular intervals, or every time there is a change in the user status. The status information is generally sent to the portable electronic device of the first user at the same time as the location information, however, may alternatively be sent at a different time.
[0024] The portable electronic device users that are displayed on the map 52 are members of a contact list of the first user. The first user is authorized to receive and view information about each member and therefore is a member of the contact list of each of the other users. Similarly, the other users are authorized to receive and view information about the first user. The authorization process between a pair of portable electronic device users is well known in the art and therefore will not be described here.
[0025] The contact list is divided into a number of groups. The first user may not want to display the location of every contact in his/her contact list all of the time so it is possible to select one or more groups to display. For example, one group may be called “Project Leaders” and contain only those colleagues who are in charge of projects. It may be useful to plot only this group on a map in order to determine their respective locations at the time a meeting is scheduled to start. Similarly, other groups may be created and plotted on a map.
[0026] The information that is stored in the contact list with respect to a particular user typically includes: email address, phone number(s), facsimile number(s) and physical address(es). A profile including a preferred avatar of the contact may also be stored with the contact information.
[0027] The contact list is not limited to including only contacts who have completed an authorization process. Contacts for whom location and status information cannot be obtained may also be included on the contact list. In addition, if a user who is an authorized contact of the first user does not wish to have his/her location or status made available at a particular time, the user may block transmission of such information, if desired.
[0028] The first user is able to view additional information associated with an avatar 54 , 56 , 58 , 60 by focusing on the avatar 54 , 56 , 58 , 60 using a mouse or other selection device. As shown in FIG. 3 , avatar 60 is “in focus”. This launches a window 68 that provides additional information from the contact list about the contact. In this case, a photograph and email address is provided, however, other information may alternatively be provided.
[0029] In use, the first user powers up portable electronic device 12 if it is not already powered up. The user then selects a group of contacts from a list of predefined groups that is provided. Following selection of the desired group, a location and status request is sent from the first user's portable electronic device to the portable electronic devices of each member of the selected group. When the requested information has been received, a map 52 is presented on the display 40 including the avatars 54 , 56 , 58 , 60 of the respective contacts as shown in FIG. 3 . As previously described, the location and status may alternatively be broadcast from the portable electronic devices of the other users and received by the portable electronic device of the first user without a request.
[0030] Once the avatars 54 , 56 , 58 , 60 have been plotted on the map 52 , the first user may focus on any one of the avatars 54 , 56 , 58 , 60 to bring up window 68 , which includes further information associated with the avatar 54 , 56 , 58 , 60 .
[0031] The map 52 may be maintained on the display 40 at all times or alternatively, the map 52 may be launched each time the first user selects a “Map my Contacts” application from a menu. In the embodiment in which the map 52 is maintained on the display 40 , the location coordinates and status are updated at regular intervals. The timing of the intervals may be set by the portable electronic device 12 of the first user. Alternatively, the location coordinates and status may only be updated when the first user clicks a “refresh” button.
[0032] In another embodiment, the avatars 54 , 56 , 58 , 60 are replaced with customized avatars that are easily differentiable from one another. One type of customized avatar is a photograph of the respective user. The customized avatars may be associated with each user's profile. Alternatively, avatars may be assigned by the first user to override the avatars associated with the user profiles.
[0033] The status of a user may be represented in various ways. For example, if the avatar is a photograph of the user, a busy status may be indicated by graying out the photograph; a not available status may be indicated by drawing an X over the photograph, a typing status may be indicated by coloring the photograph yellow or another suitable color; and an available status may be indicated by simply displaying the original photograph. It will be appreciated by persons skilled in the art that other types of status may also be visually represented. For example, if a user has manually set their portable electronic device to “do not disturb” this may be represented in a different manner than a user who has simply not responded to calls or electronic messages for a period of time.
[0034] It will be appreciated that the location and status information of the other users is displayed on the map 52 regardless of the actual distance between the other users and the first user. As long as the portable electronic device 12 of the first user is able to receive signals from the other users, the information will be displayed.
[0035] A specific embodiment has been shown and described herein. However, modifications and variations may occur to those skilled in the art. For example, although only a small number of avatars have been described, there are many types of avatars for differentiating users from one another and for indicating the status of each user that could be used. In addition, the map 52 that appears on the display 40 may be drawn from location source data using vector graphics. Other modifications and variations may occur to those skilled in the art. All such modifications and variations are believed to be within the sphere and scope of the present embodiment. | A method for visually representing information on a display of a portable electronic device includes receiving location coordinates from at least one other portable electronic device, plotting a visual identifier on a map and displaying the map on the display of the portable electronic device. The position of the visual identifier corresponds to the location coordinates received from the at least one other portable electronic device, which correspond to an actual location of the at least one other portable electronic device. The appearance of the visual identifier is selected to depict the status of the user of the at least one other portable electronic device. | 7 |
BACKGROUND OF THE INVENTION
The field of the present invention is separators employing vibratory screens.
Vibratory screen systems have long been employed for the separation of solids suspended in liquid as well as solids of various sizes. The screens are generally drawn taut, oriented in a roughly horizontal position and vibrated in such a way that material will move advantageously across the screen during the screening process. Such vibratory structures are often characterized as either being rectangular or circular, each exhibiting its own advantages, motions design features and difficulties.
Two difficulties encountered with rectangular screens have been screen sealing and the avoidance of whipping. Screen sealing is necessary to prevent bypass, a condition where material on the screen is able to pass around the frame to again comtaminate the already screened material. Whipping is a condition where the center, unsupported area of the screen is able to vibrate at a greater amplitude than the frame. This may result from a transitory or continuous condition of partial resonance. Such a condition is disadvantageous because the material on the screen does not experience sufficient residence time for proper screening. Additionally, the material is not efficiently transported across the screen under such conditions and blinding from oversize material can occur.
The foregoing problems of bypass and screen whipping are brought to the fore because solutions to each of these problems in a rectangular screen have been mutually exclusive to any satisfactory degree. To effect proper sealing, prefabricated and pretensioned screen assemblies have been found most useful. The rigid frame structure may be easily pressed against a seal about all sides to eliminate bypass. Such rigid screen assemblies have found additional advantage through the use of known inflatable pneumatic tubes employed as the sealing mechanism. Through controlled deflation of the tubes, a sreen structure may be easily placed or removed. Inflation of the seal then properly locks and seals the screen in position. However, in large rectangular screening mechanisms whipping becomes a problem for such pretensioned screen structures regardless of the sealing mechanism. Because of the difficulties of tensioning and fabrication, structural bowing of the screen and the like (a known aid against whipping) has not been found practical.
To solve the whipping of large rectangular screens, stationary stays have been introduced into the vibratory frame which are bowed or crowned. Such a construction has required post tensioning of the screen which is laid over the frame and then pulled tight on two sides. This mechanism may substantially eliminate whipping but provides a less than satisfactory seal about the edge of the screen. With certain products such as thin coating material, any oversized particles bypassed to the final product cannot be tolerated.
SUMMARY OF THE INVENTION
The present invention is directed to a vibratory screen separator providing both effective sealing capability and a crowned structure for reduced whipping. A pretensioned screen with a rigid screen frame may be employed in conjunction with advantageous pneumatic seals. The separator is arranged with opposed restraining members on two sides of the screen area such that the screen spanning the restraining members may bow upwardly under the pneumatic pressure of the sealing mechanism. As a result, pneumatic sealing of a pretensioned, rigid frame screen structure may be employed with a crown for reduced whipping.
Accordingly, it is an object of the present invention to provide an improved vibratory screen structure having effective sealing capabilities and reduced whipping. Other and further objects and advantages will appear hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an oblique view of a vibratory screen separator.
FIG. 2 is a plan view of the separator illustrated in cross section taken along line 2--2 of FIG. 1.
FIG. 3 is a cross-sectional detail taken along line 3--3 of FIG. 2 with the pneumatic seal deflated.
FIG. 4 is a cross-sectional detail taken along line 3--3 of FIG. 2 with the pneumatic seal inflated.
FIG. 5 is a cross-sectional detail taken along line 5--5 of FIG. 2 with the pneumatic seal deflated.
FIG. 6 is a cross-sectional detail taken along line 5--5 of FIG. 2 with the pneumatic seal inflated.
FIG. 7 is a plan view of a screen frame which may be employed with the present invention.
FIG. 8 is a cross-sectional end view of the separator illustrated with the pneumatic seal inflated, taken along line 8--8 of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning in detail to the drawings, FIG. 1 illustrates a vibratory screen separator. The separator includes a supporting structure, generally designated 10 which includes a rectangular base 12 with upstanding double columns 14 at each corner. Mounted on each double column 14 is a flexible support mechanism including a downwardly extending cable loop 16 attached at each end through a coil spring 18. The coil springs are mounted on cross members 20 extending between the double columns 14.
Positioned within the support structure 10 is a vibratory housing, generally designated 22. The housing 22 is rectangular in plan and has sidewalls 24 and 26 and an end wall 28, all of a convenient height for the processing for which the machine is designed. The final end wall is open for discharge of material separated by the screens. The entire vibratory housing 22 is mounted resiliently to the supporting structure 10 by wheels 29 positioned in the cable loops 16.
Associated with the vibratory housing 22 is a transverse tube 30 which encloses the rotary mounted vibratory weights which may be of conventional design. These weights are driven by a drive motor 32 fixed to the supporting structure 10, power being directed through a chain or belt located within a housing 34. A distributor 36 provides conditioned flow across the width of the vibratory housing 22 adjacent the end wall 28 downwardly into the screen area.
The vibratory housing 22 does not have a bottom but instead provides a plurality of rectangular frames 38. There are three rectangular frames illustrated in this embodiment which lie in a plane and are arranged side-by-side. These rectangular frames may be formed by four cross members, equally spaced across the housing 22, including one at each end. These rectangular frames 38 incorporate the sidewalls 24 and 26 running the length of the vibratory housing 22 on each side. As the result, three rectangular supports of equal plan are defined with open areas centrally through each support for material flow.
Located on each of the rectangular frames 38 is a pneumatic seal. The pneumatic seal is best illustrated in plan on FIG. 2 and in cross section in FIGS. 3-6. Each pneumatic seal includes a channel 40 positioned to the rectangular frame 38 and opening upwardly. The channel 40 may be conveniently fabricated of either channel material or simple upstanding flanges. Where sidewalls are available, the sidewalls themselves may form one side of the channel. Additionally, where two seals are in juxtaposition, the sidewall may be eliminated between the seals. As can be seen from the cross sections of FIGS. 3-6, the channel 40 adjacent the sidewalls 24 and 26 includes a simple angle extending inwardly from the sidewalls and upwardly to complete the channel configuration. Across the open end of the vibratory housing 22, a full channel member may be employed. At the corners of adjacent rectangular frames 38, curved flanges may extend to and be terminated at a common tangent with the seals extending as one double width channel between corners.
Located within the channel sections of the rectangular frames 38 are pneumatic tubes 42. Such pneumatic tubes are commercially available for sealing purposes and are designed to be constrained within channels such that when inflated they expand in a predictable direction to seal against a rigid surface. Pneumatic controls to direct pressurized air to each of the three pneumatic tubes 42 may also be conventionally arranged. FIGS. 3 and 5 illustrate the pneumatic tubes 42 in the deflated condition while FIGS. 4 and 6 illustrate the tubes in the inflated condition.
A restraining member 44 is located along each sidewall 24 and 26 of the vibratory housing 22. Each restraining member is placed above and spaced from a channel 40 along the sidewalls as can best be seen in FIGS. 3 and 4. The restraining members 44 thus hold a screen frame in position as will be discussed below. The restraining members 44 run the full length of each of the sidewalls 24 and 26 but do not run along the end wall 28, the open end opposite the end wall 28 or at any intermediate span parallel to the end wall 28.
Three screen panels are illustrated with the vibratory screen separator. The screen panels include screen frames 46 and screen cloth 48. The screen panels may be made according to existing techniques involving the pretensioning of the screen cloth 48 and the embedding or attaching of the tensioned screen cloth 48 to the screen frame 46. The frames 46 are substantially rigid in construction to maintain the tensioning within the screen cloth. These frames 46 are sized to fit on the rectangular frames 38 such that the pneumatic seal may effectively seal the frames upon installation. Ribs 50 are illustrated as extending in one direction at uniform spaces across each screen. These ribs 50 are parallel to the sides of the screen frames 46 which are positioned adjacent the restraining members 44. Thus, screen support is established across the screen without inhibiting the bending modulus of the structure in a direction perpendicular to the ribs.
Returning to the cross sections of FIGS. 3-6, the screen frames 46, the channels 40 and the restraining members 44 are arranged such that the screen frames 46 can slide without resistance between the restraining members 44 and the channels 40 with the pneumatic tubes 42 in the deflated condition. This easily positioned yet positively sealed arrangement is highly advantageous for processing plants where continuous operation is implemented. Very rapid and accurate screen replacement may be accomplished whenever a screen may become worn or otherwise inoperative.
The foregoing arrangement is found to be very advantageous because of the unrestricted span of the screen panels between the restraining members 44. As can best be seen in FIG. 8, the pneumatic tubes 42 exert substantial pressure on the screen frame in an upwardly direction along the full length of the frame. As a result, some bowing of the frame between restraining members 44 is induced. This establishes a crown to the screen which cannot be easily fabricated into the prestressed screen panel. This bowing of the screen acts to substantially reduce any whipping action experienced by the screen during vibratory motion. The bowing need not be very great to accomplish the foregoing result. A maximum of one-half inch vertical displacement across a span of 46 inches is considered more than sufficient.
Thus, a vibratory screen separator has been disclosed which provides highly efficient screening and sealing of materials thereon. Efficiency is increased through a reduction in screen whipping even though a prestressed screen panel is employed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims. | A vibratory screen structure which is rectangular in plan employing pretensioned screen panels and a pneumatic tube seal beneath the panels. Restraining members are positioned on two sides of the screen panels to hold the screen frames in position on the pneumatic tubes when sealed. The remaining sides are unrestrained and bow under the pressure of the pneumatic tubes to create a crown in each screen panel. | 1 |
[0001] This application claims priority to our U.S. provisional application Ser. No. 61/838,838, filed Jun. 24, 2013, which is incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The field of the invention is processing of crude oil, and especially pre-processing of lighter crude oil prior to entry into a crude or vacuum unit.
BACKGROUND OF THE INVENTION
[0003] The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0004] In the last 30-40 years, the trend in the refining industry has been to design and optimize Crude and Vacuum Units to process heavy crudes. However, with the development and adoption of fracking technology, lighter crudes are becoming increasingly available. As a result, existing units as exemplarily illustrated in Prior Art FIG. 1 often must be retrofitted to process lighter crudes (e.g., Bakken crudes) since lighter crudes typically require higher operating pressures to maintain the lighter components in the liquid phase. Alternatively, or additionally, vaporization of the lighter components will increase the throughput volume, which in most cases leads to increased backpressure that can be damaging to the unit and may decrease overall throughput and quality of the processed crude.
[0005] To overcome at least some of the difficulties associated with lighter components in a crude feed, a pre-processing train may be retrofitted to include a preflash drum as exemplarily shown in Prior Art FIG. 2 . However, the vapor phase form the preflash drum is typically fed to the crude or vacuum unit and as such adds throughput volume on the crude or vacuum unit. Moreover, the preflash drum does generally not provide for a separation of the vapor and liquid phase that would produce the vapor phase as a value product. Better separation efficiency can be obtained using a preflash column as is exemplarily shown in Prior Art FIG. 3 . Here, the crude feed is subjected to a steam stripping/separation column that produces a liquid naphtha fraction that can be used as a value product or feed to another processing plant, and the liquid phase is fed to the crude or vacuum unit. While such systems advantageously allow for withdrawal of some of the vapor phase, pressure increase in the preflash column may still be an issue.
[0006] Still other configurations and methods as, for example, described in U.S. Pat. No. 4,082,653 teach a system with multiple flash zones where the vapors and the liquids are all fed into a downstream crude column. While such system provides certain advantages, the multi-flash arrangement of the '653 patent will generally not resolve the issue of excess vapor production. Similarly, US 2011/0168523 describes a system with two flash zones for two distinct feeds for a crude unit and a vacuum unit. Once more, such system is generally inappropriate both as a retrofit and as a stand-alone system to accommodate preprocessing of light crude. All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0007] Thus, even though various systems and methods for pre-processing crude are known in the art, all or almost all of them suffer from one or more disadvantages. Therefore, there is still a need to provide improved systems and methods of pre-processing of lighter crude oil prior to entry into a crude or vacuum unit.
SUMMARY OF THE INVENTION
[0008] The inventor has now discovered that pre-processing of lighter crude oil prior to entry into a crude or vacuum unit can be substantially improved by including both a preflash drum and a preflash column. Among other advantages, it should be noted that the systems and methods contemplated herein will greatly reduce or even eliminate the need for high operating pressures. Moreover, the retrofitting can be done in most cases with minimal existing equipment changes and will so provide a much more economically attractive solution.
[0009] In one aspect of the inventive subject matter, a method of pre-processing a crude feed prior to feeding into a crude unit or vacuum unit. Especially contemplated methods will include a step of heating the crude feed to form a heated crude feed, and feeding the heated crude feed to a preflash drum to form a vapor stream and a liquid stream. In another step, the liquid stream is heated to form a heated liquid stream, and the heated liquid stream is then fed into a preflash column, where the heated liquid stream is reboiled or is subject to steam stripping to thereby form a pre-processed feed. Most typically, the vapor stream is fed the preflash column, the preflash condenser, and/or the preflash column overhead, while the pre-processed feed is fed to the crude unit or vacuum unit.
[0010] While not limiting to the inventive subject matter, it is generally preferred that the crude feed API gravity is 27° API or higher. It is further contemplated that the heated crude feed has a first temperature, the heated liquid stream has a second temperature, and that the first temperature is lower than the second temperature.
[0011] In other preferred aspects, the preflash drum and the preflash column operate at about the same pressure, and/or the heated liquid stream is subject to steam stripping in the preflash column. Most typically the vapor stream is fed to the preflash column at a level at or above a level at which the heated liquid stream is fed to the preflash column. Furthermore, it is contemplated that the preflash column overhead is partially condensed to form an overhead vapor fraction and/or a hydrocarbon liquid, and at least a portion of the hydrocarbon liquid (where desired) is used as a reflux stream to the preflash column. Where appropriate, the preflash column and the preflash drum can be stacked in a single tower, and may be separated from each other via a chimney tray.
[0012] Therefore, the inventors also contemplate a method of retrofitting a processing line for processing a crude feed prior to routing the crude feed to a crude unit or vacuum unit. In such contemplated methods, the processing line typically includes a preflash drum (PFD) or a preflash column (PFC). In one step, a retrofit preflash column (RPFC) or a retrofit preflash drum (RPFD) is coupled to the preflash drum (PFD) or preflash column (PFC), respectively, to so form a processing train that comprises a PFD-RPFC or RPFD-PFC sequence, wherein the preflash drum or retrofit preflash drum receives a heated crude feed and to produce a vapor stream and a liquid stream. In another step, a heater is coupled between the PFD or RPFD and the RPFC or PFC such that the heater heats the liquid stream to form a heated liquid stream, wherein the preflash column or retrofit preflash column receives the heated liquid stream and optionally and separately the vapor stream. Most typically, the preflash column or retrofit preflash column uses a reboiler or steam stripping unit to so form a pre-processed liquid feed, and the preflash column or retrofit preflash column are coupled to the crude unit or the vacuum unit such that the crude unit or the vacuum unit receives the pre-processed liquid feed.
[0013] In further contemplated aspects, the heated crude feed has a first temperature, the heated liquid stream has a second temperature, wherein the first temperature is typically lower than the second temperature. It is further contemplated that the PFD and the RPFC or the RPFD and the PFC operate at about the same pressure, and/or that the preflash column or the retrofit preflash column use a steam stripping unit to form the pre-processed liquid feed. Additionally, it is contemplated that the preflash column or the retrofit preflash column produce a preflash column overhead or retrofit preflash column overhead, respectively, and that the preflash column overhead or retrofit preflash column overhead is fed to a destination other than the a crude unit or vacuum unit. While not limiting to the inventive subject matter, it is contemplated that the PFD-RPFC or RPFD-PFC sequence is stacked in a single tower, optionally separated from each other via a chimney tray.
[0014] Viewed from a different perspective, the inventors also contemplate a pre-processing plant for pre-processing a crude feed. Especially preferred pre-processing plants comprise a preflash drum that is fluidly coupled to a preflash column and forms from a heated crude feed a vapor stream and a liquid stream. A heater is also included to receive and heat the liquid stream to so form a heated liquid stream, wherein the preflash column uses a reboiler or steam unit as a heat source, and wherein the preflash column receives the heated liquid stream to form a pre-processed feed using the reboiler or steam unit. Additionally, it is contemplated that the pre-processing plant will include a preflash condenser that is coupled to the preflash column and that receives the vapor stream and/or a preflash column overhead, and a conduit is included to convey the vapor stream to the preflash column, the preflash column overhead, and/or the preflash condenser.
[0015] Most preferably, the pre-processing plant will be coupled to a crude unit or vacuum unit (e.g., fluidly coupled to the preflash column to receive the pre-processed feed), and the preflash drum and the preflash column will operate at about the same pressure while the preflash column preferably uses a steam unit. Similar as discussed above, the preflash column may also comprises a preflash overhead condenser that produces an overhead vapor fraction and a hydrocarbon liquid, and optionally includes a conduit that feeds at least some of the hydrocarbon liquid as a reflux stream to the preflash column.
[0016] Various objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0017] Prior Art FIG. 1 is an exemplary schematic of a known processing line for crude oil without preflash drum or preflash column.
[0018] Prior Art FIG. 2 is an exemplary schematic of a known processing line for crude oil with a preflash drum.
[0019] Prior Art FIG. 3 is an exemplary schematic of a known processing line for crude oil with a preflash column.
[0020] FIG. 4 is an exemplary schematic of a pre-processing line for crude oil with a preflash drum and preflash column according to the inventive subject matter.
DETAILED DESCRIPTION
[0021] The inventors have now discovered that problems associated with handling lighter feed in units originally designed for a heavier feed (e.g., increased backpressure or processing volume) can be effectively addressed by combined use of a preflash drum and preflash column where the vapors are removed from the system (preferably after further processing in the preflash column) and where the liquids are heated above temperatures ordinarily encountered for preflash drums and preflash columns.
[0022] In one exemplary aspect of the inventive subject matter as schematically illustrated in FIG. 4 , a pre-processing plant 400 for pre-processing a crude feed 401 is pumped by pump 405 and heated in exchangers 410 prior to combination with wash water 402 as is commonly practiced. After passing through desalter 420 and removal of desalter effluent 403 , the washed crude is then heated by heater 412 , typically to a temperature of between about 120° C. and about 180° C. before feeding the heated crude feed 404 into preflash drum 430 . The liquid stream 432 is then passed through one or more further heaters 414 , typically to a temperature of between about 150° C. and about 240° C. to so form heated liquid stream 434 that is now fed into the preflash column 440 . Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. While FIG. 4 illustrates the preflash drum and the preflash column in a configuration in which the preflash drum and the preflash column are integrated into a single column, it should be appreciated that the preflash drum and preflash column may also be physically separate, particularly where a retrofit configuration is being built. Where the preflash column and the preflash drum are stacked in a single tower, it is contemplated that the drum and column may be separated from each other via a chimney tray (and thus operate at the same pressure).
[0023] The vapor stream 436 is fed from the preflash drum 430 to the preflash column 440 (and where desired also to the preflash column overhead and/or preflash condenser, not shown), most typically at or above a location where the heated liquid stream is fed to the preflash column. It should be recognized that by including a preflash drum in addition to the preflash column naphtha separation can be optimized in the preflash column by proper selection of the preheat temperature without being constrained by vaporization limits of the crude feed at a given operating pressure. Viewed from a different perspective, it should be appreciated that the preflash column bottom stream has a significant proportion of the lighter boiling materials removed and can therefore be preheated by heat exchange with other hot streams in the unit to a higher temperature without running the risk of partial vaporization in the heat exchanger network. While not particularly preferred, it is contemplated that in some aspects the preflash column could be replaced by a second preflash drum. Still further, it should be noted that due to the drop in pressure in the preflash drum, water and lighter components are vaporized and leave the preflash drum to enter the preflash column as a vapor stream. Finally, it is noted that while the preflash drum can be operated at a higher pressure than the preflash column, it is generally preferred that the preflash drum be operated at about the same pressure as the preflash column. As used in conjunction with a numeral herein, the term “about” refers to a +/−10% range of that numeral, inclusive. For example, the preflash drum can be operated at a pressure of about 212 kPa to 650 kPa while the preflash column can be operated at a pressure of about 205 kPa to 620 kPa. Thus, suitable pressure differences between the preflash drum and the preflash column will typically be between 7 and 30 kPa. Thus, the preflash drum pressure is typically higher than the preflash column pressure.
[0024] Heating of the liquid stream 432 is typically performed by heat exchange with available hot streams in the crude pre-processing unit or by supplementary heat sources to the temperature desired before entering the preflash column where the lighter components rise up the tower and the residue is steam stripped. It should be noted that where the crude feed is extremely light, a reboiler could be used in place of a steam unit.
[0025] The preflash column 440 preferably has a plurality of trays and is coupled to a preflash column condenser unit comprising overhead condenser 442 and overhead separator drum 440 that receives the partially condensed preflash column overhead 406 . Sour water 442 and gas 444 are withdrawn from the overhead separator drum 440 , while liquid naphtha product 446 is used as reflux 446 and/or value product stream 448 (which may be further processed or stabilized). The preflash column 440 further produces a pre-processed feed 449 that is passed though heaters 416 (e.g., heat exchangers) and fired heater 418 before feeding the heated pre-processed feed into crude or vacuum unit 450 .
[0026] With respect to the crude feed it is noted that systems and methods contemplated herein will be capable of processing a wide variety of crude feeds ranging from heavy feeds to light and very light crude feeds. For example, crude feeds that are especially suitable for the plants according to FIG. 4 include those that have an API gravity greater than 27° API. Therefore, conventional plants according to Prior Art FIGS. 1-3 will particularly benefit of an upgrade to a configuration of FIG. 4 where the crude feed has an API gravity greater than 27° API. Therefore, it should be especially noted that plants and systems according to FIG. 4 may also be equipped with conduits and switching valves (not shown) that allow bypassing of the preflash drum and/or preflash column in the event that the crude feed is switched back to a heavier feed.
[0027] Most preferably, heaters and heat exchangers will be configured and implemented in the plant such that existing heat content is recycled within the plant, or obtained from a source outside the preprocessing unit (e.g., from a downstream boiler, turbine exhaust, or other waste heat source), or a dedicated heater or heat exchanger. It should also be appreciated that the temperature of the various crude, liquid, and vapor streams are selected such that the vapor pressure in the downstream devices is sufficient to achieve a desired separation. Therefore, suitable temperatures for the heated crude feed is between about 120° C. and about 180° C., for the heated liquid stream between about 150° C. and about 240° C., for the partially condensed preflash column overhead between about 135° C. and about 25° C., and for the pre-processed feed between about 145° C. and about 235° C. Most preferably, and in a different aspect of the inventive subject matter, the temperature difference between the heated crude feed entering the preflash drum and the heated liquid stream entering the preflash column is between about 30° C. and about 100° C. Thus, the heated crude feed temperature is typically lower than the temperature of the heated liquid stream.
[0028] Therefore, it should be recognized that contemplated systems and methods allow for a higher temperature and sequential heating with at least one intermittent flash step to so form a heavier liquid product that can then be fed into the crude or vacuum unit without attendant undesired vapor generation. At the same time, as the vapors from the preflash drum and preflash column are not fed into the crude or vacuum unit, the crude or vacuum unit need not handle these vapors and existing units can be utilized (or new units can be scaled to a smaller configuration). Moreover, as at least part (and in some cases all) of the vapor is processed in the preflash column, a higher-grade naphtha (e.g., unstabilized naphtha) can be obtained that can be used as a value product or be further processed. Viewed from another perspective, the preflash column overhead (or retrofit preflash column overhead) can be fed to a destination other than a crude unit or vacuum unit.
[0029] Therefore, the inventors also contemplate a method of pre-processing a crude feed prior to feeding into a crude unit or vacuum unit. In especially preferred methods, the crude feed is first heated to form a heated crude feed, and then fed to a preflash drum to form a vapor stream and a liquid stream as already discussed above. In a further step, the liquid stream is additionally heated also addressed above to form a heated liquid stream, which is the fed into a preflash column. Depending on the chemical composition of the crude feed, it is noted that the preflash column can be operated using a reboiler or a steam unit for steam stripping to thereby form a pre-processed feed. The vapor stream from the preflash drum is then fed to the preflash column, the preflash column condenser unit, and/or the preflash column overhead, while pre-processed feed is fed to the crude unit or vacuum unit. With respect to the components, operating conditions, temperature and pressure ranges, and materials, the same considerations and aspects as discussed above for the plant configuration apply and are not reiterated here.
[0030] Of course, it should be appreciated that where a pre-processing plant is a retrofit plant, the inventors also contemplate a method of retrofitting a processing line. In most, but not all cases, the processing line has a preflash drum (PFD) or a preflash column (PFC), and the retrofitting activities include a step of coupling a retrofit preflash column (RPFC) or a retrofit preflash drum (RPFD) to the preflash drum (PFD) or preflash column (PFC), respectively, to so form a processing train that comprises a PFD-RPFC or RPFD-PFC sequence. As noted above, it is generally preferred that piping is added to the preflash drum or retrofit preflash drum to allow receiving a heated crude feed and to produce a vapor stream and a liquid stream. In another retrofit step, a heater is coupled between the PFD or RPFD and the RPFC or PFC such that the heater heats the liquid stream to form a heated liquid stream, and piping is added such that the preflash column or retrofit preflash column will receive the heated liquid stream and optionally and separately the vapor stream, and such that the preflash column or retrofit preflash column can use a reboiler or steam stripping unit to so form a pre-processed liquid feed. In yet another step, piping is added to fluidly couple the preflash column or retrofit preflash column to the crude unit or the vacuum unit such that the crude unit or the vacuum unit receives the pre-processed liquid feed. As before, and with respect to the components, operating conditions, temperature and pressure ranges, and materials, the same considerations and aspects as discussed above for the plant configuration apply and are not reiterated here.
[0031] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. | Plants and methods are presented for crude feed pre-processing before feeding the crude feed into a crude unit or vacuum unit. Pre-processing is preferably achieved with a combination of a preflash drum and a preflash column that allows for high-temperature treatment of the liquids and separate vapor phase handling, which advantageously enables retrofitting existing plants to accommodate lighter crude feeds. | 8 |
BACKGROUND
The invention relates to a device and method for optical, contactless vibration measurement of a vibrating object.
Such a method utilizes and such a device comprises a laser Doppler vibrometer with a laser as light source for a laser beam. This laser beam is split into a measurement beam and a reference beam in a first beam splitter arrangement. Either the measurement beam or the reference beam experiences a frequency shift, for which an acousto-optic modulator, in particular a Bragg cell, is usually used. The measurement beam is directed to an object to be measured and scattered back or reflected from there. A second beam splitter arrangement combines the measurement beam scattered back from the vibrating object with the reference beam and superposes the two beams, resulting in an interference signal. The superposed measurement and reference beams are fed to a detector, which generates an electric measurement signal from the interference signal.
Laser Doppler vibrometers are able to perform contactless measurements up to the megahertz range of vibrations of objects, in particular of object surfaces. This opens up applications when measuring vibrations of very small and light structures, such as in micro-systems technology. However, it is also possible to measure vibrations in the air and in fluids with the aid of a laser Doppler vibrometer. Here, the frequency of the measurement beam is modulated by the movement of the object surface to be measured as a result of the Doppler Effect during reflection. Since the laser emits coherent light, an interference signal emerges from the superposition of the measurement beam, which is frequency modulated by the object movement, and the reference beam, which remains unchanged, from which interference signal it is possible to derive the speed of the object. Hence the vibration speed of the surface of the object to be measured is acquired.
Since one of the two parts of the laser beam is frequency shifted in the presently utilized laser Doppler vibrometer and hence a heterodyne vibrometer is present, a modulation frequency of the interference signal is generated which renders it possible to determine not only the current speed of the surface of the object to be measured, but also the sign, i.e. the movement direction, and so the vibration movement of the object to be measured can be acquired uniquely using the heterodyne laser Doppler vibrometer.
The shift in frequency of the reference or measurement beam, which, as mentioned above, is typically achieved by an acousto-optic modulator (Bragg cell), is only a fraction of the frequency of the laser light. Use is typically made of a helium-neon laser (He—Ne), the frequency of which lies at 4.74×10 14 Hz. The shift in frequency of the reference or measurement beam is typically merely 40 MHz. However, thermal influences on the laser, and there in particular on the optical resonator thereof, lead to changes in the resonator length which could change the frequency of the laser beam by a multiple of the frequency shift caused by the Bragg cell. In the case of a helium-neon laser, an increase in temperature by only 0.1° C. typically leads to a shift in frequency of the laser beam by 300 MHz.
This causes particular problems if use is made of several laser Doppler vibrometers, which simultaneously direct the measurement beams thereof to a region of a vibrating object to be measured, for example in order to be able to establish three-dimensional vibrations. This is because if the frequencies of the measurement beams are too close, a crosstalk effect can occur here, i.e. the backscattered measurement beam from one vibrometer which at the same time reaches another vibrometer can falsify the measurement there or render it impossible to take a measurement. Since the center frequency of each He—Ne laser is determined by a well-defined atomic electron level, the center frequencies of a number of lasers do not differ. If the frequencies of the measurement beams of several such vibrometers are shifted due to thermal effects, such crosstalk effects occur randomly again and again.
In order to meet the aforementioned problems, it is known to stabilize the frequency of the laser employed in the laser Doppler vibrometer. Here, this laser is provided with a control loop, which, in particular, acts on the length of the optical resonator in order to compensate for temperature-induced changes in length and/or frequency shifts. At the same time, it is ensured that the laser only emits one active mode which is used for the measurement. A known frequency stabilization consists in using an unpolarized laser without a preferred polarization direction and with two active modes, taking one of the two modes by means of a polarization beam splitter and using this mode as a controlled variable.
However, such a frequency stabilized laser is disadvantageous in that it reacts very sensitively to unwanted reflections and other stray light reaching the optical resonator. Moreover, the maximum laser power of such a frequency stabilized laser is not available for carrying out a measurement. This is particularly very disadvantageous if a measurement device of the type in question should make full use of the emitted light power permitted by the selected laser class in order to achieve maximum measurement accuracy.
The aforementioned disadvantage of reduced power of a frequency stabilized laser can be avoided if a laser is employed in a device and a method of the type in question, in which the active modes are all used for the measurement. This is preferably brought about by virtue of a polarization filter being employed within the optical resonator of the laser, which polarization filter brings all active modes of the laser to the same polarization such that, firstly, the full laser power is available for the measurement and, secondly, the laser becomes very much less sensitive against back reflection and stray light as a result of the polarization filter. However, according to current knowledge, frequency stabilization of this laser is then ruled out.
Without frequency stabilization, the problems which were described at the outset, in particular in the context of using several laser Doppler vibrometers, in turn emerge. But even in the case of a vibration measurement using only one laser Doppler vibrometer, the laser of which emits more than one active mode, it is possible for the signal strength of the interference signal to collapse at certain values of a temperature induced frequency shift such that a measurement is no longer possible. This is the case, in particular, if two active modes are emitted which have approximately equal amplitudes and which interfere destructively. Vibration measurements can fail in this manner, namely if, for example, temperature influences from the surroundings lead to the laser reaching a mode state in which a measurement is not possible.
Proceeding from this prior art, the present invention is based on the object of providing a device and a method of the type mentioned at the outset, by means of which a laser of a laser Doppler vibrometer is stabilized in respect of its frequency, in particular for avoiding crosstalk effects in the case of measurements with two or more laser Doppler vibrometers, and the laser Doppler vibrometer can nevertheless be operated with almost maximum signal strength.
SUMMARY
This object is achieved by a device and method with one or more of the features of the invention. Preferred embodiments of the device and method according to the invention are discussed below and in the claims.
Thus, the method according to the invention and the device according to the invention are distinguished by virtue of the fact that the laser from the laser Doppler vibrometer is provided with a polarization filter arranged within the optical resonator thereof, which applies the same polarization to the various modes of the laser. At least one Brewster window is preferably used here as polarization filter. As a result of this polarization filter, several, usually two, modes of the laser are brought into the same polarization such that, on one hand, a mode can no longer be masked by means of a polarization beam splitter and used as manipulated variable for regulating the laser, and, on the other hand, substantially the full laser power is however available for the measurement. Nevertheless, the laser is frequency stabilized according to the invention, i.e. it is provided with an appropriate control loop.
This is because, according to the invention, it was identified for the first time that it is not necessary to use a mono-mode laser for the frequency stabilization of the laser in the laser Doppler vibrometer, but rather that using two or more active modes simultaneously for the measurement is harmless. All that is important is that one active mode is significantly stronger than the others and that the frequency of this dominant mode can be regulated to a defined value.
If the laser operates in two mode operation or in three or more mode operation, with the polarization directions of all modes being substantially equal, a beat frequency between two adjacent modes emerges. According to the invention, it was identified that acquiring this beat frequency enables regulation of the resonator length of the laser for frequency stabilization purposes. This is because a change in laser temperature brings about, firstly, a frequency shift and, secondly, a change in the amplitude distribution of the various active modes. In the case of a temperature change in the laser, the active modes thereof wander through the amplification profile of the laser, and so the active modes with one exception in each case have different intensities during the sweep. This leads to a quasi-periodic profile of the beat signal when sweeping through the active modes through the amplification profile, depending on the resonator length of the laser, which is generally linearly dependent on the temperature of the resonator.
According to the invention, it was identified further that this quasi-periodic profile of the beat signal is suitable for use as control variable for regulating the resonator length of the laser and hence for regulating the laser frequency. Particularly when the resonator length of the laser is regulated by temperature, i.e. by heating and/or cooling when required, the direct relationship, determined according to the invention, between the variations in the intensity of the beat signal and the temperature of the optical resonator can be employed for regulation purposes, to be precise expediently at a point at which the intensity of the beat signal over temperature has a sufficiently steep flank. During a mode sweep through the amplification profile of the laser, this is the case in at least two regions.
According to the invention, the evaluation of the beat signal, which is acquired as electric beat signal, is employed for stabilizing the laser frequency. If use is made of the power or the frequency or a combined measurement variable of power and frequency of the electric beat signal for regulating or stabilizing the laser frequency, a defined power ratio is obtained in the laser modes, which cause the beat signal. Within the scope of the invention, this power ratio can optionally also be zero, to be precise when the laser happens to run with one mode.
Thus, a multi-mode laser can be used with the present invention and the former can nevertheless be frequency stabilized, to be precise, in particular, at a frequency at which two or more active modes have different intensities such that the regulation remains in a stable operating state. Random temperature changes during operation as a result of heating effects and environmental influences are compensated for by the frequency regulation according to the invention such that the device according to the invention can measure vibrations in an automated manner over long periods of time without running the risk of reaching a state during the measurement in which the signal-to-noise ratio is too inexpedient for a reliable measurement result.
Particularly in the case of a vibration measurement of an object by means of several laser Doppler vibrometers there can no longer be random crosstalk effects, even in the case of relatively long-duration automatic measurement processes, because, for example, the employed lasers are subject to different temperature changes and hence frequency shifts in relation to one another due to environmental influences and heating effects. Nevertheless, the lasers of the vibrometers can be operated such that two modes of equal strength are not created since this would lead to a collapse in the signal strength.
Moreover, the lasers designed according to the invention are very insensitive to unwanted reflections and other stray light reaching the resonator due to the employed polarization filter.
Finally, the use according to the invention of frequency stabilized lasers with polarization filters can preferably be employed to operate a measurement device with several laser Doppler vibrometers which are, within the scope of the focusing accuracy, simultaneously directed to the same point of the vibrating object such that crosstalk effects are avoided. To this end, the frequency regulation of the laser, present according to the invention, can be employed for a targeted frequency shift of one or more lasers of the employed laser Doppler vibrometer, as required, in order to be able to maintain frequency spacings at which there is no or only little crosstalk effect at specific demodulation bandwidths and, at the same time, the enforced signal collapse does not become too great. To this end, the laser frequencies are regulated such that the frequencies lie apart by at least 2× the demodulation bandwidth.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the present invention will be described and explained in more detail below on the basis of the attached drawings. In detail:
FIG. 1 shows two alternative block diagrams ( FIGS. 1 a and 1 b ) of a heterodyne laser Doppler vibrometer for use in a device according to the invention;
FIG. 2 shows a schematic diagram of the amplification profile of a helium-neon laser, used in an exemplary fashion;
FIG. 3 shows four schematic diagrams like FIG. 2 , displaying the operating states of the helium-neon laser at four different temperatures;
FIG. 4 shows a schematic diagram of the frequency deviation of the dominant mode from the center frequency of the helium-neon laser, depending on the temperature of the resonator; the labels (A), (B), (C), (D) relate to the mode states depicted in FIG. 3 ;
FIG. 5 shows a schematic diagram in which the intensity of the beat signal is plotted against temperature change for the one or two mode operation of the helium-neon laser from FIGS. 2 to 4 ; the labels (A), (B), (C), (D) relate to the mode states depicted in FIG. 3 ;
FIG. 6 shows a schematic diagram in which the intensity of the beat signal is plotted against temperature change for the two or three mode operation of the helium-neon laser from FIGS. 2 to 4 ; the labels (A), (B), (C), (D) relate to the mode states depicted in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Here, a device with a laser Doppler vibrometer, which in principle has a design as depicted in FIG. 1 a , is described as exemplary embodiment for a device according to the invention. In the present exemplary embodiment, use is made of a helium-neon laser 1 with a resonator length of 20.4 cm, the coherent light of which is split by a first beam splitter S1 into a measurement beam 2 and a reference beam 3 . The reference beam 3 is routed over a mirror Sp1 through a Bragg cell 4 , which serves as an acousto-optic frequency shifter in this case, and reaches an optical detector 5 via a further beam splitter S3. Here, the Bragg cell 4 shifts the reference signal 3 in terms of its frequency by a frequency offset of typically 40 MHz.
The measurement beam 2 is routed via a second beam splitter S2 and a lambda/4 plate L1 to a vibrating measurement object 6 . The surface of the measurement object 6 scatters the measurement beam 2 back. In the second (polarization) beam splitter S2, the back-scattered measurement beam is reflected onto the third beam splitter S3 and there it is superposed on the reference beam 3 . The superposed, time coherent measurement and reference beams form an interference signal 7 , the intensity of which is received by the optical detector 5 . In another design, the lambda/4 plate L1 can be omitted such that a normal beam splitter can be used as S2.
As a result of the Doppler Effect, the light of the measurement beam 2 reflected at the vibrating measurement object 6 is frequency shifted in accordance with the current speed of the measurement object surface. This frequency shift is directly proportional to the speed of the scanned object surface. Since the measurement beam 2 , which is frequency shifted thus, is not superposed on a reference beam 3 that remained unchanged, but rather superposed on the measurement beam 3 , which was provided with a frequency offset by means of the Bragg cell 4 , it is possible to determine not only the current vibration speed of the measurement object surface from the signal of the detector 5 , but also the sign thereof. The vibration movement is therefore established uniquely.
If, for example, three such laser Doppler vibrometers are employed in a device according to the invention, a measurement object 6 or the vibration of the surface thereof can be established in three dimensions.
The laser light of the helium-neon laser, employed in the present exemplary embodiment, with a wavelength of 632.8 nm and a resonator length of 204 mm has a mean laser frequency of 474 THz. This light source is a multimode laser, in which, depending on the laser state, one or at most three active laser modes are formed. Depending on the intensity of the modes and the exact position thereof in the frequency band, the laser light is strongly influenced in terms of its intensity and frequency.
The laser modes (both active and passive) assume a mode spacing Δv, which is dependent on the resonator length. This fixed mode spacing Δv is approximately 735 MHz in the case of the helium-neon laser used in the present exemplary embodiment.
A selection of active modes is undertaken by the amplification profile of the helium-neon laser, as visualized by FIG. 2 :
FIG. 2 plots the amplification profile of the helium-neon laser, used in the exemplary embodiment, against frequency. Four laser modes, respectively with a spacing of 735 MHz, can be identified, of which two are situated within the amplification profile and above the laser threshold and are therefore the active modes. These two active modes are non-symmetrical in relation to the amplification profile such that the higher frequency mode is dominant in this case. The two modes outside of the amplification profile are not excited and are referred to as passive modes.
In the case of a temperature change in the laser resonator, the modes “wander” through the amplification profile. In the case of a temperature increase and hence an elongation of the resonator, the modes in the diagram according to FIG. 2 move from right to left and, in the case of a temperature decrease, they move from left to right. A change in temperature brings about firstly a shift in frequency and secondly a change in the amplitude distribution of the active modes. In the case of a continuous temperature change, one active mode in each case disappears on one side of the amplification profile and a new active mode appears on the other side of the amplification profile.
The frequency deviation of the dominant mode from the center frequency of the laser can be several hundred MHz. This is many times more than the frequency offset created in the laser Doppler vibrometer by the Bragg cell.
FIG. 4 shows the frequency deviation of the dominant mode from the center frequency. The frequency jump (D) is created at the point at which two equally strong modes are present; the dominant mode changes at this point. This is visualized in FIGS. 3 and 4 , wherein FIG. 3 depicts the amplification profile of the laser and the modes thereof in an illustration corresponding to FIG. 2 in four different operating states (A), (B), (C), (D). The frequency deviation of the dominant mode resulting from these operating states is depicted in FIG. 4 , where the operating states (A . . . ) are marked in the frequency curve plotted over temperature. It can clearly be identified that a symmetric three mode operation is present in operating state (B), in which the frequency of the dominant mode corresponds to the center frequency. Cooling of the laser leads to a mode shift in the direction of operating state (A), while heating of the laser causes a mode shift in the direction of operating state (C). The shifts in frequency of the dominant mode resulting therefrom can be read from FIG. 4 .
Each mode can be described as sinusoidal vibration with a mode amplitude, a mode frequency and a mode phase. If two or three modes are active simultaneously, two or three sinusoidal vibrations with different frequencies (at the mode spacing) are formed simultaneously in the resonator. By way of example, if the light from the laser is measured by a photodiode, the superposition signal at the difference frequency 735 MHz of the sinusoidal vibrations can be measured. The superposition signal at the difference frequency is referred to as beat signal.
The intensity of the beat signal for the one or two mode operation is plotted in FIG. 5 against the temperature change in the laser resonator. Here, the mode states (A), (B), (C) and (D) from FIG. 3 are plotted too. Two active modes, which form the beat signal by the mixing products thereof, are respectively present at points (A), (C) and (D). The signal collapse at point (B) is due to the fact that only one active mode is present, and so there can be no mixing of the signals and the beat signal equals zero.
FIG. 6 shows the intensity of the beat signal for two or three active modes, once again plotted against the temperature change in the resonator. Points (A), (C) and (D) correspond to the state of the amplification profile in which two active modes are present. Three active laser modes are simultaneously present where the beat signal collapses, at point (B). The laser therefore always has at least two active modes, which generate a beat signal at 735 MHz; therefore, in contrast to the example from FIG. 5 , the beat signal does not disappear completely in this case. However, the beat signal collapse at point (B) is still present.
It becomes clear from FIGS. 5 and 6 that the beat signal has flanks, depending on the temperature, at selected operating states, which are suitable as manipulated variable for regulating the laser frequency. The beat signal can be uniquely associated with the frequency of the dominant mode by the falling and rising flanks.
FIG. 1 b depicts a design alternative to the one in FIG. 1 a of a laser Doppler vibrometer which can be used within the scope of the invention, with, in this case, two detectors being present: a vibrometer detector which corresponds to the optical detector 5 from FIG. 1 a but should in this case only detect the interference signal from the vibrometer and a separate beat detector 8 which records the beat signal. For the beat detector, a corresponding signal is decoupled from a fourth beam splitter S4, which is placed into the beam path in place of the mirror Sp1. By contrast, in the design according to FIG. 1 a , the optical detector simultaneously detects the interference signal and the beat signal. The embodiment in FIG. 1 a assumes that significantly more reference light impinges on the detector than light scattered back from the measurement object so that the beat signal to a good approximation only depends on the reference light; this generally is the case.
For the application in the laser Doppler vibrometer in a device according to the invention or in a method according to the invention, it is advantageous to regulate the laser to a frequency at which one mode is dominant. The regulation of the laser temperature, and hence of the resonator length, can be undertaken by means of a regulated laser heater. The regulation of this laser heater can be brought about by evaluating the beat amplitude and/or the beat frequency of the laser.
As an alternative to a regulated laser heater, use can for example be made of a laser power supply unit with adjustable laser current; the laser current influences the temperature of the resonator.
However, it is also possible to regulate the resonator length in another manner, for example by temperature pads or piezoelectric crystals, which can change the position of the resonator mirrors in a targeted manner.
By means of the present invention it is possible, in particular, to operate devices and methods for optical, contactless vibration measurement with more than one laser Doppler vibrometer for two-dimensional or three-dimensional measuring of an object in an automated fashion over a relatively long period of time, without running the risk that laser frequency shifts occur by means of temperature influences by the surroundings or by positional changes in the laser Doppler vibrometers, which laser frequency shifts can lead to crosstalk effects, as a result of which the measurements would become unusable. | A device for the optical non-contact vibration measurement of an vibrating object, including a laser Doppler vibrometer that has a laser as the light source for a laser beam, a first beam splitter assembly for splitting the laser beam into a measuring beam and a reference beam, a means for shifting the frequency of the reference beam or of the measuring beam in a defined manner, a second beam splitter assembly by which the measuring beam back-scattered by the oscillating object is merged with the reference beam and superimposed on the same, and a detector for receiving the superimposed measuring and reference beam and for generating a measurement signal. The laser is provided with a polarization filter arranged inside the optical resonator of the laser and the laser is frequency stabilized by regulating to a beat signal of the laser. | 6 |
FIELD OF THE INVENTION
This invention relates to obstruction detectors for automatic door operators such as those used for garage doors, and more particularly to an improved door edge sensor which transmits status of the door edge to a door control mechanism in order to reverse the direction of a closing door when it contacts an obstruction.
BACKGROUND OF THE INVENTION
When implementing automatic door operators for opening doors such as garage doors, it is common to employ a motor which moves a door between opened and closed positions in response to control signals. Such control signals are typically generated by a portable radio frequency transmitter, and/or a wall mounted push button transmitter. Furthermore, techniques are provided for detecting door obstructions to prevent personal injury or property damage caused when the control door unintentionally closes on an object or person. Such obstruction detection prevents damage to the door as well as damage to the driving components which move the door. Furthermore, it is clear that a mechanically operated door poses a particular risk to children who are playing with the automatic garage door operator.
In one form, obstruction detection is performed by monitoring the tension of a drive chain interconnecting the motor with the door. Typically, the motor is coupled to the door with a chain or a screw drive mechanism. By mechanically linking the motor with the chain by a switch which is closed under normal conditions, but opened when the drive chain exceeds a predetermined amount, a switching effect can be provided for triggering the abortion of door operation. For example, a micro-controller is often used to detect such a switch state which aborts door operation when the switch is tripped to an open position. Typically, the micro-controller is programmed to stop the door when the switch is tripped while the door is opening, and stop the door and reverse its direction until it is fully opened when it detects an open switch while closing the door.
However, the aforementioned obstruction detectors provide only limited detection capability and are usually insufficiently sensitive to prevent all injuries. Therefore, attempts have recently been made to provide supplemental detection, as well as improve existing detection when sensing door obstruction. Furthermore, recent state regulatory authorities have proposed further stricter requirements which require additional obstruction detection. Such systems incorporate radiant obstruction detectors, generally using infrared or visible light, which is projected across a lower portion of the opening for a controlled door. By breaking or interrupting the radiant beam, an obstruction is detected and the automatic door operator can be directed to reverse or open up a door. An alternative additional obstruction detector utilizes a pressure sensitive strip disposed along a door's leading edge which is typically referred to as a safety edge switch. As the door is closed on an obstruction, pressure is detected on the safety edge switch which indicates the presence of an obstruction. However, these obstruction detectors require additional components, increase the cost of the systems, and require further additional power sources and electrical wiring, particularly when incorporating a switch on a door's leading edge.
SUMMARY OF THE INVENTION
A door edge safety sensor for use with an automatic door operator has a door-mounted tactile sensing switch for detecting a door edge obstruction, a door vibration detector for detecting movement of the door, a safety signal transmitter which sends a coded radio frequency transmission during movement of the door to the automatic door operator that indicates the unobstructed and obstructed status of the door, and battery powered control electronics for remotely powering the obstruction detector, vibration detector, safety signal, and control electronics. The control electronics monitor the status of the safety signal to determine the door obstruction status, and control the transmission of signals to the automatic door operator which determines obstruction of the door and triggers reversal of door motion to an open position. In a preferred embodiment, the tactile sensing switch is formed from a set of parallel conducting strips separated by a compressible insulating foam strip such that compression of the foam strip provides a conduction path between the conducting strips which varies the voltage therebetween as a result of variation of resistance across the strips. Furthermore, the vibration detector is preferably a piezoelectric element which detects movement of the door and initiates operation of the signal transmitter that wakes up the control electronics, including a microprocessor, such that the transmitter transmits a "heart-beat" signal indicating the obstruction status for the door's tactile sensing switch.
The automatic door operator receives the "heart-beat" signal while opening and closing, but only utilizes the signal while the door is closing wherein detection of the regular heart-beat signal is necessary to continue downward motion of the door. As a result, detection of a door obstruction by the tactile sensor interrupts the heart-beat signal which triggers a reversal of the motor and opening of the door under direction of the automatic door opener. When the automatic door operator fails to detect the active safety signal, or heart-beat signal, the omission is interpreted by the automatic door operator as an obstruction. Furthermore, an open or short of the two conducting strips is detected as a system failure or obstruction, respectively. Additionally, the supplemental obstruction detector is only employed while closing the door. Hence, the signal from the tactile sensing switch is ignored during door opening.
The controller includes a further provision which allows for manually overriding the obstruction signal to close a door when the tactile sensor is malfunctioning. By constantly depressing the local push button, the obstruction detector is overridden which allows one to close the door.
Objects, features and advantages of this invention are to provide a door edge safety sensor which is self contained and battery powered, lightweight, small and compact, self-supporting, rugged, durable, waterproof, readily and easily packaged in a door edge, quickly and easily repaired and maintained, and is of a simplified design and is easy and economical to manufacture, assemble and install.
Further objects, features and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional representation of the radio frequency edge monitoring system of the present invention provided on an automatic garage door;
FIG. 2 is a schematic block diagram illustrating the wireless safety edge transmitter of FIG. 1;
FIG. 3 is a timing diagram illustrating examples of various signals resulting during a normal closing operation of the present invention; and
FIG. 4 is a timing diagram illustrating an example of various signals resulting during an obstruction sequence of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in more detail to the drawings, FIG. 1 illustrates a door edge safety sensor 10 of this invention mounted on the lower edge of an overhead garage door 12. The door is moved between open and close positions through a drive chain 14 by a motor 16 in response to commands from a garage door control mechanism 18 which together form an automatic garage door operator. The door edge safety sensor 10 detects the presence of obstructions in a door path during closing which is transmitted to a radio receiver 20 provided on the garage door control mechanism such that motion of the door is reversed to an open direction upon sensor contact with an obstruction. As shown in FIG. 2, the safety sensor 10 includes a tactile obstruction detector, in this case a sensing switch 22 for detecting door edge contact with an obstruction, a comparator circuit 24 for comparing unobstructed and obstructed states of the sensing switch 22, a door vibration detector, or sensor 26, an amplifier/integrator circuit 28 for conditioning sensed vibration signals, an oscillator or clock 30 for timing operation of the safety sensor 10, a linear regulator 32 which conditions power supply to the sensor from a battery source 34, a transmitter 36 for transmitting status of the safety sensor 10 to radio receiver 20, and a microprocessor 40 having accompanying software for directing operation of the safety sensor 10. The amplifier/integrator circuit 28, clock 30, regulator 32, transmitter 36, microprocessor 40 and, comparator circuit 24 form control electronics which define a radio frequency (RF) monitoring circuit 50.
An overhead garage door 12 incorporating the door edge safety sensor 10 of this invention is preferably constructed from a plurality of hinge-connected sectional panels which travel on a pair of linear guides 42 along a door frame 44 such that raising of the door defines an opening 46. Alternatively, the sensor of this invention can be implemented on one-piece garage doors which are raised on substantially vertical guides, or which are mounted on a suspension mechanism which generally lifts the door and outwardly rotates and translates the leading edge of the door in relation to the door opening. In these alternative applications, placement of the safety sensor 10 might be slightly modified in order to assure detection of any obstructions present within the opening 46. The principal concern during operation of each of these embodiments is the accurate and responsive detection of obstructions in the path of a door while it is closing through an opening 46. For example, obstruction of the door opening by a vehicle, a child's toys, or even a child necessitates a quick and accurate detection of the obstruction in order to assure that the closing door does not damage the obstruction or that the door is not damaged. Furthermore, it is desirable to enhance the reliability and durability of such a sensing system by eliminating unnecessary wiring which is susceptible of wear and loss of electrical conductivity. Accordingly, the door edge safety sensor 10 of this invention is intended to be responsive to contact with door obstructions throughout its entire closure cycle, and to provide such detection with a remotely mounted sensor which eliminates the necessity of electrically wiring the sensor to the garage door control mechanism 18.
The door edge safety sensor 10 of this invention which is depicted in FIG. 1 is utilized with a garage door control mechanism 18 whose construction and operation are presently understood in the art, and which is further detailed in U.S. Pat. No. 5,191,268 which is assigned to the same Assignee as the present application, and is hereinafter incorporated by reference. Generally such garage door control mechanisms utilize the radio receiver 20 in conjunction with the control mechanism to operate the motor 16 which opens and closes an overhead garage door 12. Typically, a remote radio frequency transmitter 48 is provided which allows a user to remotely open and close a garage door from within a vehicle, and additionally a wall-mounted auxiliary transmitter unit 49 is provided which allows a user to open and close the garage door from within a garage. Likewise, a failure mode provision is provided such that hold down of either transmitter's trigger button allows for override opening, or closing of the door by maintaining depression of the button. The control mechanism 18 is provided with a microprocessor 47 which directs receipt of transmissions from the radio receiver 20 and furthermore identifies a particular remote transmitter in order to enable authorized door opening and closing. Further details are provided in the aforementioned patent. In order to comprehend operation of the present door edge safety sensor 10 of this invention, it is sufficient to understand that the control mechanism microprocessor 47 has separate additional software subroutines which identify and receive sensor status signals from the safety sensor 10 in conjunction with the radio receiver 20 for actuating opening and closing of the door 12. Alternatively, a further additional receiver can be provided on the control mechanism 18 for separately receiving the safety sensor signals. However, such implementation would increase the number of parts as well as the cost, and would require two separate paths of communication for making decisions when activating motor 16.
The opening and closing of overhead garage door 12 is typically directed by the garage door control mechanism 18 in response to signals received from the remote transmitting unit 48 such that radio receiver 20 receives the signals and control mechanism 18 directs motor 16 to activate opening or closing of the door.
As depicted in FIG. 1, the door edge safety sensor 10 is carried on the bottom edge of a garage door 12 by mounting the elongate sensing switch 22 along the door's bottom edge, and by further carrying the remaining portion of the sensor, namely a radio frequency monitoring circuit 50 and vibration sensor 26 adjacent the switch along the base of the door. Alternatively, the monitoring circuit and vibration sensor can be provided in a receptacle within a bottom panel of the door. Preferably, the monitoring circuit and vibration sensor are positioned proximate the sensing switch in order to decrease the length of wire required to form interconnection therebetween, and to decrease signal transmission time correspondingly.
Preferably, the sensing switch 22 is constructed from a pair of substantially parallel conductive strips 52 and 53 separated by a non-conductive compressible foam strip 54. A plurality of spaced apart through-holes 56 are formed in the foam strip to provide a path for electrical interconnection between the conductive strips such that when the foam strip is compressed by an obstruction, the conductive strips move together and provide a conductive path between the conductive strips via the through-holes. Furthermore, an end of line resistor electrically interconnects an end of each conductive strip opposite the end where they are connected to the monitoring circuit 50. In its unobstructed state, sensing switch 22 provides a resistance substantially from an end of line (EOL) resistor 58 which is monitored by the RF monitoring circuit 50. Preferably, the end of line resistor 58 is a fixed known resistor, for example, 470Ω. When the door edge comes into contact with an obstruction, the pair of conductive strips 50 and 53 are brought together which shorts out the resistor 58 such that resistance across the strips is substantially modified and is, in fact, substantially nullity if the path between the strips is a perfect conductor. Even if a resistance is still present, the difference in resistance between the shortened and unobstructed states is detectable by the monitoring circuit.
As depicted in FIG. 2, the radio frequency monitoring circuit 50 comprises substantially the control electronics, namely circuits 24 and 28, clock 30, regulator 32, transmitter 36, and microprocessor 40 which communicates with the sensing switch 22, battery supply 34, and vibration sensor 26.
The battery source 34 provides a power supply directly to the radio frequency monitoring circuit 50, and indirectly to the vibration sensor 26 and sensing switch 22. As shown in FIG. 2, the battery source 34 also provides a conditioned supply of power via linear regulator 32 which decreases threshold voltage from 9 volts down to 5 volts. Such reduced voltage supply is provided to the microprocessor 40, transistor 60 and across biasing resistor R6 resident in comparator circuit 24, and furthermore to amplifier U1 resident in the amplifier/integrator 28. Preferably, the transistor 60 is a PNP common emitter small signal transistor generally designated by the part No. 2N3906, and referenced as Q1 in FIG. 2. Finally, battery source 34 provides power supply to transmitter 36 such that safety sensor status signals are transmitted through an antenna 62 resident on the monitoring circuit 50 which directs motor control actuation of the door between open and close positions. The antenna 62 is preferably a piece of wire forming a radio frequency transmitter loop which provides radiating means for transmitting radio frequency signals to the nearby radio receiver 20. Preferably, power is furnished by a single standard 9.0 volt (transistor) alkaline battery, namely battery source 34. In conjunction with the battery, the linear regulator shall provide stepped down voltage supply in various components of the safety sensor 10. Preferably, the linear regulator is a HARRIS ICL 7663SA, generally designated as U3 in FIG. 2. The battery life shall be two years with an average of six open-closed door cycles per day, over a 365 day year.
Preferably, the vibration sensor 26 is formed from a piezoelectric element which is preferably connected with the monitoring circuit 50 through a pair of pin connectors 64. Output from the vibration sensor 26 is then amplified and conditioned, namely integrated, with an operational amplifier, namely U1, coupled with a small signal diode, D1. As a consequence, door motion vibrations which are sensed by the vibration sensor 24 are conditioned by the amplifier/integrator circuit 28 where they are input into the microprocessor 40. The amplified signal which arrives at the microprocessor is analyzed, and any output in excess of 40mVp-p (peak-to-peak) shall initiate the transmitter operation under the direction of the microprocessor 40. Such analysis and direction is provided by software within the microprocessor. The vibration sensor detects door motion and in response to a predetermined magnitude of signal, provides an amplified wake-up signal to the control electronics 38, namely microprocessor 40, which keeps the microprocessor awake, or active, during the door movement. The resulting voltage signal is provided to the microprocessor both during the up and down movements of the door. Preferably, a 2MHz crystal is utilized. Furthermore, operational amplifier U1 is preferably a National Semiconductor device No. LMC6041N, and small signal diode is preferably a 1N4148 diode, as designated by D1 in FIG. 2. Upon initiation, the transmitting device shall monitor the sensing edge periodically at the rate of slightly less than 3 times per second for the presence of the end of line (EOL) resistor 58 within the nominal value ±20%, ie., 470Ω±94Ω (typical). Alternatively, other values for the EOL resistor may be selected which conserve battery life and which are consistent with the sensing edge leakage resistance values inherent therein.
As shown in FIG. 2, the control electronics of the monitoring circuit 50 are substantially formed from the microprocessor 40 which is provided with control software for communicating with the various components coupled with the microprocessor in the safety sensor of this invention. Preferably, the microprocessor is an 86EO4, as designated by U2 in FIG. 2. As mentioned supra, the microprocessor is preferably embodied in a microprocessor circuit having read/write random access memory and a control program fixed in read only memory for directing such communication as well as receipt and transmission of data between accompanying components therebetween.
The transmitter 36 is preferably a fixed mounted, battery-powered digital UHF remote control transmitter, which is coupled with the micro-processor on the monitoring circuit 50 and which is further enclosed within a plastic case in conjunction with the vibration sensor 26. The plastic case is then either mounted to the base of a garage door, or is inserted within a recess near the base of the door. The transmitter emits a radio frequency (RF) signal which is pulse width modulated with a digital pulse train compatible with the garage door control mechanism, namely the garage door operator (GDO) receiver 20. During transmission, a light emitting diode (LED) which is provided on the case indicates whether current is being consumed by the radio frequency transmitter portion of the control electronics with the monitoring circuit 50, i.e. preferably a Printed Circuit Board (PCB) assembly. The LED illumination does not indicate remaining battery life, but instead indicates whether the transmitter is in an operating mode. Alternatively, the LED can be further provided to indicate a low battery condition. Furthermore, the transmitter is powered by the standard 9 volt "transistor" alalkaline battery mentioned supra. Additionally, the transmitter shall have operating specifications with a battery voltage of between 4.5 to 10 volts. Furthermore, the carrier frequency will preferably be adjusted to 31 0.0 MHz ±1.0 MHz at 23° C, and the radio range of the transmitter shall be 75 feet minimum, open-air, using the standard 4-6 μ volt receiver.
In operation, door motion is sensed by vibration sensor 26 which turns on the transmitter 36 to transmit a "heart-beat" signal W 1 W 2 for a period of not less than 20seconds and not more than 30 seconds. As shown in FIG. 3, upon sensing of door motion by vibration sensor 26, microprocessor 40 is turned on and monitoring circuit 50 with transmitter 36 are initiated such that the transmitter transmits the "heart-beat"signal to the garage door radio receiver 20. As shown in FIG. 3A, the "awakened"microprocessor 40 directs sampling of the EOL resistor 58 such that a series of sample pulses are applied to the series connection formed by resistor 58 and an internal resistor R8 formed in comparison circuit 24. With known values for the applied sensing voltage, the resistor R8, and resistor 58, the voltage can be calculated and predicted. The comparison circuit 24 applies and sources the sampling voltage to resistor R8 and the EOL resistor 58 such that the comparison circuit compares the voltage at respective junctions for R8 and the EOL resistor to a known reference value set by the circuit. FIG. 3 shows typical timing for the successive measurements of the EOL resistor 58.
The resistor sample pulses shown in FIG. 3A are typically taken every 300 microseconds, or slightly less than 3 times a minute. As such, when the door movement begins a resulting vibration sensor output breaks up the microprocessor which generates the resistor sample pulses of FIG. 3A which have a magnitude of E ss which is then applied to the series combination of R 8 and the EOL resistor by comparison circuit 24.
The voltage at the junction of the R 8 and EOL resistors is calculated by a simple voltage divider formula as follows: ##EQU1## where V R .sbsb.EOL will vary in accordance with resistor tolerances and conditions of the edge material. However, an acceptable "window" in V R .sbsb.EOL can be determined such that V R .sbsb.EOL ± tolerance for the test of the strip status, either "open" or "shorted" due to an obstruction of the door travel or an open conducting strip 52 or 53. After downward movement of the door begins, a pair of back to back encoded word transmissions W 1 and W 2 are transmitted to the radio receiver 20 in a spaced apart pulsed manner such that W 1 and W 2 provide a 40 microsecond duration back to back, and then each pair of W 2 W 2 pulses are spaced apart 300 Milliseconds, as depicted in FIG. 3B. Once downward movement of the door has begun, as shown in FIG. 3C, successful reception of the two encoded word transmission W 2 and W 2 is required in order to continue movement of the door in the downward direction. Such requirement is provided in software of the microprocessor resident in the garage door control mechanism 18, and is typically provided in RAM. Presence of a missing heartbeat signal, namely pulse W 1 W 2 , will cause the door travel to stop and reverse to the full open position. As shown in FIG. 3D, a typical vibration sensor output is provided for a moving garage door.
The garage door control mechanism 18 receives the "heartbeat" pulse W 1 W 2 as shown in FIG. 3B through radio receiver 20 such that its motor control electronics check for the presence of the heartbeat signal for a minimum of one pulse every second. Transmission of this heartbeat signal at the rate of 300 microseconds assures at least three such sample pulses are delivered per second. Therefore, if radio interference is encountered, duplication of the W 1 W 2 heartbeat message will tend to prevent false obstruction, resulting in inadvertent door reversals.
FIG. 4 depicts the corresponding signal transmissions for a door obstruction sequence which corresponds to those signals depicted in FIG. 3 for an unobstructed door. FIG. 3A shows the sample pulses for EOL resistor 58, and time line T O indicates the occurrence of a door obstruction. FIG. 3B shows termination of the heartbeat signal W 1 W 2 after the obstruction at T 0 . As a result, the garage door control mechanism 18 will no longer receive the heartbeat signal, such that after a maximum one second delay, the downwardly moving door is reversed in direction until it is fully opened.
Alternatively, FIG. 3D depicts a variation for the garage door control mechanism 18 which requires receipt of a separate heartbeat pulse, namely W 1 'W 2 ' which is repeatedly transmitted in nested back to back arrangement subsequent to detection of a door obstruction at T 0 . In this alternative version, contact of an obstruction with the safety sensor 10 produces a reversal "heartbeat signal" which is separate from the heartbeat signal of the previous embodiment, and which can immediately respond within a pulse with duration of a single heartbeat to produce a transmitted obstruction command to the control mechanism 18 which more quickly reverses the door's direction.
As shown by the signal transmissions in FIG. 4, at time T o , an obstruction compresses the safety sensor 10 such that an error condition is subsequently developed by comparator circuit 24 which results in an error level voltage for V R .sbsb.EOL at a later time T OBS , defined by the pulse sample size delay, a continuous sequence of error "words" of the W 1 ' and W 2 ' are generated back to back to form an error "heartbeat" which is transmitted via transmitter 36 to the radio receiver 20 in order to reverse the motion of the door motor 16 and open the door. Upon proper signal processing of a minimum of one W 1 'W 2 ' sequence, the door travel is stopped and reverse to the open direction. Thus, the approximate minimum time to reversal is defined by the time between successive "reversal heartbeat" timing pulses, or the width of one W 1 'W 2 'sequence plus any additional delay parameter.
In the case for the FIG. 4 embodiment, where radio frequency interference causes improper reception of either an error signal or the error "heartbeat signal"W 1 ' W 2 ' at a worse case, the door travel will stop and reverse within approximately one width of false sequences.
Further provision is made with the preferred embodiment of this invention for constant contact mode operation for downward direction travel or door closure with the previously mentioned external radio transmitter commonly utilized on devices in this art. In the event that a fault condition is present, for example a dead battery or a faulty sensor strip 52 or 53, the safety sensor 10 fails to transmit the "heartbeat"signal, and therefore a means must be provided to close an open door. In this case, a stationary, or permanently mounted, non-portable radio transmitter typically mounted on a wall switch control 49, is incorporated for effectuating closure of the door. This mode of operation is referred to in the industry as a "constant contact"condition for door closure, and is referred to in Underwriters Laboratory UL-325. Momentary contact from a wall switch or stationary switch, or a handheld portable transmitter, or a wall mounted transmitter, will not cause an open door to close. However, constant contact provides an override means for closing the door.
It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | An improved door edge safety sensor for use with an automatic door operator which uses a motor to move a door between open and closed conditions with a controller for controlling operation of the motor and, an improved sensor comprising a tactile obstruction detector for generating a safety signal, a door vibration detector for detecting movement of the door, a safety signal transmitter operable in response to detected door motion, and control electronics which monitor the obstruction detector and the vibration detector and direct the signal transmitter to reverse the motor upon the door engaging an obstruction which reverses the door to an upward direction. | 4 |
PRIORITY
This application claims priority under 35 U.S.C. § 119 to an application entitled “Method of Configuring and Updating Connection Identifier in a Broadband Wireless Access Communication System” filed in the Korean Intellectual Property Office on Jun. 23, 2004 and assigned Ser. No. 2004-47321, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a method of configuring and updating connection identifier (CID) information in a broadband wireless access (BWA) communication system, and in particular, to a method of configuring and updating a CID on a service-flow-by-service-flow basis between a base station (BS) and a mobile station (MS).
2. Description of the Related Art
Today's development of communication technology has been increasing user demands for higher-speed transmission/reception of larger volumes of data. In this context, the Institute of Electrical and Electronics Engineers (IEEE) 802.16 standardization group is performing studies to provide BWA services to MSs.
The IEEE 802.16 standard specifies high-speed data transmission/reception schemes for MSs.
An MS transmits and receives data by connecting at least one service to a BS. A plurality of service connections are identified by their specific CIDs.
During setup of a new service connection between the MS and the BS, the BS allocates a CID that identifies the service connection to the MS. Service CIDs must have unique values so that they can be accurately distinguished within one cell under the BS. Hence, the use of a CID is confined to one cell, and the CID can be used in setting up another service connection in another cell.
In the case where the MS moves from an old cell to a new cell, or when the MS updates all existing service connections with a serving BS and re-registers with the serving BS in the BWA communication system, the new BS or the serving BS allocates a new CID for each service connection to the MS. During a handover to the new BS or reconnection to the serving BS, the MS receives the new CID from the new BS or the serving BS by a medium access control (MAC)-layer management message.
In the conventional process a new CID is allocated to the MS; that is, a CID is updated for the MS in the following way. The BS transmits to the MS CID update information including existing CIDs and new CIDs in ordered pairs. The transmission of the existing CIDs is unnecessary and causes a waste of radio resources. If the MS uses a large number of CIDs, the volume of CID update information is large. Moreover, if a large amount of CID update information is issued for a plurality of MSs, the overall BWA communication system suffers from a significant decrease in the efficiency of radio resources at connection updates.
SUMMARY OF THE INVENTION
An object of the present invention is to substantially solve at least the above problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an object of the present invention is to provide a method of configuring smaller-size CID update information in a BWA communication system.
The above objects are achieved by providing a method of configuring and updating CIDs in a BWA communication system.
According to one aspect of the present invention, in a method of updating CID information in a BS of a BWA communication system, the BS arranges at least one first CID already allocated to an MS in a predetermined order, determines whether a second CID is allocated to substitute for the at least one first CID, maps the at least one first CID to a bit value in a bitmap according to the determination and including the bitmap in CID update information, and completes the CID update information by including the second CID in correspondence with the bit value in the bitmap.
According to another aspect of the present invention, in a CID update information configuration for updating service connections between a BS and an MS in a BWA communication system where CIDs are set on a service-flow-by-service-flow basis, first CID information includes field information in which the position of at least one first CID allocated to the MS before connection updating is mapped in a bitmap, and second CID information includes at least one second CID newly allocated to the MS based on the bitmap.
According to a further aspect of the present invention, in a method of configuring CID update information in a BWA communication system where each service between an MS and a BS has a unique CID, a registration request message is received from the MS, requesting updating of at least one old CID used for the MS. The CID update information is configured to include a bitmap area indicating whether a service corresponding to the at least one old CID is available, and a new CID area including at least one new CID in correspondence with a predetermined bit value in the bitmap area.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an example of the mapping relationship between services and CIDs in a BWA communication system;
FIG. 2 illustrates a typical data format of CID update information provided to an MS in the BWA communication system;
FIG. 3 illustrates the data format of CID update information provided to an MS in a BWA communication system according to the present invention; and
FIG. 4 is a flowchart illustrating a CID updating method between a BS and an MS in the BWA communication system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail.
In the following description, a typical CID updating method and the configuration of typical CID update information will precede an embodiment of the present invention. As to terms used herein, “first CID” refers to a CID that identifies a service connected between an MS and an old BS, and “second CID” refers to a CID that a new BS allocates to the MS. In the case where the MS is to update an existing CID associated with the old BS, the old BS may allocate a second CID to the MS, or as the MS hands over to a new BS, the new BS may allocate the second CID to the MS. An example is provided for the latter case.
FIG. 1 illustrates an example of the mapping relationship between services and CIDs in a BWA communication system.
Referring to FIG. 1 , an MS receives CID information from a BS to thereby identify packets, service-flow-by-service-flow. The MS receives three services 10 , 65 and 121 identified by CIDs 138 , 239 and 23 , respectively from an old BS 100 .
As the MS moves from the old BS 100 to a new BS 200 , the CIDs 138 and 23 are changed to 4 and 124 , respectively, in a CID updating operation of the new BS 200 . In the example illustrated in FIG. 1 , the service with the CID 239 is not serviced in the new BS 200 , that is, the service connection is terminated. Thus, the CID 239 is released. The MS, which has handed over to the new BS 200 , is now receiving the services 10 and 121 with the updated CIDs 4 and 124 , respectively from the new BS 200 .
FIG. 2 illustrates a typical format of CID update information provided to an MS in the BWA communication system.
Now, referring to FIGS. 1 and 2 , CID update information 20 (CID_Update) has type-length-value (TLV) encoding fields. A Value field 21 is configured to have first CIDs (Old_CID) and second CIDs (New_CID) in the form of TLVs.
Table 1 below illustrates the TLV encoding format of CID_Update and Table 2 below illustrates the TLV encoding format of the first and second CIDs.
TABLE 1
Name
Type (1 byte)
Length (1 byte)
Value (Variable)
CID_Update
16
Variable
Compound
TABLE 2
Name
Type (1 byte)
Length (1 byte)
Value (Variable)
New_CID
16.1
2
CID after handover
Old_CID
16.2
2
CID before handover
The values of Types in Table 1 and Table 2 are set in compliance with the IEEE 802.16 standards. Each of first and second CIDs is represented by 1-byte Type, 1-byte Length, and 2-byte CID information, having a total of 4-bytes of information.
First and second CIDs encoded in the manner illustrated in Table 1 and Table 2 are set in the Value field 21 such that a first CID 25 & a second CID 23 and a first CID 29 & a second CID 27 are arranged in pairs for corresponding services. In the case of typical CID_Update illustrated in FIG. 2 , for example, when two CIDs are updated, the Value field 21 has a total of 16-bytes of information. Therefore, the transmission of the first CIDs along with the second CIDs causes a waste of radio resources.
Accordingly, the present invention provides a method of modifying the configuration of the CID update information to minimize the amount of first CID information included in the CID update information. More specifically, the new BS 200 compresses the entire first CIDs allocated by the old BS 100 in the form of a bitmap. To do so, the new BS 200 arranges the first CIDs in a predetermined order (i.e. ascending or descending order) of CID value and indicates in the bitmap whether the first CIDs have been updated or not. The arrangement order can be the order of allocating the first CIDs by the old BS 100 , the order of recognizing the first CIDs by the new BS 200 , or a predetermined order.
In updating the first CIDs allocated by the old BS 100 , the new BS 200 sets bit values at positions corresponding to the arranged first CIDs to Is if the new BS 200 can allocate second CIDs to substitute for the first CIDs. However, if a service provided by the old BS 100 is not available to the MS in the new BS 200 (for example, the service with a first CID of 239 in FIG. 1 ) the new BS 200 sets a bit value at a position corresponding to the position of the first CID to 0, to thereby indicate whether the services with the CIDs used with the old BS 100 are successfully updated in the new BS 200 .
By configuring a first CID field in the new CID update information in this way, the first CIDs are represented in a bitmap. New CIDs substituting for old CIDs having a bit value of 1 from the least significant bit (LSB) to the most significant bit (MSB) of the bitmap are arranged successively in the TLV encoding format, following the bitmap. In this manner, the new CID update information is completely configured, which will be described in greater detail in reference to FIG. 3 .
FIG. 3 illustrates the data format of the CID update information provided to an MS in a BWA communication system according to the present invention.
Referring to FIGS. 1 and 3 , new CID update information 30 (CID_Update) of the present invention is composed of a plurality of TLV fields. These TLV fields are divided into an Old_CID_BITMAP area 33 representing services which have CIDs allocated by the old BS and are also available in the new BS, as a bitmap code of first CIDs, and New_CID areas 35 and 37 sequentially representing new CIDs corresponding to bit value 1 in the Old_CID_BITMAP area 33 .
Table 3 below illustrates an example of encoding the CID update information 30 , and Table 4 below illustrates an example of encoding the Old_CID_BITMAP 33 , New_CID 35 , and New_CID 37 .
TABLE 3
Name
Type (1 byte)
Length (1 byte)
Value (Variable)
CID_Update
16
Variable
Compound
TABLE 4
Type
(1
Length
Name
byte)
(1 byte)
Value (Variable)
New_CID
16.1
2
CID after handover
Old_CID —BITMAP
16.4
Vari-
The first one byte indicates the
able
length of the following BITMAP
in bytes. The n-th MSB of the
BITMAP set to 1 when the n-th old
CID is successfully updated to new
one. Where, the old CIDs are
sorted with increasing order.
After the BITMAP, a list of new
CID follows. The number of new
CID is equal to the number of ‘1’
in the BITMAP.
The values of Types except for Old_CID_BITMAP in Table 3 and Table 4 are set in compliance with the IEEE 802.16 standards. Each of second CIDs 35 and 37 is represented by 1-byte Type, 1-byte Length, and 2-byte CID information, having a total of 4-bytes of information. Compared to the conventional CID update information, the Old_CID_BITMAP 33 includes a bitmap field 331 indicating whether second CIDs are allocated or not for their corresponding first CIDs, thereby reducing the size of the first CID information.
Now a description will be made of an example of configuring the new CID update information according to the present invention with reference to FIG. 1 .
The old BS 100 manages the CIDs 138 , 239 and 23 corresponding to the three respective services 10 , 65 and 121 . As the MS moves from the old BS 100 to the new BS 200 , it registers to the new BS 200 . During a CID update operation in the registration, the new BS 200 need not to allocate a new CID for the service 65 because the new BS 200 cannot provide the service 65 with the first CID 239 or the MS does not need to receive the service 65 .
The new BS 200 then configures the Old_CID_BITMAP area illustrated in FIG. 3 in order to configure the new CID update information. The new BS 200 arranges the first CIDs 138 , 239 and 23 in a predetermined order (i.e. ascending or descending order) of CID value and sets bit values for the arranged first CIDs to allocation or non-allocation in a binary bitmap. Specifically, the new BS 200 arranges the first CIDs 239 , 138 and 23 in this order, maps the arranged first CIDs to bits starting from the LSB in one to one correspondence, and sets bits for the first CIDs of the services 138 and 23 each to 1 and a bit for the first CID of the service 239 to 0. As a result, the bitmap value is “011”. In “011”, “0” corresponds to “239”, “1” to “138” and the last “1” to “23”.
The new BS 200 must allocate new CIDs for the second and last “1” bits. In FIG. 1 , the new CIDs are “4” and “124”. Thus, “124” corresponding to the last “1” is mapped in the Value field of the New_CID 35 , and “4” corresponding to the second “1” is mapped in the Value field of the New_CID 37 . While the new CIDs are mapped sequentially in the order starting from the LSB, it is obvious that the new CID mapping can be carried out in the order starting from the MSB.
FIG. 4 is a flowchart illustrating a CID updating method between a BS and an MS in the BWA communication system according to the present invention.
Referring to FIG. 4 , upon receipt of a registration-request (REG-REQ) message in step 401 , the new BS arranges first CIDs allocated to the MS by the old BS in a predetermined order (for example, according to the CID values) in step 403 . The new BS determines whether an arranged first CID can be updated in step 405 and determines whether a second CID has been allocated with respect to the first CID in step 407 . If a second CID is allocated, the procedure goes to step 409 , otherwise it goes to step 411 . The second CID is a value that the new BS sets randomly. That is, the new BS creates connections for available services considering its resource state, determines new CIDs for the available service, and notifies the MS of the new CIDs in a CID updating procedure.
In step 409 , a bit value corresponding to the first CID is set to 1 in the Value field of the Old_CID_BITMAP area. In step 411 , the bit value corresponding to the first CIDs is set to 0 in the Value field of the Old_CID_BITMAP area. The new BS maps bit values sequentially starting from the LSB in the Old_CID_BITMAP area in step 413 . Steps 405 through 411 are repeated until the first CID mapping is completed.
In step 415 , the new BS encodes second CIDs corresponding to 1 s in the Old_CID_BITMAP in the TLV format, thereby generating CID update information. The CID update information is transmitted to the MS by a registration-response (REG-RSP) message for the REG-REQ message.
For accurate mapping between first CIDs and second CIDs, the first CIDs are arranged according to a criterion preset between the MS and the BS, such as CID value.
In accordance with the present invention as described above, a new BS encodes at least one CID allocated to an MS by an old BS to be compressed to a bitmap and creates new CIDs according to the bit values of the bitmap. Therefore, the amount of CID update information that the MS receives at a handover is reduced and, as a result, the use efficiency of radio resources is increased.
While the invention has been shown and described with reference to a certain preferred embodiment 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 as defined by the appended claims. | In a method of configuring connection identifier (CID) update information in a broadband wireless access (BWA) communication system where each service between an mobile station (MS) and a base station (BS) has a unique CID, a registration request message is received from the MS, requesting updating of at least one old CID used for the MS. The CID update information is configured to include a bitmap area indicating whether a service corresponding to the at least one old CID is available, and a new CID area including at least one new CID in correspondence with a predetermined bit value in the bitmap area. | 7 |
[0001] This application is a continuation-in-part of and claims the benefit of priority from PCT application PCT/EP2011/056935 filed May 2, 2011 and German Patent Application DE 10 2010 019 144.2 filed May 3, 2010, the disclosure of each is hereby incorporated by reference in its entirety.
[0002] The invention relates to an apparatus and method for fibrillating synthetic ribbons in an extrusion process to produce, for example, glass fibers.
BACKGROUND
[0003] Methods and apparatuses of this type, for fibrillating synthetic ribbons or synthetic films, which are first extruded from a thermoplastic material, are known in general and are used for the structuring of ribbons or films. In doing so, it is possible to design, in particular, the smooth surfaces of the ribbons or films with a longitudinally executed structure. A method of this type and an apparatus of this type are known, for example, from EP 0 003 490.
[0004] With the known method and with the known apparatus a film is extruded from a thermoplastic material in an extrusion process, and a multiplicity of ribbons is cut therefrom. After stretching, the ribbons are fibrillated.
[0005] The fibrillation is normally carried out through spiked rollers, as are known, for example, from EP 0 358 334. A plurality of pins are attached such that they extend outward from the circumference of the spiked rollers, such that the pins, when the ribbons are fed onto the spiked roller, penetrate the ribbons, and generate a longitudinal slit in the ribbons, depending on the wrapping of the ribbons on the spiked roller. Particular fibrillation structures can be cut in the ribbons by means of the number and offsetting of the pins on the circumference of the spiked roller.
[0006] With the known method and with the known apparatus it has been found that with an increasing thickness of the ribbons, an undesired increase in the tractive forces occurs, in order to enable the penetration and cutting of the ribbons. In extreme cases, the ribbons are simply pushed away from the pins, without the pins penetrating the ribbons. In particular with the production of grass fibers, increasingly, synthetic ribbons made of numerous material components are formed, such that different layer thicknesses having corresponding thicknesses of the overall layer are obtained. With multi-layer ribbons of this type, it has furthermore been established that imprecisely cut edges are formed, which result in a significant loss in the strength of the ribbons.
SUMMARY
[0007] It is therefore the objective of the invention to provide a method and an apparatus for the fibrillation of synthetic ribbons of the generic type, with which thicker ribbons can also be securely fibrillated and without loss to the strength thereof.
[0008] A further aim of the invention is to create a method and an apparatus for the fibrillation of a bundle of ribbons with which a uniform fibrillation structure can be generated on the ribbons.
[0009] This objective is attained by means of a method, in which the cutting of numerous short partial cuts is generated on the ribbons by means of numerous successively engaging rows of blades on the fibrillation roller, each having numerous projecting cutting tips.
[0010] The apparatus according to the invention attains the objective in that the fibrillation roller has numerous blade strips distributed uniformly on the circumference, and that on each blade strip there are numerous cutting tips disposed on a rows of blades, with extending cutting edges disposed thereon.
[0011] Advantageous further developments of the invention are defined by the characteristics and the combinations of characteristics of the respective dependent claims.
[0012] The invention has the particular advantage that the fibrillation structure in the ribbons is generated exclusively by means of slicing. In this manner it is possible to generate the fibrillation structure solely by means of a relative speed adjustment between the fibrillation roller and the ribbons, without a resulting greater penetration resistance. In addition, clean cuts are generated, having no fraying.
[0013] For the production of web shaped fibrillation structures in the ribbons, the method provides generating at least two groups of short partial cuts on the ribbons by means of offset cutting tips of two successively engaging rows of blades.
[0014] The apparatus according to the invention is designed for this in such a manner that the neighboring rows of blades on the circumference of the fibrillation roller are attached such that on the relevant blade strips their cutting tips are offset to one another. The distribution of the partial cuts in the ribbons can be affected thereby both by means of the spacing of the blade strips on the circumference of the fibrillation roller as well as by means of the spacing of the cutting tips in relation to each other.
[0015] In one embodiment of the present method, after stretching, the ribbons within the ribbon bundle may be guided in a manner spaced from one another such that the partial cuts are generated substantially symmetrical, in particular in relation to the edge regions of the ribbons. As such, the ribbons, prior to and/or after the fibrillation are calibrated individually or in groups, in such a manner that the partial cuts are generated substantially symmetrically on each ribbon, having a minimum spacing to the edges of the ribbons. A calibration of this type, of the ribbons in relation to the configuration of the rows of blades, also enables an extremely uniform fibrillation, such that, substantially, all ribbons in the ribbon bundle have a uniform fibrillation structure.
[0016] The apparatus according to the invention has, advantageously, an adjustment device for this purpose, dedicated to the fibrillation roller, and the means for adjusting the individual or numerous ribbons in relation to the position of the cutting tips on the circumference of the fibrillation roller. In this manner, the exact guidance of the ribbons can be ensured.
[0017] As a result of the stretching of the ribbons as a bundle of ribbons, greater or lesser spacings between neighboring ribbons is obtained, such that the adjustment occurs preferably with the further development of the invention in which the means are formed as a result of adjustable guidance pins or guidance rollers disposed between the ribbons. For this, the guidance pins or guidance rollers can be adjusted in groups or individually.
[0018] Due to the limited penetration resistance of the cutting tips into the material of the ribbons, it has been shown that even limited relative speeds between the circumferential speed of the fibrillation roller and the feed rate of the ribbons are sufficient for generating the fibrillation structure. As such, an alternative the method for generating the partial cuts in the ribbons may include driving the fibrillation roller at a circumferential speed that is faster than a feed rate of the ribbons.
[0019] For this, a controllable drive is dedicated to the fibrillation roller, which is connected to a machine control unit for setting predetermined circumferential speeds of the fibrillation roller. For this, predetermined process parameters, such as the stretching ratio, for example, may be used directly in the production of the ribbons, in order to set a predetermined circumferential speed of the fibrillation roller attuned to the respective process and the respective material of the ribbons.
[0020] In particular with the production of grass fibers it has been found that very adhesive and elastic materials are used, which are particularly delicate. In order to act against the friction occurring as a result of the relative speed between the fibrillation roller and the ribbons, the ribbons are advantageously guided over a friction reducing contact surface between the rows of blades in a partial wrapping on the circumference of the fibrillation roller.
[0021] The apparatus according to the invention, for this purpose, provides for the particularly preferred further development of the invention in which the fibrillation roller has a friction reducing contact surface in each of the regions between the rows of blades on its circumferences.
[0022] In order, on the one hand, to ensure limited frictional values, and on the other hand to prevent a premature wearing out of the fibrillation roller, the further development of the invention in which the contact surfaces have a multiple coating of numerous coating materials, which are formed from numerous sandwich-like individual coatings, is particularly suited for this.
[0023] Preferably, in this case, the coating material of the outermost individual coating is formed by a low-friction material for the reduction of the friction and the coating material of the inner individual coatings is formed by a protective substance for reducing the wear.
[0024] As a low-friction material, plastics, in particular PTFE are used, and for the protective material, a ceramic is preferably used. By this means, very long operational times and particularly protective ribbon feeds can be executed on the fibrillation roller.
[0025] The method according to the invention, as well as the apparatus according to the invention are suited in particular for the fibrillation of the ribbons that are relatively thick and that have a relatively large material expansion after the stretching. In this respect, the method variation for the production of grass fibers is preferably used, in which the ribbons, after stretching, have a thickness in the range of 150 μm-500 μm, and/or a material expansion of in the range of 50%-75%. Partial cuts are securely generated even with the thickest and most elastic of ribbons by means of the cutting tips and blade edges.
[0026] The method according to the invention as well as the apparatus according to the invention shall be explained in greater detail below, based on exemplary embodiments of the apparatus according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 depicts schematically, a view of a first embodiment example of the apparatus according to the invention for the execution of the method according to the invention.
[0028] FIG. 2 depicts schematically, a cross-section of a detail of the embodiment example from FIG. 1 .
[0029] FIG. 3 depicts schematically, a detail of a top view of the embodiment example from FIG. 1 .
[0030] FIG. 4 depicts schematically, a view of the fibrillation roller.
[0031] FIG. 5 depicts schematically, a view of a cutting tip of the fibrillation roller in FIG. 4 .
[0032] FIG. 6 depicts schematically, a detail of a top view of another embodiment of the apparatus according to the invention for the execution of the method according to the invention.
[0033] FIG. 7 depicts schematically, a top view of a fibrillated ribbon.
DETAILED DESCRIPTION
[0034] An embodiment of the apparatus for the execution of the method according to the invention for the fibrillation of a bundle of ribbons from an extrusion procedure is schematically depicted in FIGS. 1-3 . The embodiment example is depicted in full in FIG. 1 , it is shown in a detail from the side in the region of the fibrillation in FIG. 2 , and a top view of a detail is shown in FIG. 3 . The following description applies to all figures, insofar as no specific reference to one of the figures is made.
[0035] The embodiment of the apparatus according to the invention is shown in full in FIG. 1 . The embodiment has an extrusion apparatus 1 , for generating a film from a thermoplastic material. In this example, the extrusion apparatus 1 has an extruder 2 . The extruder 2 is connected to an extrusion die 3 , which extrudes a flat film 22 from a thermoplastic material melted by the extruder 2 .
[0036] At this point is should be noted that the extrusion apparatus 1 can also have two extruders, in order to extrude a two-color flat film or a flat film having different polymer materials.
[0037] A cooling bath 4 is associated with the extrusion die 3 . A redirection device 5 is provided at the discharge end of the cooling bath 4 , for the purpose of removing residual moisture adhering to the film 22 by means of redirection and suction. For this, the redirection device 5 is typically combined with a suction device, which draws off the adhering cooling fluid from the cooling bath 4 .
[0038] In order to cut the film 22 generated in the extrusion apparatus into a bundle of ribbons 24 , a cutting device 6 is located downstream of the redirection device 5 . In the cutting device 6 , the film 22 is cut into numerous individual ribbons 23 having a predetermined width.
[0039] To extract the film 22 , or the ribbon bundle 24 , and to stretch the ribbons 24 , a number of godet delivery devices 7 . 1 and 7 . 2 propelling godets are successively provided. The ribbons 23 are guided, adjacent and parallel to one another, with a simple wrapping about the exterior of the godets fed thereto from the godet delivery devices 7 . 1 and 7 . 2 .
[0040] A heating device 8 is disposed between the godet delivery devices 7 . 1 and 7 . 2 . The heating device 8 may, for example, take the form of a convection oven, in which the ribbons are heated to a stretching temperature. For the stretching of the ribbons, the godets from the godet delivery device 7 . 1 and 7 . 2 are propelled at different rates.
[0041] A fibrillation device 9 is disposed between the heating device 8 and the second godet delivery device 7 . 2 . The fibrillation device 9 has a fibrillation roller 10 , the circumference of which the ribbons 23 are fed with a partial wrap for the purpose of fibrillation. The fibrillation roller 10 is driven by means of an electric motor 25 , controlled by means of the control device 26 . The control device 26 is coupled to a machine control 27 , such that depending on the production speed of the ribbons, defined by the godet propulsion, a specific circumferential speed of the fibrillation roller 10 can be set. In this manner, it is possible to drive the fibrillation roller 10 at a circumferential speed for the purpose of fibrillation, which is preferably higher than the production speed of the ribbons 23 .
[0042] For further explanation of the fibrillation device 9 , additional reference is made to FIGS. 2 and 3 . FIG. 2 shows a detail of the side view of the fibrillation device 9 , and FIG. 3 shows a detail of the top view of the fibrillation device 9 .
[0043] The fibrillation roller 10 has numerous blade strips 28 distributed uniformly on the circumference thereof, each having numerous projecting cutting tips 29 . Each cutting tip 29 contains a blade, oriented toward the rotational direction of the fibrillation roller 10 . The cutting tips shall be explained in greater detail below.
[0044] At the intake end of the ribbons 24 , an adjustment device 14 is associated with the fibrillation roller 10 . The adjustment device 14 has a plurality of substantially vertical guide pins 15 , which are held on a carrier 16 . The guide pins 15 , which can alternatively be formed as freely turning guide rollers on vertical axes, each extend between two adjacent ribbons 23 of the ribbon bundle 24 . The guide pins 15 have dimensions in their outer diameter such that the ribbons 23 are fed without any substantial tolerance between two adjacent pins 15 . The carrier 16 supporting the guide pins 15 is retained in a guide track 17 and can be displaced within the guide track 17 at a right angle to the running direction of the ribbons 23 . By displacing the carrier 16 , the ribbons 23 of the ribbon bundle 24 can be adjusted in relation to the position of the cutting tips 29 on the circumference of the fibrillation roller 10 . In particular, it is possible to implement symmetrical cuts by means of the cutting tips 29 in the ribbons 23 . In particular, minimum spacings at the edge regions can be ensured in the ribbons by this means.
[0045] In order to obtain a defined wrapping of the ribbon bundle 24 on the circumference of the fibrillation roller 10 , two guide rollers 20 . 1 and 20 . 2 are provided to guide the intake and uptake of the ribbon bundle 24 .
[0046] After the fibrillation and stretching, the ribbons 23 are fed to a crimping device 12 and a coiling device 18 . The crimping device 12 , as well as the coiling device 18 has numerous texturing means 13 and coiling stations 19 , for texturing the ribbons individually or collectively, and for coiling them on spools. For this, it is possible to consolidate the ribbon bundle 24 individually or in groups by means of a guide rail 11 .
[0047] With the exemplary embodiment depicted in FIGS. 1-3 , a grass yarn is produced which can already be processed in a further processing procedure to form, directly, an artificial turf.
[0048] An exemplary embodiment of a fibrillation roller 10 is depicted in FIG. 4 . The fibrillation roller 10 has numerous blade strips 28 which are disposed uniformly on the circumference of the fibrillation roller 10 . The blade strips 28 are equipped with numerous cutting tips 29 , which are held in an extending manner as a row of blades 34 , spaced from one another. Each of the cutting tips 29 contains a blade 31 , oriented toward the turning direction of the fibrillation roller 10 . By way of example, a view of one of the cutting tips 29 is depicted in FIG. 5 . The cutting tips 29 are retained on the blade strips 28 , whereby the blade strip 28 is disposed in a groove in the fibrillation roller. The cutting tip 29 has a triangular shape, with a projecting tip. The blade 31 is ground to form a blade on one side of the cutting tip 29 , extending to the tip. The blade 31 is oriented toward the turning direction of the fibrillation roller 10 , such that when the fibrillation roller rotates, it penetrates a ribbon and generates a finite partial cut, depending on the wrapping of the ribbon.
[0049] The configuration of the cutting tips 29 and the blade strips 28 can be selected in such a manner that different fibrillation patterns result. As such, parallel configurations of cutting tips, and offset configurations of cutting tips, are possible.
[0050] Turning to FIG. 4 , it is seen that numerous contact surfaces 32 are formed on the circumference of the fibrillation rollers 10 . The contact surfaces 32 of the fibrillation rollers 10 extending between the blade strips 28 have a multiple coating 33 . In order to enable guidance of the ribbons 23 over the contact surfaces 32 that is low-friction and durable to the greatest extent possible, the multiple coating 33 is preferably formed by an inner single coating and an outer single coating, which are disposed on top of one another in the manner of a sandwich. The inner single coating is applied directly on a base material of the fibrillation roller 10 . An outer single coating lies above the inner single coating, the thickness of which may be the same or different from that of the first single coating. The outer single coating has a low-friction material as the coating material, such that the guide surface of the fibrillation roller 10 directly facing the ribbons is determined by the material characteristics of the low-friction material. The coating material of the inner single coating is formed, however, by a protective coating, which provides a wear protection coating for the base material of the fibrillation roller. As such, a ceramic is preferred for the protective material. Ceramics of this type can be applied, for example, in the form of a plasma coating. The border surface of the inner single coating to the outer single coating preferably has a rough structure, such that in the operational status, after the low-friction material in the outer coating has been worn down, a mixed surface is obtained, formed in part by the low-friction material, and in part by the protective material. A guide surface of this type has the particular advantage that the ribbons 23 can be guided with a low degree of friction and in a manner that is resistant to wear. Plastic is typically used for the low-friction material and PTFE plastic (Teflon) has been determined to be particularly advantageous, in particular, for the guidance of ribbons 23 . In this respect, the ribbons can be fed with slippage about the circumference of the fibrillation roller 10 .
[0051] In order to be able to securely fibrillate highly stretched ribbons in the production of grass fibers, another exemplary embodiment of a fibrillation apparatus is shown in FIG. 6 , which could be used for example in the extrusion process depicted in FIG. 1 . For this, a schematic detail of the top view is shown in FIG. 6 . In this case, only the components relevant to the fibrillation of the ribbons are shown.
[0052] The fibrillation roller 10 is structured identically to the exemplary example according to FIG. 4 , wherein, for the generation of the partial cuts in the ribbons 23 , in each case two rows of blades 34 . 1 and 34 . 2 are successively engaged, and in part simultaneously. The cutting tips 29 on the first rows of blades 34 . 1 are axially displaced in relation to the cutting tips 29 on the second rows of blades 34 . 2 . In this manner, two respective groups of partial cuts are generated in the ribbons 23 .
[0053] The adjustment device 14 is associated with the fibrillation roller 10 at the intake end. The adjustment device 14 is formed by numerous guide pins 15 , which are retained in a displaceable manner in a guide groove 21 of a carrier 16 . For this, two laterally displaceable pins 15 are associated with each ribbon 23 . The pins 15 are substantially vertical and form a lateral border to the ribbons 23 .
[0054] As follows from the depiction provided in FIG. 6 , the width of the stretched ribbons 23 narrows from the original cutting width B to a finite width b. In this manner, larger spacings are obtained between adjacent ribbons. In order to symmetrically fibrillate each of the ribbons 23 with a maximal cutting allocation, the ribbons 23 are adjusted via the guide pins 15 in such a manner that at each edge region of the ribbons 23 a minimum spacing between the ribbon edge and the first partial cut is maintained. This minimum spacing is indicated in FIG. 7 with the identifying letter S. FIG. 7 shows a single ribbon 23 with the generated fibrillation pattern.
[0055] The displacement set between the cutting tips 29 of the rows of blades 34 . 1 and 34 . 2 is indicated in the generated partial cuts of the ribbon 23 with the identifying letter a. In this respect, the partial cuts during fibrillation of the ribbons 23 occur with a spacing a on the ribbons 23 . In this manner, it is possible to generate very fine net-shaped fibrillation structures. The ribbon 23 shows a fibrillation pattern 30 in a net-shaped structure, which is generated by continuously repeating partial cuts from offset cutting tips on the fibrillation roller.
[0056] For fibrillation, a fibrillation roller 10 is preferably driven with a circumferential speed, which is faster than the feed rate of the ribbons. As a result of the smaller cutting resistances during fibrillation, it is possible to maintain relatively small speed differences between the ribbons and the fibrillation roller. The low cutting resistances during fibrillation are also particularly suited for providing very elastic ribbons and very thick ribbons with a uniform fibrillation structure. As such, in the production of grass yarn in particular, this method has proven itself for the fibrillation of ribbons that are preferably generated by means of co-extrusion, having thicknesses in the range of 150 μm-500 μm. The expansions of the ribbons may have values for this of over 50%. As such, it is possible to securely fibrillate ribbons having an expansion of up to 75% and more.
[0057] The method according to the invention and the apparatus according to the invention are suitable for the fibrillation of all conventional ribbons made from thermoplastic materials. In this regard, it is contemplated that the extrusion die 3 in the exemplary example depicted in FIG. 1 can be replaced with a monofilament extrusion tool, such that during the extrusion numerous individual ribbons can be generated. In this case, the cutting device depicted in FIG. 1 is eliminated. In this respect, the method according to the invention and the apparatus according to the invention are also particularly suited for the fibrillation of individually generated ribbons after stretching. In this case, in particular, high frequency rates of the partial cuts in the individual ribbons are possible. By means of adjustment, even small minimum spacings at the edges of the ribbons can be securely set and maintained. In particular, the polymer types PP, LLDPE, HDPE or PA have been shown to be reliable as the materials.
REFERENCE SYMBOL LIST
[0058] 1 extrusion apparatus
[0059] 2 extruder
[0060] 3 extrusion die
[0061] 4 cooling bath
[0062] 5 redirection device
[0063] 6 cutting device
[0064] 7 . 1 , 7 . 2 godet delivery device
[0065] 8 heating device
[0066] 9 fibrillation device
[0067] 10 fibrillation roller
[0068] 11 guide rail
[0069] 12 crimping device
[0070] 13 texturing means
[0071] 14 adjustment device
[0072] 15 guide pin
[0073] 16 carrier
[0074] 17 guide track
[0075] 18 coiling device
[0076] 19 coiling station
[0077] 20 . 1 , 20 . 2 guide roller
[0078] 21 guide groove
[0079] 22 film
[0080] 23 single ribbon
[0081] 24 ribbon bundle
[0082] 25 electric motor
[0083] 26 control device
[0084] 27 machine control
[0085] 28 blade strip
[0086] 29 cutting tip
[0087] 30 fibrillation pattern
[0088] 31 blade
[0089] 32 contact surface
[0090] 33 multiple coating
[0091] 34 . 1 , 34 . 2 rows of blades | The invention relates to a method and apparatus for fibrillating synthetic ribbons in an extrusion process for the production of, for example, grass fibers. The extrusion process creates a sheet of ribbons from an extruded foil or a multiplicity of extruded monofils, and stretches them conjointly. The ribbons are led side by side in a parallel arrangement along the circumference of a fibrillating roll with a partial wrap. To produce a pattern of fibrillation irrespective of the thickness of the ribbons and the elasticity of the ribbons, the invention provides that a multiplicity of short partial cuts is made in the ribbons by a plurality of successively engaging rows of blades on the fibrillating roll each having a multiplicity of projecting cutting tips. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
FIELD OF THE INVENTION
[0002] The present invention deals generally with a device and system for measuring relative humidity and temperature remotely from a number of points throughout a large mass of material, such as a pile of potatoes or other agricultural products, having evenly dispersed interstitial air spaces. The present invention also allows for the utilization of gas assay techniques to sample various gases in the air contained in the interstitial spaces at various points within the aforementioned large mass of material.
BACKGROUND OF THE INVENTION
[0003] The ability to store harvested potatoes and similar agricultural products for extended periods of time is an important element in ensuring an adequate food supply because cyclical growing seasons are asynchronous with the steady demand for staple foodstuffs. Globally, conventional and cold storage techniques are well known techniques for the long term storage of onions, potatoes, and the like even in relatively poorly developed nations. See e.g. K. Moazzem & K. Fujita, The Potato Marketing System and Its Changes in Bangladesh: From the Perspective of a Village Study in the Comilla District, 42 The Developing Econ. 63-94 (March 2004). Wherever such products are stored, however, monitoring environmental parameters in the stored mass of product is crucial. Chief among these parameters are relative humidity and temperature. For example, if the relative humidity is kept too low—below 90% —stored potatoes begin to dry out and desiccate. This has a variety of ramifications ranging in importance from loss of product mass and economic value (since potatoes are sold by weight) to total loss of the product. Until now, potatoes, like most agricultural products, are stored according to an articulated set of industry best practices but with no routinely deployed way of monitoring how well those practices work or are being effectuated in a particular application. See e.g.: The Commercial Storage of Fruits, Vegetables, and Florist and Nursery Stocks (K. C. Gross, C. Y. Wang & M. Saltveit eds., U.S. Dept. of Agriculture 2004). In other words, while it is possible to describe what theoretically ideal storage conditions are, it is difficult to know in actual practice whether such conditions have been attained and whether or not they are being maintained inside a mass of stored product. To a large extent, this is because the remote sensing of relative humidity and temperature in such storage environments has heretofore been economically challenging.
[0004] Over time, it became apparent that the ability to observe and measure the character and amount of various other gaseous substances besides water that are naturally present in stored agricultural products was also important. For example, normal potato respiration generates not only water but carbon dioxide. Monitoring carbon dioxide levels in potato stores is thought to be particularly crucial. For some time it was suspected that above normal carbon dioxide levels correlated to increased reducing sugar concentration thus causing brown fry color and making them unacceptable to consumers. Giuseppe Mazza and A. J. Siemens, Carbon Dioxide Concentration In Commercial Potato Storage and Its Effect On Quality of Tubers for Processing, 67 American Potato Journal 121-132 (1990). Accordingly, systems measuring relative humidity, temperature, and carbon dioxide levels in potato stores were developed. Eventually, these systems featured many useful innovations, such as unitary relative humidity and carbon dioxide sensors sampling air pumped via sample tubes from a selectable set of sources. These techniques ensured lower deployment costs and ease of calibration. Temperature measurements, on the other hand, were taken via a network of wired thermocouples embedded in the potato bins themselves. As a result, the monitoring system was electrically complex and a large part of it was non-portable and dedicated to the facility in which it was installed. An additional difficulty arose because of the thin nature of the tubes used to collect gas samples. Since such tubes had high surface area to volume ratios, they were thermally unstable and thus encouraged the formation of condensate in the tubes. D. S. Jayas, D. A. Irvine, G. Mazza & S. Jeyamkondan, Evaluation of a Computer - Controlled Ventilation System For A Potato Storage Facility, 43 Canadian Biosystems Engr. 5.5-5.12 (2001).
[0005] Eventually however, it became obvious that the role of carbon dioxide in potato storage applications was incompletely understood. More recent research has cast doubts on the earlier view, with one study suggesting that in terms of accelerating the synthesis of reducing sugars in stored potatoes, elevated carbon dioxide levels merely amplify the well-understood effects of ethylene gas. B. Daniels-Lake, R. Prange & J. Walsh, Carbon Dioxide and Ethylene: A Combined Influence on Potato Fry Color, 40(6) HortScience 1824-1828 (2005). Unfortunately, ethylene gas is not only a natural byproduct of stored potatoes and the various pathogens that afflict them, but it is also a commonly used additive to prevent premature sprouting while in storage. As a result, the shifting science and technology involving potato storage dictates that there be a new method of monitoring a wide variety of conditions and compounds inside a mass of stored potatoes. Now, not only relative humidity, temperature, and carbon dioxide levels must be monitored, but in certain circumstances it might be desirable to monitor the levels of oxygen, ethylene, and other chemicals, too.
[0006] Moreover, in terms of sensing both relative humidity and temperature and allowing for the utilization of a variety of gas assay instruments, nothing in the prior art is optimized for deployment in agricultural applications, specifically within potato storage facilities. Systems using a multiplicity of wired or wireless relative humidity and temperature sensors are unsuitable because they require a multiplicity of relatively costly sensors incapable of detecting other substances, as discussed above. Also, as discussed above, such systems must be fixed in a particular location and cannot be moved. Further, while gas sampling systems constructed with thin nylon or Tygon® tubes or the like are unsuitable as discussed above because of the possibility of condensate formation, they are also unsuitable because the tubing may become pinched or bent and thus constrict the flow of air. What is needed then, is a low cost, portable means of deploying one relative humidity and temperature sensor in such a manner that samples may be drawn from a one or more of a multiplicity of remote sample points within a pile of potatoes, or other agricultural product, while providing for the simultaneous inclusion or attachment of a gas sensing apparatus to determine the levels various gaseous chemical compounds or elements in the pile.
[0007] It is thus a first object of the present invention to provide a unitary device to measure relative humidity and temperature derived from one or more locations in one or more independent masses of stored agricultural product. It is a second object of the present invention that a gas assay apparatus such as a general purpose gas chromatograph or a dedicated purpose gas sensing device may be readily included within or attached to and removed from, the present invention. It is a third object of the present invention that the requisite air sampling tube be of low cost and rigid enough to avoid kinks and closures when deployed in a settling mass of agricultural product yet be large enough in diameter to allow sufficiently high airflow through the sampling tube such that the effect of any localized temperature variation and condensate formation in the air sampling tube is limited.
SUMMARY OF THE INVENTION
[0008] The present invention is comprised of two major parts: 1) A sample head housing the temperature and relative humidity sensing apparatus, the gas test port or dedicated gas assay device, and the air evacuating device; and, 2) A sample collection system comprising a sample collection main line and, optionally, a multiplicity of sample collection lateral lines.
[0009] The sample head is generally in the form of a hollow cylinder, closed at one end with a sample collection main line adapter capable of being removably connected to a sample collection main line and closed at the other end with an air evacuating device, such as a “muffin fan” capable of evacuating air from the interior of the sample head and thus drawing air in from the attached sample collection main line. The air evacuating device must be placed “downstream” of the various sensors in the sample head so that the temperature of the motor and energy imparted to the air, and resulting slight heating caused by the fan, does not alter the temperature of the air before it is tested. The sample head is equipped with a relative humidity sensor and a temperature sensor, both of which penetrate from the outside of the sample head into the interior of the sample head such that they measure the relative humidity and temperature, respectively, of the air inside the sample head. The relative humidity and temperature sensors may be of the “direct read” variety, i.e. have an integral digital readout to display the relative humidity and temperature, respectively, of the air presently in the sample head, or both may be of the digitizing variety wherein the digital data is transmitted to, recorded on, and displayed by a dedicated recording and display device or a general purpose computer. Similarly, a gas sample tube penetrates from the outside of the sample head to the inside of the sample head. Ordinarily, this gas sample tube is capped, but by removing the cap, a gas assay apparatus may be attached to the sample tube and through it withdraw air from the interior of the sample head. The gas assay apparatus may be any of the usual variety, ranging from a general purpose gas chromatograph to a single- or multi-purpose detector capable measuring the concentration of one or several compounds or elements, such as: oxygen, carbon dioxide, methane, methanol, ethanol, ethane, ethylene, isopropyl N-(3-chlorophenyl) carbamate, etc. In an alternative embodiment, the gas sample tube may be omitted and a direct read or digitizing gas assay apparatus may be installed into the sample head in its place.
[0010] The sample collection system typically is constructed of polyvinyl chloride (PVC) pipe and may be as simple as a single length of PVC pipe or as complex as a multi-branch network with numerous sample collection lateral lines each isolated from the sample collection main line by means of a solenoid valve. PVC is preferred as a material for a variety of reasons. First, it is inexpensive. Second, it is non-reactive with foodstuffs stored in close proximity. Third, it is semi-rigid. Specifically, it is rigid enough not to be deformed when stored material is piled on top of it, but flexible enough such that minor reconfigurations and settling in the stored material will not disrupt the system. The terminal end of the sample collection main line and each sample collection lateral line (if any) are equipped with a gas permeable, dirt impervious filter to prevent debris from being drawn into the sample collection system. Depending on environmental conditions, the sample collection system may be insulated. In the simplest embodiment, a sample collection main line is embedded in each area or bin of stored material. In complex embodiments the sample collection main line is used to collect samples from a multiplicity of sample collection lateral lines, each of which is embedded in a different mass of stored material. In this latter configuration, a solenoid valve isolates the sample collection lateral lines from the sample collection main line and a solenoid valve is installed in the sample collection main line just before the gas permeable, dirt impervious filter at its terminal end. By this means, air may be sampled from any one of the sample collection lateral lines or the sample collection main line. In this embodiment, each sample collection lateral line terminates in a pile of stored agricultural product while the sample collection main line terminates in ambient air in the storage facility. This latter port is used to precondition the sample collection main line to a known condition and thus allow the system to more accurately calculate the temperature in each area or bin. These systems also necessarily comprise a switching means, such as a manual switch panel or a multi-contact digital to analog switch device, capable of supplying activating power to each of the solenoid valves thus allowing the user to select whether one of the sample collection lateral lines or the sample collection main line will be sampled.
[0011] The simplest embodiment of the system is used in the following manner: First, some amount of stored material, such as potatoes, is placed in the storage facility. Second, the sample collection main line is placed in the storage area on the top of the stored material. Third, additional stored material is placed on top of the first layer of stored material such the sample collection main line is embedded in the mass of stored material with the free end of the sample collection main line extending to the top of the pile of stored material. Because of the insulative nature of the outer layers of a mass of stored agricultural product, temperatures in the pile are usually higher at the center of the mass. Thus, it is important that the end of the sample collection line terminates at or near the center of the mass. After the storage facility is completely filled, the sample head is attached to the free end of the sample collection main line. If the system comprises a direct read relative humidity sensor and thermometer, the user simply activates the fan in the sample head and after waiting a suitable time to transport a new air sample through the sample collection main line and into the sample head, reads the relative humidity and temperature of the air in the sample head. If the system comprises a relative humidity and temperature sensor that generates an electrical signal coded to indicate measured relative humidity and temperature, respectively, these sensors are electrically connected to a dedicated recording and display device or general purpose computer capable of storing, retrieving, and displaying the measured relative humidity and temperature in a human perceptible form. Similarly, if the system comprises a direct read gas assay device, the user reads the concentration of the one or more gasses sampled. Also, if the system comprises a gas assay device that generates an electrical signal coded to indicate the identity and concentration of one or more compounds or elements, this device is electrically connected to a dedicated recording and display device or general purpose computer capable of storing, retrieving, and displaying the identity and concentration of the one or more substances in a human perceptible form. The user then tests the next pile or bin of stored product in the same manner, and so on.
[0012] The more complex, distributed embodiment of the system are used in the following manner: Before use, the sample collection main line with its solenoid valves and all necessary control wiring is permanently affixed in the storage facility with the terminal end of the sample collection main line with its gas permeable, dirt impervious filter extending into the ambient air atmosphere in the storage facility. Next, some amount of stored material, such as potatoes, is placed in one area or bin in the storage facility. Next, a sample collection lateral line with its gas permeable, dirt impervious filter at its terminal end is connected to the sample collection main line and extended into the selected storage area or bin on the top of the stored material. Next, additional stored material is placed on top of the first layer of stored material such the sample collection branch line is largely if not completely embedded in the mass of stored material. As above, because of the insulative nature of the outer layers of a mass of stored agricultural product, temperatures in the pile are usually higher at the center of the mass. Thus, it is important that the end of each sample collection lateral line terminates at or near the center of the mass. In this more complex embodiment, a single large mass of product may require a multiplicity of sample lines to effectively sample conditions inside a large, distributed central zone of product. Alternately, in applications in which product is stored in smaller individual bins the sample collection line ideally terminates in the center of the mass of product stored in the particular area or bin. The preceding two steps are repeated until the entire facility or all of the bins are filled. Next, the sample head is attached to the free end of the sample collection main line. Next, the user then electrically opens the solenoid valve at the terminal end of the sample collection main line and activates the fan to precondition the interior surface of the sample collection main line to a temperature approximating the ambient temperature in the storage facility. Next, the user electrically closes the solenoid valve at the far end of the sample collection main line and actuates the solenoid valve that opens the sample collection branch line that extends into the first storage area or bin to be sampled. After running the fan for a period of time sufficient to transport air from the interior of the storage area or bin to the sample head, the user notes the temperature of the air passing through the sample head. The temperature of the air in the storage area or bin being sampled is calculated from the following measured or known factors: 1) The temperature difference between sampled air when flowing through the sample head and the ambient temperature of air in the storage facility; 2) The length of the sample collection main line from the sample head to the solenoid valve controlling the flow of air from the sample collection branch line being sampled; 3) The diameter of the sample collection main line; 4) The volumetric flow of the stream of air being drawn through the sample collection main line; and, 5) the “R” value of the PVC pipe (and insulation, if any) in the sample collection main line. From these observations, it is possible to closely calculate the temperature of the air being drawn into the sample collection branch line. As above, if the sample head also comprises a direct read gas assay device, the user also reads the concentration of the one or more gasses sampled. After recording the calculated temperature, measured relative humidity, and identity and concentration of other gasses (if measured), the user electrically closes the solenoid valve that opens the sample collection branch line that extends into the storage area or bin just sampled and electrically opens the solenoid valve at the terminal end of the sample collection main line to precondition the interior surface of the sample collection main line to a temperature approximating the ambient temperature in the storage facility. The user then repeats the above steps with the second storage area or bin to be sampled, and so on. If the system comprises relative humidity and temperature sensors that generate an electrical signal coded to indicate measured relative humidity and temperature, respectively, these sensors are electrically connected to a dedicated recording and display device or general purpose computer capable of storing, retrieving, and displaying relative humidity and temperature in a human perceptible form. As above, if the sample head comprises a gas assay device that generates an electrical signal coded to indicate the identity and concentration of one or more compounds or elements, this device is also electrically connected to a dedicated recording and display device or general purpose computer capable of storing, retrieving, and displaying the identity and concentration of the one or more substances in a human perceptible form. Finally, if the system incorporates a multi-contact digital to analog switch device, the general purpose computer used to store, retrieve, and display calculated temperature, measured relative humidity, and identity and concentration of other gasses (if measured) may also: 1) Calculate and store the temperature of the air in the sampled area or bin; and, 2) Automate the process of repetitively collecting samples from the various storage areas or bins.
[0013] Optionally, if the sample head does not comprise a gas assay device in lieu of the gas sample port, the user may attach a general purpose gas assay apparatus to the gas sample port, and by this means collect detailed analytical data regarding the nature and composition of the gasses passing through the sample head. If the system incorporates a general purpose computer, the general purpose computer may also store, retrieve, and display data regarding the identity and concentration of other gases as measured by the attached general purpose gas assay device as air from the various storage bins is sampled.
[0014] Monitoring gas levels in the mass of stored product is important for a host of reasons. In the case of potatoes, for example, low concentrations of ethylene gas are applied to prevent sprouting and reduce spoilage. As discussed above, it is believed that elevated carbon dioxide in the storage environment synergistically interacts with ethylene gas to raise the amount of reducing sugar in the tuber and thus has the potential to darken the fry color of potatoes stored in such an environment. Id. Remediation techniques (e.g. ventilation) cannot be undertaken on a cost effective “as needed” basis unless an accurate assessment of the concentration of ethylene and carbon dioxide in the stored product is available. This embodiment of the present invention allows this assessment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 a is a three-quarter view of the right-hand side of one embodiment of the sample head.
[0016] FIG. 1 b is a three-quarter view of the right-hand side of a second embodiment of the sample head.
[0017] FIG. 2 is a three-quarter view of the right-hand side of a third embodiment of the sample head showing it connected to a data recording and display device such as a computer.
[0018] FIG. 3 is a three-quarter view of the right-hand side of a third embodiment of the sample head showing it connected to a general purpose gas assay device such as a portable gas chromatograph and a data recording and display device such as a computer.
[0019] FIG. 4 is a schematic diagram illustrating the sample head and sample collection main line in accordance with the first embodiment of the present invention.
[0020] FIG. 5 is a schematic diagram illustrating: 1) A general purpose computer used to store, retrieve, and display measured relative humidity and temperature data and also: i) Calculate and store the temperature of the air in the sampled area or bin; and, ii) Automate the process of repetitively collecting samples from the various storage areas or bins; 2) The sample head; and, 3) A complex sample collection system comprising a sample collection main line and a multiplicity of sample collection lateral lines in accordance with the first embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention is comprised of two major parts: 1) A sample head generally comprising various forms of relative humidity and temperature sensing apparatus, a gas test port or dedicated gas assay device, and a fan; and, 2) A sample collection system comprising: i) A sample collection main line; or, ii) A sample collection main line and a multiplicity of interconnected sample collection lateral lines.
[0022] Turning now to FIGS. 1 a and 1 b , sample head 100 is generally in the form of a hollow cylinder 101 or box, closed at one end with a sample collection main line adapter 103 capable of being removably connected to a sample collection main line 200 and closed at the other end with an air evacuating means 102 such as a “muffin fan,” axial blower, centrifugal air blower, or the like, capable of evacuating air from the interior of the sample head 100 and thus drawing air in from attached sample collection main line 200 . Without regard to the particular kind of device used, air evacuating means 102 must be placed “downstream” of the various sensors and gas sample port 110 (if equipped) in sample head 100 so that the temperature of the motor and the energy imparted to the air (and resulting slight heating) caused by the air evacuating device does not alter the temperature of the air before it is tested. Without limitation, sample head 100 , sample collection main line adapter 103 , and sample collection main line 200 are comprised of polyvinyl chloride (PVC), nylon, or metal and may be insulated.
[0023] Referring to FIG. 1 a , in a first embodiment of the present invention, sample head 100 may be equipped with a direct read relative humidity sensor 104 and a direct read temperature sensor 106 , both of which penetrate from the outside of sample head 100 into the open interior of sample head 100 such that their sensing elements 105 and 107 , respectively, are capable of measuring the relative humidity and temperature, respectively, of the air inside sample head 100 . Direct read relative humidity and temperature sensors include an integral display capable of showing the current temperature and relative humidity, respectively, or, in some versions, displaying a summary of previously recorded temperatures and/or relative humidity readings. Gas sample tube 110 penetrates from the outside of sample head 100 to the open interior of sample head 100 . Ordinarily, gas sample tube 110 is closed by cap 111 , but by removing cap 111 , the collection tube from a separate gas assay apparatus may be attached to gas sample tube 110 so that the gas assay apparatus may withdraw air from the interior of sample head 100 .
[0024] Referring to FIG. 1 b , in a second embodiment of the present invention, sample head 100 is equipped with a direct read relative humidity sensor 104 , a direct read temperature sensor 106 , and a direct read carbon dioxide sensor 112 , all of which penetrate from the outside of sample head 100 into the open interior of sample head 100 such that their sensing elements 105 , 107 , and 113 are capable of measuring the relative humidity, temperature, and carbon dioxide concentration respectively, of the air inside sample head 100 . As described above, direct read relative humidity, temperature, and carbon dioxide sensors include an integral display capable of showing the current relative humidity, temperature, and carbon dioxide concentration, respectively, or displaying a summary of previously recorded relative humidity, temperature, and/or carbon dioxide concentrations.
[0025] Turning now to FIG. 2 , in a third embodiment of the present invention sample head 100 may be equipped with a digitizing relative humidity sensor 108 and a digitizing temperature sensor 109 wherein digital data coded to represent the relative humidity and temperature, respectively, of the air in sample head 100 is transmitted wirelessly or via data cables 301 to a dedicated recording and display device or a computer 300 executing a software program capable of storing, querying, and displaying stored relative humidity and temperature data. Relative humidity and temperature sensors integrated into one direct read or digital sensor device are, of course, well known in the art and may be substituted for the separate relative humidity and temperature sensors discussed above. As above, a third sensor, for example a digitizing carbon dioxide sensor, may be installed in lieu gas sample tube 110 . It should be readily apparent that any number or combination of direct read and/or digitizing sensors may be installed in sample head 100 . All such alternative configurations are included in the spirit and scope of the present invention.
[0026] Turning now to FIG. 3 , gas assay apparatus 400 may be a general purpose gas chromatograph (as shown) or a handheld single purpose detector capable of measuring the concentration of one, or several, compounds or elements, such as: oxygen, carbon dioxide, methane, methanol, ethanol, ethane, ethylene, etc. Many gas assay devices are equipped with an electrical interface wherein digital data coded to represent the identity, composition, and concentration of various detected gasses is transmitted wirelessly or via data cable 403 thus allowing the user to connect gas assay apparatus 400 to, for example, general purpose computer 402 or a network. Computer 402 executes a software program capable of storing, querying, and displaying stored data derived from gas assay device 400 .
[0027] Turning now to FIGS. 4 and 5 , the sample collection system is preferably constructed of polyvinyl chloride (PVC) pipe. The sample collection system may be as simple as a single length of PVC pipe serving as the sample collection main line 200 or as complex as a multi-branch network with numerous sample collection lateral lines 202 , 203 , and 204 each isolated from sample collection main line 200 by means of a manually operated or electrically operated valve, preferably a solenoid valve, 206 , 207 , and 208 , respectively. PVC is preferred as a material of reasons. First, it is inexpensive. Second, it is non-reactive with foodstuffs stored in close proximity to it. Third, it is semi-rigid. Specifically, it is rigid enough not to be deformed when stored material is piled on top of it, but flexible enough such that minor reconfigurations and settling in the stored material will not disrupt the system. While PVC is preferred, other materials are suitable, particularly for constructing the sample collection main line in complex sample collection systems. Such materials include, without limitation, rubber, plastic, or vinyl tube, hose or line or various types of insulated “mini-duct” tubes as often used in high velocity air conditioning systems. Like sample head 100 sample collection main line 200 may be insulated.
[0028] Referring now to FIG. 4 , in its simplest embodiment the sample collection system is comprised solely of sample collection main line 200 , which is, in turn, comprised of PVC pipes and PVC fittings. At the distal end of sample collection main line 200 , a gas permeable, dirt impervious filter 201 is installed to prevent debris from being drawn into gas sample collection main line 200 .
[0029] This embodiment of the present invention is used in the following manner: First, some amount of stored material, such as potatoes, is placed in the storage facility. Second, sample collection main line 200 is placed on the top of the stored material, such that gas permeable, dirt impervious filter 201 will be generally located in the center of the mass of stored product when the storage area or bin is filled. Third, additional stored material is placed on top of the first layer of stored material such the sample collection main line 200 is embedded generally in the center of the mass of stored material with the free end of the sample collection main line 200 extending to and accessible area at the top of the pile of stored material. This placement is crucial, because the outer periphery of a pile of stored agricultural product insulates the innermost regions. Since heat is a byproduct of respiration in potatoes, for example, the temperature at the core of the pile tends to be considerably higher than at the periphery. Thus, it is important that the end of the sample collection line terminates at or near the center or the mass. After the storage facility is completely filled, sample head 100 is attached to the free end of sample collection main line 200 . The user next activates air evacuating means 102 in sample head 100 . After waiting a suitable time to: 1) Transport sample air extracted from the pile of stored material beyond the terminus of sample collection main line 200 to sample head 100 ; 2) Fill the interior of sample head 100 ; and, 3) Allow for the measurement latency time of direct read relative humidity sensor 104 and direct read temperature sensor 106 , respectively, if any, the then used reads the relative humidity and temperature of the air in the sample head. Since the air being measured was previously located in the pile of stored material beyond the terminus of sample collection main line 200 , and the temperature of the walls of sample collection main line 200 approximate the temperature of the air in the pile of stored material, the relative humidity and temperature of the air in sample head 100 approximates the relative humidity and temperature of the air in the center of the stored pile of material at a point just beyond the terminus of sample collection main line 200 .
[0030] Referring now to FIG. 5 , a more complex embodiment of the present invention is disclosed. Here, the sample collection system is comprised of sample collection main line 200 and a multiplicity of sample collection lateral lines 202 , 203 , and 204 , each of which is, in turn, comprised of PVC pipes and PVC fittings. At the distal end of sample collection main line 200 and sample collection lateral lines 202 , 203 , and 204 , a gas permeable, dirt impervious filter 201 is installed to exclude debris. In this embodiment, sample collection lateral lines 202 , 203 , and 204 extend from sample collection main line 200 such that the terminal ends of sample collection lateral lines 202 , 203 , and 204 are placed in different areas of the stored product. Ordinarily, for example, the terminus of each of sample collection lateral lines 202 , 203 , and 204 would be placed in a different bin of stored product or would be distributed around the center area of single larger mass of stored product. In this embodiment, solenoid valves 206 , 207 , and 208 isolate sample collection lateral lines 202 , 203 , and 204 , respectively, from sample collection main line 200 . Similarly, a manually operated or electrically operated valve, preferably a solenoid valve, 205 is installed in sample collection main line 200 just before gas permeable, dirt impervious filter 201 at its terminus. In this embodiment, while each of sample collection lateral lines 202 , 203 , and 204 terminates in stored agricultural product, sample collection main line 200 terminates in ambient air in the storage facility. This latter port is used to precondition the interior of sample collection main line 200 to a known thermal state thus allowing the system to more accurately calculate the temperature in each area or bin. In this embodiment, a valve selecting means capable of powering solenoid valves 205 , 206 , 207 , and 208 is needed to select which one of the lines from which the system draws air. Such a valve selecting means may be a simple switch panel or a computer 500 with a suitable multi-contact digital to analog switch device 502 wherein computer 500 signals multi-contact digital to analog switch device 502 causing it to activate one of solenoid valves 205 , 206 , 207 , or 208 . In this embodiment, sample head 100 is equipped with digitizing relative humidity sensor 108 , a digitizing temperature sensor 109 , and digitizing carbon dioxide gas assay device 114 wherein digital data coded to represent the relative humidity, temperature, and concentration of carbon dioxide respectively, of the air in sample head 100 is transmitted via data cables 501 to computer 500 . In this embodiment, computer 500 simultaneously executes the following software programs: 1) “Program A” that: i) Collects data derived from digitizing relative humidity sensor 108 and digitizing temperature sensor 109 ; and, ii) Calculates the temperature of air in the storage area or bin being sampled; and, iii) Stores, queries, and displays relative humidity and temperature data derived from digitizing relative humidity sensor 108 and digitizing temperature sensor 109 as well as the calculated temperature of the air derived from sample collection lateral lines 202 , 203 , and 204 ; 2) “Program B” that: i) Collects data derived from digitizing carbon dioxide gas assay device 114 ; and, ii) Stores, queries, and displays carbon dioxide concentration data derived from digitizing carbon dioxide gas assay device 114 as it samples air from sample collection lateral lines 202 , 203 , and 204 ; and, 3) “Program C” that automates the sequential collection of air samples from sample collection lateral lines 202 , 203 , and 204 . By this means, computer 500 can fully automate the process of sequentially selecting a particular sample line thus allowing “Program A” to record the raw relative humidity, temperature, and the calculated temperature of the air sampled from the terminus of each line and “Program B” to record the carbon dioxide concentration of the air sampled from the terminus of each line before moving to the next sample collection lateral line.
[0031] This embodiment the present invention is used in the following manner: Before use, sample collection main line 200 with solenoid valves 205 , 206 , 207 , and 208 , multi-contact digital to analog switch device 502 , and all necessary control wiring extending from multi-contact digital to analog switch device 502 to solenoid valves 205 , 206 , 207 , and 208 is permanently affixed in the storage facility with the terminus of sample collection main line 200 with its gas permeable, dirt impervious filter 201 extending into the ambient air atmosphere in the storage facility. Next, some amount of stored material, such as potatoes, is placed in the storage area or multiplicity of bins in the storage facility. Next, sample collection lateral lines 202 , 203 , and 204 with their gas permeable, dirt impervious filters 201 at their terminal ends are connected to sample collection main line 200 and extended collectively into the storage area or individually into the multiplicity of bins on the top of the material placed there. Next, additional stored material is placed on top of the first layer of stored material such that sample collection branch lines 202 , 203 , and 204 are largely if not completely embedded in the stored material. As discussed above, the outer periphery of a pile of stored agricultural product insulates the innermost regions. As a result, the temperature at the core of the pile tends to be considerably higher than at the periphery. Thus, it is important that the end of sample collection lateral lines 202 , 203 , and 204 terminate at or near the center of the mass to be sampled. In this more complex embodiment, a single large mass of product may have a correspondingly larger central mass and thus require a multiplicity of sample lines to effectively sample conditions. Alternately, in applications in which higher-value product is stored in individual bins each of sample collection lateral lines 202 , 203 , and 204 ideally terminates in the center of the mass of product stored in a particular bin. Next, sample head 100 is attached to the free end of the sample collection main line 200 . Computer 500 is electrically connected to digitizing relative humidity sensor 108 , digitizing temperature sensor 109 , digitizing carbon dioxide gas assay device 114 and multi-contact digital to analog switch device 502 . Next, the user activates air evacuating means 102 in sample head 100 and executes the software programs described above on computer 500 . The software programs running on computer 500 perform the following steps:
[0000] 1) “Program C” opens solenoid valve 205 at the terminal end of the sample collection main line 200 thus allowing ambient temperature air to flow through sample collection main line 200 . This step is important because it preconditions the interior surface of sample collection main line 200 to a temperature approximating the ambient temperature in the storage facility. Since all samples from all areas or bins are routed from the individual area or bin to sample head 100 via sample collection main line 200 , optimal results are assured when sample collection main line 200 is returned to a known thermal state before collecting a new sample. The restoration of a known thermal state is achieved when the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 approximates the ambient temperature in the storage facility.
2) “Program C” closes solenoid valve 205 at the far end of the sample collection main line 200 and actuates solenoid valve 206 that opens sample collection lateral line 202 extending into the first storage area or bin to be sampled.
3) After “Program C” has ensured that air evacuating means 102 has operated for a period of time sufficient to transport air from the interior of the selected storage area or bin to sample head 100 , “Program A” reads and records the temperature and relative humidity of the air as measured by digitizing temperature sensor 109 and digitizing relative humidity sensor 108 , respectively, passing through sample head 100 .
4) “Program A” then calculates the temperature of the air in the storage area or bin being sampled from the following measured or known factors: i) The temperature difference between sampled air when flowing through sample head 100 and the already measured ambient temperature of air in the storage facility; ii) The length of sample collection main line 200 from sample head 100 to solenoid valve 206 ; iii) The diameter of sample collection main line 200 ; iv) The volumetric flow of the stream of air being drawn through sample collection main line 200 ; and, v) the “R” value of the PVC pipe (and insulation, if any) of sample collection main line 200 . A number of formulae are well known in the art whereby one can calculate the temperature variation experienced when delivering air at one temperature through a duct at another temperature. One such example is provided by the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE). Am. Socy. Of Heating, Refrigeration, and Air Conditioning Engrs., Handbook of Fundamentals, 4.21 (2009). For example, if the temperature desired in the storage area or bin in where sample collection lateral line 202 terminates is 50.0° F.; the ambient temperature in the storage facility is 40.0° F.; the length of sample collection main line 200 from the solenoid valve 206 is 100 ft.; the volumetric flow through sample head 100 generated by air evacuating means 102 is a nominal 30 cfm; the exterior diameter of sample collection main line 200 is 7.5 in.; and, the R-value of sample collection main line 200 is 0.5, then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 42.4° F. when a temperature of 50.0° F. has been attained in the sample area or bin in which sample collection lateral line 202 terminates. If the temperature in the area or bin drifts too high, say to 55.0° F., then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 43.6° F. Similarly, if the temperature in the area or bin drifts too low, say to 45° F., then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 41.2° F. Assuming the same scenario, but substituting a foam-insulated PVC sample collection main line with an R-value of 4, then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 46.7° F. when a temperature of 50° F. has been attained in the sample area or bin being tested. If the temperature in the area or bin drifts too high, say to 55° F., then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 50.1° F. Similarly, if the temperature in the area or bin drifts too low, say to 45° F., then the temperature of the air as measured by digitizing temperature sensor 109 in sample head 100 will be 43.4° F. These examples illustrate the desirability of insulating sample collection main line 200 in these more complex embodiments.
5) After recording the calculated temperature, measured temperature, and measured relative humidity of air drawn from the selected sample area or bin, “Program A” updates the computer's display to show, for example, calculated temperature, relative humidity, and a graphical view of the same data for some period of recent time. This is exemplified on FIG. 5 as “Program A Display.”
6) “Program B” then records the concentration of carbon dioxide gas present in the air drawn from the area or bin being sampled.
7) After recording the concentration of carbon dioxide in the selected area or bin, “Program B” updates the computer's display to show for example, the current and average carbon dioxide levels and a graphical view of the same data for some period of recent time. This is exemplified on FIG. 5 as “Program B Display.”
8) “Program C” then deactivates solenoid valve 206 closing sample collection lateral line 202 extending into the selected area or bin.
9) Computer 500 then repeats steps 1) through 7) appropriately substituting solenoid valves 207 and 208 and sample collection lateral lines 203 and 204 extending into the second and third storage areas or bins to be sampled, respectively.
[0032] “Program A”, “Program B”, and “Program C” communicate with each other to the extent that “Program A” and “Program B” are able to determine from “Program C” which of solenoid valves 205 , 206 , 207 , or 208 is selected and thus whether sample collection main line 200 or one of sample collection lateral lines 202 , 203 , or 204 , respectively, is open and being sampled. The identity of the selected solenoid valve, and thus the length of sample collection main line 200 from the selected sample line, is used by “Program A” to accurately calculate the temperature of the air in the area or bin being sampled and by both “Program A” and “Program B” to identify recorded data for later retrieval and display.
[0033] It will be obvious to one having skill in the art that “Program A”, “Program B”, and “Program C” need not be segregated into separate programs (as described) but may instead exist as software modules or objects combined into one software program. Moreover, although only a few exemplary embodiments of the present invention have been described in detail, those skilled in the art will readily appreciate that numerous minor modifications and rearrangements of the exemplary embodiments are readily conceivable. Accordingly, all such modifications and rearrangements are intended to be included within the scope of this invention as defined in the following claims. | A distributed relative humidity and temperature sensing system with optional gas assay functionality, comprising a sample head internally equipped with: 1) A relative humidity sensor; 2) A temperature sensor; 3) A gas sample port for the attachment of a gas assay device, or, an integral gas assay device; and, 4) A fan. The sample head is attached to a semi-rigid sample tube embedded in a stored mass of agricultural product and the aforementioned fan causes air from within the stored mass to be drawn through the sample head where its relative humidity, temperature, and optionally, chemical composition may be studied. An alternative embodiment allows for the deployment of a complex network of sample tubes so that samples may be drawn as required from a number of points within the stored mass. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to headphones, and in particular, relates to a pressure controlling mechanism for sound-isolating headphones.
2. Description of the Related Art
A sound isolating headphone is known as a personal speaker that is worn on a head with auricles covered therein.
As examples in related art, sound-isolating headphones with configurations disclosed in Patent Documents 1 and 2 are known.
FIG. 6 shows a configuration of a headphone disclosed in Patent Document 1. In FIG. 6 , a headphone includes an electro-acoustic transducer formed by combining a yoke B, a magnet C, and a pole piece D which are provided on a base A with a voice coil E 1 which is provided at a dome diaphragm E side. The electro-acoustic transducer is disposed at the center of a headphone housing F having an enclosure structure.
A baffle board G is integrally combined with the headphone housing F. An ear pad H is provided on the baffle board G. The baffle board G is facing a front end portion of each voice coil E 1 of the electro-acoustic transducer, and a plurality of openings G 1 are formed in the baffle board G.
FIG. 7 shows a configuration of a headphone disclosed in Patent Document 2. In FIG. 7 , a driver unit (electro-acoustic transducer) P is disposed behind a baffle board K having numerous through holes. A sub-housing L is provided behind the driver unit P, that is, at a rear space side formed by the headphone housing F. An acoustic-resisting member M composed of a buffer material is provided at an opening L 1 formed on the sub-housing L.
This configuration improves sound insulation of sound-isolating headphones.
In terms of the sound insulation, for example, an active noise-canceling headphone (not shown) is known that has a microphone therein to detect noise from outside and emits a tone of an opposite phase signal to counter the noise.
[Patent Document 1] Japanese Patent Application Laid-open No. 2003-32768
[Patent Document 2] Japanese Patent Application Laid-open No. 2003-17990
Problems to be Solved by the Invention
In sound-isolating headphones, a space around an auricle is shielded from another space at a headphone housing side by an electro-acoustic transducer or a baffle board including the electro-acoustic transducer. Accordingly, change of pressure in the spaces may sometimes break components in the electro-acoustic transducer, e.g., a diaphragm and a voice coil in particular, or lose the proper positioning of the components. When this happens, sounds may not be played properly. Further, with the noise-canceling headphone, the pressure may affect the microphone to produce unwanted sound that makes the user uncomfortable.
When the user wears a headphone, an ear pad is first pressed against a side of the head so that the headphone is in close contact with the head and then released. Upon pressing, due to shrinkage deformation of the ear pad, a space around the auricle shrinks to increase internal pressure. Upon releasing, the shape of the pad returns to its original form to make the space larger and the pressure within the space tends to be negative.
When the pressure is increased, the voice coil may collide with the magnet and break. When the pressure within the space tends to be negative, the voice coil may slip out of the position facing the magnet. Thus, the proper positioning of the voice coil and the magnet facing each other is lost and sounds cannot be played properly.
SUMMARY OF THE INVENTION
To solve the problems of the headphones in related art, the present invention provides a headphone with a configuration that prevents breaking of components and failure to play sounds properly due to a pressure change within the spaces in the headphone.
In view of the above, an aspect of the present invention provides a headphone including: a baffle board; an ear pad provided at a periphery of the baffle board and surrounding an area around an auricle of a user; an electro-acoustic transducer provided at a central portion of the baffle board and having, as major components, a diaphragm, and a magnetic pole that oscillates the diaphragm; and a headphone housing forming a rear space on a side opposite to the ear pad of the baffle board and covering the electro-acoustic transducer. The electro-acoustic transducer is supported by a frame member integrally combined with the baffle board in an opening of the baffle board. The frame member includes a valve that eliminates a pressure difference between a space around the auricle and the rear space.
The valve may be composed of a flexible piece that opens a communicating hole penetrating the frame member in a thickness direction thereof by bending in a direction of a pressure applied.
It is preferred that the communicating hole is provided at a position different from a position where an acoustic-resisting member is provided on the frame member.
In an initial state, the valve may be set to completely close the communicating hole, or have a slight gap between the flexible piece and an opening plane of the communicating hole.
The headphone according to some aspects of the present invention includes the valve that eliminates a pressure difference between the space around the auricle and the rear space formed opposite thereto. Thus, an increase of pressure and a tendency of pressure being negative within the spaces can be eliminated by the opening and closing operation of the valve. Further, by forming the valve with a flexible piece which can bend in accordance with the direction of pressure applied, the headphone can withstand a sudden change of pressure. Accordingly, breaking of the components undergoing a sudden large movement due to the increase of pressure or the tendency of pressure being negative within the spaces can be prevented. Furthermore, a pressure change that can make the user uncomfortable can effectively be prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a headphone unit according to a first embodiment of the present invention.
FIG. 2 is an enlarged view of a base frame in the headphone unit in FIG. 1 .
FIG. 3A is an enlarged cross-sectional view showing a configuration and an operation of a valve provided at the base frame in FIG. 2 when there is a pressure difference between spaces.
FIG. 3B is an enlarged cross-sectional view showing a configuration and an operation of the valve when there is no pressure difference between the spaces.
FIG. 3C is an enlarged cross-sectional view showing a configuration and an operation of the valve when there is a pressure difference between the spaces in a reverse way as that in FIG. 3A .
FIG. 4 is a cross-sectional view of a headphone unit according to a second embodiment of the present invention.
FIG. 5 shows a configuration and an operation of a valve in the headphone unit in FIG. 4 .
FIG. 6 shows an example of a headphone unit of related art.
FIG. 7 shows another example of a headphone unit of related art.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of a headphone according to the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a cross-sectional view of a headphone unit according to a first embodiment of the present invention.
In FIG. 1 , a headphone unit 1 includes a ring-shaped ear pad 2 surrounding an auricle E and is combined with one side of a baffle board 3 with any appropriate techniques. The torus-shaped baffle board 3 has an opening 3 A in the center. The ear pad 2 and the baffle board 3 are integrally combined at the periphery side of the opening 3 A so that the circumference surfaces of the ear pad 2 and the baffle board 3 are substantially coplanar. The baffle board 3 is integrally combined with a headphone housing 4 having a cylindrical shape with a bottom capable of forming a space covering an area around an auricle of the user. An electro-acoustic transducer SY is provided at the opening 3 A of the baffle board 3 .
The electro-acoustic transducer SY is also referred to as a driver unit and includes: a base frame 5 having an opening 5 A in the center; a petri dish-shaped yoke 6 which is flatter and has a smaller diameter compared to the base frame 5 , fitted to the opening 5 A of the base frame 5 ; a flat magnet 7 fixed to the center of the inner bottom of the yoke 6 ; a plate-like pole piece 8 fixed to a face of the magnet 7 ; and a voice coil cylindrically wound around a dome diaphragm 9 to be integrally combined thereto.
On the base frame 5 , a plurality of penetrating holes 5 B where acoustic-resisting members 11 are attached are provided. With the acoustic-resisting members 11 made of felt or the like, the penetrating holes 5 B serve as a sound absorbing unit.
The base frame 5 also includes a feature of the present invention, namely, valves 12 that eliminate a pressure difference between spaces.
FIG. 2 is an enlarged view of the base frame 5 . In FIG. 2 , each valve 12 includes: a communicating hole 12 A provided at positions different from positions where the penetrating holes 5 B for attaching the acoustic-resisting members 11 are provided at the base frame 5 ; and a flexible piece 12 B that opens and closes the corresponding communicating hole 12 A.
When the user is using the headphone, the ear pad 2 is contacted to a side of the face of the user with a pressure applied to form a space L 1 surrounded by the ear pad 2 , and enclosed with the side of the face, a part of the baffle board 3 , and the electro-acoustic transducer SY. The communicating holes 12 A penetrate in the thickness direction of the base frame 5 . Thus, the space L 1 and a rear space L 2 formed at the headphone housing 4 side (see FIG. 1 ) can be in communication. The flexible pieces 12 B are provided at one opening end of the communicating holes 12 A in the penetrating direction, specifically, at the opening end on the ear pad 2 side in FIG. 2 .
In FIG. 2 , the communicating holes 12 A are constituted of, in the thickness direction of the base frame 5 , two portions: a small-diameter portion, and a large-diameter portion. The two portions are continuously formed.
Thus, the flexible pieces 12 B, described later in detail with reference to FIG. 3 , can swing without causing interference at disposed positions of the flexible pieces 12 B regardless of whether the pressure applied increases or tends to be negative. Therefore, the number of components used for eliminating the pressure change can be reduced.
As shown in FIG. 3 , each flexible piece 12 B is a flexible sheet fixed in a cantilever manner. Specifically, a base end is fixed to a periphery of the opening end at the large-diameter portion of the corresponding communicating hole 12 A, whereas the other end of the flexible pieces 12 B can swing within the large-diameter portion of the opening plane of the corresponding communicating hole 12 A so as to open and close the corresponding communicating hole 12 A. Thus, the other sides of the flexible pieces 12 B can bend in a swinging manner in the direction of the pressure applied to the flexible pieces 12 B.
The flexible pieces 12 B swing in accordance with the pressure difference between the spaces L 1 and L 2 . Therefore, when there is no pressure difference between the spaces L 1 and L 2 , as shown in FIG. 3B , the flexible pieces 12 B close the opening planes of the communicating holes 12 A, which is set as an initial state. When a pressure difference between the spaces L 1 and L 2 is generated, as shown in FIGS. 3A and 3C , the flexible pieces 12 B open the communicating holes 12 A by bending in the direction of the pressure applied.
In the initial state as shown in FIG. 3B , the space L 1 on the ear pad 2 side is in a closed state as in a configuration without the communicating holes 12 A. Thus, the acoustic-resisting member 11 operates effectively and predefined acoustic characteristics can be obtained.
The flexible pieces 12 B are made of a sheet such as a Mylar film and a nonwoven fabric having sufficient flexible rigidity for promptly opening the communicating holes 12 A with a slight pressure difference.
With the configuration of the first embodiment, the pressure in the space L 1 on the ear pad 2 side is increased when the ear pad 2 is pressed against the auricle upon wearing the headphone unit 1 , while the pressure is reduced due to the a tendency of pressure being negative in the space on the ear pad 2 side when the pressing is released or the headphone unit 1 is removed from the auricle. In both cases, the flexible pieces 12 B of the valves 12 swing in the direction of pressure applied from the spaces L 1 or L 2 to open the communicating holes 12 A. This facilitates air flow between the spaces L 1 and L 2 to eliminate the pressure change promptly.
Consequently, collision of the yoke 6 with the voice coil due to the increase of pressure can be prevented. Further, the voice coil can be prevented from being darted out of a magnetic gap. Accordingly, breaking of components can surly be prevented and proper playing of sounds is guaranteed.
In the first embodiment described above, the flexibility of the flexible pieces 12 B may be adjusted so that the level of opening and the timing for opening the communicating holes 12 A can be set as desired. Thus, acoustic characteristics may be adjusted as required.
A second embodiment according to the present invention will be described.
FIG. 4 is a cross-sectional view of the headphone unit according to the second embodiment of the present invention. A feature of the second embodiment lies in the configuration of flexible pieces 120 B provided to valves (denoted by a numeral 120 in FIG. 4 ) and opening and closing communicating holes 120 A.
Similar to the configuration shown in FIG. 3 , each flexible piece 120 B is a member fixed in a cantilever manner, and only a base end is fixed to a base frame 5 so that the other end can swing. In addition, spacers 121 are provided between the base end side and the base frame 5 to provide slight gaps S between opening planes of the communicating holes 120 A and the flexible pieces 120 B. Accordingly, even when the flexible pieces 120 B are in the initial state, the spaces L 1 and L 2 are communicated through the gaps S.
The configuration is different from that of the first embodiment shown in FIG. 3 in that the flexible pieces 120 B are provided alternately to the front and the rear of the base frame 5 with respect to the plurality of communicating holes 120 A. That is, the communicating holes 120 A having the flexible pieces 120 B on the front side do not have the flexible pieces 120 B on the rear side, whereas the communicating holes 120 A having the flexible pieces 120 B on the rear side do not have the flexible pieces 120 B on the front side.
In the second embodiment, when the flexible pieces 120 B are in the initial state, i.e., when there is no pressure difference between the spaces L 1 and L 2 , as shown in FIG. 5A , the flexible pieces 120 B face the communicating holes 120 A with the slight gaps S between the flexible pieces 120 B and the opening planes of the communicating holes 120 A.
The size of the gaps S is set so as to make an acoustic resistance due to an air flow resistance therein to be in parallel with the resistance of the acoustic-resisting member 11 .
In the second embodiment, when there is no pressure difference between the spaces L 1 and L 2 , the flexible pieces 120 B of the valves 120 face the opening planes through the gaps S formed on the opening planes of the communicating holes 120 A therebetween. As with the acoustic-resisting member 11 , an acoustic pressure can be selectively controlled with the gaps S serving as air resisting-members.
Either of the flexible pieces 120 B provided on the front or the rear side of the base frame 5 bends to open the opening planes when pressure in the space L 1 on the ear pad 2 side of the headphone unit 1 increases as shown in FIG. 5B , or reduces due to the tendency of pressure being negative as shown in FIG. 5C .
Accordingly, the pressure difference between the spaces L 1 and L 2 is promptly eliminated. Thus, as in the first embodiment shown in FIG. 3 , the collision of the yoke 6 with the voice coil can be prevented. Further, the voice coil can be prevented from being darted out. Accordingly, the breaking of components can surly be prevented and proper playing of sounds is guaranteed.
In addition, with the configuration in the second embodiment, the acoustic resistance can be set to a proper value by setting the length from the base end to the swinging end of the flexible pieces 120 B properly because the flexible pieces 120 B are provided outside the communicating holes 120 A. | A headphone with a configuration that prevents breaking of components and failure to play sounds properly due to a pressure change within spaces in the headphone, comprising: a baffle board; an ear pad provided at a periphery of the baffle board and surrounding an area around an auricle of a user; an electro-acoustic transducer provided at a central portion of the baffle board and including a diaphragm and a magnetic pole that oscillates the diaphragm, as major components; and a headphone housing forming a rear space on a side opposite to the ear pad of the baffle board and covering the electro-acoustic transducer: and the electro-acoustic transducer is supported by a frame member arranged in an opening of the baffle board and integrally combined with the baffle board, and the frame member includes a valve that eliminates a pressure difference between a space around the auricle and the rear space. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of Ser. No. 09/878,947 filed on Jun. 13, 2001, and now U.S. Pat. No. 6,665,984.
BACKGROUND OF THE INVENTION
The invention is directed to a door or lid which is normally hinged to a washer opening to define a top-loading or a front-loading washer. Conventionally such doors or lids have been made of metal with or without a glass panel through which the interior of the washer can be viewed.
DESCRIPTION OF THE RELATED ART
U.S. Pat. No. 4,695,420 granted on Sep. 22, 1987 and assigned to Caterpillar, Inc. makes reference to the desirability of injection molding plastic articles having a variety of complex shapes and sizes including panels and doors of vehicles or equipment enclosures, such as cab doors. Such cab doors were originally manufactured by utilizing a flat rigid frame fabricated from metal to which is unitized a window in what is termed a costly and time-consuming operation. The window or glazing is floated in a soft gasket channel isolated from the frame to reduce shock-loads and thermal stresses induced by varying coefficients of thermal expansion between the metal frame and the glazing/glass panel. It is believed that the process just described is workable because the window panes in all cases are sheets of transparent plastic material, such as polycarbonate and acrylic with the preferred material being a polycarbonate having a silicone hard coat applied thereto to make the polycarbonate glazing or window pane more scratch-resistant. The silicone hard coat on the peripheral edge is removed by sanding or grinding to assure good bonding between the eventually molded frame and the polycarbonate glazing.
With the advent of excellent molding qualities of modern plastic materials, an effort was made to form a door by first manufacturing a pre-shaped pane of transparent glass and subsequently integrally molding the latter into a door frame as the window thereof. Following this process, the window pane was distorted and wavy and the door frame had a tendency to warp. However, by utilizing a high modulus plastic material, such as polyurethane and a shrink-reducing filler material, undesired high temperature rise from exothermic reaction was moderated, particularly when a catalyst was added in sufficient amounts to control the weight of the reaction and the heat evolution. Also, by heating the glass and forming the frame by reaction injection molding, both the frame and the glass window pane thermally contract similarly absent window pane buckle and with bonding of the edges of the glass window pane to the frame.
Glass and specifically tempered glass have heretofore never been provided with an injection molded polymeric/copolymeric frame to form a door or lid, and particularly a washer lid. However, injection-molding polymeric/copolymeric material as an encapsulation or border to form a shelf is well known, as is evidenced by U.S. Pat. No. 5,273,354 granted on Dec. 28, 1993; U.S. Pat. No. 5,362,145 granted on Nov. 8, 1994; U.S. Pat. No. 5,403,084 granted on Apr. 4, 1995; U.S. Pat. No. 5,429,433 granted on Jul. 4, 1995; U.S. Pat. No. 5,441,338 granted on Aug. 15, 1995; U.S. Pat. No. 5,454,638 granted on Oct. 3, 1995; U.S. Pat. No. 5,540,493 granted on Jul. 30, 1996 and U.S. Pat. No. 5,735,589 granted on Apr. 7, 1998.
Other patents dealing with glass to which material is injection molded normally include windshields to which a gasket is molded and/or cured in situ so as to encapsulate a marginal peripheral edge of the windshield. Typical of such window assemblies and methods of forming the same are found in such patents as U.S. Pat. No. 4,778,366 granted on Oct. 18, 1998; U.S. Pat. No. 4,688,752 granted on Aug. 25, 1987 and U.S. Pat. No. 4,732,553 granted on Mar. 22, 1988.
Other patents which were located during the search of the instant invention include U.S. Pat. No. 4,543,283 granted on Sep. 22, 1987; U.S. Pat. No. 3,843,982 granted on Oct. 29, 1974; U.S. Pat. No. 6,146,574, granted on Nov. 14, 2000 and U.S. Pat. No. 4,336,301 granted on Jun. 22, 1982.
SUMMARY OF THE INVENTION
The present invention is specifically directed to a door or lid for a washer, but contrary to the door of U.S. Pat. No. 4,695,420, the transparent panel is constructed from tempered glass and an open frame-like encapsulation is preferably a polymeric/copolymeric synthetic plastic material in the form of acrylonitrile/styrene/acrylate polymer blended with mica glass beads at a ratio of substantially 70%–30% to 90%–10% by weight, but preferably 80%–20% by weight. The latter specifics of the blended material which is injection molded to form the open frame-like encapsulation achieves a much lower shrink ratio and elasticity, as compared to polypropylene which is normally used in the injection molding of a tempered glass substrate to form a shelf (not a door). Since tempered glass or a similar glass substrate has virtually a zero coefficient of expansion, the same obviously will not expand or contract in relationship to the expansion or contraction of conventional polymeric/copolymeric material, such as polypropylene. Consequently, typical “weld lines” created in the injection molded open frame-like encapsulation or border tend to fracture, particularly as such parts experience temperatures varying between −30° F. to +104° F. However, through the utilization of the specific blended materials latter defined at the ratios stated, such fracture has been essentially eliminated and the washer door or lid of the present invention achieves unexpected longevity, absent deterioration, and aesthetic characteristics at competitive prices, particularly at higher price-ranged washers.
The aesthetics of the washer lid are also enhanced by designing the exterior of the frame-like encapsulation which is exposed to the consumer as a relatively smooth, unbroken surface except as might otherwise be desired by a washer manufacturer who might specify a recess in the outer surface for reception of a decal, label or the like carrying trademark or other information. The interior of the washer lid which is less susceptible to scrutiny because of it being opened essentially only when the washer is being loaded or unloaded is engineered to include structural characteristics necessary for optimum functionality of the washer lid including, for example, an internally stepped relatively thick inner periphery of the frame-like encapsulation which securely grips and reinforces the peripheral edge of the tempered glass panel, an outboard depending peripheral skirt achieving exterior peripheral rigidity of the frame-like encapsulation, an indiscrete handle portion along an underside of a front wall of the encapsulation which is essentially unobservable when the washer lid is closed, a reinforced corner for a switch actuator, and opposite rear corners rigidly supporting hinges which are utilized to hinge the washer lid to an associated washer opening for movement between open and closed positions thereof.
With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claims and the several views illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary top perspective view, and illustrates a washer with a washer lid or door of the present invention hinged thereto in its closed position.
FIG. 2 is a fragmentary perspective view of the washer of FIG. 1 , and illustrates the washer lid in its open position.
FIG. 3 is a bottom plan view of the washer lid or door, and illustrates a tempered glass panel bonded by an open frame-like encapsulation formed of one-piece injection molded polymeric/copolymeric plastic material.
FIG. 4 is a fragmentary cross sectional view through a corner portion of two identical rear corners of the washer lid, and illustrates a generally L-shaped hinge defined by a mounting portion and a pintle portion with the former being fastened to a depending peripheral skirt of the frame-like encapsulation and the pintle portion passing through a slot of the depending peripheral skirt.
FIG. 5 is an exterior fragmentary side elevational view of the hinge of FIG. 4 , and illustrates the details thereof.
FIG. 6 is an interior fragmentary side elevational view of the hinge of FIG. 4 .
FIG. 7 is a fragmentary bottom plan view of a forward corner of the frame-like encapsulation, and illustrates a switch actuator seated upon reinforcing ribs projecting from a top panel of the frame-like encapsulation and being secured to the peripheral skirt by fasteners.
FIG. 8 is an outside fragmentary side elevational view of the forward corner illustrated in FIG. 7 , and illustrates details of the switch actuator.
FIG. 9 is a fragmentary cross sectional view of the peripheral skirt of the corner of FIG. 7 , and illustrates further details of the switch actuator.
DETAILED DESCRIPTION OF THE INVENTION
A washer 10 is illustrated in FIGS. 1 and 2 of the drawings and includes a conventional washer body 11 having an interior tub or chamber 12 including an upper frame 13 to which is hinged a novel washer lid or door 20 of the present invention. The upper frame 13 defines an upstanding inner peripheral wall 14 ( FIGS. 2 and 4 ) at opposite rear corners (unnumbered) which the upper frame 13 is provided with openings 15 ( FIG. 4 ) for hinging the washer lid 20 thereto in a manner to be described more fully hereinafter.
A conventional agitator (not shown) is mounted in the tub or chamber 12 and reciprocates arcuately in a conventional fashion. A conventional safety switch or “ON”/“OFF” switch 18 ( FIG. 2 ) is carried by and beneath an apertured horizontal frame portion 16 of the upper frame 13 of the washer 10 , and is switched “on” and “off” by the washer lid 20 in a manner to be described more filly hereinafter.
The washer lid or door 20 includes a tempered glass panel 21 of a predetermined peripheral configuration defined by a substantially continuous peripheral edge 22 . The glass panel 21 further includes opposite inner and outer surfaces 23 , 24 , respectively, bridged by the peripheral edge 22 . A peripheral portion 25 of the glass panel 21 is defined by the peripheral edge 22 and immediately adjacent surface portions of the opposite inner and outer surfaces 23 , 24 , respectively.
An open frame-like encapsulation or border 30 is formed as a one-piece of injection molded polymeric/copolymeric synthetic plastic material. The polymeric/copolymeric synthetic plastic material is preferably acrylonitrile-styrene-acrylate polymer blended with mica glass beads at a ratio of substantially 70%–90% of the polymer and substantially 30%–10% of the mica glass beads, respectively, by weight. The preferable range by weight of the blend is substantially 80% of the polymer to substantially 20% of the mica glass beads. The latter ranges of the polymer and the mica glass beads achieve an extremely low shrink ratio and elasticity, as compared to polypropylene. As the injection molded blended polymer of the open frame-like encapsulation 30 cools, its virtually minimal shrink ratio parallels the almost zero coefficient of expansion of the tempered glass panel 21 . Consequently, weld lines of the injection molded frame-like encapsulation 30 will not fracture, particularly when subject to temperature anywhere between −30° F. to 140° F.
The open frame-like encapsulation 30 includes an outer peripheral portion 31 and an inner peripheral portion 32 with the inner peripheral portion 32 entirely encapsulating the glass panel outer peripheral portion 25 including the peripheral edge 22 and immediately adjacent surface portions of the opposite inner and outer surfaces 23 , 24 , respectively. The frame-like encapsulation 30 further includes an inner or lower surface 34 and an outer or upper surface 35 defining therebetween the overall inner and outer surface configurations of the frame-like encapsulation 30 and the wall thickness thereof. The frame-like encapsulation inner surface 35 is stepped ( FIG. 2 ) at the frame-like inner peripheral portion 32 and defines thereat a relatively thicker wall thickness than the wall thickness at the outer peripheral portion 31 . However, the outer surface 34 has a configuration which is substantially continuous and unstepped which presents an aesthetic appearance to the washer lid 20 when in the closed position ( FIG. 1 ), and all remaining injection-molded characteristics are formed along the inner surface 35 and are hidden from view ( FIG. 1 ) except, of course, when the washer lid 20 is opened ( FIG. 2 ).
The outer peripheral portion 31 of the washer lid 20 is defined as continuously downward depending peripheral wall or skirt which is smooth and unbroken except along a front edge (unnumbered) of the frame-like encapsulation 30 . At the front edge ( FIGS. 1–3 ) of the frame-like encapsulation 30 a curved wall portion 38 ( FIGS. 2 and 3 ) of the depending skirt 31 is recessed inwardly and opens concavely outwardly to define a handgrip recess 40 in association with an overlying ledge or lip 39 of the frame-like encapsulation 30 . In order to open the washer lid 20 , a person merely inserts one or more fingers within the handgrip area 40 ( FIG. 1 ) and lifts upwardly against the ledge 39 to pivot the washer lid 20 from the position shown in FIG. 1 to the position shown in FIG. 2 .
The frame-like encapsulation 30 also includes substantially identical corner portions 50 , 50 ( FIGS. 1 and 4 ) defined by the peripheral skirt 31 with a radius (unnumbered) of each corner portion 50 including an elongated curved slot or opening 52 ( FIGS. 4 and 5 ). Two bosses 53 , 54 project inwardly of the peripheral skirt 31 and each includes a respective bore 55 , 56 . Hinge means in the form of a hinge pin 60 is associated with each corner portion 50 and is of a generally L-shaped configuration defined by a pintle portion 61 connected by a radius portion 62 to a mounting portion 63 which includes respective flattened recessed portions 64 , 65 seated upon and receiving therein the bosses 53 , 54 , respectively. Threaded fasteners 64 ′, 65 ′ are fed through bores (unnumbered) of the bosses 53 , 54 and are threaded into threaded openings (unnumbered) of the flattened portions 64 , 65 , respectively, of the mounting portion 63 of each hinge 60 thereby rigidly attaching each of the hinges 60 to the peripheral skirt 31 adjacent an associated one of the rear corner portions 50 . The pintle portions 61 of the hinge pins 60 lie in coaxial relationship to each other and project in opposite directions. Each pintle portion 61 is fitted in one of the openings 15 ( FIG. 4 ) of the inner peripheral wall 14 of the upper frame 13 of the washer body 11 to thereby permit pivoting movement of the washer lid 20 between the positions shown in FIGS. 1 and 2 of the drawings.
At the corner portion 50 adjacent the hand recess 40 ( FIGS. 3 , 7 , 8 and 9 ), a one-piece molded switch-actuator mechanism 69 defined by a mounting block 70 having a switch actuator leg 71 rests upon four substantially parallel relatively spaced reinforcing ribs 72 which project downwardly from the inner surface 34 of the frame-like encapsulation 30 . The peripheral skirt 31 in the area of the ribs 72 includes two bores 74 through which pass fasteners 75 which are threaded into the mounting block 70 to rigidly secure the same in the manner illustrated in FIGS. 7 through 9 of the drawings. The leg 71 of the switch-actuating mechanism 69 is aligned with the safety “ON”/“OFF” switch 18 to close the latter when the washer lid 20 is closed ( FIG. 1 ) and open the latter when the washer lid 20 is open ( FIG. 2 ) to respectively start and stop the washer agitator (not shown) in a conventional manner.
A substantially inwardly directed flange 85 is located at each of the front corners 50 , 50 of the washer lid 20 in spaced relationship to the inner surface 34 ( FIGS. 3 , 7 and 9 ). The flange 85 illustrated at the upper left hand corner 50 of FIG. 3 includes an opening 86 carrying a rubber or similar flexible stop (not shown) which contacts and rests upon the horizontal frame portion 16 of the upper frame 13 of the washer body 11 when the washer lid 20 is in the closed position thereof ( FIG. 1 ). The leg 71 of the switch-actuating mechanism 69 passes through and is radially supported by the opening 86 of the flange 85 ( FIGS. 7 and 9 ).
As is most readily apparent from FIG. 1 of the drawings, the washer lid 20 presents an extremely aesthetic appearance to the overall washer 10 due to the relatively smooth and unbroken upper/outer surface 35 of the encapsulation 30 . Even in the open position ( FIG. 2 ) of the washer lid 20 , the interior of the washer lid 20 is relatively aesthetic in appearance since the hinges 60 , 60 are unobtrusive, as is the design and location of the switch block 69 which is partially hidden by the flange 85 ( FIG. 7 ). However, most important is the fact that, even though the panel 21 is constructed from glass, the specific blend of the polymer and the mica glass beads from which the frame-like encapsulation 30 is injection molded achieves an intimate bond between the components, absent fracture or weakening of the encapsulation 30 due to the similarities between the low shrink ratios and elasticities of these materials. Since the tempered glass panel 21 has almost a zero coefficient of expansion, there will obviously not be any material of the expansion or contraction of the same relative to the injected polymeric/copolymeric material of the encapsulation 30 at temperatures ranging between −30° F. to −140° F., temperatures which heretofore would cause injection molded polypropylene to fracture. Hence, a strong, durable and aesthetic acceptable washer lid 20 is achieved by the present invention, though usage is as other than a washer lid is well within the breadth of the present disclosure.
Although a preferred embodiment of the invention has been specifically illustrated and described herein, it is to be understood that minor variations may be made in the apparatus without departing from the spirit and scope of the invention, as defined by the appended claims. | A washer door or lid as defined by a tempered glass panel bordered by an open frame-like encapsulation of one-piece injection molded polymeric/copolymeric synthetic plastic material. The latter material is preferably acrylonitrile/styrene/acrylate polymer blended with mica glass beads at a ratio of substantially 70%–30% to 90%–10% by weight, but preferably 80%–20% by weight. Further specifics of the washer lid include a relatively thick inner periphery of the encapsulation which securely grips and reinforces an outer peripheral edge of the tempered glass panel, a rigid outer peripheral skirt, an indiscrete handle, a reinforced hand corder for a switch actuator and opposite rear corners carrying hinges for securing the washer lid to an associated washer opening. | 3 |
FIELD OF THE INVENTION
[0001] The present disclosure is directed to a frequency estimator. More specifically, the present disclosure is directed to a frequency estimator having a recursive architecture for unmodulated signals.
BACKGROUND
[0002] Frequency estimation techniques are used to synchronize the clock in communication systems. The clock received with the communication has a frequency offset from the internal clock of the receiver. Determining the offset and adjusting the internal clock by the frequency offset is necessary to achieve good performance in a communication system.
[0003] Frequency estimation at low signal to noise ratio (SNR) is needed for modern coding schemes. However, frequency estimation often has a threshold effect at low SNR. As the SNR decreases, a significant degradation of performance of the system occurs.
[0004] High performance frequency estimation is often complex, due to the number of calculations necessary, and non-recursive.
[0005] Classical optimum frequency estimators employ system data to compute a periodogram by Fourier transforming the signal using, for example, discrete fourier transform (DFT). Getting an accurate estimate using this method requires computation of a large number of frequency points. Such an estimator is suitable for one-shot block processing.
[0006] Known estimators apply either single-shot DGFT processing or simplified recursive processing.
[0007] One example of a simplified recursive processor has been discussed, for example, by Umberto Mengali, wherein an estimator chooses the value with the greatest frequency, and recomputes the estimator each time.
[0008] In order to accommodate the performance and costs associated with synchronization applications, a low complexity recursive formulation is needed.
SUMMARY
[0009] A recursive architecture computes the ML estimate of frequency offset. The ML estimator uses all data to estimate the frequency offset. Frequency points can be computed serially, in parallel, or in some combination based on the selected update rate based on an alternate quantity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 illustrates an embodiment of a frequency estimator adapted to receive and compute a recursive value for the estimator from an unmodulated input signal.
DETAILED DESCRIPTION
[0011] In accordance with the principles herein, a recursive DFT based estimator is achieved that provides both good performance and low complexity.
[0012] Thus, as illustrated in FIG. 1 , for each frequency f at time N an alternate quantity {tilde over (Λ)}(ƒ,N) 2 to the absolute value of the periodogram can be derived responsive to an input signal 110 with a system, shown generally at 100 that achieves a peak value at the same frequency as the classical optimum estimator.
[0013] The input signal 110 for a frequency estimation algorithm is given as
[0000] T z ( n )= T I ( n )+ jT Q ( n )=√{square root over ( P S )}exp( j 2πƒ 0 n+jφ )+ N ( n ).
[0000] In accordance with the principles herein, it is assumed that N(n) is an additive white Gaussian noise. For a system 100 wherein N(n) is additive white Gaussian noise, the maximum likelihood frequency estimator is given as
[0000]
f
^
ML
=
arg
max
f
∈
[
-
0.5
,
0.5
]
∑
n
=
1
N
T
z
(
n
)
exp
[
-
j
2
π
fn
]
=
arg
max
f
∈
[
-
0.5
,
0.5
]
Λ
(
f
,
N
)
.
[0000] Two metrics need to be recursively computed from an input signal to implement the ML estimator, such as, for example,
[0000]
Λ
(
f
,
N
)
and
Γ
(
f
,
N
)
=
∑
n
=
1
N
T
z
(
n
)
exp
[
-
j
2
π
fn
]
.
[0000] Since the recursion for Γ(ƒ,N) is straightforward, as
[0000]
Γ
(
f
,
N
)
=
∑
n
=
1
N
T
z
(
n
)
exp
[
-
j
2
π
fn
]
=
Γ
(
f
,
N
-
1
)
+
T
z
(
N
)
exp
[
-
j
2
π
fN
]
.
[0000] represents phase noise of the signal, and is stored in a memory device 120 provided in or operatively connected to the system 100 .
[0014] Without loss of optimality, the ML metric can be Λ(ƒ,N) 2 , and a similar recursion for
[0000] Λ(ƒ,N) 2 is enabled since
[0000]
Λ
(
f
,
N
)
2
=
∑
n
=
1
N
T
z
(
n
)
exp
[
-
j
2
π
fn
]
2
=
Γ
(
f
,
N
-
1
)
+
T
z
(
N
)
exp
[
-
j
2
π
fN
]
2
=
Γ
(
f
,
N
-
1
)
2
+
T
z
(
N
)
2
+
2
Re
[
Γ
(
f
,
N
-
1
)
(
T
z
(
N
)
)
*
exp
[
j
2
π
fN
]
]
=
Λ
(
f
,
N
-
1
)
2
+
T
z
(
N
)
2
+
2
Re
[
Γ
(
f
,
N
-
1
)
(
T
z
(
N
)
)
*
exp
[
j
2
π
fN
]
]
.
[0000] As |T z (N)| 2 and constants are not frequency dependant quantities, these terms can be ignored in the computation of the ML estimator, i.e.,
[0000] {tilde over (Λ)}(ƒ, N ) 2 ={tilde over (Λ)}(ƒ, N− 1) 2 +Re└Γ (ƒ, N− 1)( T z ( N ))*exp[ j 2πƒ N]┘.
[0000] As a result, the ML estimator uses all data to estimate the frequency offset. Further, if phase noise is present in the system, it is important to place too much weight on the earlier data in the offset calculation. Over reliance on the phase noise is easily avoided in the system, employing a recursive algorithm, constructed in accordance with the principles herein. To this end, an exponentially weighting factor is applied in the update of Γ(ƒ, N), i.e.,
[0000] Γ(ƒ, N )=γΓ(ƒ, N− 1)+ T z ( N )exp[− j 2πƒ N].
[0015] The structure of the estimator is useful for digital implementation as the accuracy of the frequency estimation is determined by the number of discrete frequency points that are considered and the updates for each of these different frequency points can either computed serially or in parallel (or some combination) depending on the update rate that needs to be maintained.
[0016] The memory device 120 can include, for example, any suitable data storage mechanism or device, such as, for example, a server, ROM, RAM, or other suitable digital device adapted and constructed to perform operations in accordance with the principles herein or incorporated into other digital devices. An alternate quantity {tilde over (Λ)}(ƒ,N) 2 , is then computed and stored either in the memory device 120 via a control 130 or in a separate, suitable memory device, such as device 140 shown in FIG. 1 , depending on the requirements of the system 100 . The alternate quantity can be computed recursively using the relationship between the alternate quantity and Γ(ƒ,N) in the calculation of the frequency estimator. For each signal received, a system constructed in accordance with the principles herein advantageously simplifies the update to the estimator based on the recursive nature of the estimator, and the inherent parallelism of modern digital signal processing can be advantageously applied as well. As a result, each frequency can be processed in parallel, serially, or both serially and in parallel, in accordance with the principles herein. Further, each calculation of the estimator can be updated using {tilde over (Λ)}(ƒ,N) 2 and, Γ(ƒ,N), which removes phase noise, for each signal sample. As a result, the frequency estimate is the value of f that produces a maximum value for {tilde over (Λ)}(ƒ, N) 2 .
[0017] The system 100 eliminates the need and cost for a complex system to compute and update the frequency offset between a locally generated clock of the system 100 and a received clock. After the offset frequency is determined, the signal can be locked and the data demodulated.
[0018] If there is an offset frequency, then the system 100 makes a best estimate of the difference between the locally generated clock and the received clock.
[0019] In accordance with the principles herein, a simple way to make the frequency offset estimate recursive is achieved. In accordance with these principles, the estimator is updated with a limited number of computations N+1, whereas the known systems use all of the data over. Thus, the system 100 herein only calculates Γ to have a simple way to find a maximum for λ, as for each new signal sample Λ{tilde over ( )}(f,N) 2 can be derived from Γ(f,N), which removes phase noise, and the frequency offset can be updated based on the offset so generated. In other words, the system 100 provides a frequency estimate based on the value of the frequency f that produces the maximum value of Λ{tilde over ( )}(f,N) 2 . The estimator of the system 100 constructed in accordance with the principles herein uses all data to calculate the frequency offset. By applying an exponentially weighting factor to the update, avoids undue reliance on a phase noise aspect in the frequency offset estimate is avoided, given the assumption that N(n) is an additive white Gaussian noise.
[0020] A system and method constructed in accordance with the principles herein is suitable for use in systems wherein unmodulated signal are received, such as, for example, antennas, automotive electronics, avionics, communications systems, electronics, energy systems, lasers, materials, MEMS, military, photonics, satellite communications, semiconductors, sensors, space, superconductors, medical equipment, musical instruments, and associated devices, and other systems adapted to receive unmodulated input signals.
[0021] Further, the simple recursive architecture of a system constructed in accordance with the principles herein is optimized for implementation in digital integrated circuits, and in systems implementing or in operative communication with digital integrated circuits.
[0022] Thus, in accordance with the principles herein, near optimum estimation performance is achieved in a simple recursive architecture that is optimized for implementation in digital integrated circuits, and in systems implementing or in operative communication with digital integrated circuits.
[0023] The embodiment(s) set forth herein include principles achieved via a system and method adapted and constructed to operatively facilitate demodulation of communication data packets between transmitting and receiving devices. As such, each exemplary system or method herein contemplates the operative connection of signals to a communication, wireless, or other network over which data is capable of being transmitted between devices.
[0024] The embodiments herein have been described and shown for purposes of illustration only, and are not to be construed as constituting any limitations of the present principles. Modifications will be obvious to those skilled in the art, and all modifications that do not depart from the spirit of the principles herein are intended to be included within the scope of the appended claims. 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 principles.
[0025] Therefore, the foregoing is considered as illustrative only of the principles herein. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the principles 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 principles described herein. | A system for receiving signals is set forth. The system includes an open loop frequency offset updating system adapted to receive an input signal. The open loop frequency offset updating system updates a frequency offset recursively, using a real time update value for value Γ(ƒ,N). The system samples the signal and calculates an alternate quantity based on Γ(ƒ,N) to determine a maximum value of the alternate quantity. | 7 |
This is a continuation in part of Ser. No. 06/662,831 filed 10/19/84, now U.S. Pat. No. 4,538,795.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates to devices for insufflating gas into a mass of molten metal.
2. Description of the Prior Art
Prior structurs of this type have generally employed permeable plugs through which the gas is introduced into the molten metal. Such typical devices may be seen in U.S. Pat. Nos. 2,811,346, 3,330,645, 3,610,602, 3,834,685 and 4,053,147. In all of these prior art devices, the gas must flow upwardly through a gas permeable body which in U.S. Pat. No. 3,811,346 is a porous refractory material. The same porous material is disclosed in Patent 3,330,645 and this patent additionally proposes to form tubular passageways through the porous material. The body of the device in U.S. Pat. No. 3,610,602 is formed of permeable refractory as is the body of the device shown in U.S. Pat. No. 3,834,685 and the same is true of the body of the device shown in U.S. Pat. No. 4,053,147.
French Pat. No. 2,451,945 has a porous stopper plug as has U.S. Pat. No. 3,208,117.
The present invention comprises an improvement with respect to my U.S. Pat. Nos. 4,396,179 and 4,483,520 wherein a non-permeable refractory plug is disclosed having a spaced stainless steel jacket thereabout forming an annular passageway through which the gas is introduced into the molten metal. A displaceable cap is provided in these devices for initially protecting the upper end of the device and the annular gas passageway from being plugged by molten metal introduced into the ladle in which the device is positioned.
In actual practice, it has been determined that the cap is frequently displaced by the molten metal and the molten metal tends to plug the annular gas passageway unless a substantially higher gas pressure is employed to move the molten metal away from the annular gas emitting opening.
Furthermore, the molten metal first introduced into a ladle equipped with the device tends to freeze almost instantaneously and frequently before the gas is introduced or during the initial introduction of the gas and thus closes the annular gas passageway and renders the device ineffective.
The present invention adds a hot metal dam above the annular gas emitting passageway of the device and protects the passageway and the upper portion of the device from the molten metal whether the gas is flowing or not and when the gas flows, it improves the stirring action sustantially by forming a large and distinct and jet-like stream of the gas bubbles which result in increased turbulence and stirring action in the molten metal.
SUMMARY OF THE INVENTION
A device for introducing gas into molten metal upon the filling of a ladle or the like with such molten metal uses a pocket block of refractory which is incorporated in the bricked or rammed lining of the ladle, the block having a vertically extending passageway therethrough and a plug positioned therein comprising a non-permeable refractory plug with a spaced stainless steel and/or ceramic shell thereabout to define a gas passageway through the block. A combined shield and hot metal dam in the form of an upwardly extending circular extension of the stainless steel and/or ceramic shell is positioned above the opening defined thereby and protects the non-permeable refractory plug whereby gas for agitating, stirring rolling and/or affecting the desired chemistry of the molten metal can be introduced into the molten metal in suitable streams substantially increasing the agitating, stirring, and rolling action obtained.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side elevation of a ladle showing the device for introducing gas into molten metal installed therein;
FIG. 2 is an enlarged cross sectional detail of the device or introducing gas into molten metal and illustrating the hot metal dam with arrows indicating the stream of gas occasioned by its presence; and
FIG. 3 is an enlarged cross sectional detail with parts broken away and parts in cross section of the device of the invention in an eroded pocket block.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the form of the invention chosen for illustration herein, the device for introducing gas into molten metal in an improved manner may be seen in FIGS. 1, 2 and 3 of the drawings in a ladle 10 having a refractory brick lining 11 incorporating a rammed refractory base 12. An opening 13 in the bottom of the ladle 10 is provided with a tube 14 through which gas is introduced. A pocket block 15 is provided with a conical passageway centrally thereof which is arranged in registry with the inner upper end of the tube 14. A frustoconical shell 16, preferably made of stainless steel or a fired ceramic or a ceramic coated metal as best seen in FIG. 2 of the drawings, has an open upper end 17 extending substantially above the pocket block 15 so as to form a protective hot metal dam 18 with respect to the open end 17 of the frusto-conical shell 16.
By referring to FIG. 2 of the drawings, it will be seen that the bottom of the frusto-conical shell 16 comprises a circular disc 20 having an annular depending flange 21 centrally thereof about an opening therethrough, the flange 21 being adapted for registry over the tube 14 through which the gas is introduced into the ladle as illustrated by the arrows.
The majority of the interior of the frusto-conical shell 16 is filled by a non-permeable ceramic plug 22 which is substantially the same height as the shell 16 and the configuration 23 on the exterior of the plug 22 or alternately on the interior of the shell 16 provide for the spacing of the shell 16 with respect to the plug 22 so that a gas passageway annular in cross section is formed through the pocket block 15 and thus provides that the gas introduced into the tube 14 will flow around the exterior of the plug 22 and outwardly through the opening 17 and be effectively directed by the hot metal dam 18 as shown by the arrows in FIG. 2 of the drawings. The vertical dimension of a typical pocket block (15) is at least 12 inches and the shell 16 and plug 22 are of substantially greater height than said pocket block.
By referring to FIG. 2 of the drawings in particular, it will be observed that the arrows indicating the gas flow paths as occasioned by the hot metal dam forming the upper end of the frusto-conical shell 16 has the highly desired effect of substantialy increasing the agitating, stirring and rolling action of the molten metal through which the gas streams move.
In FIG. 1 of the drawings, the device is shown in operable arrangement in the ladle 10 and it will be observed that it is of a size and so located in the ladle that the stream of gas emerging from the device by reason of the hot metal dam 18 will occupy a substantially higher overall area in the ladle 10 than has heretofore been possible with the prior art devices.
In operation, the device is installed in the conical passageway in the pocket block 15 immediately prior to the installation of the pocket block 15 in the lining of the ladle 10. Such installation is facilitated by the presence of the hot metal dam 18 as the same forms a convenient handle in holding and adjusting the device in the conical passageway of the pocket block 15 and insuring the positioning of the device and more particularly the frusto-conical shell 16 thereof in engaging relation in the conical passageway as the pocket block 15 is positioned in the lining of the ladle for registry with the opening in the refractory base 12 through which the tube 14 extends.
In FIG. 3 of the drawings, the upper end of the shell 16 and the plug 22 are illustrated as extending upwardly above the eroded sides of the pocket 15 so that the shell 16 continues to protect the plug 22 and the adjacent portions of the pocket block 15 from rapid erosion.
The arrangement is such that the hot metal dam 18 is protected by the cooling effect of the gas being introduced through the device and directed thereagainst by the formation of the end 17 with the result that metal initially poured into the ladle 10 and striking the hot metal dam 18 does not adversely affect the shell 16 which remains in position through the initial pouring stages and thereafter when the molten metal has covered the same, all due to the effective cooling, stirring, agitating and rolling action of the molten metal as occasioned by the jet stream of the gas being introducted thereinto.
It will occur to those skilled in the art that the device disclosed herein protects the frusto-conical shell thereof as well as preventing the plugging of the annular gas passageway defined between the shell 16 and the plug 22 as would otherwise occur upon the introduction of molten metal into the ladle. The solid ceramic plug 22 cannot be filled with metal as occurs in the prior art devices wherein the plugs are formed of porous refractory material and the device thereby insures the desirable immediate introduction of gas into the molten metal which has heretofore been seriously delayed by the blocking of the prior art devices with the molten metal and the unprotected defusing plugs and the like.
The vertical dimension of the pocket block 15 adjacent the conical passageway is substantially smaller than the height of the solid ceramic plug 22, and the height of the shell 16 with the hot metal dam 18 is greater than the height of the pocket block 15 so as to form the hot metal dam around the annular gas passageway.
Although but one embodiment of the present invention has been illustrated and described, it will 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 and having thus described my invention. | A solid non-permeable refractory plug has a spaced stainless steel and/or ceramic jacket and is located in a pocket block for incorporation in the normal refractory brick lining of a ladle to provide a passageway through which gas can be introduced into the molten metal. The stainless steel and/or ceramic jacket extends above the refractor plug and the pocket block to form a hot metal dam that protects the passageway from metal and/or slag penetration during the filling of the ladle with molten metal. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to data communication apparatus and, more particularly, to apparatus for digitally generating bandpass signals.
Data transmission over voice frequency channels is generally accomplished by modulating a baseband data signal onto a carrier signal, developing thereby a bandpass signal, and then transmitting the modulated signal to a distant receiver wherein the signal is demodulated. The transmitter's modulation process generally includes low pass filtering to insure that the baseband signal is of a finite known bandwidth, modulating onto a carrier by means of any of a variety of modulation schemes, and bandpass filtering to insure that the transmitted signal occupies a finite known frequency band.
With the present trend of semiconductor technology toward large scale integration, a number of attempts have been made to implement the transmitter functions by digital techniques in a fashion that lends itself to integration. In an article entitled "In-Band Generation of Synchronous Linear Data Signals," IEEE Trans. on Comm., Vol. COM 21 No. 10, Oct. 1973, page 1116, Kalet and Weinstein describe a bandpass signal generator employing a finite number of fixed filters which, in combination, develop bandpass signals. In an article entitled, "Microcoded Modem Transmitters," IBM J. Res. Develop., July 1974, pp. 338-351, Choquet et al described a transmitter design employing a digital finite impulse response filter and programmable, cyclically modified, filter coefficients to obtain the desired bandpass signal. Both the Kalet and the Choquet apparatus are useful only when the ratio of the desired carrier frequency to the filters' processing rate is a rational number.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a bandpass signal generator which is not limited to rational number ratios of carrier frequencies to a filter's processing rate.
This and other objects are achieved by multiplying a sampled applied input signal by a particularly defined precessing phasor signal and by convolving the product with a fixed low pass filter. More particularly, incoming symbol signals, which may comprise real and imaginary components, are sampled at a preselected rate. The sampled signals are multiplied by a time precessing phasor of unit magnitude, and the complex product signals are applied to a complex low pass filter. The low pass filter convolves the applied complex product signals with a particularly defined fixed impulse response and develops the real part of the convolved signals as the desired bandpass signal.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 depicts a schematic block diagram of a prior art bandpass signal generator;
FIG. 2 illustrates a general block diagram of the signal generator in accordance with the principles of this invention;
FIG. 3 is a block diagram of the generator illustrated in FIG. 2 suitable for signals available in cartesian coordinates;
FIG. 4 depicts the generator illustrated in FIG. 2 suitable for generating Phase Shift Keying modulated signals; and
FIG. 5 is a block diagram of a particular embodiment of element 50 of FIG. 2 which is suitable for implementations which generate Differential Phase Shift Keying modulated signals.
DETAILED DESCRIPTION
In general, a bandpass signal generated by a data communication transmitter can be represented by ##EQU1## where a n and b n are the symbols to be transmitted, h(t) and g(t) are Nyguist pulses, T is a symbol period and ω c is the carrier's radian frequency. A Nyguist pulse g(t) is an analog signal having the property g(t-nT) = 0 for t = mT when m ≠ n, and g(0) = 1.
A more compact representation of equation (1) is obtained by using complex signals. Thus, equation (1) can be represented by ##EQU2## where
C.sub.n = a.sub.n + j b.sub.n (3)
and
R(t-nT) = g(t-nT) + j h(t-nT). (4)
in accordance with prior art teachings, the z(t) expression of equation (2) can be rewritten as ##EQU3## where δ(t-nT) is the standard delta function (δ(t)= 0 for all t≠0 and ∫δ(t)dt about 0 is 1), and where the symbol "*" designates convolution. A perusal of equation (5) indicates that signal z(t) can be computed by sampling the C n signals, by convolving the sampled signals in a filter whose impulse response is e j .sup.ω.sbsp.cnT R(t) e j .sup.ω.sbsp.ct, and by summing the filter's output signals for all values of n. This is basically the approach taken by Kalet and Choquet as described in the aforementioned articles. From equation (2) it may be seen that the desired bandpass signal is obtained by evaluating the real part of z(t). Accordingly, substituting equations (3) and (4) into equation (5) and taking the real part thereof yields ##EQU4##
Equation (6) indicates that the bandpass signal s(t) may be implemented by combining the output signals of four circuits. In each one of the circuits, a predetermined symbol signal (a n or b n ) is sampled and is applied to a filter having a predetermined impulse response (e.g., g(t)cos ω c (nT+t)). It should be noted that all of the filters specified by equation (6) have an impulse response which is different for different values of n. Therefore, as n changes with time, so must the impulse response of the filters. It can be said, therefore, that implementation of the signal s(t) in accordance with the teachings of equation (6) requires the use of time varying filters.
If ω c /2π and T are not related by a rational number, the impulse responses required by equation (6) change in a noncyclical manner. Under such circumstances, the impulse response of the filters must be computed anew for each n=0,1,2, . . . ∞. Such computations require a substantial amount of hardware. If, on the other hand, ω c /2π and T are related by a rational number, then the necessary impulse responses repeat cyclically, permitting the use of impulse responses which are modified by the contents of a read-only-memory.
The cyclical repetition of the required impulse responses is the reason behind the "rational number" requirement of the Kalet and Choquet apparatus mentioned above.
In order to more fully appreciate the improvements comprising this invention, FIG. 1 is presented to illustrate an implementation of a prior art bandpass signal generator characterized by equation (6) and having ω c /2π related to T by a rational number. The symbol signals a n and b n are applied, in FIG. 1, to samplers 10 and 11, respectively, which may simply comprise controllable analog gates. The output signal of sampler 10 is applied to filters 20 and 21, and the output signal of sampler 11 is applied to filters 22 and 23. Associated with filters 20 and 21 are read-only-memory (ROM) units 30 and 31, respectively. Filter 20 in combination with ROM unit 30 is arranged to possess an impulse response g(t)cos ω c (nT+t), which is variable with respect to n under control of ROM unit 30. Filter 21 in combination with ROM unit 31 is arranged to possess an impulse response h(t)cos ω c (nT+t), which, as in the filter 20-ROM 30 interconnection, is variable with respect to n and is under control of ROM unit 31. Associated with filters 22 and 23 are ROM units 32 and 33, respectively. As in the filter 20-ROM 30 interconnection, each of filters 22 and 23 with its associated ROM unit possesses an impulse response which is variable with n and which is controlled as to this variability by the associated ROM unit. In accordance with equation (6), filter 22 is arranged to possess an impulse response characterized by h(t)sin ω c (nT+t), and filter 23 is arranged to possess an impulse response characterized by g(t)sin ω c (nT+t).
Element 40 of FIG. 1 develops the bandpass signal s(t) by arithmetically combining the output signals of filters 20, 21, 22 and 23. More specifically, signal s(t) is developed by summing the output signals of filters 20 and 22 with the negative of the output signals of filters 21 and 22. Element 40 may be an adder/subtractor circuit implemented in accordance with the teachings of I. Flores, The Logic of Computer Arithmetic, Prentice-Hall Inc., 1963, Chapter 4.
As illustrated, the bandpass signal generator implementation of FIG. 1 requires extensive use of read-only-memories. Additionally, the FIG. 1 circuit requires the carrier frequency ω c /2π to be related to the symbol period T by a rational number.
These disadvantages have been eliminated in view of the discovery that the z(t) expression of equation (2) may be rewritten as ##EQU5## A perusal of equation (7) reveals that terms which vary with respect to n appear only on the left side of the convolution equation--which defines the applied signal--and not on the right side of the convolution equation--which defines the impulse response of the filter. Therefore, no time varying filters are necessary for developing the z(t) signal of equation (7). However, since the left hand side of equation (7) now has the e j .sup.ω.sbsp.cnT term, a time variation requirement is introduced on the sampled C n signals (which are, of course, time varying).
On first blush, it appears that the time variation requirement by the e j .sup.ω.sbsp.cnT signal of equation (7) is identical to the filters' time variation requirement of equations (5) and (6) and that, therefore, no savings are realized. Upon a closer look, however, it can be seen that it is considerably easier to accurately multiply the C n values by arbitrary phasors than it is to multiply whose sets of filter coefficients. First, there are fewer values to multiply (C n signals generally take on only a small set of values), and second, for many applications, the relevant C n signals lie on a unit circle. With such C n signals (as will be shown below), multiplication by the phasor e j .sup.ω.sbsp.cnT takes the form of the simple addition of phase angles.
FIG. 2 is a block diagram of a circuit which in, accordance with the principles of this invention, is capable of developing the complex bandpass signal z(t) as defined by equation (7). In FIG. 2, the complex symbol signals C n are sampled in sampler 70 and are multiplied in complex multiplier 50 by the time precessing phasor e j .sup.ω.sbsp.cnT which is increasing in phase with increasing n. If C n is available in polar coordinates, multiplier 50 may be implemented with an adder which adds the phase angle of each C n signal to the phase angle ω c nT. If C n is available in cartesian coordinates, multiplier 50 may be implemented with a circuit for converting the applied cartesian coordinate C n signals to polar coordinate C n signals. Alternatively, multiplier 50 may comprise a plurality of multipliers for calculating the desired produce signals directly in cartesian coordinates. One embodiment of such a multiplier is described below in reference to FIG. 3.
The multiplied output signals of multiplier 50 of FIG. 2 are applied to filter 60. In accordance with equation (7), filter 60 possesses an impulse response characterized by R(t) e j .sup.ω.sbsp.ct, where R(t) is as defined by equation (4). Filter 60 may, generally, be a recursive or a nonrecursive filter. Its specific embodiment, however, is dependent on the characteristics of the incoming signal (polar or cartesian) and on the user's preference. When the C n e j .sup.ω.sbsp.cnT signal is available in cartesian coordinates, it is generally found easier to perform the filtering process entirely in cartesian coordinates -- particularly since only the real part of the signal z(t) is desired as indicated by equation (2).
To characterize the hardware implementation of equation (7) in cartesian coordinates, it is necessary to substitute equations (3) and (4) into equation (7) and take the real part thereof, yielding ##EQU6##
Equation (8) is similar in format to equation (6) in that both indicate the use of four filters. However, unlike the filters of equation (6), the impulse responses of the filters of equation (8) are not dependent on the variable n, and are therefore time invariant.
FIG. 3 depicts a block diagram schematic for the cartesian coordinate implementation of the FIG. 2 circuit in accordance with equation (8).
In FIG. 3, signals a n and b n are sampled at a rate of 1/T by sampling circuits 71 and 72, respectively. Like samplers 10 and 11 of FIG. 1, samplers 71 and 72 may comprise controllable analog gates. The sampled a n and b n symbol signals are applied, as in FIG. 2, to multiplier 50 wherein the sampled symbol signals are multiplied by the variable phasor e j .sup.ω.sbsp.cnT. Within multiplier 50, multiplier unit 51 multiplies the sampled a n signal by an applied cosine signal, cos ω c nT, and multiplier unit 52 multiplies the sampled a n signal by an applied sine signal, sin ω c nT. Similarly with respect to the b n signal, multiplier unit 53 multiplies the sampled b n signal by the applied sine signal, sin ω c nT, and multiplier unit 54 multiplies the sampled b n signal by the applied cosine signal, cos ω c nT. In subtractor 55, the output signal of multiplier unit 53 is subtracted from the output signal of multiplier unit 51 to develop the signal (a n cos ω c nT-b n sin ω c nT)δ(t-nT). In adder 56, the output signal of multiplier unit 52 is added to the output signal of multiplier unit 54 to develop the signal (b n cos ω c nT+a n sin ω c nT)δ(t-nT). The output signals of subtractor 55 and adder 56 are applied to filter block 60.
Within filter 60, the output signal from subtractor 55 is applied to filters 61 and 62 which respectively convolve their input signals with impulse responses g(t)cos ω c t and h(t)sin ω c t. Similarly, the output signal from adder 56 is applied to filters 63 and 64 which respectively convolve their input signals with impulse responses h(t)cos ω c t and g(t)sin ω c t. Also within filter 60, the output signals of filters 62, 63 and 64 are subtracted from the output signal of filter 61 in summing network 65, providing thereby an output signal for filter 60 which is equal to the desired signal s(t) of equation (8). Summing network 65 may be implemented in a manner similar to the implementation of network 40 of FIG. 1.
Filters 61-64 may be of any construction. They may be recursive filters or nonrecursive (transversal) filters. In some situations, however, transversal filters are preferable because of their linear phase characteristics and because of their ease of implementation. For example, a transversal filter may simply comprise a shift register with signal taps at every stage of delay, means for multiplying the output signal of each tap by a filter coefficient, and means for adding the multiplied signals. Another advantage of non-recursive filters relates to the case of specifying a selected impulse response. As is well known, a transversal filter may be made to possess a selected impulse response simply by specifying the tap signal multiplication coefficients to be the sampled values of the desired impulse response.
Of course, the sampled values of the desired impulse response are not obtained by sampling the impulse response at the symbol rate of sampling signals a n and b n (which is at the rate of 1/T seconds). Rather, the impulse response is sampled at a rate that relates to the digital realization of the bandpass signal s(t) in the digital transversal filters. In accordance with well-known sampling theorems, since the signal s(t) is centered about a carrier ω c , the filter realization must proceed at a sampling rate that is at least equal to 2(ω c +B) where B is half the bandwidth of s(t). That is the sampling rate which is used to obtain the transversal filters coefficients.
Since the circuit of FIG. 3 implements the expression of equation (8), it can be appreciated that the FIG. 3 circuit is capable of generating signals having the form of equation (1). A number of specific modulation approaches, however, have characteristic forms which may be classified as subsets of equation (1). For example, the familiar expressions for Quadrature Amplitude Modulation (QAM) and Differential Phase Shift Keying modulation (DPSK) can be obtained by letting h(t)=0 in equation (1). Similarly, the expression for Single Sideband modulation may be obtained by lettering b n = 0. From the above, it may be realized that for specific modulation approaches, the implementation of the FIG. 2 circuit is simpler than shown in FIG. 3. The following are some of the more unusual examples.
a. Phase Shift Keying (PSK)
A PSK signal can be written as ##EQU7## yielding a signal z(t) equal to ##EQU8## where e j .sup.φ.sbsp.n defines the signal constellation C n (on the unit circle). In accordance with equation (7), the z(t) signal of equation (10) may be rewritten, yielding ##EQU9## Interestingly, the phasor multiplication of element 50 degenerates to a simple addition of the angles φ n and ω c nT.
FIG. 4 is a block diagram of a PSK modulator characterized by equation (11). Contained in multiplication block 50 of FIG. 4 is an adder 57 and a read-only-memory (ROM) 58. Adder 57 sums the symbol signal φ n (sampled by sampler 70) with the precessing angle ω c nT, and ROM 58, in response to adder 57, develops the sine and cosine values of the summed angle (φ n + ω c nT) on output leads 41 and 42, respectively.
Since adder 57 sums angles, it must perform the summation in modulo 2π. If ROM 58 contains the sine and cosine tables from 0 to 2π in 2 k memory locations, then adder 57 has to operate in modulo 2 k . This, of course, is not a difficult requirement on adder 57 since all binary adders naturally do add in modulo 2 k , where k is the number of addition stages. Therefore, adder 57 may simply be a binary adder having k addition stages, and ROM 58 may be a memory having 2 k addresses -- storing in these addresses the values of the sine and cosine functions over the range of 0-2π. To those skilled in the art, it will be apparent that in employing a small amount of logic circuitry, various trigonometric relationships of the sine and cosine function may be utilized to reduce the size of ROM 58.
Within filter block 60 of FIG. 4, filter 66 convolves the cosine signal on lead 42 with an impulse response g(t)cos ω c t, and filter 67 convolves the sine signal on lead 41 with an impulse response g(t) sin ω c t. The output signal of filter 67 is subtracted from the output signal of filter 66 in unit 68, developing thereby an output signal of filter 60. It can be shown that the output signal of unit 68 is equal to the real part of the z(t) of equation (11), which is the desired s(t) signal.
b. DPSK Modulation
In DPSK Modulation, the transmitted signal has the form of equation (9) but the transmitted symbol is contained in a differential angle Δφ n = φ n - φ n -1 . To obtain the (φ n + ω c nT) signal required at the input terminal of ROM 58 of FIG. 4, it is only necessary to replace the precessing ω c nT signal applied to adder 57 with a fixed ω c T signal, and to interpose an accumulator 59, as depicted in FIG. 5, between adder 57 and ROM 58. By applying the symbol signal Δφ n to adder 57 together with the fixed ω c T signal, the accumulated output signal developed by accumulator 59 is ##EQU10## which is equal to φ n + ω c nT as required by equation (9).
Interestingly, adder 57 may be simplified for special values of ω c nT. In the extreme, if ω c T is equal to 2π, adder 57 may be completely eliminated since it adds in modulo 2π and is, therefore, insensitive to input signals which equal to 2π. | Disclosed is apparatus for generating carrier signals modulated by baseband symbol signals. The disclosed apparatus includes samplers for sampling input symbol signals, multipliers for multiplying the sampled signals by a precessing phase that is a function of the carrier signal's frequency, and modified filters for convolving the multiplied signals with a complex (real and imaginary) low pass impulse response and for selecting the real part of the convolved signals. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to solid state imaging systems and more particularly to the suppression of pattern noise in solid state imaging systems.
2. Description of the Prior Art
Solid state imagers, including both charge injection devices and charge coupled devices, consist of arrays of sensors in which rows and columns are activated in a regular manner by two separate series of pulses which scan the array. The horizontal scanning is done by a pulse which is stepped by a horizontal shift register along each sensor element in the row. This pulse creates a transient, which is the principal source of pattern noise. During the time period allocated for reading out the video signal stored on an element, the transient decays. When a long period can be allocated to the readout of each element, the video signal can be sampled late enough to allow a substantial decay in the transient and the derivation of a relatively noise free signal. As arrays have achieved higher resolution, however, the time allocated for reading each element has diminished, and other techniques to reduce the pattern noise have become necessary.
It has been recognized that the pattern noise is duplicated as row after row of sensors is read out, the pattern noise being primarily a function of parasitic capacities in the individual stages of the horizontal shift registers and in the enabling gates associated with each column of sensors. In other words, the pattern noise transients formed in all sensor elements tied to the same stage of the horizontal shift register and to the same horizontal enabling gates are substantially identical. At the same time, there is a substantial variation in the pattern noise transients from element to element in the same horizontal row of sensors.
Several techniques, in addition to delayed sampling, have been proposed to reduce the pattern noise. Since the pulses have an average dc content, it is known to add a fixed sample of the horizontal switching pulse in opposite polarity and suitable magnitude to effect a first reduction in the average amount of pattern noise. It is also known to filter out high frequency components of the transient. These techniques lead to a signal to noise ratio on the order of 10 or 20 to 1. Better signal to noise ratios are desirable.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved solid state imaging system.
It is a further object of the present invention to provide a solid state imaging system in which pattern noise is reduced.
It is another object of the invention to provide a solid state imaging system using a charge injection device as the imager in which pattern noise is reduced.
These and other objects of the invention are achieved in a novel combination including a solid state imager, delay means and combining means. The solid state imager is one in which pattern noise is present in the video output in the form of a succession of variable amplitude pulses, which occur once for each light sensing element in each row and which are duplicated from row to row. The imager is arranged to generate a video signal in which a row storing video information is read out destructively at a given horizontal line rate followed by readout of the same row at the given horizontal line rate before video information has been re-established. In the process, a first video signal is formed in which each line of video information containing pattern noise is followed by a line containing no video and repeating the pattern noise. The imager output is coupled to the delay means for delaying the first video signal by one horizontal line interval. The undelayed and delayed first video signals are then combined in the combining means in opposite polarities to form a second video signal in which the video information occurs in a line pair, the video information of the first line of the pair being repeated in opposite polarity in the second line, and the pattern noise being reduced by cancellation to a small residue of like polarity in both lines of each line pair (after the first line pair).
In accordance with a further aspect of the invention, the odd sensor rows are read out in consecutive order to form a first field, and the even sensor rows are read out in consecutive order to form a second field. In addition, switching means are provided to which the second video signal is applied. The switching means inverts one line of each line pair to form a third video signal in which the pattern noise residue of the first line is of opposite polarity to that of the second line while the video information is of like polarity. Further switching means are provided to select the first members of each line pair from one sensor field in consecutive order to form a first display field and to select the second members of each line pair from the second sensor field in consecutive order to form a second display field. In this manner, a fourth video signal is formed in which the polarity of the pattern noise residue in the first display field opposes that in the second display field so as to provide visual cancellation.
In accordance with a further aspect of the invention, a synchronizing pulse generator is provided for adding horizontal synchronizing pulses to the fourth video signal to facilitate display of an integral number of lines per field with the odd sensor rows being displayed in alternation with and equally spaced between the even sensor rows. Preferably, the synchronizing pulse generator produces horizontal pulses twice per line, these pulses starting both odd and even sensor fields at the beginning of the line. The "sync" pulses cause the display monitor to sweep once with a video signal and once without a video signal (respectively) per line pair for one field, and once without a video signal and once with a video signal (respectively) per line pair for the alternate field.
BRIEF DESCRIPTION OF THE DRAWING
The novel and distinctive features of the invention are set forth in the claims appended to the present application. The invention itself, however, together with further objects and advantages thereof may best be understood by reference to the following description and accompanying drawings, in which:
FIG. 1 is a block diagram of a solid stage imaging system using a CID imager whose output is available on a pair of output terminals and processed in parallel for an initial reduction in pattern noise. The video outputs are combined and processed in accordance with the invention to provide line to line electrical and field to field visual pattern noise cancellation;
FIG. 2 illustrates the pattern noise waveforms during the initial parallel processing;
FIG. 3 illustrates waveforms relevant to line to line electrical and field to field visual pattern noise cancellation, graphed at the horizontal line rate;
FIG. 4 is an electrical circuit diagram of the portions of the FIG. 1 imaging system which produce line to line electrical and field to field visual pattern noise cancellation; and
FIG. 5 illustrates the waveforms relevant to field to field visual pattern noise cancellation, graphed at the field rate.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to FIG. 1, a block diagram of a solid state imaging system is shown. The input block of the system is a CID (charge injection device) imager 11, upon which an image is focused. The imager 11 is coupled to a scanning generator 12, which controls the conversion of the image formation on the sensor array into a pair of time variant electrical signals, available at two output terminals. Following the imager are the blocks 13 through 28, which are known, and which operate upon the output signals from the imager to reduce the pattern noise to 1/10th to 1/20th the level of the video signal. In the process, the ratio of the random noise to the signal is also reduced. The known noise reduction circuit is followed by a further pattern noise reduction network incorporating the invention. The novel pattern noise reduction network involves the blocks 29 through 37 with some modification of other parts of the system. At the output of the system, the signal to noise ratio is typically 400 to 1. The final element in the FIG. 1 system is the monitor 38 for displaying the signal. A conventional monitor is used.
The CID imager 11 includes vertical and horizontal shift registers and vertical and horizontal enable gates which assist in scanning the image focused on the sensor array. In a typical arrangement, the imager consists of an array of optical sensors with 244 in the vertical dimension by 320 in the horizontal dimension, all integrated on a common substrate. Each sensor element in the array has two terminals, one of which is associated with vertical selection and the other of which is associated with horizontal selection. The "vertical" terminals are interconnected in buses which extend in the horizontal dimension and which are spaced along the vertical dimension. These buses are called "rows". The horizontal terminals are interconnected in buses which extend in the vertical dimension and which are spaced along the horizontal dimension. These buses are called "columns".
The rows are selected one row at a time by a vertical enabling pulse acting in conjunction with a vertical pulse upon a two input, enable gate (also integrated). The vertical shift register, which is integrated on the common substrate, has 122 stages, each of which is coupled to a pair of enable gates. An enable pulse, which lasts for a "field" turns "on" the first input of the first gate of all the pairs of vertical enable gates. As the vertical pulse is propagated along the vertical shift register, its presence at each stage in conjunction with the enabling pulse turns on the first of each pair of vertical enable gates. When all "odd" rows have been sampled to complete one field, a second vertical enable pulse turns on the second of each pair of vertical enable gates. As the next vertical pulse is propagated down the vertical shift register, the second of each pair of vertical enable gates is turned on. The result is a selection of odd sensor rows in a first field and even rows in the second field.
Once a row has been selected at the slower vertical rate, it is swept rapidly at the faster horizontal rate. The sensor elements are arranged in the horizontal dimension in the 160 odd and 160 even "columns". The columns are selected one pair at a time by a horizontal pulse propagated along a 160 stage shift register, also integrated on the common substrate. Each stage of the horizontal shift register is coupled to a pair of horizontal enable gates (also integrated). Each horizontal enable gate controls a column of sensors, the odd gate of the pair coupling the sensor element to an odd (e o ) video signal output and the even gate of the pair coupling the sensor element to an even (e e ) video signal output. As the horizontal pulse is propatated along the horizontal register, consecutive adjacent pairs of sensor elements are "enabled", producing a simultaneous pair of odd (e o ) and even (e e ) video output signals at the respective output terminals of the array.
The scanning generator 12 operates the vertical and horizontal shift registers and the enable gates on the array. It provides rectangular vertical pulses (V d ) and the two vertical clocking pulses (V.sub.φ1, V.sub.φ2), which propagate the vertical pulses along the vertical shift register. The scanning generator also provides the vertical enable pulse for individual row selection. It also provides the horizontal pulses H.sub.(d) and the two phase horizontal clocking pulses (H.sub.φ1 and H.sub.φ2) which propagate the horizontal pulse along the horizontal shift register. In short, the scanning generator generates the timing waveforms which scan the array.
The scanning is done in a unique manner which facilitates noise reduction. The scanning generator scans the sensor array in a raster pattern modified in several significant respects.
The basic raster scan is achieved in the manner indicated above. The scanning generator acting through the vertical shift register selects a pair of rows. The first row in that pair and the following pairs is activated by the vertical enabling pulse, and the horizontal shift register steps along the two, two adjacent horizontal elements at a time. In succession, the first row of the second pair of row, i.e., row 3, which is also activated by the enabling pulse, is scanned followed in succession in each of the odd rows until the first field is completed. After the first field is completed, the vertical enabling pulse now enables the second row of the first pair of rows and the second row of all the following pairs of rows. In succession, the second, fourth and all the even rows are scanned until the second field is completed. The process of scanning the odd rows is then repeated for the third field, etc.
The first significant modification in the scanning over that of a more conventional raster scan is that the odd and even column signals are collected simultaneously on two separate output terminals. The odd column elements are coupled to the e o signal output of the imager and the even column elements are coupled to the e e signal output of the imager. These outputs are processed in parallel and then combined in a manner to produce a first reduction in random noise.
The second significant modification in the scanning process is that after each row has been read out in the conventional destructive manner it is immediately re-read before a renewed image induced charge has been acquired by that row of elements. This second reading of the line is used to acquire a noise signal which may be used to cancel noise from a succeeding line in the scanned image. Double reading of a selected row is achieved by omitting alternate vertical clocking pulses in the scanning generator output.
A third modification in the scanning process over that of the conventional interlaced scanning is designed to achieve field to field noise reduction in the display. This is achieved by starting the horizontal line of each field at the start of the horizontal clocking interval, rather than at the middle of the horizontal clocking interval as in the conventional field interlace. In addition, two fields are displayed together in a mutually interlaced pattern, the full raster occupying alternate line positions on a conventional 525 line display. The implications of these modifications in the noise reduction process is a principal subject of the following discussion.
Pulse operated scanning generates objectionable "pattern" noise which accompanies the video signal and which must be reduced for satisfactory use of the imager output. The scanning process depends on the selection of sensor rows and sensor columns by a sequence of pulses. The horizontal pulse, in particular, are repeated in the register outputs at the same rate that the sensor elements are selected. They create pattern noise at each active sensor and at each active enable gate output, through stray gate to source and gate to drain capacity. At the instant of selection, the pattern noise takes the form of a short duration spike occurring at the beginning of the period assigned to each picture element and having an amplitude many times greater than the amplitude of the video signal level. The spike results from differentiation of the leading edge of the clocking pulse in these stray capacities, The video signal takes the form of a smooth dc voltage. Both pattern noise and signal are established across the capacity of the active sensor element and any additional capacity at the output of the active enable gate. The spikes stored in this capacity begin to decay immediately, and toward the end of the period allocated in each picture element, the stored voltage most closely approximates the true value of the video signal. The separation of the video signal from the pattern noise is a principal function of the circuitry following the imager.
The foregoing imager scanning represents a practical arrangement in which the shift register complexity on the array is reduced approximately in half and results in major improvements in the signal to noise ratio. The two advantages more than offset the disadvantage of some degree of parallel signal processing. The parallel processing will now be described.
The known imager parallel processing network comprises the elements 13 through 28. Elements 13, 15, 17 and 19 treat the odd column output signal (e o ); elements 14, 16, 18 and 20 treat the even column output signal (e e ); while the remaining elements 21-28 combine the two signals and then act upon them jointly.
The initial elements in each video channel are the noise cancellers 13 and 14. The noise cancellers operate on the principle that the imager output waveform contains a large amount of polarized pattern noise at the horizontal clocking frequency. The imager output signals e o and e e are coupled to a first signal input of the noise cancellers 13 and 14, respectively. A sample of the horizontal clocking pulse is coupled to a second input of each canceller. The sample is selectably in reference phase (H.sub.φ1) or out of reference phase (H.sub.φ2) and of a magnitude which is adjustable by the potentiometer indicated within each block. The adjustments are designed to add pattern noise directly to the video signals in proper phase and amount for maximum noise cancellation. Since the pattern noise varies from element to element in a given row of sensors, but is largely identical from row to row, being primarily a property of array capacities in the horizontal enable gates, the setting of the canceller is fixed at a setting which compensates for the average level of pattern noise. This setting leaves the pattern noise only partially compensated in the typical sensor element but produces a very general improvement in the signal to noise level of the total signal.
The output of the noise cancellers 13 and 14 is applied to the preamplifiers 15 and 16. The canceller output waveform is the first waveform illustrated in FIG. 2. Even after cancellation, the waveform may be seen to contain a succession of relatively short duration, high amplitude peaks at the beginning of the horizontal element which decays to a dc level towards the end of the horizontal element, representing the video signal level with some noise superimposed. At this point in the system, the pattern noise may be 10 to 20 times as large as the desired video component. The preamplifiers 15 and 16 amplify the separate (e o and e e ) signals and apply them to the low pass filters 17 and 18.
The low pass filters 17 and 18 have a roll off set at the horizontal element frequency (typically 1.5 megahertz) and have a null at double that frequency. The roll off reduces the higher harmonics in the pattern noise spikes. The null is particularly useful in reducing heterodyne noise generated in the sampling process which operates at twice the clock frequency. In the absence of "nulling", this noise would be converted to "base band" and would lie in the lower portion of the desired video spectrum. The filters produce an improvement on the order of 10 to 20 db in the signal to noise ratio in the video signal. This is the second waveform illustrated in FIG. 2.
The sample and hold circuits 19 and 20 are designed to sample the signal at the last practical moment before the next horizontal pulse. The sampling pulse for these circuits is the third waveform shown in FIG. 2, and it is derived from the scanning generator. The output of the sample and hold networks is the fourth waveform shown in FIG. 2. Assuming that a white bar is being imaged throughout the illustrated portion of the image, the dc video level has an average amplitude of 10 units (for example) while the element to element fluctuation due to pattern noise has now been reduced to approximately 1 comparable unit. At the output of the sample and hold network the signal is usable, but the signal to noise ratio is well below an ideal value.
The remaining elements (21-28) in the parallel processing network enter into the process of combining the odd (e o ) and even (e e ) imager outputs. They combine the signals in such a way as to retain the high frequency information in the separate e o and e e channels and at the same time achieve a 3 db improvement in the random noise. The buffer amplifier 21 at the end of the e o channel couples its output to the adder 24. The buffer amplifier 22 in the e e channel is followed by a delay element 23 designed to delay the signal by one horizontal element. The output of delay element 23 is coupled to the other input of the adder 24. A combined output of the e o and e e channels appears at the "positive" input to the differential amplifier 28.
The combining process performed in the adder 24 blurs transitions, and in effect attentuates the higher frequency information in the video signal. This "blurring" may be explained as follows. Let us assume that a transition or picture edge, for instance going from black to white, occurs at some element in the array. The odd channel signal e o produces a step between a pair of array sensors at this transition. Similarly, the even channel signal e e produces a step. Because of the delay in the delay element 23, the even channel signal shows the same step delayed one horizontal element. The result is a sloping, two step transition as opposed to a steep, single step transition. It is evident that the two steps can not be coincident because of the delay of one signal in relation to the other. The same effect is present when the reverse transient occurs.
An analysis of the waveshapes of the transition shows that if a pulse representing the difference between e o and e e delayed is added in proper polarity to the summed signal, that the steepness of both transitions can be restored and the "blurring" eliminated. This is achieved by the elements 25, 26 and 28. (The noise clipper 27 is present in the network, but not relevant to this process.) The differential amplifier 25, which is coupled to the outputs of the e o and e e channel buffers, produces a pulse which is equal to the signal difference at the transition. The difference pulse is coupled to a controlled phase inverter 26, whose phase is controlled by the switching waveform (e sw ) at twice the horizontal element rate (on the array). If the edge of the transition occurs between unpaired line elements in the row, the phase inverter produces an inverted signal. If the edge of the transition occurs between paired line elements in a row, the phase inverter produces a non-inverted output. The correction pulse is applied to a noise clipper 27, which is set to reduce base line noise. After clipping, the correction pulse is subtracted at the differential amplifier 28 from the (e o + e e d) signal.
The result of the double combination of the odd and delayed even signals, in which both sum and differences are used, as to preserve the full video spectrum without high frequency attenuation. The second result of the combination of the e o and e e signals is to produce a signal of approximately twice the initial signal level, while the randon noise, which is non-coherent, adds in quadrature. The arrangement produces a 3 db improvement in signal to noise ratio.
The novel pattern noise suppression circuitry operates upon the consolidated signal. It consists of the blocks 29 to 39. The operation of these blocks will be explained with reference to the waveforms of FIG. 3. The circuit details of a practical embodiment of the invertion are illustrated in FIG. 4.
The initial block in the novel pattern noise suppression circuitry is the 1 horizontal line delay 29. At the input of the delay block 29, the video signal takes the form illustrated in the first waveform in FIG. 3, and denominated "e". Four horizontal line positions are depicted in that waveform. The four horizontal line positions correspond respectively to the first line of the charge sensor, the emptied first line reread, the third line, and the emptied third line reread. All are derived from the same odd row field. The line in the first position to the left commences with a blanking pulse, goes to a black level, and then rises to a white level for perhaps 1/6th of the line and returns to black for the balance of the line. This illustrates the video waveform of a white bar. Superimposed on the video waveform at the first horizontal line position is pattern noise illustrated by a pair of upwardly pointing arrows of arbitrary magnitude, intended to illustrate the observed polarization of the pattern noise. The second horizontal line position contains an initial blanking pulse, a uniformly black video level denoting the absence of a video signal and upon which a second pair of upwardly pointing arrows depicting pattern noise are superimposed. The third horizontal line position has the video signal with pattern noise, while the fourth line position has no video and does have pattern noise. As previously explained, a zero video output on the even horizontal line positions (in the illustrated manner) is achieved by immediately scanning the same row on the CID imager a second time. The second scan must occur after the row has been destructively read out and before the row of sensors has had an opportunity to acquire fresh image charges. While the initial "e " waveform shows only four consecutive lines of waveform, the same alteration between video and no video, with appreciable upwardly polarized pattern noise continues for 122 lines in the odd field and 122 lines in the even field.
The one line delay block 29 delays the e waveform by 1 line interval. The delayed waveform, which appears at the output of block 29, is shown in the second waveform (e d ) of FIG. 3. In the e.sub.(d) waveform it may be seen that the initial line position in FIG. 1 is empty but that the second line position now has video information with upwardly polarized pattern noise. The third line position of the delayed waveform has no video information but has upwardly polarized pattern noise, and the fourth line position has video information and upwardly polarized pattern noise, and so forth. The second line position now contains the first line of the image sensor; the third line position contains the emptied first line reread; and the fourth line position contains the third line of the image sensor. The sequence continues as before through the odd and even fields.
The circuit means by which the line delay is achieved is illustrated in detail in FIG. 4. The delay element itself is a quartz delay line (DL-1). Since the delay line is operated at 7 megahertz, the video signal is AM modulated on a 7 MHz carrier. AM modulation on the carrier is performed in the integrated circuit Z1. The modulated carrier is then filtered to pass the requisite side bands and applied to a buffer amplifier Z2 before application to the delay line. After passage through the delay line, the video signal is recovered by synchronous detector Z3. The synchronous detector is followed by the buffer transistor stage Q 1 .
The differential amplifier 30 substracts the delayed video signal from the undelayed signal. The differential amplifier is a portion of a conventional integrated circuit (Z4, FIG. 4). One input of the differential amplifier is coupled to the output of the buffer Q 1 at which the delayed video signal is available, and the other input is coupled to the undelayed video input line. In FIG. 4, the undelayed video input is coupled via the emitter follower Q 8 to the differential amplifier input.
The subtraction performed in differential amplifier 30 is illustrated in the third waveform (e -e d ) of FIG. 3. In the first line position, the subtracted waveform repeats the first line of the original video waveform (e), with upwardly polarized pattern noise at full intensity. In the second line position, the video signal (which repeats the video information of the first line) is now of inverted signal polarity and contains a small residue of polarized pattern arbitrarily shown as upwardly extending. On the third line position, the video signal corresponding to the third line of the sensor is of uninverted polarity, and contains a small residue of upwardly polarized pattern noise. On the fourth line position, the video signal of the third line is inverted, and contains a small residue of upwardly polarized pattern noise. The subtracted waveform continues through the 122 odd lines of the odd field and the 122 even lines of the even field.
Several properties of the subtracted (e -e d ) waveform are significant. The polarity of the video signal alternates from odd line position to even line position. After the first line, the pattern noise is reduced to a "residue", which retains a common polarity from line to line. This does not imply that each element of pattern noise is of one polarity, but rather that the line pattern noise as a whole is polarized. As will be hereinafter explained, it is possible to oppose these pattern noise residues to effect further cancellation of the pattern noise.
The switching inverter, block 31, follows the differential amplifier and generates a video signal in which the video in even line positions is erected, so that all lines are of like polarity. At the same time, the pattern noise residues are polarized upwardly in odd line positions and downwardly in even line positions.
The switching inverter 31 may be regarded as consisting of three "equivalent" elements, as illustrated in FIG. 1: an inverter 32, a single pole, double throw switch 33, and switch control means 34 operated at half the horizontal line rate (H/2). One stationary contact of the switch 33 is coupled to the input of the inverter 32 and the other stationary contact is coupled to the output of the inverter 32. The pole of the switch, at which output of the switching inverter is derived, is switchable at half the line rate (H/2) under the control of the control means 34 between the two stationary contacts. The control means 34 is synchronized with the video signal so that the first line of the difference waveform is obtained directly from the difference amplifier 30 without inversion. During the second line, the video signal occurring at the second line position is obtained via the inverter 32, which reinverts the line to the erect polarity. In the third line position the switch 31 selects the uninverted waveform, and in the fourth line position, the switch selects the inverted waveform.
The actual circuit of the switching inverter 31 is shown in FIG. 4. The switching inverter is a portion of an integrated circuit (Z4), which includes a pair of differential amplifiers and an electrically controlled gate for selecting the output of one of the two differential amplifiers. The delayed video signal is coupled to the positive terminal of one differential amplifier and to the negative terminal of the other differential amplifier. The undelayed video signal is coupled to the negative terminal of the "one" differential amplifier and to the positive terminal of the "other" differential amplifier. In this manner, an uninverted difference signal is available at the output of one difference amplifier, and an inverted difference signal is available at the output of the other difference amplifier. The electrically controlled gate is controlled by the H/2 waveform to select the output of either the first or the second differential amlifiers.
The waveform at the output of the switching inverter 31 is denoted e sw (e - e d ) in FIG. 3. While each line of video information is of the same polarity, the polarity of the pattern noise residue alternates from line to line. In particular, the noise residue at the first line position is polarized upwardly, while the noise residue at the second line position is polarized downwardly. In short, the switched video output e sw (e - e d ) contains a raster in which each line of video information is repeated a second time. The video in each line position is of proper polarity, and the pattern noise, which is repeated from line to line, is polarized upwardly in the odd line positions and downwardly in the even line positions. As will now be shown, further pattern noise cancellation may be achieved by using the video in the "odd" line positions to form a first field in a visual display and the video in the "even" line positions to form a second field. Since the pattern noise is inverted from field to field, further visual cancellation may be achieved.
Field to field visual pattern noise cancellation is accomplished in the remaining blocks 35, 38 and 39. The line rate field switch 35, which is coupled to the output of the switching inverter, is the initial block. Its output is coupled to the video processor 38, in which blanking and synchronizing pulses are added and in which clipping takes place. The output from the video processor 38 is then coupled to the monitor 39.
The line rate field switch 35 selects the video from the odd line positions for the odd fields and the video from the even line positions (of FIG. 3) for the even fields for eventual display. The line rate field switch may be schematically represented (as in FIG. 1) as consisting of an electrically controlled single pole-single throw switch 36, controlled by the control means 37. When the switch 36 is in the open position, the video waveform is interrupted in its passage to the output circuitry. When the switch 36 is in the closed position, the video waveform passes to the output circuitry. The line rate field switch is turned on for a period or off for a period dependent on the control voltage applied to the control means 37. The control waveform for the control means 37 is shown at e 3 in FIG. 3 for the odd and even fields. The e 3 waveform consists of a series of pulses synchronized with the line positions of FIG. 3 for providing an "on" switch condition for a line duration followed by an "off" switch condition for a line duration. The " on" condition is achieved by a plus voltage condition and the "off" condition is achieved by a zero voltage condition. For the first field, using odd imager lines, the e 3 waveform of FIG. 3 for field 1 is applied in the control means 37. This turns on the switch 36 during the first, third and following odd line positions to the output circuitry. The output waveform for the odd line field is illustrated at e o (field 1). During the second field from the imager, using even imager lines, the e 3 waveform for the field 2 is applied to the control means 37. This turns on the switch 36 during the second, fourth and following even line positions of the e sw (e - e d ) waveform, and couples the video in the corresponding even line positions to the output circuitry. The output waveform for the even line field is illustrated at e o (field 2). It may be seen that the video information is erect in the fields while the pattern noise in field 1 is polarized oppositely to that in field 2, and thus alternates between odd and even fields.
The actual circuit of the line rate field switch 35 is shown in FIG. 4. It consists of an FET transistor Q9 and a bipolar transistor Q10. The FET transistor Q9, to which the e 3 waveform is applied, acts as both switch 36 and as control means 37. The transistor Q10 is an emitter follower buffer for coupling the sampled video to the video processor 38.
The e 3 control waveform for the line rate field switch 35 is generated by the elements 40 to 44 of FIG. 1, forming the control waveform generator. The relevant waveforms are illustrated in FIG. 5. The time scale of the FIG. 5 waveforms are greatly compressed in relation to those in FIG. 3, and somewhat simplified. In FIG. 5, the illustrated period is that occupied by two fields (as opposed to four lines in FIG. 3), and each field is represented as being composed of a few lines (6 in the illustration), whereas each field may have 122 lines in a practical case.
The vertical drive waveform (V drive ) is shown in FIG. 5. It consists of a short duration pulse at the beginning of each field. That waveform is available in the scanning generator 12. It is used to produce the V/2 and V/2 waveforms illustrated in FIG. 5 and used as inputs to the control waveform generator. The V/2 waveform is the inverse of the V/2 waveform and consists of an "on" voltage during odd fields and an "off" voltage during even fields. The V/2, V/2 waveforms are at half the frequency of the vertical drive waveform. The other input waveforms to the control waveform generator are the H/2 and H/2 waveforms of FIG. 5. The H/2 waveform is the inverse of the H/2 waveform and consists of an "on" voltage during odd lines (in both fields) and an "off" voltage during even lines (in both fields). The H/2, H/2 waveforms are at half the frequency of the horizontal waveform.
The control waveform generator generates the output waveforms e 3 (field 1) and e 3 (field 2) of FIG. 5 by application of the V/2, V/2 and H/2, H/2 thereto. As noted above, the control waveform generator includes the elements 40 to 44. These elements include a pair of AND gates 42, 43 and a pair of inverters 40 and 41, and an OR gate 44. The H/2 and V/2 are applied to the AND gate 42 to obtain the e 1 waveform of FIG. 5. The e 1 waveform consists of a succession of pulses of horizontal line duration which are "on" for the odd lines for field 1. For field 2, the e 1 waveform is off (zero volts). The H/2 and V/2 waveforms are applied to the inverters 40 and 41, respectively, to obtain the inverse functions H/2 and V/2. The inverse waveforms are then applied to the inputs of the second AND gate 43 to produce the e 2 waveform of FIG. 5. The e 2 waveform consists of a succession of pulses of horizontal line duration, which are on for the even lines for field 2. For field 1 the e 2 waveform is off (zero volts). The e 1 and e 2 outputs of the AND gates 42 and 43 are then "OR'd" by the OR gate 44 to obtain the control waveform e 3 of FIG. 5. the e 3 control waveform consists of a series of "on" pulses for odd lines in field 1 and "on" pulses for even lines in field 2, required for operation of the line rate field switch 35.
The line rate field switch 35 thus produces a video output for the first field in which the odd line video information is shown at e o (field 1) with the pattern noise residues upwardly polarized. The second field contains even line video information as shown at e o (field 2) with downwardly polarized pattern noise residues.
The e o signal from the line rate field switch 35 is now applied to the video processor, block 38, in which system blanking, clipping and synchronizing signals from generator 45 are applied to the video signal. The sync generator 45 is modified to facilitate appropriate treatment of the two video fields. In particular, the generator 45 is modified to start the first line of each field at the beginning, as opposed to starting the even fields at the half line for interlace. Thus, the generator operates at a count of 262 per field as opposed to 2621/2 per field for normal interlace. When the odd field is being applied to the monitor 39, the odd sensor lines are supplied to every fourth line of a conventional 525 line display until the 122 lines for that field have been displayed. The blanked lines of e o (field 1) waveform are not displayed. When the even field is being applied to the monitor 39, the even sensor lines are supplied intitially to line 3 of the 525 line display, and so on for every fourth line until the 122 lines for that field have been displayed. The blanked lines for the e o (field 2) waveform are not displayed.
The result of combining the two 122 line fields is that the display has a total of 244 lines, at approximately double the usual spacing between lines, and corresponding to the positions occupied by the odd field in a conventional 525 line display. The odd field lines thus alternate on the display with the even field lines to form a compound raster of half the vertical line resolution of the conventional 525 line display. The odd field lines contain pattern noise of upward polarity, while the alternate even field lines contain pattern noise of downward polarity. When the two fields are viewed concurrently, the eye integrates the pattern noise between the successive fields, even though viewed on adjacent lines, and produces a very significant visual cancellation of the pattern noise.
The actual circuitry for the video processor is shown in FIG. 4. Video amplification of the sampled video waveform is performed by the integrated circuit Z5, the blanking waveform being added via Q 3 , and the synchronizing waveform being introduced via Q6. The video output, which is now in a suitable form for display on a conventional TV monitor, is available at the output of the emitter follower Q 5 . | The present invention relates to a solid state imaging system in which pattern noise is cancelled both electrically and visually. Pattern noise takes the form of a succession of variable amplitude pulses occurring as each light sensing element in a row of elements is read out. The pattern noise is duplicated from row to row. Since pattern noise is initially many times larger than the video signal, it must be reduced to a fraction of the video signal for satisfactory imager operation. In accordance with the invention, a first video signal is formed in which each row of sensors is first scanned with video and pattern noise present followed by a second scanning with video absent and pattern noise present. The first video signal, delayed one horizontal line, is then combined subtractively with an undelayed first video signal to form a second video signal in which the video information in the first member of the line pair is of one polarity and of opposite polarity in the second member while the pattern noise is cancelled to a small residue of like polarity in both members of the line pair. A third video signal is formed with the video in each line pair of like polarity and the pattern noise residues of opposite polarity. The third video signal is now in a form suitable for visual cancellation of the pattern noise residues. This is accomplished by causing the third video signal to be displayed with the pattern noise of one polarity on odd lines of the monitor and of opposite polarity on even lines of the monitor. | 7 |
[0001] This application claims the benefit of priority to U.S. provisional patent application 61/576,017 filed on Dec. 15, 2011.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method for decorating non-washable shoes, apparel, and accessories with images, designs, artwork, messages, etc. . . .
BRIEF SUMMARY OF THE INVENTION
[0003] An object of this invention is to provide a convenient and simple method for a user to manually apply designs, artwork, messages, etc. . . . to shoes, clothing, and accessories. It is common for users to want to decorate items of clothing, accessories, and shoes. A number of methods are known for doing this. For shoes such methods may include swapping shoe laces with laces in a new color, a length of textured ribbon or printed twill tape. Wrapping lace around sandal straps, gluing decorative trim to flip-flops or using ribbon and jump rings to add charms to a shoe. Other methods include, for example, adding a clip-on earring, affixing metal studs or self-adhesive rhinestones, arranging small gems around the tops or toes of shoes. It is also known to use iron-on patches and add stickers or decals to shoes. Hook and loop fasteners (a.k.a. “velcro”) may be used to semi-permanently attach decorative items to shoes, accessories or articles of clothing. The use of fabric markers and paint for decorative purposes is also known.
[0004] All of the aforementioned methods of decorating a shoe or accessory however don't give a user a convenient, easy, and quick way of manually applying permanent high quality pre-made artwork, designs, or messages to shoes, clothing or accessories. The present invention achieves this through a user applied apparel tattoo.
[0005] Tattoos as applied the skin of a person are well known in the art. Traditional tattoos are made by inserting indelible ink into the dermis layer of the skin to change the pigment. Such traditional tattoos are permanent. Not everyone is interested in a permanent tattoo, so temporary tattoos have been developed. A temporary tattoo is a non-permanent image on the skin usually resembling a permanent tattoo. Temporary tattoos can be drawn, painted, or airbrushed, as a form of body painting but most of the time these tattoos are transferred to the skin
[0006] The modern temporary transfer tattoo generally consists of the following elements: a sheet of paper with a front side and a back side, an adhesive, ink and a removable protective sheet. It comes in two general forms: One which is applied through the use of water, and the other which is a dry transfer or waterless tattoo. Temporary tattoos that are applied with water to the skin use an adhesive waterslide material on a paper substrate. The adhesive waterslide material is typically comprised of dextrose. Such a tattoo will transfer the ink image to skin when water has fully penetrated the paper backing to release the waterslide material which transfers to the skin surface along with the ink image. The adhesive waterslide material when dry will temporarily bond the ink image to the skin surface. A typical waterslide tattoo is applied by the user by pressing the tattoo against the skin and applying water to it, usually with a sponge, until it is well soaked. The backing is then removed with the ink image adhering to the skin surface.
[0007] The dry transfer tattoo does not require the application of water, and has grown in popularity due to sanitary concerns with waterslide tattoos. Specifically, children who are a primary user of temporary tattoos frequently use saliva rather than water to apply the waterslide tattoos. A waterless tattoo usually comprises a base layer, such as for example paper. The base layer has a transfer coating applied to a front surface, and an ink image is applied to the transfer coating. A pressure sensitive adhesive layer is applied on top of the ink layer, followed by a removable protective layer applied on top of the adhesive layer. A user applies the dry transfer tattoo by removing the protective top layer and applying the pressure sensitive adhesive layer to the skin surface, such that the base layer faces away from the skin surface. The user then applies pressure to the base layer for a period of time. The pressure causes the adhesive layer to bond with the skin surface and also bonds the ink image to the adhesive. The user then removes the base layer with the adhesive layer bonding the ink image to the skin surface.
[0008] While the use of temporary tattoos such as described above (and in greater detail herein) is well known for applying images to human skin surfaces, it has not been previously used to apply images, artwork, designs, or messages to the surfaces of non-washable shoes, apparel or accessories. It is the object of the present invention to apply such temporary skin tattoo technology towards a new use on the surfaces of non-washable shoes, apparel and accessories. It should be noted that while such temporary skin tattoo technology is temporary when applied to human skin (which is washed, and where the outer skin cells are shed over time) its effect is of a more permanent nature when applied to articles of non-washable shoes, apparel and accessory items (e.g. purses, bags, etc. . . . ). Thus, the use of such “temporary” tattoo technology can achieve a convenient, affordable, and easy way for a user to manually apply permanent high quality pre-made artwork, designs, or messages to non-washable shoes, clothing or accessories.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustrating a cross-section of a dry transfer tattoo as used in the present apparel tattoo method.
[0010] FIG. 2 is a flow chart of a method for applying an image to an article of manufacture such as apparel, shoes, or accessories using a dry transfer tattoo.
[0011] FIG. 3 is a schematic illustrating a cross-section of a waterslide tattoo as used in the present apparel tattoo method.
[0012] FIG. 4 is a flow chart of a method for applying an image to an article of manufacture such as apparel, shoes, or accessories using a waterslide tattoo.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In a first preferred embodiment of the present invention a dry transfer tattoo is used to manually apply a permanent image, design, artwork, message, etc. . . . to non-washable shoes, apparel and accessories. Referring to FIG. 1 , a tattoo 100 according to one embodiment of the present invention is comprised of a base layer 110 ; a transfer coating 120 ; an ink layer 130 ; an adhesive layer 140 ; and a top layer 150 . The base layer 110 and the top layer 150 may be made of plastic film or of paper. The base layer 110 and the top layer 150 may also be different materials. For example, the base layer 110 may be paper and the top layer 150 may be plastic film. The material composition of layers 110 , 120 , 130 , and 140 as well as the cumulative thickness 160 of tattoo 100 should be such that tattoo 100 with top layer 150 removed is thin and flexible enough so that it may be readily bent and be applied with full surface contact of adhesive layer 140 across a curved or contoured surface of the article that the ink image is intended to be applied to (e.g. the heel of a shoe).
[0014] The transfer coating 120 is releasably adhered to base layer 110 and enables base layer 110 to be peeled off once adhesive layer 140 is applied to an apparel surface. Transfer coating 120 allows ink layer 130 to be deposited on either paper or plastic film substrates by providing a treated surface that helps with ink integrity and ink adhesion. Transfer coating 120 does not permanently bond to base layer 110 , and allows ink layer 130 to be transferred to adhesive layer 140 . The transfer coating may be comprised of a non-stick silicone release coating applied to base layer 110 , with an overlaying transfer film on top of the silicone layer. The overlaying transfer film is the surface that ink layer 130 is deposited on and may be composed of gelatin or other polymeric materials such as polyvinyl alcohol or polyvinyl pyrollidone. These materials are designed to be strong enough to adhere to the backing paper during printing yet flexible enough to be easily released during application.
[0015] The ink layer 130 is deposited on transfer coating 120 Ink layer 130 may comprise, for example and without limitation, artwork, a design, a picture, a symbol, text, a message, a logo, etc. . . . Ink layer 130 may be made up of multiple layers of different colors of ink to produce an image with multiple colors. Ink layer 130 may be comprised of, but is not limited to, flexography ink (either water based or solvent based), silk screen ink, offset ink or gravure ink
[0016] Adhesive layer 140 is deposited on the ink layer 130 . Adhesive layer 140 may be a pressure sensitive adhesive, such as for example, an aqueous flexographic pressure sensitive adhesive. Acrylic and polyurethane compositions may also be used. The particular adhesive composition may be varied for particular material surfaces that it is contemplated the tattoo may be applied to. For example, there could be a particular formulation of adhesive that is best suited to bonding with plastics, another for leather, and perhaps another for cloth.
[0017] Top layer 150 is releasably applied to the adhesive layer 140 . Top layer 150 may preferably be a silicone coated substrate, where the substrate may be a plastic film or paper. In this way top layer 150 is removable from adhesive layer 140 .
[0018] The dry transfer tattoo 100 may be easily used to manually apply the image printed on it to a non-washable article of manufacture. FIG. 2 is a flowchart of a method of applying a dry transfer tattoo made.
[0019] The first step of FIG. 2 is to remove top layer 150 of tattoo 100 . This exposes adhesive layer 140 . The next step is to locate tattoo 100 over a position on the surface of the article of apparel, shoes, or accessories (hereinafter the “article”) where the tattoo image is desired to be placed. Tattoo 100 is then placed on the surface of the article with adhesive 140 on the article surface. The surface of the article where the tattoo is placed should be clean and dry. The next step is to apply pressure to tattoo 100 . The application of pressure may be done manually with a hand or finger. Alternatively it may be done with the aid of a tool (e.g. a blunt end of stylus, pen, etc. . . . ). Pressure may preferably be applied continuously and uniformly across the tattoo surface, although a rubbing motion against the tattoo surface may also be used in appropriate circumstances. In a preferred embodiment of the method pressure is maintained on tattoo 100 for at least 1 minute. The application of pressure causes pressure sensitive adhesive to bond with the article surface, and also ink layer 130 . In the next step the user manually removes base layer 110 by peeling it away from the article surface. Transfer coating 120 allows base layer 110 to be separated from adhesive layer 140 and ink layer 130 which is now bonded to adhesive layer 140 , and is thereby bonded to the article surface.
[0020] In some embodiments transfer coating 140 may also adhere to adhesive layer 140 and remain on the article surface overlaying ink layer 130 . In other embodiments transfer coating 140 may remain bonded to base layer 110 and separate from ink layer 130 and adhesive layer 140 .
[0021] The use of a dry transfer tattoo is well suited for application to a wide variety of articles of apparel, shoes, and accessories. Waterslide tattoos may also be used to apply images, designs, artwork, or text to articles that can be wetted with water and not be damaged. A general configuration of a waterslide tattoo 200 is shown in FIG. 3 . As with tattoo 100 , the material composition of layers 210 , 220 , and 230 as well as the cumulative thickness 260 of tattoo 200 should be such that tattoo 200 with top layer 250 removed is thin and flexible enough so that it may be readily bent and be applied with full surface contact of ink layer 230 across a curved or contoured surface of the article that the ink image is intended to be applied to (e.g. the heel of a waterproof shoe).
[0022] The method of applying a waterslide tattoo 200 is illustrated in FIG. 4 . The first step is to remove top layer 250 of tattoo 200 . This exposes ink layer 230 . The next step is to locate tattoo 200 over a position on the surface of the article of apparel, shoes, or accessories (“article”) where the tattoo image is desired to be placed. Tattoo 200 is then placed on the surface of the article with ink layer 230 on the article surface. The surface of the article where the tattoo is placed should be clean and dry. The next step is to apply water to the outward facing surface of base layer 210 while firmly pressing tattoo 200 on the article surface. The application of water and pressure may be done manually, for example, with a wet sponge. Pressure may preferably be applied continuously and uniformly across the tattoo surface, although a rubbing motion against the tattoo surface may also be used in appropriate circumstances. Once tattoo 200 is thoroughly soaked with water the pressure should be maintained across tattoo 200 for preferably 2-3 minutes. The application of water and pressure causes waterslide material 220 to release from base layer 210 and adhere to the article surface, transferring ink layer 230 to the article surface. In the next step the user manually removes base layer 210 by peeling or sliding it away from the article surface, leaving ink layer 230 and waterslide material 220 on the article surface. After at least several minutes the water will evaporate from the article surface leaving behind the image of ink layer 230 and dried waterslide material 220 . | A convenient and simple method to apply permanent designs, artwork, messages, etc. . . . to shoes by manually by applying a tattoo having a base layer, a top layer, and an intermediate ink layer containing the design, artwork, or message to applied. The ink layer is permanently transferred to the shoe by manually applying pressure or water. | 2 |
BACKGROUND OF THE INVENTION
In U.S. Pat. Nos. 3,883,333 and 4,158,557, continuous glass strand mat is shown being produced by traversing continuous strands across the width of a moving conveyor to provide a mat of a given depth. The mat is passed from the conveyor to a needle loom where it is punctured with barbed needles to entangle the strands to provide a mat having mechanical integrity. The strands of this mat are normally moisture laden as they are placed on the conveyor, i.e. moisture content of 10 to 20 percent or more, since as they are formed, they have an aqueous size applied to them. The mats prepared in the aforementioned patent have found particular utility in the production of fiber glass reinforced thermoplastic stamped parts. The size material utilized in coating the strands used to manufacture the mat are typically aqueous emulsions. The size disclosed in U.S. Pat. No. 3,849,148 being typical of the sizes employed.
In one modification shown in U.S. Pat. No. 4,158,577, mat is produced using forming packages as the strand source rather than fiber forming bushings. The forming package strands still have moisture on them though to a lower degree than the strands used in the bushing process i.e. (5 to 8 percent by weight being typical).
It has been found in the production of needled glass strand mat from wet, sized, continuous glass strand mats, the considerable production time is lost in cleaning of the needle looms used since they become fouled with glass and binder or size ingredients which are coated on the strands. A reduction or elimination of such production losses is therefore desirable.
THE PRESENT INVENTION
In accordance with the instant invention, an improvement in the needling efficiency of processes involving the needling of wet continuous strand mat is achieved by imparting to such mats a series of environmental treatments prior to and during the needling. Thus, in a preferred embodiment of the invention, wet, continuous strand mat after formation is passed through a drying zone in which it is contacted with a low relative humidity gas, preferably air, at temperatures maintained below 120° F. The mat as it emerges from the drying zone is then contacted with a low humidity gas at temperatures below 120° F. at the surface opposed to the surface through which gas was passed in the drying zone. This surface treatment of the mat in the second zone removes residual moisture that tends to form on the mat surface opposed to the surface through which gas was passed in the drying zone. The mat is then passed into a needling zone which is provided with a low humidity environment at temperatures below 120° F. and is maintained as such during needling.
It has further been found that the maintenance of a low humidity environment at temperatures below 120° F. in a needling zone in which glass strand mat containing 1 to 2 percent moisture is being needled in and of itself will reduce fouling in the zone to a significant degree.
BRIEF DESCRIPTION OF THE DRAWING
While the novel features of the invention are set forth more particularly in the appended claims, a full and complete understanding of the invention may be had by referring to the detailed description as set forth hereinafter and as may be seen in the accompanying drawings in which:
FIG. 1 is a diagrammatic side elevation of a continuous strand mat making operation involving mat needling incorporating the present invention; and
FIG. 2 is a diagrammatic, isometric view of a continuous strand mat making operation including a final needling and using the process of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, continuous strand glass mat 1 is formed from a plurality of fiber glass strands 4, 5, 6, and 7 which are projected downwardly onto a conveyor 2, preferably a wire neck chain. While not evident from the drawing, the strands 4, 5, 6, and 7 are traversed across the width of the conveyor 2 on a continuous basis to cover the conveyor 2 with glass strands. The strands 4, 5, 6, and 7 may be drawn directly from a glass fiber forming bushing or from a forming package as shown in the aforementioned U.S. Pat. No. 4,158,557.
The mat 1 having been layered by the plurality of strands 4, 5, 6, and 7 to a desired depth typically contains moisture. If the strands 4, 5, 6, and 7 are originating from a glass fiber forming bushing, this will be in the range of 20 percent or less, typically 12 to 15 percent. If the strands 4, 5, 6, and 7 are being fed from a forming package feed, the moisture content is usually 8 percent or less, typically 4 to 6 percent. The mat 1 is continuously passed through an oven 10. The oven 10 is connected to a duct 11 which is provided with a heater 12, preferably a resistance heater, to heat the gas passed into duct 11. The heated gas which is preferably air is passed into a hood 10a of oven 10 which covers the mat conveyor 2 across its width and extends a distance along the length of the conveyor sufficient to provide a residence time for mat in the oven proper of between 50 and 120 seconds, preferably 70-90. Duct 11 is fed with air at a relative humidity of 60 percent or less, typically at least 20 percent and below 60 percent, preferably 40 percent to 50 percent. The air passes from duct 11 through hood 10a and through the mat 1. The air after passage through the mat 1 is exhausted through the chamber 10b to duct 14.
The mat 1 after passing through the oven 10 is conveyed over an elongated duct 20 which has a slot like opening 21 which extends to across the width of mat 1. Duct 20 is also provided with a heater 22 to heat gas passed into the duct 20 and the gas, again preferably air, is controlled to provide low relative humidity, i.e. 60 percent or less, typically at least 20 percent and below 60 percent. The preferred air stream is passed into contact with the under surface of mat 1 and removes from the surface residual moisture that tends to collect on the bottom surface strands and those close to that surface as a result of the drying in oven 10. It has been found that in oven 10 as the gas passes through the mat, it tends to become saturated or nearly saturated so that, while the bulk of the mat 1 is dried, there is a tendency for the under surface of the mat to retain some moisture.
The mat 7 is then passed between nip roll 3 and drive roll 9 which with roll 8 is used to continuously advance conveyor 2 through the mat forming area. Drive roll 30, and chain 31 associated therewith and idler roll 32, around which chain 30 rides are operated at speeds to draft mat 1 from nip roll 3 to the desired density. Thus mat 1, at whatever its thickness, can be stretched by chain 30 to provide a mat of lower density than the mat between rolls 3 and 9, if desired.
The mat 1 is conveyed from the surface of chain 30 to the needler 50. As shown, needler 50 has a needle board 51 to which are affixed a plurality of needles 52, typically arranged in parallel rows. The needler 50 is provided with a stripper plate 53, with appropriate drilled holes 54, arranged in rows so that needles 52 can readily pass through them during needling. A bed plate 55 is also provided in needler 50 which also has a plurality of holes 56 arranged in rows and sized so that needles 52 of needle board 51 may pass through them. Plate 55 also serves as a surface on which mat 1 rests during its passage through the needler 50. As shown, the needle board 51 reciprocates as depicted by the arrows to push needles 52 through mat 1 and both of the plates 53 and 55 to thereby entangle the strand forming mat 1 during its passage through the needler 50. Mat 1 is advanced through the needler 50 by the drive roller 58 which exerts a pulling force on mat 1. Track 59 is supplied to catch broken glass filaments passing through the holes 56 of plate 55.
The needler 50 and in particular the needling zone, i.e. the area between plates 53 and 55 in needler 50 is environmentally controlled to maintain that zone at temperatures of between about 50° F. to 120° F. and a relative humidity of below 60 percent, typically at least 20 percent and below 60 percent and preferably 40 to 60 percent. The environment is controlled by continually passing gas at low relative humidity into the needling zone from duct 41. Duct 41 has a heater 42 associated with it so that gas passing into the duct can be heated to a desired value and the gas is humidity controlled to provide the requisite relative humidity. The end of duct 41 is provided with a generally rectangular slot 42 extending the width of the needling zone to insure even distribution of the low humidity gas across the entrance to the needler 50.
In FIG. 2, the configuration of the ducts 20 and 41 and their associated slots 21 and 43, respectively, can be seen with more particularity. Similarly, the configuration of the heating oven 10 can be appreciated by view of this FIG. 2.
In practicing the invention in accordance with the system shown in FIGS. 1 and 2, mat containing substantial moisture therein typically 4 to 15 percent is fed continuously to the oven 10. Air at temperature between 70° F. to 120° F. is passed through mat 1 from hood 10a to the collecting duct 14 in sufficient quantities to provide the mat leaving oven 10 with a substantially reduced moisture content, i.e. 1 to 2 percent basis weight of the mat 1. Air is passed across the width of the mat 1 from duct 20 at 70° F. to 120° F. to reduce the moisture content of the mat further and provide the mat entering needler 50 at a moisture content of 0.5 to 1 percent. In needler 50, with the environment controlled at 70° F. to 120° F. and low relative humidity below 60 percent, the continuous strand mat is needled and emerges at a final moisture content of 0.3 percent or less.
It has been found in operating a needled mat production unit in accordance with the environmental procedure set forth hereinabove that bed plate and stripper plate plugging has been substantially reduced thereby providing less process interruptions and a consequent increase in production.
When the system was operated, for example, to produce 100 inch needled mat at a mat feed rate of 16 feet per minute using all three modes of environmental control, oven drying, bottom drying and needler environmental control in an eight hour shift, only one shutdown for cleaning of bed plates was required. Without the bottom dryer on in a similar eight hour run, three shutdowns for cleaning were required. This represented a 40-minute loss of production compared to the first eight hour run. Further, it has been found that with or without the bottom drying system in operation, the environmental control of the needler has substantially eliminated stripper plate build-up that occurs when it is not used.
While the invention has been described with reference to certain specific preferred embodiments, it is not intended that it be so limited except insofar as appears in the accompanying claims. | A process is described for improving needling efficiency in the preparation of continuous fiber glass strand needled mat involving subjecting the continuous glass strand mat to environmental treatments before and during needling to control mat moisture and temperatures. A low relative humidity and warm temperature environment is maintained during needling and the mat is exposed to similar treatment prior to needling. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is related to a co-pending application entitled a same title with the present application, assigned to the same assignee of this application and filed on the same date. The disclosure of the co-pending application is wholly incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention generally relates to illuminating devices, and particularly to an illuminating device incorporating light emitting diodes (LEDs) used for reducing glare generated by the illuminating device.
[0004] 2. Description of Related Art
[0005] With the continuing development of scientific technology, LEDs have been widely used in illumination devices to substitute for conventional cold cathode fluorescent lamps (CCFL) due to their high brightness, long lifespan, and wide color gamut. Relevant subject matter is disclosed in an article entitled “Solid State Lighting: Toward Superior Illumination”, published in a magazine Proceedings of the IEEE, Vol. 93, No. 10, by Michael S. Shur et al. in October, 2005, the disclosure of which is incorporated herein by reference.
[0006] However, glare generated by the illuminating devices is an intense and blinding light, which is harmful to people's eyes.
[0007] Therefore, what is needed is a new illuminating device, which can reduce the glare generated by the illuminating device.
SUMMARY
[0008] The present invention relates to an illuminating device. According to an exemplary embodiment, the illuminating device includes an LED and a light guiding plate. The light guiding plate includes a light incident surface and a light output surface. The LED faces toward the light input surface. The light guiding plate defines a plurality of recesses therein. A fluorescent material is applied to the light guiding plate. The LED is used to emit first light of a first wavelength to excite the fluorescent material thereby producing second light of a second wavelength. The LED and the fluorescent material are arranged in a manner that the combined first and second light emitted from the light output surface appears to be white light.
[0009] Other advantages and novel features of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Many aspects of the present illuminating device can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present illuminating device. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0011] FIG. 1 is a schematic, cross-sectional view of an illuminating device in accordance with a first embodiment of the present invention.
[0012] FIG. 2 is a schematic, cross-sectional view of an illuminating device in accordance with a second embodiment of the present invention.
[0013] FIG. 3 is a schematic, cross-sectional view of an illuminating device in accordance with a third embodiment of the present invention.
[0014] FIG. 4 is a schematic, cross-sectional view of an illuminating device in accordance with a forth embodiment of the present invention.
[0015] FIG. 5 is a schematic, cross-sectional view of an illuminating device in accordance with a fifth embodiment of the present invention.
[0016] FIG. 6 is a schematic, cross-sectional view of an illuminating device in accordance with a sixth embodiment of the present invention.
[0017] FIG. 7 is a schematic, cross-sectional view of an illuminating device in accordance with a seventh embodiment of the present invention.
[0018] FIG. 8 is a schematic, cross-sectional view of an illuminating device in accordance with a eighth embodiment of the present invention.
[0019] FIG. 9 is a schematic, cross-sectional view of an illuminating device in accordance with a ninth embodiment of the present invention.
[0020] FIG. 10 is a schematic, cross-sectional view of an illuminating device in accordance with a tenth embodiment of the present invention.
[0021] FIG. 11 is a schematic, cross-sectional view of an illuminating device in accordance with an eleventh embodiment of the present invention.
DETAILED DESCRIPTION
[0022] Referring to FIG. 1 , an illuminating device 10 in accordance with a first embodiment of the present invention includes a light emitting component, a light guiding plate 13 and a fluorescent material 15 . In the present embodiment, the light emitting component is an LED 11 .
[0023] The LED 11 is disposed at a lateral side of the light guiding plate 13 , for serving as a primary light source.
[0024] The plate 13 is made of transparent materials, such as silicone, resin, glass, polymethyl methacrylate (PMMA), quartz, polycarbonate (PC), epoxy, polyacrylate and so on. The plate 13 has light transparency of 70% and refractive index of 1.4-1.7. The plate 13 has a rectangular shape. The plate 13 includes a light incident surface 136 , a light output surface 132 and a bottom surface 137 opposite to the light output surface 132 . The light incident surface 136 faces toward the LED 11 . A light reflective layer 131 is evenly disposed on the bottom surface 137 , so as to reflect the light emitted from the LED 11 toward the light output surface 132 . It should be understood that the light reflective layer 131 can be disposed on both of the bottom surface 137 and a lateral side surface opposite to the light incident surface 136 .
[0025] The plate 13 defines a plurality of tiny recesses 133 in the light output surface 132 thereof. The recesses 133 are spaced from each other and evenly defined in the light output surface 132 . Each recess 133 has a strip shape from a front end toward a rear end. A width of each recess 133 at a topmost end thereof is less than 5 mm. Each recess 133 includes two slanted sidewalls 135 (only one sidewall is labeled) opposite to each other. Each sidewall 135 is a planar surface. It should be understood that the sidewall 135 can be a curved surface, such as a paraboloid and so on. The recesses 133 can coarsen the slippery light output surface 132 of the plate 13 , thereby preventing total reflection of light at the light output surface 132 . Thus, the light can easily enter the light output surface 132 , and exit out of the plate 13 . In addition, the recesses 133 can minimize an incident angle of the light with respect to the light output surface 132 , which enables the light to form an irregular reflection at the light output surface 132 . Accordingly, the light is emitted out of the light output surface 132 along different directions thus it is evenly distributed. It should be understood that the sidewalls 135 of the recesses 133 can be rough, thereby further enables the light to form an irregular reflection at the light output surface 132 .
[0026] The recesses 132 in the light output surface 132 can be made by micro electro mechanical system (MEMS), injection molding, micro electroforming, lithography, etching and so on.
[0027] The fluorescent material 15 can be made of sulfide, aluminate, oxide, silicate or nitride, such as Ca 2 Al 12 O 19 :Mn, (Ca, Sr, Ba)Al 2 O 4 :Eu, Y 3 Al 5 O 12 :Ce 3+ (YAG), Tb 3 Al 5 O 12 :Ce 3+ (TAG), BaMgAl 10 O 17 :Eu 2+ (Mn 2+ ), Ca 2 Si 5 N 8 : Eu 2+ , (Ca,Sr,Ba)S:Eu 2+ , (Mg, Ca, Sr, Ba) 2 SiO 4 :Eu 2+ , (Mg, Ca, Sr, Ba) 3 Si 2 O 7 :Eu 2+ , Ca 8 Mg(SiO 4 ) 4 Cl 2 :Eu 2+ , Y 2 O 2 S:Eu 3+ , (Sr, Ca, Ba)Si x O y Nz:Eu 2+ , (Ca, Mg, Y)SiwAl x O y N z :Eu 2+ , CdS and so on.
[0028] The fluorescent material 15 is received in the recesses 133 in the light output surface 132 , for serving as a secondary light source. A combination of the fluorescent material 15 and the LED 11 is selected from a group consisting of yellow fluorescent material and blue LED; red and green fluorescent material and blue LED; red, green and blue fluorescent material and ultraviolet LED. The fluorescent material 15 is excited by a part of the light emitted from the LED 11 and emits divergent light along different directions. The light from the fluorescent material 15 is mixed together with the other part of the light emitted from the LED 11 to generate white light.
[0029] Before being received in the recesses 135 , the fluorescent material 15 is mixed together with a liquid-state colloid, such as resin, epoxy, silicone and so on. The mixed fluorescent material 15 is filled into the recesses 135 , and then solidified via heating or ultraviolet. The fluorescent material 15 mixed together with the colloid can prevent the fluorescent material 15 from contacting with outside atmosphere as possible as it can. Thus, the fluorescent material 15 is isolated from the outside atmosphere and can not metamorphose due to contact with the outside atmosphere.
[0030] When the illuminating device 10 operates, the light emitted from the LED 11 enters into the plate 13 through the light incident surface 136 . A part of the light entering into the plate 13 directly emits toward the light output surface 132 of the plate 13 . The other part of the light entering into the plate 13 emits toward the bottom surface 137 , and is reflected by the light reflective layer 131 . The light reflected by the light reflective layer 131 changes its original direction, and emits toward the light output surface 132 of the plate 13 . A part of the light arrived at the light output surface 132 exits the plate 13 at a non-recess position of the light output surface 132 . Another part of the light arrived at the light output surface 132 is refracted through the slanted sidewalls 135 of the recesses 133 , and emits toward the fluorescent material 15 in the recesses 133 . The fluorescent material 15 is accordingly excited by the light and emits divergent light which exits the plate 13 along different directions. The other part of the light arrived at the light output surface 132 is further reflected by the light output surface 132 and the light reflective layer 131 , and finally emits toward the fluorescent material 15 in the recesses 133 . The fluorescent material 15 is accordingly excited and emits divergent light which exits the plate 13 along different directions.
[0031] In the illuminating device 10 , the LED 11 is disposed adjacent to the light incident surface 136 of the plate 13 , and the fluorescent material 15 is received in the recesses 133 of the plate 13 . Namely, the LED 11 is in a distance away from the fluorescent material 15 , which can prevent the fluorescent material 15 from overheating. Accordingly, the lifespan and the performance of the illuminating device 10 can be improved. In addition, the recesses 133 of the plate 13 can prevent total reflection of light at the light output surface 132 as possible as it can, thereby improving the utilization rate of the light. Furthermore, the fluorescent material 15 is received in the recesses 133 in the light output surface 132 , whereby the fluorescent material 15 is excited by the light and emits divergent light exiting the plate 13 along different directions. Accordingly, the light can evenly distribute on the light output surface 132 , which can reduce glare, thus making the light feel more comfortable to the user's eyes.
[0032] Moreover, the fluorescent material 15 is excited by a part of the light emitted from the LED 11 to emit light. The light emitted from the fluorescent material 15 has a different wavelength from the light emitted from the LED 11 . The light emitted from the fluorescent material 15 mixes together with the other part of the light emitted from the LED 11 to generate white light at the light output surface 132 . The white light is favorable to be used in illumination field. Specially, the wavelength of the light emitted from the fluorescent material 15 is greater than that of the light emitted from the LED 11 .
[0033] It should be understood that the LED 11 is not limited to the above-described location. Referring to FIG. 2 , in the illuminating device 20 of the second embodiment, the LED 21 is received in the plate 23 . The LED 21 is embedded in a lateral side of the plate 23 , and is in a distance away from the fluorescent material 15 . The light incident surface 236 is formed at a position of the plate 13 facing toward the LED 21 .
[0034] It should be understood that the recesses 133 in the illuminating device 10 , 20 can also have other arrangements and configurations, as shown in the following embodiments.
[0035] Referring to FIG. 3 , an illuminating device 30 in accordance with a third embodiment of the present invention is shown. The illuminating device 30 is similar to the illuminating device 10 in the first embodiment. In the present embodiment, the recesses 333 in the light output surface 332 of the plate 33 are contiguous with each other. A transmitting manner of the light in the illuminating device 30 is similar to that in the illuminating device 10 .
[0036] Referring to FIG. 4 , an illuminating device 40 in accordance with a forth embodiment of the present invention is shown. The illuminating device 40 is similar to the illuminating device 30 in the third embodiment. In the present embodiment, the recesses 433 in the light output surface 432 of the plate 43 have a depth gradually increasing in a direction away from the LED 11 . An incident angle of the light emitted toward the recess 433 remote from the LED 11 is greater than that the light emitted toward the recess 433 adjacent to the LED 11 , so that the light emitted toward the recess 433 remote from the LED 11 can generate total reflection easily. The recesses 433 having increased depth can prevent the light from generating total reflection. A transmitting manner of the light in the illuminating device 40 is similar to that in the illuminating device 10 .
[0037] Referring to FIG. 5 , an illuminating device 50 in accordance with a fifth embodiment of the present invention is shown. The illuminating device 50 is similar to the illuminating device 40 in the forth embodiment. In the present embodiment, the recesses 533 are defined in the bottom surface 537 of the plate 53 .
[0038] During operation, the light emitted from the LED 11 enters into the plate 53 through the light incident surface 136 . A part of the light entering into the plate 53 directly emits toward the light output surface 132 of the plate 53 . The other part of the light entering into the plate 53 directly emits toward the bottom surface 537 of the plate 53 , or is reflected by the light output surface 132 and emits toward the bottom surface 537 .
[0039] The light arrived at the bottom surface 537 is refracted through the slanted sidewalls 135 of the recesses 533 , and emits toward the fluorescent material 15 in the recesses 533 . The fluorescent material 15 is accordingly excited by the light and emits divergent light along different directions. A part of the light emitted from the fluorescent material 15 directly emits toward the light output surface 132 of the plate 53 . The other part of the light emitted from the fluorescent material 15 is reflected by the light reflective layer 131 , and emits toward the light output surface 132 of the plate 53 .
[0040] A part of the light arrived at the light output surface 132 directly exits the plate 53 through the light output surface 132 . The other part of the light arrived at the light output surface 132 is reflected by the light output surface 132 , and emits toward the recesses 533 on the bottom surface 537 . The fluorescent material 15 in the recesses 533 is accordingly excited by the light and emits divergent light along different directions. As a result, the light emitted from the fluorescent material 15 exits the plate 15 along different directions at the light output surface 132 after further reflection by the light output surface 132 or/and the light reflective layer 131 .
[0041] Referring to FIG. 6 , an illuminating device 60 in accordance with a sixth embodiment of the present invention is shown. The illuminating device 60 is similar to the illuminating devices 40 , 50 in the forth and fifth embodiment. In the present embodiment, the recesses 633 are defined in both of the light output surface 632 and the bottom surface 637 of the plate 63 . A transmitting manner of the light in the illuminating device 60 is similar to that in the illuminating device 10 , 50 .
[0042] It should be understood that the fluorescent material 15 in the illuminating device 10 , 20 , 30 , 40 , 50 , 60 can also have other arrangements, as shown in the following embodiments.
[0043] Referring to FIG. 7 , an illuminating device 70 in accordance with a seventh embodiment of the present invention is shown. The illuminating device 70 is similar to the illuminating device 10 in the first embodiment. In the present embodiment, the fluorescent material 75 is evenly distributed on the bottom surface 737 of the plate 73 and spaced from each other. In other words, the fluorescent material 75 is sandwiched between the bottom surface 737 and the light reflective layer 131 of the plate 73 . The fluorescent material 75 is formed on the bottom surface 737 via imprint technics and so on.
[0044] The light emitted from the LED 11 emits toward the fluorescent material 75 on the bottom surface 737 , and activates the fluorescent material 75 to emit divergent light along different directions. The light emitted form the fluorescent material 75 emits toward the light output surface 732 , and exits the plate 73 after refraction through the recesses 133 .
[0045] Referring to FIG. 8 , an illuminating device 80 in accordance with an eighth embodiment of the present invention is shown. The illuminating device 80 is similar to the illuminating device 70 in the seventh embodiment. In the present embodiment, the fluorescent material 85 is further discretely received in the recesses 833 in the light output surface 832 of the plate 83 .
[0046] Referring to FIG. 9 , an illuminating device 90 in accordance with a ninth embodiment of the present invention is shown. In the present embodiment, the illuminating device 90 includes a light guiding plate 93 , a plurality of LEDs 91 and a plurality of light coupling portions 97 .
[0047] The plate 93 includes a light incident surface 931 at a top end thereof and a light output surface 932 opposite to the light incident surface 931 . The plate 93 defines a plurality of tiny recesses 933 in the light output surface 932 thereof. The recesses 933 are contiguous with each other and evenly defined in the light output surface 932 . A fluorescent material 95 is received in the recesses 933 . The materials made of the fluorescent material 95 is the same as that made of the fluorescent material 15 in the first embodiment. The fluorescent material 95 is excited by a part of the light emitted from the LEDs 91 and emits divergent light along different directions. The light from the fluorescent material 95 is mixed together with the other part of the light emitted from the LEDs 91 to generate a white light.
[0048] The light coupling portions 97 have one-to-one corresponding relationships with respect to the LEDs 91 . Each light coupling portion 97 has a truncated conical shape, and tapers from a bottom end to a top end thereof. Each light coupling portion 97 includes a light incident coupling surface 971 at the top end thereof, a light output coupling surface 972 at the bottom end thereof, and a slanted light reflective surface 973 interconnecting with the incident coupling surface 971 and the output coupling surface 972 . The incident coupling surface 971 is disposed adjacent to the corresponding LED 91 . The output coupling surface 972 faces toward the light incident surface 931 of the plate 93 . The light coupling portions 97 are made of transparent materials, such as silicone, resin and so on. The light coupling portions 97 has light transparency of 70% and refractive index of 1.4-1.7.
[0049] During operation, the light emitted from the LED 91 enters into the corresponding light coupling portion 97 through the incident coupling surface 971 . A part of the light entering into the light coupling portion 97 directly exits the light coupling portion 97 through the output coupling surface 972 . The other part of the light entering into the light coupling portion 97 is total reflected by the light reflective surface 973 , changing its original direction, and exits the light coupling portion 97 through the output coupling surface 972 . The light exiting the light coupling portion 97 enters into the plate 93 through the incident coupling surface 931 . The light entering into plate 93 emits toward the light output surface 932 . The light arrived at the light output surface 932 is refracted through the slanted sidewalls 935 of the recesses 933 , and emits toward the fluorescent material 95 in the recesses 933 . The fluorescent material 95 is accordingly excited by the light and emits divergent light exiting the plate 93 along different directions.
[0050] Referring to FIG. 10 , an illuminating device 90 a in accordance with a tenth embodiment of the present invention is shown. The illuminating device 90 a is similar to the illuminating device 90 in the ninth embodiment. In the present embodiment, the plate 93 a includes a plurality of cavities 934 , a fluorescent material 938 and a dielectric material 939 .
[0051] The cavities 934 are irregularly distributed in an inside of the plate 93 a from the incident coupling surface 931 to the light output surface 932 . The plate 93 a is irradiated by electromagnetic wave having high energy density. As a result, an inner structure of the plate 92 a is destroyed, so as to form the cavities 934 .
[0052] The fluorescent material 938 and the dielectric material 939 are irregularly distributed in the inside of the plate 93 a . The material made of the fluorescent material 938 is the same as that made of the fluorescent material 95 . The dielectric material 939 is made of Al 2 O 3 , TiO 2 , SiO 2 , SiN x , CaF 2 , BaSO 4 , ZnO, B 2 O 3 , Nb 2 O, Na 2 O or Li x O y and so on. The dielectric material 939 enables the light entering into the plate 93 a to scatter, which is favorable to make the light evenly distribute on the light output surface 932 .
[0053] During operation, the light emitted from the LED 91 passes through the corresponding light coupling portion 97 , and enters into the plate 93 a . A part of the light entering into plate 93 a directly emits toward the recesses 933 in the light output surface 932 . Another part of the light entering into plate 93 a emits toward the dielectric material 939 , changing its original direction and emitting toward the recesses 933 in the light output surface 932 . The other part of the light entering into plate 93 a emits toward the fluorescent material 938 . The fluorescent material 938 is accordingly excited by the light, and emits divergent light along different directions toward the recesses 933 in the light output surface 932 . The light emitting toward the recesses 933 in the light output surface 932 is refracted through the slanted sidewalls 935 of the recesses 933 , and emits toward the fluorescent material 95 in the recesses 933 . The fluorescent material 95 is accordingly excited by the light, and emits divergent light exiting the plate 93 a along different directions.
[0054] Referring to FIG. 11 , an illuminating device 90 b in accordance with an eleventh embodiment of the present invention is shown. The illuminating device 90 b is similar to the illuminating device 90 a . In the present embodiment, there is no recess in the light output surface 932 b of the plate 93 b.
[0055] During operation, the light emitted from the LED 91 passes through the corresponding light coupling portion 97 , and enters into the plate 93 b . A part of the light entering into plate 93 b is directly refracted through the light output surface 932 b out of the plate 93 b . Another part of the light entering into plate 93 b emits toward the dielectric material 939 , changing its original direction, and exits the plate 93 b through the light output surface 932 b . The other part of the light entering into plate 93 b emits toward the fluorescent material 938 . The fluorescent material 938 is accordingly excited by the light, and emits divergent light exiting the plate 93 b along different directions.
[0056] Alternatively, the light coupling portion 97 can be detachably engaged with the plate 93 , 93 a , 93 b , or integrally formed with the plate 93 , 93 a , 93 b as a single piece.
[0057] It is believed that the present invention and its advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention. | An illuminating device ( 10 ) includes an LED ( 11 ) and a light guiding plate ( 13 ). The light guiding plate includes a light incident surface ( 136 ) and a light output surface ( 132 ). The LED faces toward the light input surface. The light guiding plate defines a plurality of recesses ( 133 ) therein. A fluorescent material ( 15 ) is applied to the light guiding plate. The LED is used to emit first light of a first wavelength to excite the fluorescent material thereby producing second light of a second wavelength. The LED and the fluorescent material are arranged in a manner that the combined first and second light emitted from the light output surface appears to be white light. | 6 |
BACKGROUND OF INVENTION
This is a continuation-in-part of my application Ser. No. 339,333 entitled, "A Vaulted Membrane Structure" filed Mar. 8, 1973 which is a continuation-in-part of my application Ser. No. 93,293 filed Nov. 27, 1970, now abandoned.
These applications are related to my arch supported shelter patents such as U.S. Pat. Nos. 3,215,153; 3,273,574; 3,820,553; 3,388,711; 3,856,029 and others that feature both inclined and vertical arch structures with highly tensioned membranes in double curvature.
SUMMARY OF INVENTION
The principal object of this invention is to provide a shelter of this type in which the tendency of the covering material and/or membrane to wrinkle and to flutter or vibrate in gusty or strong winds is minimized and the ability of the covering material to carry heavy loads of snow, ice and wind without undue stain is increased by sufficient curved depression of the tensioned covering material.
Another object of this invention is to provide a simplified membrane attachments to the arches which support it and an economical method to tension the membrane(s) between the arches.
Still another object of this invention is to provide a membrane that can be stretched over or between the arches, with the curvature between arches desired, and tensioned to the base to provide a practically wrinkle-free covering.
Another object of this invention is to provide sufficient sag or inward curvature between the arches of at least 5-10% of the distance between the arches. When the membrane is tensioned to a stiffened, wrinkle-free state, it will oppose deflection and movement of the arches and add great stability and resilent rigidity to the shelter.
Another object of this invention is to provide openings in the membrane side walls for ventilation, ingress-egress, etc., under tension rings embodied in the lower part of the membrane between arches, that can be easily opened or closed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation of a vaulted structure in accordance with the invention.
FIG. 2 is a left end elevation of FIG. 1.
FIG. 3 illustrates one method of assembling the structure shown in FIG. 1 and 2.
FIG. 4 is a simplified schematic sketch of pivotal arches with offset hinges to move the arches apart in the erected position.
FIG. 5 shows a membrane attachment to the arches in the section 6--6 in FIG. 1.
FIG. 5a shows another membrane attachment to an arch suitable for small structures.
FIG. 5b illustrates a membrane attachment to an arch for a one piece cover or for large sections that span several arches.
FIG. 6 is a section at the base of lines 6--6 in FIG. 1.
FIG. 7 is a section at a right angle to FIG. 6 through the lower end of an arch.
FIG. 8 is a top plan view of another shelter in accordance with the invention.
FIG. 9 is an enlarged view of the section line 9--9 of FIG. 8.
FIG. 10 is an enlarged view of the section of one of the arches shown in FIG. 9.
FIG. 11 is a view of the line 11--11 of FIG. 9.
FIG. 12 is a thumbnail perspective of a typical small shelter of this specie.
FIG. 13 is a schematic sketch illustrating the tangential pull of an inwardly curved membrane on a support arch.
FIG. 14 schematically illustrates one method of fabricating an inward curvature in a roof membrane between support arches.
FIG. 15 schematically illustrates how an arch is "captured" by tension members much like spokes of a bicycle wheel captures the rim and prevents rim deflection.
FIG. 16 schematically illustrates how tension members or a membrane captures the arch in these structures.
FIG. 17 illustrates a sub-base such as a base rail with a sliding arch attachment means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The vaulted structure shown in FIGS. 1 & 2 series of curved arches 1 mounted on the ground or other base 2 to serve as a frame to support a tensioned membrane 3 which extends between the arches and is operatively attached to them. The membrane usually consists of a suitable fabric, coated fabric or other flexible membrane material that is stretchable within limits and is selected to serve within its elastic limits.
When the shelter is made in modules the membrane 3 is usually made in panels that extend between the arches and is attached to them through the intermediary of a fastening means 4, 4' and 4" such as shown in FIGS. 5, 5a & 5b respectfully.
This fastening means 5, and 4' consists of tunnel 5 and 5' in FIG. 5 and FIG. 5a respectfully, through which a beaded edge 9 and 9' of the membrane extends with the membrane emerging through a slit 7 and 7' in the tunnel wall respectfully. In the case of FIG. 5, the fastening means 10 is made of a fairly hard rubber type material so that the slots 7 can be opened to admit the beaded edge into the tunnels 5 when tunnel 6 is empty. After the beads 9 are inserted in the tunnels 5, a filler strip is inserted in the tunnel 6 that locks the lips 7 of tunnel 5 to retain the beaded edge in the tunnel 5.
The fastening means 4' shown in FIG. 5a, is usually made of metal with fixed tunnels 5' which can be extruded in the fastener or the arch. In this case, the beaded edges 9' must be inserted in the tunnels 5' by threading the beaded edge 9' in the tunnel 5' by sliding the membrane 3 in the slot 7' along the arch 1' or sliding the arch along the edge of the membrane. The fastener 4' can be fastened to the arch 1' by spot welding or metal fasteners. This fastener is used mostly for small structures where the arches and membranes to be attached are easy to handle.
The fastening means illustrated in FIG. 5b is adaptable when the membrane 3 is made in one piece or in large pieces that span several arches 1". The membrane 3 fits over the arches 1" and is usually attached to the arches 1" by a fastening means 4" that is in the form of a boot that enclosed the arch 1". The lacing 10" that holds boot together between grommets 10'", could be comparable to the lips 10 and 10' of the fasteners in FIG. 5 and FIG. 5a. The boot 4" is welded or sewn to the cover 3. The boot 4" is usually installed on the crown on the arches and extends over only 10-20% of the arch span.
The panels of the covering material are made in curved trough-shaped surfaces 13 to minimize the tendency of the material to flutter and vibrate in gusty winds and to enhance its ability to carry heavy loads of snow, ice and wind without undue strain. The maximum depression of the panels between the arches is preferably at least 5-10% of the distance between the arches.
The frame of arches 1 can be erected in various ways: by pivoting the arches on the base, with or without the membrane attached; by lifting each arch individually and fixing it in space by such means as the cables 22, 23 & 24, by pivotal raising or just lifting several arches, with or without the membrane attached, to their erected position; then fixing them in place by means of the cables 24, or purlins 35, or by means of the end closure 25 comprised of membranes 29 with arches 27 or the end closure 26 comprised of membranes 30 and semi-arches 28.
The arches 1 can be properly spaced by moving their ends apart on the base and spacing their summits by stretching the membranes 3 to a predetermined tension, or by the use of purlins, or the cable 22. The latter can act as a safety means to prevent collapse in case of membrane failure. In any case, the arches can be properly aligned in their upright position by guys 23 connected to the middle pair of arches and to the base 2. Guys 24 are connected to the outermost arches and to the base to hold the arches apart when the membrane 3 is tensioned or the guys 24 can also be used to pull the arches apart to tension the membrane above the base and to align the arches. Pulling down on the arches 27 in the end closure 25, on the right side of FIG. 1, can also tension the membrane 3.
To impart a wrinkle free trough-shape to the widths of covering material in some shelters, the following expedient can be employed instead of starting with exact preformed widths:
To start with, a width of covering material 3 of of nearly rectangular or other appropriate shape and of the length necessary to follow the contour of the arches 1 and with an inward curvature or trough shape having the proper width with beaded edges 9 is employed. This width is attached to a pair of arches 1 in the manner described. Then the edges of width are stretched to the extent necessary to make them of the same length as the periphery of the arches by drawing their ends down to the bottoms of the legs of the arches as diagrammatically indicated in FIG. 3 in which the broken line a indicates the disposition of the lower edge of the width before the lateral edges are stretched. This may be done either by pulling the lower ends of the edges of the width to the bottoms of the legs or by anchoring the lower ends of the edges and raising the bottoms of the legs. When the lateral edges of the width have been drawn down to the bottoms of the legs of the arches, they are clamped there by bolts 16 and jaws 17. The stretching operation is illustrated as it is in FIG. 3 primarily to facilitate and simplify illustration, but it may also actually be done while the arches are in upright positions as well as when they are in recumbent positions.
In somewhat larger or medium size structures, it is much easier to tension the lower portion of the panels 13 between the arches by stretching the panels toward the base by the use of tension rings as described in FIGS. 8-11. The membrane can continue under the tension ring to the base. A detachable arrangement is generally used so that the portion of the membrane below the tension ring may be raised to create an opening under the tension ring for egress, ventilation or both.
Suitable closures may be provided for one or both ends of the structure such as the accordion-like structures 25 and 26 shown in the drawing, which may be collapsed to open the ends. The closures 25 and 26 are generally similar in construction to the body of the structure in that they are made up of arches 27 in the case of the closure 25 and semi-arches 28 in the case of the closure 26 and widths 29 and 30 of flexible covering material which extend between and are attached to the arches. Membrane base rail 48 or to a sub-base. In some structures such as car parts or farm shelters it is not necessary to provide floor slabs or base rails as the arches can be separated manually and staked to the ground. The membrand 52 under the tension ring 53 may be omitted and the roof membrane may extend to the ground where it can be fastened continuously or intermittently to the ground or to a spacer, such as wood strut, between the ends of the arches 51.
The inward curvature between the arches 54 illustrates very well how the membrane captures the supporting arches 51 and 49 and opposes arch deflection. This allows the use of smaller arch cross-section and/or lower moment of inertia. The arches can be flexible like aircraft wings or automobile frames and still serve as a stable, safe and dependable support frame for the tensioned membranes.
FIG. 13 illustrates further how the membrane captures the arches if sufficient inward curvature is fabricated in the membrane 55 supported by the arches 56. The tangent line 57 indicates the line of force exerted by the tensioned membrane 55.
FIG. 14 illustrates one method of fabricating the inward curvature or trough shaped membrane between the support arches. Panels 58 are patterned in hour glass shapes, then fastened together 59 to form a trough 60. This trough can be varible from crown to the base or it can be always the same depth for economy or to meet required environmental conditions as the inward curvature enables the membrane to carry heavy live loads without undue stress and the double curvature opposes vibration and flutter of the membrane. The membrane panels 58 do not need to be cut or patterned in this shape but they must be fastened together with seams of this shape or otherwise to create the curved trough shape. FIG. 14 was included in the application Ser. No. 225,899 filed Feb. 14, 1972 in which it was shown as FIG. 16.
FIG. 15 illustrates how an arch 61 would be captured by spokes 62 similar to a bicycle wheel with a wide hub.
In FIG. 16 the same analogy is used to illustrate how the arch 63 is captured with spokes 64 that have a similar slope as the tangents 57 in FIG. 13. By assuming the components are the same in FIGS. 15 & 16, except for the length of the spokes, the arch in FIG. 16 has sacrificed some vertical stability but has gained some lateral stability and also gained ground area covered by the spokes. The comprise to provide sheltered are without sacrificing too much vertical stability is apparent.
In FIG. 17 illustrates a means whereby the arches can be mounted to swing and also moved toward and away from each other as stated previously. A base rail 65 can be anchored to a base or the ground by bolting or otherwise anchoring through the hole in plate 66 which is fastened to the base rail in a location that will not interfere with the movement of the arches to tension the membranes. The arch is pivotably attached to the component 67 which slides on and encompasses the base rail thus securing the arch to the base. Actually, once the shelter is erected and the membrane is anchored to the base, or a sub-base or base rail, the anchoring of the arch becomes only a positioning device as the strong membrane can keep the shelter from blowing away. The base rail 65 can be continuous or segmented. In smaller structures, the arches can be mounted directly on a base or non-sliding sub-bases.
However, the arches 27 of the closure 25 are mounted on the base 2 near the lower ends of one of the outermost arches 1 to swing about a horizontal axis upwardly to collapse the closure and open the end of the structure and downwardly to close it.
The summits of the semi-arches 28 of the closure 26, on the other hand, converge at the summit of the other outermost arch 1. The closure 26 is made in two halves which meet at a projection of the center line of the structure to close the end of the structure. The semi-arches are, however, mounted to swing about a vertical axis at the point of convergence of their summits to collapse each half against a leg of the end arch 1 and open the end of the structure.
Vaulted structures in accordance with my invention may be curvilinear of circular or ellipsoidal in shape instead of straight and include modules of different widths, shapes and materials.
Different means of attachment of the covering material to the arches and different methods of depressing and tensioning the flexible covering material between the arches may be also employed. A structure in which some of these and additional features are employed is illustrated in FIGS. 8-11.
The structure shown in FIGS. 8-11 is shaped like an ellipsoid or an elongated doughnut. It consists of two similar straight sections 32 disposed side by side with their ends interconnected by curved sections 33.
The sections 32 are similar in a general way to the body of the structure shown in FIGS. 1-7 and the sections 33 are also generally similar except in the arches 34 converge toward their inner sides and the modules are, therefore, frusto-triangular instead of rectangular in plan. The arches 34 are kept properly spaced by purline 35. An entry or entries 36 with door or doors in them may be provided in one or more of the modules.
The arches may or may not be mounted to swing on the ground or other base 2 but, in either event, they are mounted so that they may be moved toward and away from each other to facilitate the attachment of covering material 37 to the arches to align the arches 1 and, in some cases, to adjust the tension in the membrane 13.
The arches 1 & 34 may be made of curved laminated wood, metal, composites or other material. Another method of attaching the flexible membrane panels 37 to the arches is shown in FIG. 10, where there is provided in each side of the arches, a tunnel 38 into which extends a lock slot 39 through which the beads 40 on the edges of the widths 37 may be introduced into the tunnels. To hold the beads in the tunnels there are provided lock strips 41.
After the panels of covering material are attached to the arches and the arches are erected, one method of tensioning the panels is to move the arches apart sufficiently to tension the panels within their lower elastic limit. The cables 24 may be used to hold the arches apart or the end closures 25 & 26 with their respective arches and membranes can be used to hold the arches apart. The panels 3 are then pulled downward, toward the base 2 and attached to it to maintain the tension in the lower portion of the membrane.
In the panels 37 of covering material employed in the structure shown in FIGS. 8-11, a means to tension and depress the panels of covering material between the arches near the base, in large structures, there is provided, near the lower edges of the panels, one or more tension rings 42 of the type disclosed in my application entitled, "Prestressed Arch Supported Membrane Shelter," Ser. No. 336,228 filed Feb. 27, 1973 , now abandoned. Where tension rings are used there should be provided at least one tension ring for each surface 13. Each of these tension rings consists of a cable 43 which extends through an arches tunnel 44 embodied in or on the panel of covering material with its ends attached to the base 2 or to the ends of the arches 34. The cable may itself be a spring member or be attached to the base by a spring as shown in my application above identified.
In any event the cables 44 are tensioned sufficiently to draw the edges of the panels of covering material towards the base, tension the membrane widths with a depressed, intermediate portion of the panels as indicated at 45 in FIGS. 9 & 11. The curved depression can vary from crown to base, as desired, or load conditions dictate.
The roof membrane may be attached directly to the base without an inward depression along the base, if side snow loads, by drifting or piling, are below the membrane elastic limit. Above this area, the membrane curves transversely with the arches and inwardly between the arches longitudinally.
While such structures as this are classed as "tentage," these structures are as different from the popular tents of yesterday as day and night. Large tents were mad primarily of canvas that was dimensionally sensitive to humidity which made it a constant maintainance problem. It was also comparatively weak in tensile stress -- usually around 50 lbs. per inch of width. In tents, these low strength membranes only served as the roof of the shelter that vibrated and galloped in high winds to destructive states. It contributed nothing to the horizontal stability of the tent.
The membranes available today have tensil strengths of up to 30 or more times the strength of the canvas used in the old tents, are reasonably stable in wide ranges of weather conditions and have much longer life expectancy. in these new structures, the curved membranes not only serve as strong roof and walls, but they contribute vital stability without vibration to the shelter. In intermediate and large structures, the horizontal movement of the arches apart from each other tensions the membrane longitudinally which, in turn, decreases the inward curvature of the membrane (to a pre-determined degree) which simultaneously tensions the membrane transversely. The degree of decrease in curvature depends on the fabric weave and the stretch due to tension. Wrinkle-free membranes, stiffened under high initial tension in a double curvature configuration within the lower range of their elastic limits, make these structures feasible and economical. | A vaulted membrane shelter comprising a multiplicity of vertical arches with curved bights, spaced apart, mounted on a base forming a frame that supports a flexible highly tensioned roof membrane operatively attached to the arches and curved concavely inward between them sufficiently to enhance its live roof load carrying capacity, to oppose arch deflection thereby increasing stability and to form a roof of double curvature to prevent membrane vibration and flutter. The membrane being tensioned longitudinally by arch separation movement which, in turn, tensions it transversely by slightly decreasing its inward curvature. Sufficient inward membrane curvature controls arch deflection within the elastic limits of membrane, similar to the way bicycle wheel spokes control deflection of the rim. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/236,373 (CK063L), filed Aug. 24, 2009, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The embodiments discussed herein cover the fabrication and use of a free floating element in a micro electro mechanical system (MEMS) that is un-tethered during the release process. The embodiments can be used in a rocker design where the free floating element lands on a rocking post and has two stable positions, either leaning to the left or leaning to the right. Such a structure can be used as a bi-stable switch for optical applications. An array of these floating rockers can be used for video projectors. These projectors can be used in conjunction with a computer for presentations or for video entertainment or in high definition applications as a cinema projector. The same technology can also be used for back projection TV. Because it is not mechanically tethered like a cantilever or tethered rocker, the floating rocker is only held in any stable position by adhesion forces. The floating rocker can be switched using any force, from inertial, magnetic and electrostatic. The advantage of not having a spring like cantilever attachment means that the floating rocker can move between one stable state and the next very quickly as there is no spring like restoring force from the cantilever to overcome. This allows for faster dithering and giving a better image with less perceptible flicker and better control of color and grey scale. It is also better for games applications or sports programs. Not having the restoring spring reduces the cost of manufacture as fewer processing steps are utilized to fabricate the device and variation in the production of the spring arms is removed. Also, not having a restoring spring like arm, variations in temperature do not alter the switching properties, making the switching properties less susceptible to temperature variations. Because the mirror is now not attached, more of the area can be used for reflection as there is no need to connect the mirror to the substrate with a via as is required if it is tethered.
2. Description of the Related Art
One problem that is often encountered with the fabrication of MEMS devices is that when they are designed as cantilevers, there is a variation in the restoring force of the cantilever due to variations in the width, thickness and length as well as adhesion forces at the cantilever. The spring like arm which is normally used to hold a spring like rocker in position is removed in the case of the floating rocker. This spring like arm sets the voltage required for switching and is sensitive to variations in the processing parameters such as the lithographic width and length.
When the rocker touches down, variations in adhesion also come into play. In making a display, it is important that each pixel is closely spaced giving a high packing density. This means that there is not room to fit the restoring arm in the same metallization layer as the reflective pixel material. Also, the reflective pixel material has to be optimized for high reflectivity and so can not be made at the same time as the spring arm which needs to be thin to make it compliant.
The use of a free floating element has been discussed before in U.S. Pat. No. 6,441,405 (B1). That patent discussed the use of a free floating element and how it has advantages over a cantilever, but does not fully disclose how this can be used to make a bi-stable rocker display which will not switch due to variations in temperature.
SUMMARY OF THE INVENTION
Using a floating rocker, the variations in the spring like restoring arm are removed and the adhesion is used to hold the rocker either rocked one way or the other. In normal operation as a switch, the floating rocker would be operated by applying voltages to an electrode under one side or other of the rocker. With a transparent package above the floating rocker, this device could be used as a pixel in a projection display chip. By measuring the electrical resistance through the rocker pivot to one end or the other, the position of the rocker can be continually monitored.
The current disclosure shows how to make a fast switching array of mirrors for projection displays. Because the mirror does not have a via in the middle connecting to the underlying spring support, there is an improved contrast ratio that results from not having light scatter off the legs or vias like existing technologies. Because there are no supporting contacts, the mirror can be made smaller making smaller pixels that can be used to make higher density displays. In addition, because there is not restoring force from any supporting spring support, the mirror stays in place facing one or other direction due to adhesion. This means there is no need to use a voltage to hold the mirror in position. This means that less power is required to run the display.
To operate the display each pixel can be twinned with an SRAM memory cell so the information required for the pixels next action is stored into the SRAM. The fact there is no restoring force also means full mechanical latching based on stiction. This allows for the data under the pixel to be written prior to reset for better memory efficiency and better overall optical efficiency. When the memory state of the SRAM is changed, the pixel won't follow because the adhesion keeps it in place until the reset pulse is applied. This reset pulse is large enough to overcome the adhesion force.
In one embodiment, a floating rocker MEMS device fabrication method is disclosed. The method includes depositing a first titanium nitride layer over a substrate, patterning the first titanium nitride layer and etching the first titanium nitride layer. The method also includes depositing a second titanium nitride layer over the etched, first titanium nitride layer, patterning the second titanium nitride layer and etching the second titanium nitride layer. The method also includes depositing a first sacrificial layer over the etched, second titanium nitride layer, patterning the first sacrificial layer and etching the first sacrificial layer. The method also includes depositing a mirror layer over the etched, first sacrificial layer, depositing a second sacrificial layer over the mirror layer and depositing a transparent layer over the second sacrificial layer to encapsulate the second sacrificial layer, the mirror layer, the etched, first sacrificial layer, the etched, second titanium nitride layer and the etched, first titanium nitride layer. The method also includes etching a hole through the transparent layer, plasma etching the second sacrificial layer and the etched, first sacrificial layer to form a discrete, floating rocker and filling the hole with a material selected from the group consisting of metal and dielectric material.
In another embodiment, a floating rocker MEMS device fabrication method is disclosed. The method includes depositing a first titanium nitride layer over a substrate, patterning the first titanium nitride layer and etching the first titanium nitride layer. The method also includes depositing a second titanium nitride layer over the etched, first titanium nitride layer, patterning the second titanium nitride layer and etching the second titanium nitride layer. The method also includes depositing a first sacrificial layer over the etched, second titanium nitride layer, patterning the first sacrificial layer and etching the first sacrificial layer. The method also includes depositing a mirror layer over the etched, first sacrificial layer, depositing a second sacrificial layer over the mirror layer and depositing a transparent layer over the second sacrificial layer to encapsulate the second sacrificial layer, the mirror layer, the etched, first sacrificial layer, the etched, second titanium nitride layer and the etched, first titanium nitride layer. The method also includes patterning the transparent layer, plasma etching the second sacrificial layer and the etched, first sacrificial layer to form a discrete, floating rocker and packaging the discrete, floating rocker.
In another embodiment, a floating rocker MEMS device fabrication method is disclosed. The method includes depositing a conductive layer over a first sacrificial layer and one or more conductive electrodes and depositing a second sacrificial layer over the conductive layer. The method also includes enclosing the first sacrificial layer, conductive layer and second sacrificial layer within a cavity. The method additionally includes removing the second sacrificial layer and the first sacrificial layer to release the conductive layer within the cavity such that the conductive layer forms a discrete, floating rocker that rests on a fulcrum and pivots into and out of contact with the one or more conductive electrodes. The cavity is then sealed.
In another embodiment, a floating MEMS device fabrication method is disclosed. The method includes depositing a conductive layer over a first sacrificial layer and a plurality of conductive electrodes, patterning the conductive layer to form a first mirror element and a second mirror element, and depositing a second sacrificial layer over the first mirror element and the second mirror element. The method also includes enclosing the first sacrificial layer, first mirror element, the second mirror element and second sacrificial layer within a cavity and removing the second sacrificial layer and the first sacrificial layer to release the first mirror element and the second mirror element within the cavity such that the first mirror element is a discrete, floating first rocker that rests on a first fulcrum and pivots into and out of contact with a first conductive electrode of the plurality of conductive electrodes and the second mirror element is a discrete, floating second rocker that rests on a second fulcrum and pivots into and out of contact with a second conductive electrode of the plurality of conductive electrodes. The cavity is then sealed.
In another embodiment, a method includes applying a first electrical current to one or more electrodes to pivot one or more discrete mirror elements on a fulcrum, shining light through a first lens onto the one or more discrete mirror elements, and shining the reflected light through a second lens onto a screen.
It is to be understood that the first sacrificial layer, the reflective metal layer (or mirror layer) and the second or top sacrificial layer may be etched together in the same step and same process using the same etchant.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1A i-vii shows part of the fabrication process.
FIG. 1B i-iv shows the second half of the fabrication process.
FIG. 1C i-iv shows an alternative fabrication process which is later packaged with a transparent top window in a controlled atmosphere.
FIG. 2 shows a floating rocker arrangement according to one embodiment.
FIG. 3 shows a floating rocker arrangement according to another embodiment.
FIG. 4A shows a top view of four pixels after the switching electrodes (P 2 and P 1 ), landing electrodes (D and C) and post G have been fabricated.
FIG. 4B shows a top cap patterned 14 deposited on top of FIG. 4A and then etched to reveal the side tabs of the sacrificial layers.
FIG. 4C shows the sacrificial material of FIG. 4B removed.
FIG. 5 shows light shining through lens L 1 and focused through the spinning color wheel.
FIG. 6 shows light coming from a 3 color (red, yellow and blue) LED light source through lens L 1 onto the array of tilting mirrors.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.
DETAILED DESCRIPTION
FIG. 1A shows how the floating rocker device could be manufactured. Initially the substrate material is prepared with vias 3 from metal tracks 2 leading up through an insulating layer that could be silicon dioxide or silicon nitride or some other insulating or semi-insulating layer. This could be the interlayer dielectric of a CMOS device with active CMOS addressing for the mirror array defined underneath. The first MEMS layer to be deposited could be a TiN layer which will be used for part of the base for the post 6 which the rocker will land on when released. The first MEMS layer is patterned using optical lithography processes usually found in semiconductor processing plant. The optical lithography processes could include wet etching of the metal layer under a patterned resist layer or dry etching of the layer using a plasma etch process.
After the first MEMS layer is etched to leave the base of the post 6 , a second layer which may also be TiN, will be deposited. The second layer is then patterned and etched to form the landing electrodes 8 and 10 as well as the switching electrodes 7 and 9 and the top part of post 6 . Next a sacrificial layer 11 is put down. The sacrificial layer 11 could be a SiN layer or a spin on glass or any other sacrificial layer that can be removed using reactive ion etching. The sacrificial layer 11 is then patterned into a shape that could also have lateral protrusions (see later figure) which could provide lateral release channels to allow the sacrificial layer 11 to be etched out through a hole in a side wall surrounding the mirror.
The mirror layer 12 is then deposited onto the sacrificial layer 11 . The mirror layer 12 could consist of a thin TiN base to provide good electrical contact to the central pillar capped with a thick Al layer which is thermally heat treated to ensure a very smooth reflective surface.
A second sacrificial layer 13 is then deposited onto the wafer and then patterned into an appropriate shape. The second sacrificial layer 13 could be the same sacrificial material as sacrificial layer 11 or could be a different material. For designs which are micro encapsulated, a transparent layer 14 is not deposited over the second sacrificial layer 13 . The second sacrificial layer 13 could be silicon dioxide or silicon nitride with a thickness that provides mechanical strength but does not lead to any significant optical absorption. The two sacrificial layer thicknesses and pillar height are chosen so that the rocker can pivot without touching the top window. The top sacrificial layer and top window also has to be chosen so that when the rocker pivots it does not cause Fabry-Perot resonances between light reflected off the rocker interfering with light reflected off the inside of the window.
A hole is then etched through the material coating the top sacrificial layer, either from the top as shown or from the side. The sacrificial layer is then etched away using a plasma etch process. The etch holes are positioned to etch out the sacrificial material first around the post and landing electrodes. This ensures that they are clean before the rest of the sacrificial layer is removed and the rocker is pulled down to the substrate by van der Waals forces. The ratio of the top sacrificial layer to the bottom sacrificial layer is chosen so that the adhesion forces are larger underneath the rocker than those above. This ensures the rocker is always pulled down on release.
In some embodiments it may be useful to use an indium tin oxide or other conducting transparent electrode for the top window. This ensures the rockers are not disturbed by external electric fields. Finally a metal layer (or dielectric layer) 16 is deposited to fill the hole through which the sacrificial material has been removed. The metal or dielectric layer 16 is then removed from over the top of the window where the rocker mirror is. The metal or dielectric layer 16 should be deposited in the same chamber of a cluster tool that the sacrificial material was removed in. This ensures that the devices are never exposed to air during the release and seal process creating a cavity for each mirror which has a low pressure controlled atmosphere.
The device could also be made with no top window as is shown in FIG. 1C . In this case the fabrication process is stopped at position ii in FIG. 1B . Then, a cap layer is added over the top sacrificial layer. This could be a transparent insulator or a reflective metallic layer. The cap layer is then patterned to open a large hole over the mirror. The cap layer is designed to have an opening as large as possible, but small enough to prevent the mirrors from coming out through the hole once the sacrificial layer is removed. FIG. 1C ii shows the removal of the sacrificial layer and the mirror dropping down on the post.
In the next process the device is housed in a package with a controlled atmosphere and a transparent optical window. The packaging process is a post processing process similar to that used in current MEMS packaging. The device is tested before being diced and packaged it is then coated with a sacrificial layer which holds the mirrors in place. This is shown in as layer 17 in FIG. 1C iv.
It is to be understood that the first sacrificial layer, the reflective metal layer (or mirror layer) and the second or top sacrificial layer may be etched together in the same step and same process using the same etchant. Additionally, while description of the MEMS layer, landing electrodes, and mirror layer have been described with reference to titanium nitride, it is to be understood that the material may comprise an aluminum overcoat to increase the reflectivity of the material. Another suitable conductive material that may be used is TiAlN. Regardless of what material is used for the MEMS layer, landing electrodes, and mirror layer, the materials may be overcoated with a reflective material such as aluminum.
FIG. 2 shows two rocker mirrors in their own encapsulation. Rocker A sits on post G and can be switched from left to right using electrodes P 1 and P 2 . The rocker lands on electrodes C and D. The state of the rocker can be inferred by measuring the resistance between C and G. In this embodiment each element is housed in its own cavity made from transparent material.
The mirrors have two stable states, either rocked to the left with the rocker landed on post A and touching landing electrode D or leaning to the right with the rocker on post A and touching landing electrode C. The rocker is moved from left to right using pull in electrode P 1 and from right to left using pull in electrode P 2 .
For efficient operation of the display the pixels can be positioned above an SRAM memory cell. The data required for the next pixel operation is housed in the SRAM cell and then the voltage pulse is sent to the pixel to switch it to the next state. Because the switching voltage needs to overcome the adhesion force, the stray voltages applied to the SRAM would normally cause the mirror to move slightly, this is not an issue in the case of the unattached mirror because it is held in place by the adhesion force.
FIG. 3 shows the embodiment which is packaged with a top window instead of being micro encapsulated during processing. Rocker A sits on post G and can be switched from left to right using electrodes P 1 and P 2 . The rocker lands on electrodes C and D. The state of the rocker can be inferred by measuring the resistance between C and G. In this embodiment each element is housed in its own cavity made from transparent material.
The packaged rockers can be designed to move over a wider range of angles, but is more expensive to produce. Two possible implementations for using such a device are shown in FIGS. 5 and 6 . In FIG. 5 the array is shown to the left and is positioned such that when a mirror pixel is fully to the left the light shines on the optical sync and if it rocks to the right is shines through lens L 3 to be focused on to the screen.
FIGS. 4A-4C show a top view of an array of four pixels at various times during the fabrication process. The patterned first sacrificial layers 11 and 13 (shown transparent) and the floating pixel rocker shown transparent grey with doted line edges 12 or A.
FIG. 4B shows the top cap patterned 14 , deposited on top, and then etched to reveal the side tabs of the sacrificial layers. The side tabs then provide a channel for etching out the sacrificial material under the top cap in the same chamber the seal material is then deposited as shown in FIG. 4C .
In FIG. 4C , the sacrificial material has been removed from under and above the rocker and a sealing layer 16 has been applied to provide a sealed transparent cavity over the floating rocker which is in turn sitting on a rocking post above the switching and landing electrodes.
In FIG. 5 , light shines through lens L 1 and is focused through the spinning color wheel. The light is then focused through lens L 2 onto the array of tilting mirrors. If the mirrors are tilting one way the light from the color wheel is directed through lens L 3 to the screen. When the mirror is tilted in the other direction the light is focused into a light sync where it is captured. The individual mirrors are dithered in time with the red, blue, yellow and white sectors of the light wheel to produce the correct color on the screen. The color are mixed by modulating faster than the eye can see so that over a short period of time each pixel can project different colors for different periods of time to give a combined color. In the case of FIG. 5 a white light is used in combination with a color wheel to produce a strobe of red, yellow blue and white. By rotating the mirrors in time with the appropriate flashing color that color can be projected onto the screen.
An alternative technique is shown in FIG. 6 where the color wheel and white lamp is replaced by different colored bright light emitting diodes (LEDs). These can be very quickly electrically switched making it easier to switch quickly which fits in well with the fast switching speed of these free floating rockers.
In FIG. 6 , the light comes from a 3 color (red, yellow and blue) LED light source through lens L 1 onto the array of tilting mirrors. If the mirrors are tilting one way, the light from the color LED is directed through lens L 3 to the screen. When the mirror is tiled in the other direction the light is focused into a light sync where it is captured. The individual mirrors are dithered in time with the red, blue, and yellow LEDs to produce the correct color on the screen. The color are mixed by modulating faster than the eye can see so that over a short period of time each pixel can project different colors for different periods of time to give a combined color.
The floating rocker device described herein may be used in a non-volatile pixel mode so holding a pixel state latched via electrostatic voltage is not required. The state of the display would remain without additional power being consumed. The floating rocker device may be used in a nonvolatile pixel operated in a mode where only the changing data is sent to the array allowing for a reduction in data bandwidth requirements. The non changing data would not lose its state. The floating rocker device may also be used in a nonvolatile pixel operated in a mode where the entire display is parked in the dark state (all pixels in the array are parked where the reflected light cone is out of the display aperture) and then only bright state bits are updated reducing data bandwidth requirements. The floating rocker device may also be used in a nonvolatile pixel enabled from a single transistor for bright state changes while the off state electrode is driven for an array wide clear or a clear in blocks. The floating rocker device may also be used in a nonvolatile pixel that is cross-point addressed, that is not encapsulated and packaged using tradition means, that is used to optically read the memory bit state after a power failure or during a catastrophic event, that is used for imaging UV light (printing), that is used for imaging coherent IR light (communications), and uses two memory cells per pixel so incoming data can be cached prior to state change thereby eliminating the need for a off chip frame store. Thus, a nonvolatile pixel using the floating rocker device discussed herein is very useful to minimize the electronics overhead of a digital display.
The floating rocker discussed herein is discrete. Because the floating rocker is discrete, the floating rocker is a separate entity that is individually distinct from the other elements in the device. In other words, the floating rocker constitutes a separate entity that is an unconnected and distinct piece. In fact, the floating rocker is not attached to anything within the cavity after it is released. The floating rocker simply rests on a fulcrum.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | The current disclosure shows how to make a fast switching array of mirrors for projection displays. Because the mirror does not have a via in the middle connecting to the underlying spring support, there is an improved contrast ratio that results from not having light scatter off the legs or vias like existing technologies. Because there are no supporting contacts, the mirror can be made smaller making smaller pixels that can be used to make higher density displays. In addition, because there is not restoring force from any supporting spring support, the mirror stays in place facing one or other direction due to adhesion. This means there is no need to use a voltage to hold the mirror in position. This means that less power is required to run the display. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a liquid crystal display panel; in particular, to a liquid crystal display panel having display capability on both sides.
2. Description of the Related Art
Notebook computer manufacturers use a variety of liquid crystal display (LCD) panel types in the manufacture of notebook computers to reduce cost and to increase production levels. Recently, there is also a growing need for mobile is communication devices using the LCD panels. For example, the LCD panels can be applied in mobile phones and personal digital assistant (PDA) devices.
A conventional LCD panel 10 is shown in FIG. 1 a , FIG. 1 b and FIG. 1 c . Numeral 11 represents a liquid crystal module. The liquid crystal module 11 comprises a substrate, liquid crystal molecules and other material. However, since the detail structure of the liquid crystal module 11 is irrelative to the characteristic of this invention and is well known by persons skilled in the art, their detail description is omitted.
The liquid crystal display module 11 is provided with a front polarizer 12 at one side and a rear polarizer 13 at the other side. Generally, the polarized axis of the front polarizer 12 and the polarized axis of the front polarizer 13 are perpendicular, and the alignment of the liquid crystal molecules in the liquid crystal module 11 is well controlled. Specifically, light passes through the polarizer 12 , 13 by the arrangement of the polarizer 12 , 13 and the alignment of the liquid crystal molecules in the liquid crystal module 11 . As a result, depending on whether the light passes through or not, different images are shown on the LCD panel 10 .
The rear polarizer 13 is provided with a reflector 14 . By means of the reflector 14 , characters and graphs can be shown on the front polarizer 12 . That is, viewing from a direction by an arrow A of FIG. 1 b , characters shown in FIG. 1 c can be seen on the LCD panel 10 .
Furthermore, there is a need for mobile communication devices with an LCD panel having display capability on both sides.
For example, a PDA mobile phone 30 is shown in FIG. 2 a and FIG. 2 b . The PDA mobile phone is a communication device with PDA function and mobile phone function. When a keyboard portion 31 and a display portion 32 combine, a first screen 33 of the display portion 32 is used as a screen for the mobile phone function. When a keyboard portion 31 and a display portion 32 separate, a second screen 34 of the display portion 32 is used as a screen for the PDA function.
However, in the conventional PDA mobile phone, two LCD panels are used as the first screen and the second screen respectively. Thus, the cost is increased, and the whole thickness is also increased. As a result, it is difficult to miniaturize the PDA mobile phone.
SUMMARY OF THE INVENTION
In order to address the disadvantages of the aforementioned LCD panel, the invention provides an LCD panel having display capability on both sides.
Another purpose of this invention is to minimize the thickness of a PDA mobile phone.
Accordingly, the invention provides a liquid crystal display panel. The LCD panel comprises a liquid crystal module, a first polarizer, a second polarizer, a first reflector, and a second reflector. The liquid crystal module is provided with a first surface and a second surface opposite to the first surface. The first polarizer is disposed on the first surface of the liquid crystal module, and the second polarizer is disposed on the second surface of the liquid crystal module. The first reflector is disposed on part of the first polarizer, and the second reflector is disposed on part of the second polarizer. The other part of the second polarizer and the first reflector overlap completely in a direction perpendicular to the first surface of the liquid crystal module.
Furthermore, the liquid crystal module comprises a substrate, and liquid crystal molecules.
In another preferred embodiment, this invention provides another liquid crystal display panel. The LCD panel comprises a liquid crystal module, a first front polarizer, a first rear polarizer, a first reflector, a second rear polarizer, a second front polarizer, and a second reflector. The liquid crystal module is provided with a first surface and a second surface opposite to the first surface, and the first front polarizer is disposed on one portion of the first surface of the liquid crystal module. The first rear polarizer is disposed on the second surface of the liquid crystal module. The first front polarizer and the first rear polarizer overlap completely in a direction perpendicular to the first surface of the liquid crystal module. The first reflector is disposed on the first rear polarizer, and the second rear polarizer is disposed on the other portion of the first surface of the liquid crystal module. The second front polarizer is disposed on the second surface of the liquid crystal module. The second front polarizer and the second rear polarizer overlap completely in a direction perpendicular to the first surface of the liquid crystal module. The second reflector is disposed on the second rear polarizer.
In another preferred embodiment, this invention provides another adapted for a PDA mobile phone having a first screen and a second screen. The LCD panel comprises a liquid crystal module, a first polarizer, a second polarizer, a first reflector, and a second reflector. The liquid crystal module is provided with a first surface and a second surface opposite to the first surface. The first polarizer is disposed on the first surface of the liquid crystal module, and the second polarizer is disposed on the second surface of the liquid crystal module. The first reflector is disposed on one portion of the first polarizer, and the second reflector is disposed on one portion of the second polarizer. The other portion of the second polarizer and the first reflector overlap completely in a direction perpendicular to the first surface of the liquid crystal module. The other portion of the first polarizer is used as the first screen, and the other portion of the second polarizer is used as the second screen.
In another preferred embodiment, this invention provides another adapted for a PDA mobile phone having a first screen and a second screen. The LCD panel comprises a liquid crystal module, a first front polarizer, a first rear polarizer, a first reflector, a second rear polarizer, a second front polarizer, and a second reflector. The liquid crystal module is provided with a first surface and a second surface opposite to the first surface. The first front polarizer is disposed on one portion of the first surface of the liquid crystal module and used as the first screen. The first rear polarizer is disposed on the second surface of the liquid crystal module. The first front polarizer and the first rear polarizer overlap completely in a direction perpendicular to the first surface of the liquid crystal module. The first reflector is disposed on the first rear polarizer, and the second rear polarizer is disposed on the other portion of the first surface of the liquid crystal module. The second front polarizer is disposed on the second surface of the liquid crystal module and used as the second screen. The second front polarizer and the second rear polarizer overlap completely in a direction perpendicular to the first surface of the liquid crystal module. The second reflector is disposed on the second rear polarizer.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is hereinafter described in detail with reference to the accompanying drawings in which:
FIG. 1 a is a schematic view depicting a conventional LCD panel;
FIG. 1 b is an enlarged view depicting a part D of FIG. 1 a;
FIG. 1 c is a side diagram viewing from an arrow A of FIG. 1 b;
FIG. 2 a and FIG. 2 b are schematic views depicting a PDA mobile phone;
FIG. 3 a is a schematic view depicting an LCD panel of a first embodiment as disclosed in this invention;
FIG. 3 b is an enlarged view depicting a part E of FIG. 3 a;
FIG. 3 c is a side diagram viewing from an arrow B of FIG. 3 b and FIG. 4 b;
FIG. 3 d is a side diagram viewing from an arrow C of FIG. 3 b and FIG. 4 b;
FIG. 4 a is a schematic view depicting an LCD panel of a second embodiment as disclosed in this invention; and
FIG. 4 b is an enlarged view depicting a part F of FIG. 4 a.
DETAILED DESCRIPTION OF THE INVENTION
First Embodiment
Referring to FIG. 3 a , FIG. 3 b , FIG. 3 c and FIG. 3 d , a liquid crystal display panel 20 , as disclosed in a first embodiment of this invention, comprises a liquid crystal module 21 , a first polarizer 22 , a second polarizer 23 , a first reflector 24 , and a second reflector 25 . Like the conventional device, the liquid crystal module 21 comprises a substrate, liquid crystal molecules and other material, and is provided with a first surface 211 and a second surface 212 opposite to the first surface 211 .
The first polarizer 22 is disposed on the first surface 211 of the liquid crystal module 21 , and the second polarizer 23 is disposed on the second surface 212 of the liquid crystal module 21 . The first reflector 24 is disposed on part of the first polarizer 22 , and the second reflector 25 is disposed on part of the second polarizer 23 . The first reflector 24 and the second reflector 25 do not overlap in a direction perpendicular to the first surface 211 of the liquid crystal module 21 . In other words, the liquid crystal module 21 is divided into an upper portion and a lower portion by a dash line X. The first reflector 24 is disposed on the upper portion of one side of the liquid crystal module 21 , and the second reflector 25 is disposed on the lower portion of the other side of the liquid crystal module 21 .
Since the second reflector 25 is disposed on the second polarizer 23 , characters can be shown on part, without disposing the first reflector 24 , of the first polarizer 22 . That is, viewing from a direction by an arrow B of FIG. 3 b , characters shown in FIG. 3 c can be seen on the LCD panel 20 . As well, since the first reflector 24 is disposed on the first polarizer 22 , characters can be shown on part, without disposing the second reflector 25 , of the second polarizer 23 . That is, viewing from a direction by an arrow C of FIG. 3 b , characters shown in FIG. 3 d can be seen on the LCD panel 20 .
Thus, by means of one LCD panel, characters can be shown on both the upper portion of one side and the lower portion of the other side. As a result, the cost is reduced, and the whole weight and thickness of product using the LCD panel is also reduced.
When the LCD panel in this embodiment is applied in the PDA mobile phone as shown in FIG. 2 a , part, without disposing the second reflector 25 , of the second polarizer 23 can be used as the first screen for mobile phone function, and part, without disposing the first reflector 24 , of the first polarizer 22 can be used as the second screen for PDA function.
It is noted that characters, shown on the LCD panel 20 in FIG. 3 d , are abnormal; that is, they are mirror images of normal characters. However, they can be changed to normal characters by means of software. Since this method is well known by persons skilled in the art, their description is omitted.
In addition, it is understood that the proportion between the first screen and the second screen of the PDA mobile phone can be changed by adjusting the size of the reflectors 24 , 25 .
Second Embodiment
Referring to FIG. 4 a , FIG. 4 b , FIG. 3 c and FIG. 3 d , a liquid crystal display panel 40 , as disclosed in a second embodiment of this invention, comprises a liquid crystal module 41 , a first front polarizer 46 , a first rear polarizer 42 , a first reflector 44 , a second rear polarizer 43 , a second front polarizer 47 , and a second reflector 45 . Like the first embodiment, the liquid crystal module 41 comprises a substrate, liquid crystal molecules and other material, and is provided with a first surface 411 and a second surface 412 opposite to the first surface 411 .
The liquid crystal module 41 is divided into an upper portion and a lower portion by a dash line X. The first front polarizer 46 is disposed on the upper portion of the first surface 411 of the liquid crystal module 41 , and the second rear polarizer 43 is disposed on the lower portion of the first surface 411 of the liquid crystal module 41 . The first rear polarizer 42 is disposed on the upper portion of the second surface 412 of the liquid crystal module 41 , and the second front polarizer 47 is disposed on the lower portion of the second surface 412 of the liquid crystal module 41 . The first reflector 44 is disposed on the first rear polarizer 42 , and the second reflector 45 is disposed on the second rear polarizer 43 . That is, the first front polarizer 46 , the first rear polarizer 42 and the first reflector 44 overlap completely in a direction perpendicular to the first surface 411 of the liquid crystal module 41 . As well, the second front polarizer 47 , the second rear polarizer 43 and the second reflector 45 overlap completely in a direction perpendicular to the first surface 411 of the liquid crystal module 41 .
Since the second reflector 45 is disposed on the second rear polarizer 43 , characters can be shown on the second front polarizer 47 . That is, viewing from a direction by an arrow B of FIG. 4 b , characters shown in FIG. 3 c can be seen on the LCD panel 40 . As well, since the first reflector 44 is disposed on the first rear polarizer 42 , characters can be shown on the first front polarizer 46 . That is, viewing from a direction by an arrow C of FIG. 4 b , characters shown in FIG. 3 d can be seen on the LCD panel 40 .
Thus, by means of one LCD panel, characters can be shown on both the upper portion of one side and the lower portion of the other side. As a result, the cost is reduced, and the whole weight and thickness of product using the LCD panel is also reduced.
When the LCD panel in this embodiment is applied in the PDA mobile phone as shown in FIG. 2 a and FIG. 2 b , the first front polarizer 46 can be used as the first screen for mobile phone function, and the second front polarizer 47 can be used as the second screen for PDA function.
It is noted that characters, shown on the LCD panel 40 in FIG. 3 d , are abnormal; that is, they are mirror images of normal characters. However, they can be changed to normal characters by means of software. Since this method is well known by persons skilled in the art, their description is omitted.
In addition, it is understood that the proportion between the first screen and the second screen of the PDA mobile phone can be changed by adjusting the size of the polarizer and the reflectors.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above, and all equivalents thereto. | A liquid crystal display panel (LCD) having display capability on both sides. The LCD comprises a liquid crystal module, a first front polarizer, a first rear polarizer, a first reflector, a second front polarizer, a second rear polarizer, and a second reflector. By replacing a portion of the original front polarizer with the first rear polarizer and the first reflector, and replacing a portion of the original rear polarizer and the original reflector with the first front polarizer, the LCD having display capability on both sides can be attained. | 7 |
TECHNICAL FIELD
The embodiments of the disclosed invention relate generally to headliners for vehicles. More particularly, the embodiments relate to a multi-segmented headliner for a vehicle which can be readily installed on the roof of the vehicle.
BACKGROUND OF THE INVENTION
Vehicle headliners are used to both cover the bare material (usually metal) of the vehicle roof and to provide protection to the vehicle occupant in a crash event. Headliners are typically composed of multiple layers which include a relatively rigid or semi-rigid backing and an outer cover of a woven or non-woven material which is color-coordinated to the rest of the vehicle for aesthetic purposes.
Headliners are typically composed of a single molded piece of material. The outer cover may be added to the molded piece after formation or may be molded with the backing in a single mold during a single or multi-stepped process. The headliner of a vehicle must be wide enough not only to provide coverage for the roof, but also must be wide enough to cover the area between the roof and the side walls. In vans and in sport utility vehicles the headliner is both wide and long, usually long enough to cover the entire area of the roof from the windshield opening to the rear door or liftgate opening. Ordinarily the considerable width prohibits passage of the headliner through the rear opening of the van or sport utility vehicle. On initial vehicle assembly this prohibition is not usually a problem as the windshield has not yet been installed and the headliner can be passed through the windshield opening. However, replacement of a van or sport utility headliner after the vehicle has been assembled is a time-consuming task. In the modern vehicle the windshield is maintained in position by a weather sealing strip that is attached by very strong adhesives to the walls that define the windshield opening. This makes removal of the windshield anticipatory to the removal of the old headliner and installation of the replacement headliner very difficult and costly.
As an alternative to removing the windshield, attempts have been made to pass the single piece headliner through the rear opening of the van and the sport utility vehicle. However, this opening is most ordinarily narrower than is the windshield opening and, as a consequence, the single piece headliner is too wide to permit the passage of the headliner through the rear opening without bending the piece and creating a permanent crease mark in the outer cover. Complicating this procedure is the fact that rear door and tailgate components (such as the doors and tailgates themselves as well as the liftgate struts) interfere with the procedure.
Accordingly, as in so many areas of vehicle technology, there is room in the art of vehicle headliner design for providing a headliner arrangement which may be installed or replaced in a vehicle's interior without the need to remove the vehicle's windshield.
SUMMARY OF THE INVENTION
The headliner assembly for a vehicle is set forth herein in its different configurations. In general, the disclosed headliner assembly includes a headliner which has three segments. The headliner has a long axis. One of the three segments is an intermediate segment that has a first longitudinal edge that is substantially parallel to the long axis of the headliner. The intermediate segment also includes a second longitudinal edge that is substantially parallel to the long axis of the headliner. The other two segments are side segments which include a first side segment and a second side segment. The first side segment has a longitudinal edge that is fittable to the first longitudinal edge of said intermediate portion. Similarly, the second side segment has a longitudinal edge that is fittable to the second longitudinal edge of the intermediate portion.
In one configuration the intermediate and side segments are initially provided separate from one another and form the complete headliner assembly on the roof of the vehicle. Once the three segments are positioned within the interior of the vehicle, they may either be joined and then installed on the vehicle roof as a joined assembly or the segments may be individually attached to the roof. If individually attached to the roof the intermediate segment may be attached to the roof first with the side segments entirely or partially holding the intermediate segment in place. Alternatively the side segments can be installed first followed by installation of the intermediate segment.
In another configuration the intermediate and side segments are joined together when manufactured, with the side segments being movable relative to the intermediate segment. Both configurations permit the replacement of the headliner of a van or sport utility by moving the headliner either in separate segments or folded if a single piece through the opening defined by the rear door or liftgate of the vehicle.
Other features of the various embodiments of the invention will become apparent when viewed in light of the detailed description of the preferred embodiments when taken in conjunction with the attached drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein:
FIG. 1 illustrates a partial perspective view of the headliner assembly in relative position as it would appear prior to placement in a vehicle, also shown in partial perspective view;
FIG. 2 is a sectional view of a portion of a joint of two panels connected by a clip according to the first embodiment of the panel-connecting arrangement of the invention;
FIG. 3 is a sectional view of a portion of a joint of two panels connected by a clip according to the second embodiment of the panel-connecting arrangement of the invention;
FIG. 4 is a sectional view of a portion of two panels illustrating an arrangement for attaching the panels to the roof of a vehicle according to the first embodiment of the panel-attaching arrangement of the invention;
FIG. 5 is a sectional view of a portion of two panels illustrating an arrangement for attaching the panels to the roof of a vehicle according to the second embodiment of the panel-attaching arrangement of the invention;
FIG. 6 is a perspective view of an alternate embodiment of the headliner of the invention;
FIG. 7 is a sectional view of the headliner of FIG. 6 taken along lines 7 - 7 of that figure; and
FIG. 8 is a sectional view of the alternate embodiment of the headliner of the invention similar to that shown in FIG. 7 showing the side panels in their folded positions for fitting through an area defined by the inside edge of a vehicle liftgate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for plural constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting.
With reference to FIG. 1 , a partial perspective view of an embodiment of the headliner assembly of the disclosed invention, generally illustrated as 10 , is shown. The headliner assembly 10 is shown in its general position prior to installation in the roof of a vehicle of which a partial vehicle, generally illustrated as 12 , is shown. While the present invention finds particular utility in a passenger van or in a sports utility vehicle, it is to be understood that the headliner of the present invention may well be fitted in other vehicles while still achieving the general goal of the present invention which is to provide a headliner which can be readily installed in a vehicle interior without the need to remove the vehicle's windshield. By providing a headliner of the disclosed invention which can be reduced from its installed dimension to a pre-installation dimension, the headliner can be passed through openings of the vehicle including the tailgate and door opening for replacement. This arrangement also allows for added flexibility at the installation stage.
The headliner assembly 10 includes a first side panel 14 , a second side panel 16 positioned opposite said first side panel 14 , and an intermediate panel 18 . The panels 14 , 16 and 18 are shown spaced apart from one another as they would appear prior to installation according to the present embodiment of the invention. While three panels 14 , 16 and 18 are disclosed, it is to be understood that as few as two panels and more than three may be used while keeping within the spirit of the present invention.
The panels 14 , 16 and 18 may be made from materials known in the art. In general the panels 14 , 16 and 18 include an inner structural layer and an outer cover layer. Other layers may be included as desired for both structural and acoustic enhancement. Preferably, but not exclusively, the side panels 14 and 16 are composed of a structural, impact-absorbing material while the intermediate panel 18 is an acoustic panel. The acoustic material may be any of a variety of materials, including a sound absorbing foamed layer or a fibrous polyethylene terephthalate material. The structural, impact absorbing material may also be of any of a variety of materials, including ABS plastic and fiberglass. The outer cover layer (or the A surface) is generally composed of a fabric which is attached to the inner layer either during the formation process or after each layer is prepared individually. The outer cover layer may also be composed of a variety of materials, including woven and non-woven cloth.
The suggested layering of the panels 14 , 16 and 18 are illustrated in FIGS. 2 through 8 . Referring first to FIG. 2 , a portion of the intermediate panel 18 is shown. The intermediate panel 18 includes an inner acoustic layer 20 and an outer cover layer 22 . Also shown in FIG. 2 is a portion of the side panel 14 which includes an inner impact absorbing layer 24 and the outer cover layer 22 .
The panels 14 , 16 and 18 of the present invention may be joined to one another and to the roof of the vehicle 12 by different methods. Such methods are disclosed in FIGS. 2 through 5 which are intended as being illustrative rather than limiting. In addition to showing the possible layering of the outer panel 14 and the intermediate panel 18 , FIG. 2 also illustrates an embodiment of the method of joining two adjacent panels. According to this embodiment, the side panel 14 includes a joining end 26 which is angled relative to the rest of the outer panel 14 . Similarly, the intermediate panel 18 includes a joining end 28 which is angled relative to the rest of the intermediate panel 18 . The joining end 26 and the joining end 28 are positioned so that they abut one another as illustrated. A spring clip 30 is provided to maintain the abutment illustrated in FIG. 2 . The spring clip 30 may be a long, continuous clip that is fitted substantially along the length of the abutment defined by the joining end 26 and the joining end 28 or may be one of several of the same clips positioned at spaced intervals along the length of the abutment. A visually pleasing appearance is formed at the abutment of the two panels 14 and 18 .
An alternative method of joining two adjacent panels is illustrated in FIG. 3 which shows two sectional views of a side panel 40 and an intermediate panel 42 . The panels 40 and 42 are similar respectively to the panels 14 and 18 in configuration and composition. However, the arrangement for joining the two panels varies from the arrangement illustrated in FIG. 2 . Specifically, the side panel 40 includes an attachment end 44 which includes a channel 46 that is formed substantially along the entire length of the attachment end 44 . The attachment end 44 also includes a fastener attachment surface 48 and a fastener-passing aperture 50 formed therethrough. The intermediate panel 42 includes an attachment end 52 which has a flange 54 formed substantially along the entire length of the attachment end 52 . As illustrated, the attachment end 52 nests substantially within the channel 46 . A visually pleasing appearance is formed along the seam of the mated panels 40 and 42 .
The attachment end 52 of the intermediate panel 42 also includes a fastener surface 56 to which the base of a fastener 58 is attached by an adhesive or by mechanical attachment. The fastener 58 has a stud portion 60 extending therefrom and through the fastener-passing aperture 50 of the attachment end 44 of the side panel 40 . The attachment end 44 of the side panel 40 is drawn tight against the attachment end 52 of the intermediate panel 42 by fitting of a nut such as a pal nut 62 on the stud portion 60 as illustrated in FIG. 3 . Alternate fasteners may be employed other than the arrangement illustrated provided that the side panel 40 is snugly mated with the intermediate panel 42 .
The panels 14 and 18 shown in FIG. 2 and the panels 40 and 42 shown in FIG. 3 may be attached to the roof of the vehicle 12 by any of a number of known methods of attachment including mechanical fasteners or adhesives. Possible methods of attaching the panels to the vehicle ceiling as well as to one another are shown in FIGS. 4 and 5 .
With reference to FIG. 4 , a sectional view of a portion of two panels, a side panel 70 and in intermediate panel 72 is shown in relation to a portion of a vehicle, generally illustrated as 74 . The vehicle 74 includes an outer roof structural portion 76 having an outer edge 78 , an inner roof structural portion 80 having an outer edge 82 , and an intermediate roof structural portion 84 having an outer edge 86 . The outer edges 78 , 82 and 86 convene along a common edge 88 and are fastened to one another to form the common edge 88 by spot welding or by other known joining techniques. The structural roof portions 76 , 80 and 84 are shown for illustrative purposes only and are not intended as being limiting as other configurations could be adapted for use as well.
The side panel 70 includes an inner edge 90 , an outer edge 92 , and a body 93 . The outer edge 92 is held in place adjacent to the common edge 88 by a polymerized weather strip 94 having a channel 96 formed therein which is held in place along the common edge 88 by friction. The weather strip 94 also has a lip 98 which extends vehicle inward.
The inner edge 90 generally defines an area of the side panel 70 that is inwardly folded back onto itself as illustrated in FIG. 4 .
The intermediate panel 72 includes a body 100 which generally defines a first plane and an outer edge 102 which generally defines a second plane, the first and second planes being different. The body 100 and the outer edge 102 are joined by a wall 104 . The outer edge 92 of the outer panel 70 is held in position relative to the roof of the vehicle 74 by tension of the lip 98 of the weather strip 94 . The inner edge 90 substantially nests along the wall 104 and the outer edge 102 of the intermediate panel 72 and thereby holds the intermediate panel 72 in place against the inner roof structure portion 80 . Fasteners or adhesives, while usable for this fitting, are thus rendered unnecessary in holding the intermediate panel 72 in place.
In addition to the lateral support provided by the lip 98 of the weather strip 94 , the side panel 70 is held in place by one or more mechanical fasteners which may be of a variety of different configurations. A preferred fastener is a spring fastener 106 . The spring fastener 106 may be a stand-alone fastener or, as illustrated, may be part of a grab handle assembly 108 . As illustrated, the grab handle assembly 108 includes a grommet 110 having a peripheral flange 112 . A fastener aperture 114 is formed through the body 93 of the side panel 70 through which the spring fastener 106 extends. The peripheral flange 112 abuts the outer area surrounding the fastener aperture 114 and thus assists in holding the side panel 70 in place against the inner roof structural portion 80 .
While the spring fastener 106 as part of the grab handle assembly 108 is illustrated as the method of attaching the side panel 70 to the inner roof structural portion 80 , it is to be understood that other methods of attachment may be employed. Such arrangements for attachment include nylon “Christmas tree” style fasteners and other spring fasteners which are attached to the inner layer of the side panel 70 so as not to be seen by the vehicle passenger.
A variation of the arrangement for attaching the intermediate and side panels to the roof of a vehicle is shown in FIG. 5 . With respect to that figure, a sectional view of a portion of two panels, a side panel 120 and an intermediate panel 122 , is shown in relation to a portion of a vehicle, generally illustrated as 124 . The vehicle 124 includes an outer roof structural portion 126 having an outer edge 128 , an inner roof structural portion 130 having an outer edge 132 , and an intermediate roof structural portion 134 having an outer edge 136 . The outer edges 128 , 132 and 136 convene along a common edge 138 and are fastened to one another to form the common edge 138 by spot welding or by other known joining techniques. As shown, the inner roof structural portion 130 does not extend as far vehicle inward as does the inner roof structural portion 80 of the embodiment shown in FIG. 4 .
With reference still to FIG. 5 , the side panel 120 includes an inner edge 140 , an outer edge 142 , and a body 143 . The inner edge 140 is angled back slightly toward the body 143 . The outer edge 142 is held in place adjacent to the common edge 138 by a polymerized weather strip 144 having a channel 146 formed therein which is held in place along the common edge 138 by friction. The weather strip 144 also has a lip 148 which extends vehicle inwardly.
The intermediate panel 122 includes a body 200 which generally defines a first plane and an outer edge 202 which generally defines a second plane, the first and second planes being different. The body 200 and the outer edge 202 are joined by a wall 204 . The outer edge 142 of the outer panel 120 is held in position relative to the roof of the vehicle 124 by tension of the lip 148 of the weather strip 144 . A portion of the inner edge 140 substantially nests along the wall 204 and the outer edge 202 of the intermediate panel 122 and thereby holds the intermediate panel 122 in place against the underside of the outer roof structural portion 126 . Consistent with the method of holding the intermediate panel 72 in place as set forth in FIG. 4 , fasteners or adhesives, while usable for this fitting, are thus rendered unnecessary in holding the intermediate panel 122 in place.
In addition to the lateral support provided by the lip 148 of the weather strip 144 , the side panel 120 is held in place by one or more mechanical fasteners of which the illustrated fastener is a spring fastener 206 . The spring fastener 206 may be a stand-alone fastener or, as illustrated, may be part of a grab handle assembly 208 . The grab handle assembly 208 includes a grommet 210 having a peripheral flange 212 . A fastener aperture 214 is formed through the body 143 of the side panel 120 through which the spring fastener 206 extends. The peripheral flange 212 abuts the outer area surrounding the fastener aperture 214 and thus assists in holding the side panel 120 in place against the inner roof structural portion 130 .
While the spring fastener 206 as part of the grab handle assembly 208 is illustrated as the method of attaching the side panel 120 to the inner roof structural portion 120 , it is to be understood that other methods of attachment may be employed as set forth above with respect to FIG. 4 .
Also as set forth above, one object of the disclosed invention is to provide a practical and time-efficient approach to replacing or repairing the headliner of a vehicle without the need to remove the windshield. The embodiment disclosed in FIGS. 1 through 5 is a multi-piece headliner. On assembly or repair, the intermediate panel is brought into the vehicle interior followed by the outer panels. The side panels are then attached to the intermediate panel to form a headliner assembly. The headliner assembly is then attached to the roof of the vehicle. This is the approach of the embodiment shown in FIG. 2 . As an alternative, and as shown in the embodiments of FIGS. 3 through 5 , the intermediate panel is brought into the vehicle interior and is then installed on the roof of the vehicle. The outer panels are then brought into the vehicle interior and are installed. Both of these approaches rely on the headliner being provided as separate pieces. As an alternative to the multi-piece headliner, a single-piece headliner may be used as illustrated in FIGS. 6 through 8 .
With reference to FIG. 6 , a single-piece headliner, generally illustrated as 220 , is shown. The single-piece headliner 220 has a leading edge 222 which faces vehicle forward when installed and a trailing edge 224 . The single-piece headliner 220 further includes an intermediate portion 226 , a first side portion 228 and a second side portion 230 . The first side portion 228 is attached to the intermediate portion 226 along a longitudinal, flexible joint 232 . The second side portion 230 is attached to the intermediate portion 226 along a longitudinal, flexible joint 234 .
The single-piece headliner 220 is preferably multi-layered and is composed of the same or similar materials as disclosed above with respect to the embodiments shown and discussed in relation to FIGS. 2 and 3 . The single-piece headliner 220 may be composed of an inner layer and an outer layer or may be composed of more layers. Proposed layering of the single-piece headliner 220 is disclosed in FIGS. 7 and 8 , of which FIG. 7 is a sectional view taken along lines 7 - 7 of FIG. 6 . As illustrated, the single-piece headliner 220 is shown in its unfolded configuration as would be the case if it was installed in the vehicle interior.
The single-piece headliner 220 has an inner cover layer 240 which runs the entire width (and length) of the headliner 220 as shown. The inner cover layer 240 is a single piece of material. The single-piece headliner 220 also includes an inner layer 242 which may be a combination of an acoustic layer 244 which backs the intermediate portion 226 and an inner impact absorbing layer 246 which backs the side portions 228 and 230 as illustrated or the inner layer 242 may be composed of a single material. In either event, the inner layers which back the side portions 228 and 230 are integral with the intermediate portion 226 and are flexibly joined therewith along the longitudinal, flexible joints 232 and 234 respectively. The longitudinal, flexible joints 232 and 234 are formed along and between the intermediate portion 226 and the side portions 228 and 230 by molding or by post-mold forming through cutting or routing.
As shown in FIG. 7 , the width of the single-piece headliner 220 is considerable and would not be passable through the rear of the vehicle as defined by the rear door or lift-gate opening of a van or a sport utility vehicle, respectively. Such an opening is illustrated as the outline 250 of the lift-gate opening shown in FIG. 8 . To enable insertion of the single-piece headliner 220 into the vehicle's interior without removing the windshield, the side portions 228 and 230 are folded along the longitudinal, flexible joints 232 and 234 as illustrated in FIG. 8 . The folding of the side portions 228 and 230 reduces the overall width of the single-piece headliner 220 to allow for insertion through the rear door or lift-gate opening. Once the single-piece headliner 220 has been placed into the vehicle's interior, the side portions 228 and 230 are generally unfolded to be returned to the configuration illustrated in FIG. 7 . The single-piece headliner 220 is then attached to the roof of the vehicle by fasteners or adhesives.
The foregoing discussion discloses and describes exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims. | The multi-segmented headliner for a vehicle includes an elongated intermediate segment, an elongated first side segment, and an elongated second side segment. In one configuration the segments are separate and form the complete headliner on assembly inside the roof of the vehicle. In another configuration the segments are joined together in a single piece, with the side segments being movable relative to the intermediate segment. Both configurations permit the replacement of the headliner of a van or sport utility by moving the headliner either in separate segments, or folded if a single piece, through the opening defined by the rear door or liftgate of the vehicle. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a securement band and connecting means therefor in which the band is adapted to encircle a body, object or article and to be selectively tightened thereabout and retained in such selected tightened relation. The securement band and connector means for joining opposite end portions of the band are constructed and arranged to provide unique coupling of the band ends and also to provide a universal reversible band and connector receptive of decorative treatment and aesthetic appeal. The securement band and connector means therefor are adapted for use as watch bands, belts for use on apparel, fashion wear and other commercial and industrial fastening applications such as luggage, band clamps and the like.
Prior proposed strap belt or band fastening means have included bands in which a plurality of spaced holes are pierced through one end portion of the band for reception of a hook or tine carried by a buckle. The usually large spacing of the holes in the face of the belt provides adjustability limited to the wide spacing of the belt holes. In such prior proposed belt and buckle arrangements, the free end of the belt is extended beyond the buckle and is either free to flap about the outside of the belt or is long enough to be inserted in a belt loop provided on the article of apparel. In industrial applications such as a band clamp, the metal of the band is provided with relatively large openings which reduces the strength of the metal band and is secured by screw-type or ratchet means which draws the free end of the metal band through a housing in order to tighten the band.
While some prior proposed belt constructions have incorporated material of different color on opposite sides of the belt, the buckle is usually of different material and structure and may be of a neutral color to provide a satisfactory aesthetic effect.
Such prior proposed band-type fastening means in both fashion wear and industrial applications have utilized the side faces of the belt or band to provide means for cooperating with a buckle or coupling or clasp means which utilized the width of the belt to provide such means.
Some proposed buckles, bands, clasps, and coupling means therefor include the following U.S. patents. In U.S. Pat. No. 4,288,892, a buckle is disclosed for joining the ends of a watchband which is provided with longitudinally spaced indentations transversely arranged in the edge of the band, the indentations cooperating with upright teeth on side walls of a coupling member between which the band passes. To interengage the indentations with the teeth on the side walls, the band must be pressed toward the bottom wall of the coupling member by a pressure bar.
In U.S. Pat. No. 215,956, a bracelet is shown in which one end of the bracelet band is provided with edge notches in the form of saw teeth. An external pivoted arm provided with a pin at one end extends through a cap or cover to engage the notches.
Other patents disclosing clasp and band arrangements are U.S. Pat. Nos. 3,385,229; 4,068,355; 2,455,2364,292,692; and 4,577,375.
The above-mentioned U.S. patents disclose generally prior proposed arrangements for coupling together opposite ends of a band and do not contemplate the novel construction of the present invention nor provide the unique advantages of the present invention.
SUMMARY OF INVENTION
The present invention contemplates a novel arrangement of a securement band and connector means therefor in which the edge faces and edge portions of the band and also of the connector means are utilized to provide variable fine adjustment of the band about a body being encircled thereby without disturbance or marring of side surfaces of the band. The invention contemplates a securement band and connector in which both front and back surfaces of the band and connector may be utilized for decorative treatment and thereby providing a multi-purpose band readily adapted for use with different apparel.
It is therefore an object of the present invention to provide a novel securement band and connector means therefor utilizing edge portions of the securement band and connector means in a novel manner.
An object of the invention is to provide a securement band provided with a plurality of lock holes having openings in the longitudinal edge face of the band.
Another object of the invention is to provide the securement band of uniform width and selected length and having continuous uninterrupted side faces for attachment thereto of decorative material.
Still another object of the invention is to provide a connector means for a securement band as mentioned above in which the connector means has a lock member operable along the edge face of the connector means, in concealed relation thereto, and providing fine adjustability of the tightness of the band.
A still further object of the present invention is to provide a connector means having a lock member with lock pins operable along a longitudinal edge portion of the connector means in which the lock member is movable about an axis for movement of the lock pins into and out of locking engagement with the holes in the longitudinal edge faces of the band.
A still further object of the invention is to provide a connector means having a through passageway therein for end portions of a securement band, a lock member at a longitudinal edge portion of the connector means for movement toward and away from the edge of a band contained within the connector means, and a movable keeper means on the connector means for positively actuating the lock member into locked position.
The present invention particularly contemplates a securement device having a securement band with longitudinal edge faces and locking holes in the edge faces, a connector means having a passageway for said band and for reception of the end portions of said band, a lock member with lock pins extending alongside the locking holes at said band edge faces, and a keeper means movable along said connector means for moving the lock member into locking engagement with the locking holes.
Various other objects and advantages of the present invention will be readily apparent from the following description of the drawings in which exemplary embodiments of the invention are shown.
IN THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a securement band embodying this invention.
FIG. 2 is a fragmentary bottom view of the band shown in FIG. 1 taken in the plane indicated by line II--II of FIG. 1.
FIG. 3 is a fragmentary sectional view taken in the plane indicated by line III--III of FIG. 1.
FIG. 4 is an assembled view of the securement band of FIG. 1 with a connecting means, the connecting means being shown in band release position, a portion of the face of the connecting means being broken away to show a free end of the band.
FIG. 5 is a top view of the connecting means and band shown in FIG. 4, the connecting means being shown in locked position.
FIG. 6 is a longitudinal sectional view taken in the plane indicated by line VI--VI of FIG. 5.
FIG. 7 is a fragmentary sectional view of one end of the connecting means, the section being taken in the plane indicated by line VII--VII of FIG. 6.
FIG. 8 is a perspective view of the bottom lock member of the connecting means as shown in FIG. 6.
FIG. 9 is a sectional view taken in the plane indicated by line IX--IX of FIG. 8 to illustrate the shape of one of the lock pins.
FIG. 10 is an exploded view of two identical parts forming the lock and release keeper means of the connecting means, the parts being shown in exploded position prior to assembly.
FIG. 11 is an assembled partially sectional view of a different embodiment of the connecting means of this invention in lock position and with the free end of the band passing through and beyond the connecting means.
FIG. 12 is a fragmentary sectional view of the securement band and connecting means of FIG. 11, the view being taken in the plane indicated by line XII--XII of FIG. 11.
FIG. 13 is a fragmentary view of a still different embodiment of the invention utilizing a spring biassed pivotally mounted locking member.
FIG. 14 is a perspective view of a connecting means and securement band embodying a still different modification of the connecting means.
FIG. 15 is a fragmentary sectional view taken in the plane indicated by line XIV--XIV of FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of the invention is shown in FIG. 4, in which opposed ends of a securement band 20 are partially inserted within a through passageway 21 of a connecting means 22. Lock members 24 are operable along opposite longitudinal edge faces of the connecting means 22 and are driven into locked and/or released relation with respect to the securement band 20 by a keeper means 26 slidably movable longitudinally of the connecting means 22.
The securement band 20 is shown in detail in FIGS. 1-3. Securement band 20 in this example may comprise a belt 30 or a strap or a suitable elongated strip body member. The material of belt 30 may be an extruded or an injection molded thermoplastic material which is pliant, flexible, and which has a selected tensile strength for the purpose for which it is to be used. Suitable exemplary materials may be polyvinyl chloride, polyethylene, polyesters, neoprene synthetic rubbers, and nylon strips.
The belt 30 in its extruded form has uniform width and thickness. In this example, the belt 30 is provided with longitudinally extending edge ribs 32 along opposite longitudinal edge portions of belt 30 to provide shallow longitudinally extending recesses 34 for the length of the belt 30. Longitudinal recesses 34 provide longitudinally extending belt surfaces 36 to which may be bonded or suitably secured decorative strips 38 by adhesive or other fastening means. Decorative strips 38 may include thin strips of leather, bonded leather, vinyl, other plastic decorative materials, cloth, fabric, or any other suitable thin decorative material. The decorative strip 38 on one side of belt 30 may be of one selected color such as black, and on the other side of belt 30 may be of a selected white color so that the belt may be reversed and readily used with different trousers or apparel.
Longitudinal edge faces 40 of belt 30 are of uniform width, an exemplary width being about 1/8 of an inch. The edge faces 40 are merged with ribs 32 to provide curved rounded edges. Along the longitudinal edge portions of belt 30 forming longitudinal edge faces 40 are provided a plurality of holes 42 of cylindrical shape with the axes of the cylindrical holes lying generally along a longitudinal plane bisecting the thickness of belt 30. Holes 42 are spaced apart at uniform intervals for the entire length of belt 30. Each hole 42 may be approximately 0.080 inches in depth and approximately 0.046 inches in diameter. The holes 42 in the longitudinal edge faces of belt 30 are not readily apparent in wearing of a belt 30 and do not distract from the decorative patterns which may be applied to the side surfaces 36 of the belt or from the general appearance of the belt.
Holes 42 may be readily formed in belt 30 during the extrusion of belt 30 and while the belt material is hot. A hot extruded belt 30 may be passed between a pair of matching gears, one on each side of belt 30. During passage of the belt between such a set of gears having the desired size and shape of gear teeth, the gear teeth will readily penetrate the edge face of the belt and form holes at selected uniform intervals along the edge face of the hot belt. The holes in both edge faces are formed in transverse alignment.
Another method of forming holes 42 in the edge face of a belt may comprise placing the hot belt material in a press in which one or both sides of the press is provided with longitudinally aligned and spaced press pins which upon moving transversely of the belt will penetrate under pressure the longitudinal edge faces of belt 30 to form the holes 42. It will be understood that other methods may be used to form holes such as 42 or their equivalent in the longitudinal edge faces 40 of
Belt 30 may be made in any suitable selected length and when utilized as hereinafter described, may be readily cut to a selected length.
The clasp, buckle, coupling or connecting means 22 is best shown in FIGS. 4, 5, 6 and 7. Connecting means 22 may comprise a connector body generally indicated at 50 and comprises two body plates 52 and 54 of similar shape and size. Both plates 52 and 54, in this example, are of corresponding rectangular configuration. At each end, plate 52 is provided with a pair of end abutments 56, each having a transversely extending projection 58 adapted to be received within a mating socket 60 formed in the end portion of body plate 54. The two body plates 52 and 54 thus form a longitudinally extending through passageway 21 having an opening 62 at one end of the connector body. At the other end of the connector body a through opening 64 is provided; the interior surfaces of the adjacent abutments 56 being provided with outwardly flaring surfaces 66 to facilitate entry of a free end 68 of securement belt 30. The interengagement of each projection 58 in socket 60 may include a plastic type frictional fit to hold the two body plates in assembly and may be further secured, if desired, by adhesive.
As shown in FIG. 7, the other fixed end 70 of belt 30 is secured by sockets 72 formed on body plate 52 adjacent the open end 62. The fixed end of belt 30 is provided with a pair of openings 74 spaced apart and alignable with sockets 72 so that upon inserting the end to be fixed of belt 30 into opening 62 the openings 74 in the belt 30 may be registered with sockets 72. Upon assembly of body plate 54 with plate 52 as by moving the plates in alignment toward each other into pressure friction engagement of projections 58 and sockets 60, the end of belt 30 is thus fixedly secured to the connecting means 22.
Connecting means 22 also includes an elongated bar-like lock member 24 which is shown in detail in FIG. 8. Lock member 24 includes a lock portion 80 and a release portion 82, such portions being straight and joined in slightly obtuse angular relation at a vertex 84. Adjacent vertex 84 lock portions 80 and 82 are provided with outwardly extending correspondingly angularly related flanges 86 adapted to be received within recesses 88 provided in opposed relation in body plates 52 and 54. Each of recesses 88 include a straight inboard edge wall 90 and angularly related recess walls 92 opposite to straight wall 90. Lock member 24 is assembled with the connector body plates 52 and 54 when the plates are separated so that the flanges 86 may be received within the recesses 88. As the two body plates are pressed together, lock members 24 are rockingly held in the edge opening 120 adjacent to longitudinal edge faces of the connector means on both sides thereof as shown in FIG. 6. It will be apparent from FIG. 6 that the angularly related recess faces 92 in recess 88 limit rocking movement of the lock member 24 when assembled with the connector body plates 52 and 54 so that ends of the lock bar will not project above longitudinal edges of the connector body 50.
At one end of each lock bar member 24 are provided a plurality of lock pins 94 in uniform spaced relationship corresponding to the spacing of holes 42 in the edge face of belt 30. As shown in FIG. 9, each pin 94 comprises a cylindrical base portion 96 and a tapered end portion 98 which facilitates entry of the pin into the holes 42. The diameter of the cylindrical base portion of lock pin 94 may be approximately 0.040 inches, which is slightly smaller than the 0.046 inches diameter of hole 42 to facilitate sliding entry of the lock pins 94 into the holes 42 when the lock member is moved into locked position. Each pin 94 may have a pointed shape, such as a saw tooth adapted to form a pierced hole in the edge face.
At opposite ends of lock member 24 and on the face opposite to the location of pins 94, the remote ends of each lock part 80 and 82 are provided with an enlargement 100 to provide an inboardly facing stop face 102 for a keeper means 26.
Keeper means 26 may be best seen and described in FIG. 10 in which the keeper means comprises a pair of identical U-shaped plastic members 110 having a pair of parallel legs 112, one of said legs 112 being provided with a reduced diameter pin 114. The other leg 112 is provided with an enlarged socket 116 adapted to receive pin 114 of the opposite part 110 of the keeper means 26. It will be apparent from FIG. 10 that when the keeper means 26 is assembled with the connector body the two parts 110 embrace opposite sides of the connector body and as they are moved towards each other, they will be assembled with pins 114 in sockets 116 and in assembled relation with the connector body.
Each keeper U-shaped member 110 includes an internal actuator or guide lug 118 centrally located between legs 112 and extending toward the open end of said legs from transverse base 120 of the keeper means. When the keeper means 26 is assembled with the connector body, the guide lugs 118 are received within the longitudinally extending edge opening 120 outwardly of or above lock member 24. Edge opening 120 is formed by assembly of the body plates 52 and 54. Guide lug 118 slidably contacts the outboard surface 124 of lock member 22. As seen in FIG. 6, when the keeper means 26 is moved to the left in FIG. 6, guide lug 118 causes the lock member to depress its lock part 80 and to drive lock pins 94 into recesses 42 of a free belt end which has been inserted through the opening 66. In such movement because of the angular relation of lock parts 80 and 82, the tapered portion 98 of each pin will seek the opening of an opposed hole 42 and as the keeper member 26 drives the lock part 80 into parallel relation with the edge face of the free belt end and with the edge of the connector body, the cylindrical base of the lock pins 94 will be driven into close locking engagement with at least three holes 42 as illustrated in FIG. 6.
To release lock member 24, the keeper means 26 is moved to the right in FIG. 6 and as it is moved, the guide lugs 118 travel in slidable engagement along the outboard surface 124 of the lock member until the release part 82 is driven into parallel relation with the edge of the connector body and the edge of the base. The keeper means 26 is then in the position shown in FIG. 4 where the lock member has been rocked about its vertex 84 to lift the pins 94 out of engagement with the holes 42. The lugs 118 on the keeper means are limited in their movement longitudinally of the connector body by the stop faces 102 at ends of the lock member 24 as shown in FIG. 6.
As best seen in FIGS. 4 and 6, the free end 68 of belt 30 may be inserted in the passageway 21 of the connector means until it moves into abutment with the fixed end 70 of belt 30. In the event the body encircled by the securement band 30 is small and the band is loose, the free end 68 may be withdrawn from the connector body and may be readily cut off to a selected length. The free end 68 is then inserted within the connector body in spaced relation to the fixed end 70 under conditions where the belt 30 is in desired tightness about the encircled body. Since the holes 42 may be located along the entire length of the edge faces of the belt, adjustment of the length of the belt to a selected length and tightness is readily accomplished.
It has been described above that the belt 30 is provided with decorative strips 38 on its opposite faces for the entire length of the belt. Connecting means 22 may be provided with decorative strips 134 on the opposite surfaces 130 and 132 of body plates 52, 54. Decorative strips 134 may correspond to the decorative strips 38 provided on the belt or may be formed of a different type of material if it is desired to accentuate the appearance of connecting means 22. When the decorative strips 38 and 134 are the same, it is will be apparent that the belt 30 and connecting means 22 generally have the same configuration and appearance.
In the modification of the invention shown in FIGS. 11 and 12, for purposes of brevity, only the differences in the connecting means will be described. In FIG. 11, the belt 30' has a free end 68' which is passed through a slot 140 formed in this example in body plate 54. Slot 140 has opposed beveled surfaces to facilitate the passage through the opening of slot 140 of the free end 68' of the belt 30'.
This modification of the connecting mean permits the securement belt 30' to be of a length which will exceed the normally selected length which requires termination of end 68 in the connecting means 22. Thus, belt 68' may be employed for encirclement of articles or bodies of widely different circumference. Since holes 42 are continuous along the length of the belt 30', the locking function may be effected at any location along the length of the belt. It will also be understood that the free belt end 68, may be worn interiorly of the belt main portion adjacent to the connecting means 22 or, if desired, the connecting means 22 may be reversed and the belt portion free end 68, may be exteriorly positioned of the belt 30,
In FIG. 13, a still different modification of the connecting means is illustrated, only a portion of the connecting means being shown. In this embodiment, one of the body plates such as 52" may have attached thereto at the sockets 72" a base 142 of a U-shaped locking spring means 144. Locking spring means 144 includes a pair of normally outboardly biased locking arms 146 which include on their inboard free end surfaces a plurality of locking pins 148. Fixed and free ends of a belt are assembled within the connecting means as in the prior embodiment. When the keeper means 26" is moved to the left as shown in FIG. 11, it will be apparent that keeper 26" will cause the outboardly biased lock arms 146 to be urged inwardly to engage the lock pins 148 with the openings 42 in the edge of the belt 30 within the connecting means as in the prior embodiment.
When the keeper means 26" is moved to the right as shown in FIG. 13, the spring biased force in the spring arms 146 causes the arms to release lock pins 148 from engagement with holes 42 in the edge of the belt.
In the event such automatic spring biased release does not occur when the keeper means 26 is moved to release position, each free end of each lock arm 146 may be provided with an outwardly directed tab 150 which may be grasped to facilitate such release and which also acts as a stop for movement of the keeper means 26' at its full locked position.
In a still further embodiment of the invention as shown in FIGS. 14, 15, locking arm means 160 at each edge of the connecting means 162 may be pivotally mounted about a transverse pin 164 centrally of the length of the connecting means. Lock arm 160 is biased into locking position as shown FIG. 15 by a spring means 166 having a spring arm 168 bearing against a pin 170 carried internally of lock arm 160. The opposite leg 172 of spring 166 bears against a pin 174 carried by one of the connector body plates such as 52".
Lock means 160 may have a channel section body and is provided with an inturned flange 176 provided with inwardly directed lock pins 178 for locking engagement with the edge holes of a belt 30 such as described in the first embodiment. The lock means 160 includes an extension lip 180 which bears against a surface 182 of plate 52" at its corner to limit pivotal movement of lock means 160 about pin 164.
The opposite end 184 of look means 160 is raised above the edge faces of the connecting means 162 when the lock means is in locked position. Release of the lock member 160 from engagement with the belt is accomplished by pressing downwardly on the lock arm end 184 to release locking pins 178 against the bias of the spring 166.
The advantages of the securement band and connecting means of this invention as described above will be readily apparent to those skilled in the art. The locking holes 42 in the longitudinal edges of the belt are almost invisible and are normally not noticeable. The locking holes 42 do not weaken the belt since there is substantial material between the edges of the belt which has not been reduced by holes or perforations. With respect to the first embodiment which is the preferred embodiment, the locking arm is essentially concealed along the longitudinal edges of the connecting means. The limited rocking movement of the locking member is also not visible and the sliding movement of the keeper means from one end of the connecting means to the other provides positive movement of the locking member into locking engagement with the belt and also into released position with the locking pins positively withdrawn from the edge of the belt. In some instances, it will be understood that the locking belt and the connecting means may be provided with locking holes along jut one edge of the belt and the along the corresponding edge of the connector body for engagement with the belt.
The length of the belt is readily closely adjustable to a selected precise length because the spacing of the holes is relatively close. The length of the connector body may be any selected length and adjustment of the length of the belt to provide a free end terminating within the connector body provides normally sufficient end play to provide a readily acceptable adjustable tightness of the belt.
When the material selected for the band is rubber-like and relatively soft, pre-formed holes in the band edge face may be omitted and the holes in the edge face may be formed by piercing movement of the lock pins of saw-like form on the lock member into locked position. Upon movement of the lock member into release position and the retraction of the lock pins from the holes made thereby, the memory of the material along the edge face will cause the pierced holes to substantially disappear.
It should also be noted that adjustment of the belt once a selected length has been cut may be readily made without removing the free end of the belt from the connector body. The keeper means is moved to release position. The free end of the belt is moved within the connector body to its new selected position and then the keeper means is moved to the belt locked position. This is accomplished without withdrawing the free end of the belt from the connector body.
In the preferred embodiment as shown in FIGS. 1-7, there is no exposed free belt end and, therefore, there is continuity of appearance of the belt throughout its length. In the second embodiment of the invention shown in FIGS. 11, 12, a free extended end portion of the belt is provided in the event it is not desired to terminate the free end of the belt within the connector body.
It will be readily apparent from the above description that the present invention provides a unique, attractive, streamlined belt for use with clothing apparel. The concept of the invention is not limited to use with clothing apparel and it would be readily apparent that by suitably proportioning the width length and thickness dimensions of the band, the provision of at least a plurality of holes along at least a selected length portion of the band and the connector means the device of this invention has utility with respect to watchbands, bracelets, and industrial applications such as a band clamp, cinch-type fastening means and other like purposes since the band is capable of minute adjustments along its length and such adjustments are readily accomplished by reason of the plurality of closely spaced edge holes in the band and the arrangement of lock member and keeper means with the connector body. While the above description has referred to a band of flexible characteristics, it will be understood that a portion of the length of the band may be of relatively rigid material in which the plurality of edge holes may be made in a relatively rigid length portion of the band since such variation may have utility with respect to industrial applications of the securement band and connector means.
Various modifications and changes may be made in the securement device described above that come within the spirit of this invention and all such changes and modifications coming within the scope of the appended claims are embraced thereby. | A securement band and connector therefor in which the securement band is flexible, uninterrupted along its width and in which locking holes are provided along longitudinal edges of the band. A connector for such a securement band in which one end of the band is fixed in a through passageway in a connector body and in which the free end of the securement band is adjustable to a range of positions within the connector body after the securement band has been cut to a selected length. A pivoted locking member is provided at a longitudinal edge opening of the connector body, the locking member having at one end or more locking pins movable in the plane of the band into locking engagement with the locking holes in the edge of the securement band. A keeper ring encircles the connecting body and locking member and is provided with an actuator lug which positively engages the lock member so that the lock member is moved into a locking position when the keeper ring is moved in one direction along the connector body and is positively released from locking engagement with the band when the keeper ring is moved in an opposite direction along the connector body. A securement band and locking device which is reversible front to rear and which may include similar or dissimilar decorative treatment of the band and of the connector. | 8 |
This application claims the benefit of U.S. Provisional Application 60/521,767 filed on Jul. 1, 2004.
BACKGROUND
1. Field of Invention
The present invention pertains to a downhole completion assembly having at least one control line, and particularly to a completion assembly in which the at least one control line has at least one splice.
2. Related Art
It is often desirable to run one or more control lines in, on, or through assemblies to be placed in a well. Control lines include, but are not limited to, hydraulic conduits, electrical line conduits, and fiber optic cables. A control line is generally used to communicate in some manner with one or more tools placed in the well. For example, a packer placed downhole may be set by hydraulic fluid pressure communicated from the surface to an actuator mechanism of the packer. Alternatively, a fiber optic cable may be pumped through a control line and used, for example, to measure the temperature profile of the well, or communicate a command to a tool downhole.
Control lines can be comprised of two or more segments. Those segments are typically (but not always) joined at the surface. Using segments may require the control line to have one or more splice. Once assembled, the control line is typically attached to the tubular or completion assembly being run into the well and the combined tubular or completion assembly and control line are run in the well together.
SUMMARY
The present invention provides for a completion assembly having a line slack compensator to provide or remove slack in a control line.
Advantages and other features of the invention will become apparent from the following description, drawings, and claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view illustrating a line slack compensator constructed in accordance with the present invention.
FIGS. 2A-2C is a schematic view illustrating an alternate embodiment of a line slack compensator constructed in accordance with the present invention.
FIG. 3 is a perspective view of a ring used in the embodiment of the line slack compensator of FIGS. 2A-2C .
FIG. 4 is a schematic view of a completion assembly incorporating a line slack compensator constructed in accordance with the present invention.
FIG. 5A is a schematic view of a line slack compensator constructed in accordance with the present invention.
FIG. 5B is a schematic view of a component of the line slack compensator of FIG. 5A .
FIG. 6A is a schematic view of a line slack compensator constructed in accordance with the present invention.
FIG. 6B is a schematic view of a component of the line slack compensator of FIG. 6A .
FIG. 7A is a schematic view of a line slack compensator constructed in accordance with the present invention.
FIG. 7B is a schematic view of a component of the line slack compensator of FIG. 7A .
FIG. 8 is a schematic view of a line slack compensator constructed in accordance with the present invention.
FIG. 9 is a schematic view of a line slack compensator constructed in accordance with the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1 , a line slack compensator 10 comprises a coiled control line section 12 and a straight control line section 14 . Control line sections 12 , 14 include, but are not limited to, hydraulic conduits, electrical line conduits, and fiber optic cables conduits. Fiber optic cable conduits include conduits having one or more fiber optic strands pumped therethrough or pre-packaged fiber optic strands housed in a self-contained protective covering. Straight control line section 14 can be above or below coiled control line section 12 , or both. Coiled control line section 12 comprises coils 16 that can expand or contract to allow or take up slack, as desired.
Coiled control line section 12 is carried on a mandrel 18 . An upper slider sleeve 20 or a lower slider sleeve 22 , or both, are also carried on mandrel 18 and engage coils 16 with slots 24 . Mandrel 18 may have threads on its outer surface complementary to threads on the inner surfaces of sleeves 20 , 22 so sleeves 20 , 22 can be axially displaced along mandrel 18 when sleeves 20 , 22 are rotated relative to mandrel 18 . Alternatively, the outer surface of mandrel 18 and the inner surface of sleeves 20 , 22 may be smooth to allow sliding displacement of sleeves 20 , 22 along mandrel 18 . A protective sleeve 26 covers at least coiled control line section 12 and protects it from damage. Slider sleeves 20 , 22 can be releasably fixed to mandrel 18 , for example, by set screws. Those set screws or other fixing means are accessed through openings in protective sleeve 26 . Guide lines may be provided to assist alignment.
A possible assembly method includes attaching mandrel 18 to a top sub 28 . Upper slider sleeve 20 is installed on mandrel 18 . Coiled control line section 12 is placed on mandrel 18 and upper slider sleeve 20 is spun down to engage coils 16 . Preferably a few turns of coils 16 are positioned above upper slider sleeve 20 . The upper portion of straight control line section 14 is joined to the upper portion of coiled control line 12 to allow fluid communication therethrough.
Lower slider sleeve 22 is installed on mandrel 18 and spun onto coiled control line 12 with slots 24 engaging coils 16 . Preferably a few turns of coils 16 are positioned below lower slider sleeve 22 . Protective sleeve 26 is mounted over coiled control line section 12 and slider sleeves 20 , 22 , for example, by joining it to top sub 28 . Set screws, locking bolts, or other fixing means are passed through openings in protective sleeve 26 and releasably secure slider sleeves 20 , 22 to mandrel 18 . The lower portion of straight control line 14 is joined to the lower portion of coiled control line 12 to allow fluid communication therethrough. A bottom sub 30 may be joined to the lower end of mandrel 18 .
In operation, say to provide slack at the lower end of line slack compensator 10 , the set screws (fixing means) holding lower slider sleeve 22 to mandrel 18 are loosened sufficiently to allow lower slider sleeve 22 to be moved downward. As lower slider sleeve 22 moves downward, coils 16 are stretched, producing slack at the lower end of line slack compensator 10 . To remove the slack, lower slider sleeve 22 is displaced upward to compress coils 16 . The extra coils below lower slider sleeve 22 compensate if the full slack provided is not all returned. Slack at the upper end of line slack compensator 10 is achieved in the same manner using upper slider sleeve 20 .
An alternate embodiment of a line slack compensator 100 is shown in FIGS. 2A-2C . In this embodiment, rings 102 are used to provide or remove slack. Preferably three rings 102 are used, but the invention may have more or fewer rings 102 , as desired. For ease of discussion, an embodiment using three rings 102 is discussed below.
In the embodiment shown, each ring 102 has at least one longitudinal or axially-directed hole 104 running through the sidewall 106 of ring 102 , as shown in FIG. 3 . Hole 104 may have some curvature as it passes through sidewall 106 . Ring 102 also has at least one radially-directed hole 108 through sidewall 106 . Rings 102 are carried on a mandrel 110 . Upper and lower rings 102 are fixed to mandrel 110 with holes 104 aligned. Middle ring 102 is free to rotate on mandrel 110 . Hole 108 can be used to allow access to mandrel 118 to releasably secure ring 102 to mandrel 110 . For example, hole 108 may have threads to receive a set screw.
Control line 112 is fed through holes 104 . When holes 104 of each ring 102 are aligned, slack is provided. While slack is provided, splicing operations may be performed with control line 112 . To remove slack, middle ring 102 is turned in either direction, wrapping control line 112 around mandrel 110 . Once the desired amount of slack is removed, middle ring 102 can be fixed to mandrel 110 . Using more rings 102 will permit management of larger amounts of slack in control line 112 .
Although rings 102 are described as having holes 104 therethrough, control line 112 can also be clamped or otherwise secured to ring 102 so as to rotate with ring 102 . For example, the embodiment of line slack compensator 10 shown in FIG. 5A has a curved groove 300 on ring 302 in which control line 112 is carried. FIG. 5B shows an enlarged view of ring 302 and groove 300 . If desired, a strap could be placed over control line 112 once placed in groove 300 to protect and restrain control line 112 .
Similarly, in FIG. 6A a catch 304 is shown releasably mounted on mandrel 110 . Catch 304 preferably has a curved nose 306 with a channel 308 to carry control line 112 without inducing undue bending stress in control line 112 . FIG. 6B shows an enlarged view of catch 304 .
FIG. 7A shows yet another embodiment of line compensator 10 in which a hook 310 is used to capture control line 112 and remove slack therefrom. Hook 310 is removably mounted on mandrel 110 and has a curved end 312 to snare control line 112 . FIG. 7B shows an enlarged view of hook 310 .
In FIG. 8 , an alternate arrangement of catches 304 is shown. In this embodiment, catches 304 are longitudinally and radially misaligned or offset. Control line 112 is laced or woven around catches 304 to remove slack therefrom. FIG. 9 shows a similar arrangement in which catches 304 are longitudinally staggered around the circumference of mandrel 110 . Control line 112 is again interlaced or interwoven around catches 304 to take up or remove slack therefrom. Many other variations are possible and within the scope of this invention.
Referring to FIG. 4 , line slack compensator 10 can be incorporated into a completion assembly 210 comprising a contraction joint 212 , a line slack compensator 10 , a make-up sub 216 , and a stinger 218 . In the embodiment shown, a fiber optic cable 220 , having at least one splice, extends from the surface to stinger 218 .
When assembled and ready to be run into the well, contraction joint 212 is joined to line slack compensator 10 , line slack compensator 10 is joined to make-up sub 216 , and make-up sub 216 is joined to stinger 218 .
An assembly method includes joining stinger 218 and make-up sub 216 and placing that combination in the rotary. In the embodiment shown, a lower free end of fiber optic cable 220 extends from the stinger/make-up sub combination. Contraction joint 212 and line slack compensator 10 are joined and that combination is stabbed or otherwise joined to the stinger/make-up sub combination, preferably without rotation of either combination. An upper free end of fiber optic cable 220 extends from the contraction joint/line slack compensator combination.
The upper and lower free ends of fiber optic cable 220 must be spliced together before assembly 210 can be run into the well. If slack is need, it may be obtained from line slack compensator 10 . Once the splice is made, slack is removed by line slack compensator 10 . If desired, a splice of fiber optic cable 220 can also be made between contraction joint 212 and line slack compensator 10 . Line slack compensator 10 can provide or remove slack at its upper and lower ends.
Line slack compensator 10 is able to provide or remove slack by extension or contraction of various turns of fiber optic cable 220 wrapped around a mandrel 18 in line slack compensator 10 . Movement of those loosely wrapped coils allows extension or contraction similar to that of a coil spring.
Make-up sub 216 is a tool well known in the art, and is sometimes referred to as a “quick connect” or “make-up union”. It comprises upper and lower halves with a clutch interface to transmit torque when the two halves are joined. The two halves are stabbed together and the collar (and only the collar) is rotated to secure the two halves together.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. | A completion assembly has one or more control lines. The control lines can develop differing degrees of slack depending on the completion assembly configuration and also on the particular use of the completion assembly. A line slack compensator cooperates with the completion assembly to provide or remove slack in one or more control lines as necessary for a given operation and a given completion assembly. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to fuel compositions for internal combustion engines and more particularly to fuel compositions which are characterized as containing a lubricant. The compositions disclosed herein are especially suitable for operating two-cycle combustion engines.
It is an ongoing goal of the world's automotive industries to continuously develop more efficient combustion engines which at the same time release decreased levels of undesirable gaseous emissions during their operation. The most common type of combustion engine presently in popular usage is the four-cycle engine. During normal operation four strokes or motions of the piston and connecting rod assembly in the cylinder bore comprise one complete engine cycle. These strokes are: 1) fuel-air intake stroke, 2) compression stroke, 3) power stroke, and 4) exhaust stroke. This cycle is repeated over and over at a constant or varied rpm in order to provide a useful work output. One of the drawbacks of the four-cycle engine is that only one power stroke occurs during every two revolutions of the crankshaft to which the piston and its connecting rod are attached.
Two-cycle engines, on the other hand produce one power stroke for every one revolution of the crankshaft. Typical operation is as follows: On the upstroke of the piston a partial vacuum is created in the crankcase and the piston is simultaneously caused to uncover a fuel mixture inlet port forcing the fuel mixture to enter the crankcase. This occurs while the charge currently in the cylinder is being compressed. The compressed charge is then fired and the piston decends on its power stroke, compressing the mixture in the crankcase. At the bottom of the power stroke, the piston uncovers the exhaust port(s) and fuel transfer ports. The exhaust gasses exit the engine while fresh fuel mixture is admitted to the cylinder. The cycle then repeats.
For two cycle engines conventional fuel mixtures comprise a gasoline and a gasoline-soluble lubricating additive such as a petroleum oil in a ratio of about 16 parts gasoline to 1 part of lubricating additive. Several different lubricating additives are available under the name of "2-cycle engine oil". The main requirement of such an oil is to provide sufficient lubrication of the moving engine components so as to avoid engine seizure and undue wear while preventing build-up of carbon deposits in the combustion chamber. From a manufacturing standpoint, an advantage of using a fuel/lubricant mixture is that no oil flow passages must be cast in or machined in the engine block and that no oil recirculating system or pump is required. Therefore the cost of manufacturing two cycle engines is considerably less when compared to four-cycle engines. Also, since the engine delivers one power stroke per engine revolution using fewer moving parts, greater power is produced with relatively less cost and less pollution.
The major disadvantage of combusting fuel/lubricant mixtures and the main reason why these types of engines do not enjoy the same popularity as their four-stroke counterparts is that the amount of unburned hydrocarbons, carbon monoxide, or nitrogen oxides emmitted during their operation is too great for the current emmission standards maximum levels imposed by the US EPA and other similar organizations worldwide even when state-of-the-art catalytic convertors are utilized. Obviously if it were possible to reduce the quantity of undesirable emissions while maintaining sufficient lubrication for normal engine operation then the automotive industries and society as a whole would benefit greatly.
SUMMARY OF THE INVENTION
In accordance with the present invention, the problems associated with the high amounts of undesirable exhaust gas emissions of two-cycle engines operated using conventional fuel mixtures are greatly reduced. This is accomplished by partial or complete substitution of the lubricating component of a conventional or prior art two-cycle engine fuel composition by a hydrocarbon-soluble fullerite species. is used in this specification and the appended claims the term "fullerite" denotes one or more hydrocarbon-soluble or dispersible allotrope(s) of elemental carbon which may exist in the general form of a closed spheroidal cage structure comprising truncated icosahedra including those allotropes which contain 60, 70, and 84 carbon atoms. For example, the simplist fullerite contains 60 carbon atoms, and such a material is described in the publication "Nature", vol. 318, page 162. Other similar carbon allotropes which exist in a cage structure are also possible, and allotropes containing 70, and 84 carbon atoms have also been described (Nature, vol. 350, page 20). A material which is to be considered representative of fullerite for purposes of the present invention is obtained by electrically evaporating carbon electrodes in an inert atmosphere such as helium at a pressure of about 100 torr. The 60 and 70 carbon atom fullerites are believed to comprise over 90% of the total hydrocarbon-soluble residue so produced. It is presumed that fullerite produced by some other means than described herein is also suitable for the present invention, provided that it imparts the same lubricating quality to the gasolines employed.
I have found that when the hydrocarbon-soluble portion of the material obtained by electrically evaporating graphite electrodes in a helium atmosphere at about 100 torr of pressure (fullerite) is dissolved in commercially available gasoline, that in addition to changing its color of the gasoline, the fullerite imparts a heretofore unobserved lubricating quality to the gasoline. It was subsequently found that a two-cycle engine suffered no increased wear and appeared to function normally when a significant portion of the conventional lubricative component of its fuel was removed and replaced by the fullerite. While the engine was operated the levels of undesirable exhaust gas components emitted were reduced and the normal blue smoke and odor which is characteristic of a two-cycle engine during its operation was not observed.
Accordingly, an object of the present invention is to provide a fuel composition which allows for reduced exhaust emmisions of two cycle engines during their normal operation.
DESCRIPTION OF THE INVENTION
The fuels contemplated for use in the fuel compositions of the present invention are normally liquid hydrocarbon fuels in the gasoline boiling range, including hydrocarbon base fuels. The term "petroleum distillate fuel" also is used to describe the fuels which can be utilized in the fuel compositions of the present invention and which have the above characteristic boiling points. The term is, however, not intended to be restricted to straight-run distillate fractions. The distillate fuel can be straight-run distillate fuel, catalytically or thermally cracked (including hydrocracked) distillate fuel, or a mixture of straight-run distillate fuel, naphthas and the like with cracked distillate stocks. Also, the base fuels used in the formation of the fuel compositions of the present invention can be treated in accordance with well-known commercial methods such as acid or caustic treatments, hydrogen solvent refining, clay treatment, etc.
Gasolines are supplied in a number of different grades depending upon the type of service for which they are intended. The gasolines utilized in the present invention include those designed as motor and avation gasolines. Motor gasolines include those defined by ASTM specification D-439-73 and are composed of a mixture of various types of hydrocarbons including aromatics, olefins, parafins, isoparafins, naphthalenes, and occasionally diolefins. Motor gasolines normally have a boiling range within the limits of about 20 degrees C. to about 230 degrees C., while avation gasolines have narrower boiling ranges, usually within the limits of about 37 degrees C. to 165 degrees C.
The Fullerite Containing Fuel Composition
The fuel compositions of the present invention will contain elemental carbon in one of its fullerite forms or a mixture of two or more fullerites. The currently preferable form of fullerite for use in the fuel compositions of the present invention is the hydrocarbon-soluble portion of the material obtained when graphite electrodes are electrically evaporated in an inert atmosphere such as helium. The mixture of fullerites obtained in this process is presently believed to principally comprise primarily the C-60 and C-70 structures, and it is also presently believed that it is these species which impart the lubricative characteristics to the fuel compositions of the present invention.
The C-60 and C-70 fullerite allotropes are separable using chromatographic methods, but such procedures will add to the cost of the fuel compositions of the present invention. Since no obvious deleterious effects were observed when the mixture of allotropes was utilized, there is presently no reason for separating these species and excluding one or the other from the fuel compositions.
Since gasolines vary from refiner to refiner with respect to such components as total aromatic content, oxygenate content, additive content, etc., it may be necessary in some cases to include in the fuel compositions polymeric dispersants which would tend to assist in keeping the fullerites in solution or in increasing the solubility of the fullerites in a given gasoline. A large number of polymeric dispersants have been suggested as being useful in lubricating oil formulations, and such polymeric dispersants are useful in the fuel compositions of the present invention. Often, such additives have been described as being useful in lubricating formulations as viscosity index improvers with dispersing characteristics. The polymeric dispersants are generally polymers or copolymers having a long carbon chain and containing polar groups to impart the dispersancy characteristics. Polar groups which are useful in this regard include amines, imines, imides, hydroxyl, etc. For example, the polymeric dispersants may be copolymers of methacrylates or acrylates containing additional polar groups or vinyl acetatefumaric acid ester copolymers.
Many such polymeric dispersants have been described in prior art. The following are U.S. patents which described polymeric dispersants: U.S. Pat. Nos. 4,402,844, 3,356,763, and 3,891,721. Other polymers which may be useful as dispersants in the fuels in this invention are described in the following U.S. Pat. Nos. 3,687,849, 3,687,905, 4,476,283, 4,181,618, 3,243,481, 3,723,575, 3,475,514, 4,026,167, 4,085,055, 4,409,120, 4,077,893, 4,358,565, 4,141,847, 4,346,193, and 4,160,739. Essential material contained in these patents is herein incorporated by reference. U.S. Pat. No. 4,402,844 describes nitrogen-containing copolymers prepared by the reaction of lithiated hydrogenated conjugated dienemonovinylarene copolymers with substituted aminolactams. U.S. Pat. No. 3,356,763 describes a process for producing block copolymers of dienes such as 1,3-butadiene and vinyl aromatic hydrocarbons such as ethyl styrenes. U.S. Pat. No. 3,891,721 describes block polymers of styrene-butadiene-2-vinylpyridine. A number of polymeric dispersants may be prepared by grafting polar monomers to polyolefinic backbones. For example, U.S. Pat. Nos. 3,687,849 and 3,687,905 describe the use of maleic anhydrides as a graft monomer to a polyolefinic backbone. Maleic acid or anhydride is widely used as a graft monomer because of its low cost and its role of providing incorporation of dispersant nitrogen compounds into polymers by further reaction of the carboxyl groups of the maleic acid or anhydride with, for example, nitrogen compounds or hydroxy compounds. U.S. Pat. No. 4,160,739 describes graft copolymers obtained by the grafting of a monomer system comprising maleic acid or anhydride and at least one other different monomer which is addition copolymerizable therewith, the grafted monomer system then being post-reacted with a poly-amine. The monomers which are copolymerizable with maleic acid or anhydride are any alpha, beta-monoethylenically unsaturated monomers which are sufficiently soluble in the reaction medium and are reactive towards maleic acid or anhydride so that substantially larger amounts of maleic acid or anhydride can be incorporated into the grafted polymeric product. Suitable monomers include esters, amides and nitriles of acrylic and methacrylic acid, and no monomers containing no free acid groups. The inclusion of heterocyclic monomers into graft polymers is described by a process which comprises a first step of graft polymerizing an alkyl ester of acrylic acid or methacrylic acid, alone or in combination with styrene, onto a backbone copolymer which is a hydrogenated block copolymer of styrene and a conjugated diene having 4 to 6 carbon atoms to form a first graft copolymer. In the second step, a polymerizable hetero-cyclic monomer, alone or in combination with a hydro-phobizing vinyl ester is copolymerized onto the first graft copolymer to form a second graft copolymer.
The hydrocarbon-substituted phenolic dispersants useful in the fuel compositions of the present invention include the hydrocarbon-substituted phenolic compounds wherein the hydrocarbon substituents have a molecular weight which is sufficient to render the phenolic compound fuel-soluble. Generally, the hydrocarbon substituent will be a substantially saturated, hydrocarbon based group of at least about 30 carbon atoms.
Also useful in the fuel compositions of the present invention are fuel-soluble alkoxylated derivatives of alcohols, phenols, and amines. A wide variety of such derivatives can be utilized so long as the derivatives are soluble in the fuel employed. As is well known to those skilled in the art, the solubility characteristics of the alkoxylated derivatives of phenols, alcohols, and amines can be controlled by proper selection of molecular moieties. Examples of commercially available alkylene oxide derivatives which may be used as dispersants in the fuel compositions of present invention are: Ethomeen S/12, tertiary amines of ethylene oxide condensation products of the primary fatty amines (Armak Industries), and Plurafac A-24, an ethoxylated straight chain alcohol available from BASF Wyandotte Industries.
A number of acylated, nitrogen-containing compounds having a substituent of at least 10 aliphatic carbon atoms and made by reacting a carboxylic acid acylating agent with an amino compound are known to those skilled in the art. In such compositions the acylating agent is bonded to the amino compound through an imido, amido, amidine, or acyloxy ammonium linkage. The substituent of 10 aliphatic carbon atoms may be in either the carboxylic acid acylating agent derived portion of the molecule or in the amino compound derived portion of the molecule. The acylating agent can vary from formic acid and its acylating derivatives to acylating agents having high molecular weight substituents of up to 20,000 carbon atoms. The amino compounds can vary from ammonia itself to amines having aliphatic substituents of up to about 30 carbon atoms.
In cases where the fuel compositions of the present invention are to be exposed to ultraviolet light for any extended time, additives such as ultraviolet light absorbers (UVA) or hindered amine light stabilizers (HALS) may function to retard any reaction between the fullerite and the components of the gasoline. Again, this will depend upon the relative amounts of various components present in the gasoline used in the fuel composition. Examples of hindered amine light stabilizers are: 1) Dimethyl succinate polymer with 4-hydroxy-2,2,6,6-tetramethyl-1-piperidine ethanol, and 2) N,N'-bis(2,2,6,6,-tetramethyl-4-piperidinyl)-1,6-hexanediamine polymer with 2,4,6-trichloro-1,3,5-triazine and 2,4,4-trimethyl-1,2-pentamine. An example of a UV absorber is 2-Hydroxy-4-n-octyloxy benzophenone.
The fuel compositions of the present invention can be prepared by either adding the individual components to a liquid hydrocarbon fuel, or a concentrate can be prepared comprising the components either pure or in a hydrocarbon diluent such as mineral oil. The following examples illustrate the fuel compositions in accordance with the present invention.
EXAMPLE 1
Unleaded gasoline is caused to remain in contact with fullerite until saturated with the fullerite. Then a volume of fresh unleaded gasoline equal to 5% by volume of the original amount of unleaded gasoline is added to the fullerite-containing gasoline. This fullerite-containing gasoline (which is nearly saturated with the fullerite) is then blended with SAE 5W-30 motor oil in a volume to volume ratio of 50 parts of the gasoline to 1 part motor oil to produce a two-cycle engine fuel composition.
EXAMPLE 2
To the fuel composition of example 1 is added about 0.5% by weight of a hindered amine light stabilizer.
In addition to the additives of this invention, the use of other conventional fuel additives is contemplated. Thus the fuel compositions may also contain surface ignition suppressants, demulsifiers, dyes, gum inhibitors, oxidation inhibitors, etc.
The present invention is generally directed to fuel compositions, but in particular to fuel compositions for two-cycle internal combustion engines. While fuel compositions of the present invention (which are preferably unleaded gasolines) are intended to be burned in internal combustion engines, the fuel compositions of the present invention have also been found to function as multi-purpose lubricants. | Fuel compositions for internal combustion engines and more particularly, fuel compositions for 2-cycle internal combustion engines comprising a gasoline, a hydrocarbon-soluble allotropic form of carbon, and a dispersing agent are provided. Engines operated utilizing the fuel compositions provided produce considerably lessened amounts of undesirable exhaust gas emmissions. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-151604, filed May 21, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method, apparatus, and computer program product for controlling write requests from a plurality of users with respect to structured documents stored in a storage that stores a plurality of structured documents with different document structures.
2. Description of the Related Art
In recent years, along with the development of information processing technologies, document data to be processed includes not only document data as a simple character string such as text data, but also document data with prescribed components that form a document such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), and the like.
Some documents such as patent specifications, weekly reports, and the like have predetermined formats, and are standardized to these formats. In addition to such documents that are standardized to given formats, many documents with free formats are also present. Hence, a demand for storage and management of such documents with various formats as structured documents described in XML and the like will be increasing in the future.
A plurality of users may often read out, edit, and write identical document data. If the edit contents from the users are consistent, all write requests should be permitted; if they are inconsistent, such write requests should be denied. Inconsistency of the contents due to a plurality of write accesses is called “conflict”.
Since a database is premised on accesses from a plurality of users, means for controlling write accesses from a plurality of users is indispensable. In a conventional relational database, under the condition that relations are designed to satisfy:
#First Normal Form
#Second Normal Form
#Third Normal Form
#Fourth Normal Form
#Boyce-Codd Normal Form, controls of write requests from a plurality of users are handled with a transaction management in units of tuple. This transaction management denies a plurality of write accesses originated simultaneously to an identical tuple. Specifically, to avoid the “conflict” in units of tuple, the transaction management handles controls of write requests so as to deny another write request during write access to a given tuple.
However, the “conflict” may occur since the relational database does not perform any transaction management in a unit that exceeds tuples.
As another example of a system for controlling write requests from a plurality of users, CVS (Concurrent Versions System) is known.
In the CVS, “line” is fixed as a write unit to each text as document data. If a plurality of write accesses are made to a single line, even when their write contents are independent from each other, the CVS determines them as “conflict”.
If the conflict has occurred, the CVS accepts all write requests that caused it, and the CVS then writes a mark indicating occurrence of conflict in document data. The user recognizes the conflict by observing that mark, and issues a new write request by checking the plurality of write contents.
In this way, the “tuple” in the conventional RDB and the “line” in the conventional CVS, which are fixedly set, are used as units to monitor if the conflict occur or not when a plurality of write accesses are requested. Hence, these techniques are not sufficient to be utilized for the above mentioned structured document processing such as XML, to prevent the conflict appropriately.
BRIEF SUMMARY OF THE INVENTION
The present invention has its object to provide a method, apparatus, and computer program product for performing exclusive access control which controls write accesses from a plurality of users with respect to an identical structured document in a flexible manner.
According to the present invention, there is provided a method of exclusively controlling write requests from a plurality of user terminals to an identical structured document, wherein the identical structured document includes a plurality of elements each containing document content, the method comprising: setting a monitor field in units of the elements within the identical structured document; accepting one write request from one user terminal; determining if the one write request is directed to the document content under monitoring by referral to the monitor field; and handling the one write request to reject overwriting of the document content despite the one write request if the document content has been rewritten by another write request from another user terminal in advance.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a schematic block diagram showing an example of the arrangement of a document data management system according to an embodiment of the present invention;
FIG. 2 is a schematic block diagram showing an example of the arrangement of a field-designated document data generation unit in a field-designated document data management apparatus;
FIG. 3 is a block diagram showing an example of the arrangement of a difference document generation unit in a terminal;
FIG. 4 is a block diagram showing an example of the arrangement of a document data write unit in the field-designated document data management apparatus;
FIG. 5 is a block diagram showing an example of the arrangement of a monitor field designation change unit in the field-designated document data management apparatus;
FIG. 6 shows an example of field-designated document data;
FIG. 7 shows an example of field-designated document data that is stored in a field-designated document data storage unit after a last write time is recorded in a monitor field;
FIG. 8 shows a storage example of identification information of a document structure, and field-designated document data in a correspondence table;
FIG. 9 shows another example of a structured document with a different document structure;
FIG. 10 illustrates a storage example of document data in the field-designated document data storage unit;
FIG. 11 is a flow chart for explaining the processing operation of the field-designated document data generation unit;
FIG. 12 is a flow chart for explaining the processing operation of the difference document generation unit shown in FIG. 3 ;
FIG. 13 shows an example of a difference document with the edit type=“rewrite”;
FIG. 14 shows an example of a difference document with the edit type=“add”;
FIG. 15 shows an example of a difference document with the edit type=“delete”;
FIG. 16 shows an example of a write request generated based on the difference document shown in FIG. 13 ;
FIG. 17 is a flow chart for explaining the processing operation of the document data write unit shown in FIG. 4 ;
FIG. 18 shows the rewritten state of the field-designated document data shown in FIG. 7 , which is stored in the field-designated document data storage unit, upon execution of the write request shown in FIG. 16 ;
FIG. 19 is a flow chart for explaining the processing operation of a monitor field change unit of the field-designated document data management apparatus;
FIG. 20 shows another example of a write request;
FIGS. 21A and 21B show still other examples of write requests for two monitor fields;
FIG. 22 shows the rewritten state of the field-designated document data shown in FIG. 7 , which is stored in the field-designated document data storage unit, upon execution of the write request shown in FIG. 20 ;
FIG. 23 shows field-designated document data of “member address book” information;
FIG. 24 shows an example of a difference document used to delete a browse-only, non-editable component;
FIG. 25 is a view for explaining the processing operation for changing a monitor field, and shows a state wherein attribute information “monitor 13 field=“true”” is deleted from all components “member” designated in the field-designated document data shown in FIG. 7 ;
FIG. 26 is a view for explaining the processing operation for changing a monitor field, and shows a state wherein new monitor field designation data is registered in the correspondence table;
FIG. 27 is a view for explaining the processing operation for changing a monitor field, and shows field-designated document data in which a new monitor field is designated;
FIG. 28 is a block diagram showing another example of the arrangement of the field-designated document generation unit;
FIGS. 29A , 29 B and 29 C show an example of a relational database; and
FIG. 30 shows an example of field-designated document data with respect to the document data shown in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described hereinafter with reference to the accompanying drawings.
FIG. 1 schematically shows an example of the arrangement of a document data management system according to this embodiment. The document data management system roughly comprises a field-designated document data management apparatus (to be simply referred to as a document data management apparatus) 1 which serves as a server for storing and managing a plurality of document data, and a terminal 2 which serves as a client such as a PDA, portable phone, personal computer, or the like for, e.g., editing field-designated document data read out from the document data management apparatus 1 .
Note that the document data management apparatus 1 corresponds to a structured document management apparatus, and the terminal 2 corresponds to a structured document edit apparatus.
The document data management apparatus 1 comprises a field-designated document data generation unit 11 , field-designated document data storage unit 12 , monitor field designation change unit 13 , document data write unit 14 , document data read-out unit 15 , time management unit 16 , and correspondence table storage unit 17 .
The terminal 2 comprises at least a write request generation unit 21 , difference document generation unit 22 , and document data edit unit 23 .
Document data to be processed by the document data management system shown in FIG. 1 is a structured document having an arbitrary document structure. The structured document includes those described in, e.g., SGML, XML, and the like. SGML (Standard Generalized Markup Language) is a standard specified by ISO (International Organization for Standardization). XML (extensible Markup Language) is a standard specified by W3C (World Wide Web Consortium). These are structured document rules that can structure documents.
The following explanation will be given taking a document described in XML as an example of a structured document. That is, a document data management system which is designed to process structured documents described in XML will be explained, but the gist of the present invention to be described below can be applied to structured documents described in description languages other than XML.
The field-designated document data generation unit 11 receives document data of a structured document, identification information used to identify the type of document structure of that document data, and monitor field designation data (to be described later), and then generates field-designated document data (to be described later) based on these data. When field-designated document data is generated by inputting monitor field designation data to document data, the monitor field designation data used in this case is registered in the correspondence table 17 in correspondence with the type of document structure of that document data. When document data with document structure, the monitor field designation data of which has already been registered in the correspondence table 17 , is input to the field-designated document data generation unit 11 later, field-designated document data is generated using the monitor field designation data registered in the correspondence table 17 .
That is, when there are a plurality of document structures, if monitor field designation data is input to only one document data corresponding to each document structure, field-designated document data can be generated without inputting monitor field designation data to other document data of the identical document structure (by designating only the identification information of the document structure).
The field-designated document data generated by the field-designated document data generation unit 11 is stored in the field-designated document data storage unit 12 .
The document data management system shown in FIG. 1 is designed to process a plurality of structured is documents of different document structures. Therefore, these plurality of structured documents are categorized based on the types of document structures corresponding to the structured documents, and are then stored in the field-designated document data storage unit 12 .
FIG. 10 depicts a storage example of document data in the field-designated document data storage unit 12 . The storage unit 12 stores identification information (e.g., “address book”, “schedule”, and the like) of document structures, and files of document data corresponding to the identification information of respective document structures in the form of a table in association with each other.
The document data read-out unit 15 reads out field-designated document data from the field-designated document data storage unit 12 in accordance with a request from the terminal 2 .
The monitor field designation change unit 13 is used to change designation of a monitor field for a document structure, in which the monitor field has already been designated, and field-designated document data, which has that document structure and has already been stored in the field-designated document data storage unit 12 .
The time management unit 16 provides a last write time (to be described later) to the document data write unit 14 and field-designated document data generation unit 11 .
The document data edit unit 23 in the terminal 2 is used to edit field-designated document data read out from the document data management apparatus 1 .
The difference document generation unit 22 compares field-designated document data before and after the edit process for each monitor field to extract a difference, thus generating a difference document (to be described later).
The write request generation unit 21 generates a write request to the document data management apparatus 1 based on the generated difference document.
The document data write unit 14 in the document data management apparatus 1 receives a write request sent from the terminal 2 , and writes in the field-designated document data storage unit 12 on the basis of this write request and time data provided by the time management unit 16 .
FIG. 2 shows an example of the arrangement of the field-designated document data generation unit 11 . The generation unit 11 comprises a document data input unit 111 , monitor field designation unit 112 , monitor field designation data input unit 113 , last write time data input unit 114 , and write unit 115 . The arrangement and processing operation of the field-designated document data generation unit 11 will be described below with reference to FIG. 2 and the flow chart shown in FIG. 11 .
Field-designated document data is generated from a structured document data having a document structure formed of a plurality of components such as XML, and field designation data for designating a monitor field consisting of at least one component.
The monitor field can be set for at least one component of one document structure. In this embodiment, the monitor field is set for each data range consisting of at least one of a plurality of components of a document structure. The monitor field corresponds to a range of data used to control write accesses from a plurality of users, as will be described later.
For example, assume that one structured document includes a component that describes a company name, and a component that describes a company telephone number, which are set in different monitor fields. In this case, assume that when write accesses from a plurality of users are made for that structured document and write control (to be described later) is done for respective monitor fields, rewrite of the component that describes the company name is permitted, and rewrite of the component that describes the company telephone number is denied. As a result, the contents of the two components might become inconsistent. A data range consisting of a plurality of components having a relationship in which rewrite of the value of at least one component cause inconsistency with the values of other non-rewritten components (such relationship will be referred to as dependency hereinafter) of a plurality of components of a document structure is set as a monitor field, and write accesses from a plurality of users (to be described later) are controlled for each monitor field, thus easily avoiding conflict that causes inconsistent contents.
Write control is done for respective monitor fields as follows. For example, when a plurality of users make write accesses to data of an identical version of an identical monitor field of an identical structured document, only a write request, which has arrived at the earliest time, of those from the plurality of users, is executed, and other write requests are denied.
More specifically, the time when the last write access corresponding to the version number of data of a given monitor field was made to that monitor field (last write time) is recorded for respective monitor fields. This recorded time is compared with the last write time written in the monitor field before rewrite used in the current write access, and if the former time is later than the latter one, the current write access is denied.
In this embodiment according to the present invention, the monitor field set for each document structure is variable of its range.
An XML document is a standard document format as a structured document. XML forms a structured document by arranging components called nodes in a tree structure.
For example, XML data (document data) that expresses “address book” information is as follows:
<address_book>
<member>
<name>Taro Yamada</name>
<mail>yamada@taiyo-tusin.com</mail>
<office>Taiyo Tusin</office>
</member>
<member>
<name>Hanako Suzuki</name>
<mail>hanako@kanagawa-gass.co.jp</mail>
<office>Kanagawa Gas</office>
</member>
</address_book>
This document data has a document structure in which a component (node) “address_book” has a plurality of child components “member”, and each component “member” has child components “name”, “mail”, and “office”. Each component is bounded by tags (<component name>) that represents the component name.
For example, assume that identification information of the aforementioned document structure of the above document data, i.e., “address book” information, is “address_book”.
XML will be briefly explained below.
XML uses tags to express a document structure. The tags include start and end tags. By bounding each component of document structure information by start and end tags, a character string (text) delimiter in a document and a component to which that text belongs in terms of a structure can be clearly described.
Note that a start tag is defined by closing a component name (tag name) by “<” and “>”, and an end tag is defined by closing a component name by “</” and “>”. The contents of a component that follows a tag are text (character string) or repetition of a child component. Also, the start tag can be set with attribute information like “<component name attribute=“attribute value”>”. A component which does not contain any text like “<mail></mail>” can also be simply expressed by “<mail/>”.
In this embodiment, “address book/member” is used to designate the range of data consisting of a component group present below node “member” as one of child components of tag “address_book”, and “address book/member/name” is used to designate the range of data consisting of a component group present below node “name” as a child component of “member”. Such expressions (“address book/member”, “address book/member/name”) used to designate specific areas (data ranges) in the structured document will be referred to as paths.
A case will be examined below wherein monitor fields are set for, e.g., respective components “member” in the document data of the “address_book” information, i.e., for respective data ranges consisting of component groups present below component “member”. For example, if the format of monitor field designation data is “monitor field=(path to monitor field)”, monitor field designation data in this case is “monitor_field=address book/member”.
The following explanation will be given while taking as an example a case wherein document data such as the “address_book” information described above is newly stored in the document data management apparatus 1 .
The document data input unit 11 receives document data like the “address book” information, and identification information (e.g., “address_book” in this case) of the document structure of that document data (step S 1 in FIG. 11 ). The input document data and the identification information of the document structure of that document data are passed to the monitor field designation unit 112 .
At this time, only when it is determined with reference to the correspondence table 17 that no monitor field designation data corresponding to the input identification information of the document structure is registered (step S 2 in FIG. 11 ), the monitor field designation unit 112 displays a predetermined message to prompt the user to input monitor field designation data. In this case, the user can only input monitor field designation data, e.g., “monitor_field=address book/member” in the monitor field designation data input unit 113 (step S 3 in FIG. 11 ). The monitor field designation data input to the monitor field designation data input unit 113 is passed to the monitor field designation unit 112 .
The monitor field designation unit 112 registers the received monitor field designation data (“monitor_field=address book/member”) in the correspondence table 17 in correspondence with the identification information (e.g., “address_book”) of the document structure of the field-designated document data, as shown in FIG. 8 (step S 4 in FIG. 11 ).
On the other hand, if it is determined in step S 2 in FIG. 11 that the monitor field designation data corresponding to the input identification information of the document structure has already been registered in the correspondence table 17 (the user need not input new monitor field designation data), the monitor field designation data corresponding to the input identification information of the document structure is read out from the correspondence table 17 . The control skips steps S 3 and S 4 , and jumps to step S 5 .
In step S 5 in FIG. 11 , the monitor field designation unit 112 generates field-designated document data using the document data which is input from the document data input unit 11 and in which no monitor fields have not been set yet, and the monitor field designation data input from the monitor field designation data input unit 113 (or monitor field designation data read out from the correspondence table 17 ) (step S 5 in FIG. 11 ).
For example, based on the monitor field designation data “monitor_field=address book/member” and the document data of the “address book” information, field-designated document data shown in FIG. 6 is generated.
As indicates by the second and seventh lines in FIG. 6 , information which indicates a component designated as a monitor field by the monitor field designation data is added as attribute information of that component. More specifically, attribute information “monitor_field=“true”” is set in the start tag of the component (component with component name “member”) designated as the monitor field.
The last write time data input unit 114 inputs time data provided by the time management unit 16 as the last write time data. The write unit 115 records the last write time as a write time in the field-designated document data storage unit 12 in each monitor field of the generated field-designated document data (step S 6 in FIG. 11 ).
For example, in case of the field-designated document data shown in FIG. 6 , a monitor field is designated for each component “member”. Also, assume that time data received as last write time data upon storing the field-designated document data shown in FIG. 6 in the field-designated document data storage unit 12 is, for example, “2001/3/3 10:23”. At this time, the write unit 115 further sets “last_write_time=“2001/3/3 10:23”” as attribute information to the start tag of each component designated as a monitor field in the field-designated document data shown in FIG. 6 , as indicated, e.g., by the second and sixth lines in FIG. 7 .
The write unit 115 finally stores a file of the field-designated document data (e.g., file name “address book A”) shown in FIG. 7 , in which attribute information indicating a monitor field and attribute information indicating the last write time are set for each component set as a monitor field, in the field-designated document data storage unit 12 in FIG. 1 , as shown in FIG. 10 (step S 7 in FIG. 11 ).
In the above description, one document data file of one document structure has been exemplified. However, in practice, a plurality of document data with different document structures are present, and monitor fields are set for those document structures, as described above (field-designated document data is generated and is registered in the correspondence table 17 ).
When the monitor fields are set for arbitrary one document data of arbitrary one document structure, the identification information of that document structure and corresponding monitor region designation data are registered in the correspondence table 17 , as shown in FIG. 8 . After that, monitor fields can be set (designated) in identical components in other document data with the same document structure.
For example, assume that a structured document shown in FIG. 9 is present as document data of a document structure different from that of the document data of the “address book” information.
The structured document shown in FIG. 9 is document data of “schedule” information having a document structure in which component (node) “schedule” includes a plurality of child components “Item”, and each component “Item” has child components “Date”, “Time”, “Subject”, “Place”, and “Body”.
For example, assume that identification information of the aforementioned document structure of the document data of “schedule” information shown in FIG. 9 is “schedule”.
A case will be examined below wherein monitor fields are set for, e.g., respective components “Item” in the document structure of the document data shown in FIG. 9 , as in the case of the document data of the “address book” information (see FIG. 30 ). In this case, monitor field designation data is “monitor field=schedule/Item”.
When the structured document in FIG. 30 is newly stored in the document data management apparatus 1 according to FIG. 11 , the identification information “schedule” of the document structure, and the monitor field designation data “monitor field=schedule/Item” are registered in the correspondence table 17 , as shown in FIG. 8 . Also, a file of the document data shown in FIG. 9 (e.g., file name “schedule A”) is stored in the field-designated document data storage unit 12 , as shown in FIG. 10 .
FIG. 28 shows another example of the arrangement of the field-designated document data generation unit 11 , which is substantially the same as that in FIG. 2 , except that a document structure recognition unit 116 is connected to the monitor region designation unit 112 .
The document structure recognition unit 116 has a parser, which recognizes the document structure of input document data. The document structure recognition unit 116 pre-stores a DTD (Document Type Definition) for each of different document structures. Each DTD is stored in correspondence with the identification information of that document structure.
When new document data is input from the document data input unit 111 , the parser in the document structure recognition unit 116 obtains identification information of a DTD, which matches the document structure of the input document data, using the pre-stored DTDs one by one, so as to determine a document structure corresponding to the input document data. Hence, if this document structure recognition unit 116 is arranged, no identification information of the document structure need be input.
The subsequent processing operation is the same as that in FIG. 11 .
The terminal 2 will be explained below.
Field-designated document data shown in FIG. 2 , which is read out from the field-designated document data storage unit 12 by the document data read-out unit 15 in response to a request from the terminal 2 , is browsed and edited by the document data edit unit 23 .
The difference document generation unit 22 compares field-designated document data before and after the edit process for each monitor field to extract their difference, thus generating a difference document (to be described later).
FIG. 3 shows an example of the arrangement of the difference document generation unit 22 . The generation unit 22 comprises field-designated document data input units 221 and 222 , field extraction unit 223 , and field comparison unit 224 .
The field-designated document data input unit 221 receives field-designated document data before edit, and the field-designated document data input unit 222 receives field-designated document data that has been edited by the document data edit unit 23 .
The field extraction unit 223 extracts corresponding monitor fields from the field-designated document data before and after the edit process.
The field comparison unit 224 compares two corresponding monitor fields extracted from the field-designated document data before and after the edit process to generate a difference, i.e., a difference document (to be described later).
The write request generation unit 21 receives the difference document, extracts a field indicated by the difference document (to be described later) and write contents, and generates a write request containing them.
The description will revert to that of the document data management apparatus 1 .
FIG. 4 shows an example of the arrangement of the document data write unit 14 in the document data management apparatus 1 . The write unit 14 comprises a last write time recording unit 141 , field write unit 142 , field detection unit 143 , and write request reception unit 144 .
The write request reception unit 144 receives a write request sent from the terminal 2 . The request includes information (write objective field information) indicating a write objective monitor field in field-designated document data, and information (write content information) indicating the contents to be written in practice.
The field detection unit 143 detects a write objective field from the field-designated document data stored in the field-designated document data storage unit 12 on the basis of the write objective field information.
The field write unit 142 writes based on write content information contained in the received write request in the write objective field (write objective monitor field) detected from the field-designated document data.
The last write time recording unit 141 records a write time as an attribute value of attribute information “last write time” in the monitor field that has undergone the write access of the field write unit 142 .
FIG. 5 shows an example of the arrangement of the monitor field designation change unit 13 . The change unit 13 comprises a monitor field designation change request reception unit 131 , monitor field designation delete unit 133 , and monitor field designation generation unit 134 .
The monitor field designation change request reception unit 131 receives a monitor field designation change request from the user.
The monitor field designation delete unit 133 deletes the current monitor field designation in field-designated document data with a designated document structure stored in the field-designated document data storage unit 12 on the basis of information, which is contained in the monitor region designation change request and designates a document structure and components as the old and new monitor fields.
The monitor field designation generation unit 134 generates monitor field designation data on the basis of information, which is contained in the monitor region designation change request and designates a document structure and components as the old and new monitor fields, and rewrites monitor field designation data corresponding to the identification information of the document structure in the correspondence table 17 by the generated monitor field generation data. Then, the unit 134 writes attribute information “monitor_field=“true”” in the start tag of a component designated as a new monitor field in field-designated document data of the designated document structure stored in the field-designated document data storage unit 12 , thereby setting that component as the monitor field.
A case will be explained below wherein the user establishes connection between the terminal 2 and document data management apparatus 1 , and browses and edits field-designated document data stored in the document data management apparatus 1 at the terminal 2 .
Upon receiving a read-out request from the terminal 2 , the document data read-out unit 15 of the document data management apparatus 1 reads out field-designated document data corresponding to identification information (file name in this case) of field-designated document data contained in the request from the field-designated document data storage unit 12 , and outputs the readout data to the terminal 2 .
In the terminal 2 , the field-designated document data is input to the difference document generation unit 22 as that before edit, and also to the document data edit unit 23 .
After that, the user can browse and edit the field-designated document data using the document data edit unit 23 .
In general, the edit process includes rewrite, delete, new addition and generation, and the like of some of the field-designated document data.
The difference document generation unit 22 compares the field-designated document data obtained as a result of such edit process, and the field-designated document data before edit for respective monitor fields, and generates a difference document indicating the type and location of edit.
Assume that there are three types of edit, e.g., “add”, “rewrite”, and “delete”.
Assume that the user has rewritten “Hanako Suzuki” in the eighth line of the field-designated document data shown in FIG. 7 to “Hanako Ogawa” using the document data edit unit 23 . As a result, a difference document generated by the difference document generation unit 22 is as shown in FIG. 13 .
In the difference document shown in FIG. 13 , the first and second lines describe the type of edit “rewrite”, the third to eighth lines describe data of the monitor field of interest before edit as an objective field, and the ninth to 14th lines describe data of the monitor field of interest after edit to indicate the rewrite result. More specifically, as can be understood from the difference document shown in FIG. 13 , “Hanako Suzuki” before edit (fifth line) is rewritten to “Hanako Ogawa” after edit (11th line).
On the other hand, assume that the user has written data that adds the following component “member” for one person between the 11th and 12th lines at the end of the field-designated document data in FIG. 7 in the edit process. It is preferable to add data at the end of the document.
“<member monitor_field=“true” last_write_time=2001/4/4/
10:23>
<name>Hajime Tanaka</name>
<mail>tanaka@kanto-system.com</mail>
<office>Kanto System</office>
</member>”
As a result, a difference document generated by the difference document generation unit 22 is as shown in FIG. 14 .
In the difference document in FIG. 14 , the first and second lines describe the type of edit “add”, and the third to eighth lines describe data of one added monitor field to indicate the added data.
Assume that the user has deleted component “member” for one person in the seventh to 11th lines in the field-designated document data shown in FIG. 7 using the document data edit unit 23 in the edit process. As a result, a difference document generated by the difference document generation unit 22 is as shown in FIG. 15 .
In the difference document shown in FIG. 15 , the first and second lines describe the type of edit “delete”, and the third to eighth lines describe data of the monitor field of interest deleted by edit as an objective field.
The processing operation of the difference document generation unit 22 in FIG. 3 will be described below with reference to the flow chart shown in FIG. 12 .
Assume that the user has rewritten “Hanako Suzuki” in the eighth line of the field-designated document data shown in FIG. 7 to “Hanako Ogawa” using the document data edit unit 23 in the edit process.
The field-designated document data input unit 221 of the difference document generation unit 22 receives the field-designated document data before edit shown in FIG. 7 , and the field-designated document data input unit 222 receives field-designated document data after edit (step S 11 in FIG. 12 ).
The field extraction unit 223 loads the input field-designated document data before and after edit, and extracts corresponding monitor fields (e.g., in the order of appearance) one by one from these two field-designated document data (step S 12 in FIG. 12 ).
If a pair of corresponding monitor fields are extracted from the field-designated document data before and after edit, they are compared (step S 14 in FIG. 12 ).
Upon comparison between data of the two corresponding monitor fields, if some data in the monitor field of interest in the field-designated document data after edit are different from those in the monitor field of interest in the field-designated document data before edit, it is determined that the type of edit is “rewrite”, and the flow advances to step S 17 .
If the field-designated document data after edit does not have any monitor field corresponding to the monitor field of interest in the field-designated document data before edit, it is determined that the type of edit is “delete”, and the flow advances to step S 16 .
On the other hand, if the field-designated document data before edit does not have any monitor field corresponding to the monitor field of interest in the field-designated document data after edit, it is determined that the type of edit is “add”, and the flow advances to step S 15 .
In step S 15 , a difference document which has the type of edit “add”, as shown in FIG. 14 , is generated.
In step S 16 , a difference document which has the type of edit “delete”, as shown in FIG. 15 , is generated.
In step S 17 , a difference document which has the type of edit “add”, as shown in FIG. 13 , is generated.
Note that attribute information which permits only browse but denies any edit processes such rewrite, delete, and the like can be set in a component of document data to be processed by the document data processing system shown in FIG. 1 . For example, when an attribute that allows only browse is to be set for data of component “name” in the third line in FIG. 7 , attribute information “browse-only=“true”” is written in the start tag of component “name” as follows:
“<name browse-only=“true”>Taro Yamada</name>”
If data of the monitor field extracted as a field to be compared in the field-designated document data after edit in step S 17 in FIG. 12 contains a component with the above attribute information “browse-only=“true””, that component is deleted from the monitor field to obtain data of the monitor field extracted as a field to be compared in the field-designated document data after edit.
After comparison is made for all monitor fields in the field-designated document data before and after edit (step S 13 ), all generated difference documents are output to the write request generation unit 21 , thus ending the processing (step S 19 ).
Note that the difference document may contain, e.g., a file name as identification information of the field-designated document data to be processed.
The write request generation unit 21 of the terminal 2 generates a write request on the basis of the input difference documents. The write request contains, e.g., a file name as the identification information of field-designated document data, information (write object field information) indicating a write objective field in the field-designated document data, and information (write content information) indicating the contents to be actually written.
If the type of edit described in the difference document is “add”, a write request in which write objective field information is “empty” and write content information is data described in a column “change contents” in the difference document is generated.
If the type of edit described in the difference document is “delete”, a write request in which write objective field information indicates a monitor field described in a column “objective field” in the difference document, and write content information is “empty” is generated.
If the type of edit described in the difference document is “rewrite”, a write request in which write objective field information indicates a monitor field described in a column “objective field” in the difference document, and write content information indicates data described in a column “change contents” in the difference document is generated. For example, a write request shown in FIG. 16 is generated on the basis of the difference document shown in FIG. 13 .
The write request shown in, e.g., FIG. 16 , which is generated by the write request generation unit 21 of the terminal 2 is sent to the document data management apparatus 1 .
The document data write unit 14 of the document data management apparatus 1 starts operation upon reception of the write request shown in, e.g., FIG. 16 .
The processing operation of the document data write unit 14 in FIG. 4 will be described below with reference to the flow chart shown in FIG. 17 .
The write request shown in FIG. 16 is received by the write request reception unit 144 of the document data write unit 14 (step S 21 ).
Write objective field information and write content information are extracted from the received write request (step S 22 ).
If it is determined in step S 23 that the write objective field information is empty (that is, in case of a write request which includes the type of edit=“add” and writes to add a monitor field), the flow advances to step S 24 , and the field write unit 142 generates a new monitor field in designated field-designated document data stored in the field-designated document data storage unit 12 using the write content information contained in the write request (step S 24 ). The last write time recording unit 141 records the last write time as attribute information in the start tag of the newly written monitor field (step S 30 ).
If it is determined in step S 23 in FIG. 17 that the write objective field information is not empty, the flow advances to step S 25 .
In step S 25 , the field-designated document data detection unit 143 detects a monitor field designated by the write objective field information from the designated field-designated document data stored in the field-designated document data storage unit 12 . In this case, the designated monitor field can be simply detected by matching between the value of each component in the write objective field information, and that of each component in each monitor field in the designated field-designated document data stored in the field-designated document data storage unit 12 .
If detection of the designated monitor field from the designated field-designated document data stored in the field-designated document data storage unit 12 has succeeded, the flow advances to step S 26 ; otherwise, the processing ends.
In step S 26 , the field write unit 142 checks conflict by comparing the last write time as attribute information of the monitor field in the write content information and that of the monitor field as the detected write objective field.
If the last write time of the write objective field is newer than that of the monitor field in the write content information, since another user has made write access to the same monitor field in the same field-designated document data after that field-designated document data was read out from the field-designated document data storage unit 12 for the current edit process, the presence of conflict can be determined. Hence, the current write request is denied, and the processing ends.
On the other hand, if the last write time of the write objective field is older than or equal to that of the monitor field in the write content information, since no conflict occurs even when the current write request is permitted, the flow advances to step S 27 to proceed with the processing.
If it is determined in step S 27 that the write content information is empty (that is, in case of a write request which has the type of edit “delete” and deletes a monitor field), the flow advances to step S 29 ; otherwise (that is, in case of a write request which has the type of edit “rewrite”, and rewrites some data in a monitor field), the flow advances to step S 28 .
In step S 28 , the field write unit 142 writes in the write objective field, detected in step S 25 , of the designated field-designated document data stored in the field-designated document data storage unit 12 using the write content information contained in the write request. The last write time recording unit 141 rewrites the value of the last write time as attribute information of the start time of the rewritten monitor field using time data provided from the time management unit 16 at that time (step S 30 ).
For example, when “Hanako Suzuki” in the field-designated document data shown in, e.g., FIG. 7 is rewritten to “Hanako Ogawa” at the terminal 2 , the difference document shown in FIG. 13 is generated, and the write request shown in FIG. 16 is also generated. When the document data write unit 14 receives this write request, the field-designated document data, which is stored in the field-designated document data storage unit 12 and shown in FIG. 7 , is rewritten, as shown in FIG. 18 , via the aforementioned processes. In this case, the value of component “name” in the eighth line in FIG. 18 has been rewritten to “Hanako Ogawa”. Since such write access was made at time “2001/3/3 12:31”, last_write_time=“2001/3/3 12:31” is written as attribute information in component “member” in the seventh line in FIG. 18 .
In step S 29 , the field write unit 142 deletes the write objective field, detected in step S 25 , of the designated field-designated document data stored in the field-designated document data storage unit 12 .
Finally, the processing operation of the monitor field change unit 13 for changing monitor fields set for respective document structures will be described below with reference to the flow chart shown in FIG. 19 . A case will be exemplified below wherein the current monitor field set in component “member” in the document structure of the field-designated document data shown in FIG. 7 is re-set in components “name”, “mail”, and “office”.
The monitor field designation change request reception unit 131 receives a monitor field designation change request from the user (step S 41 ). This monitor field designation change request contains identification information of the document structure (in this case, “address_book”), and information indicating old and new components to be set as monitor fields (in this case, information that designates a change from “address book/member” to “address book/member/name”, “address book/member/mail”, and “address book/member/office”).
The monitor field designation delete unit 132 deletes the current monitor field designation in all field-designated document data which are stored in the field-designated document data storage unit 12 and have the designated document structure, on the basis of the identification information of the document structure contained in the monitor field designation change request. That is, the unit 132 deletes attribute information “monitor_field=“true”” that designates a monitor field (step S 42 ).
For example, in case of the field-designated document data shown in FIG. 7 , all pieces of attribute information “monitor_field=“true”” are deleted from components “member”, as shown in FIG. 25 .
The monitor field designation generation unit 134 generates monitor region designation data on the basis of the information which is contained in the monitor field designation change request, and designates old and new components to be set as monitor fields (step S 43 ), and rewrites the monitor field designation data corresponding to the identification information of the document structure in the correspondence table 17 by the generated monitor field designation data (step S 44 ). The unit 134 then writes attribute information “monitor_field=“true”” in start tags of components designated as new monitor fields in field-designated document data with the designated document structure, which are stored in the field-designated document data storage unit 12 , thereby setting these components as monitor fields (step S 45 ).
For example, monitor field designation data “monitor 13 field=address book/member/name”, “monitor 13 field=address book/member/mail”, and “monitor 13 field=address book/member/office” are generated in this case. In a column of identification information “address book” of the document structure in the correspondence table 17 , the above three monitor field designation data are registered, as shown in FIG. 26 . Also, attribute information “monitor_field=“true”” is written in tags “name”, “mail”, and “office” of each document data from which attribute information “monitor_field=“true”” has been deleted, as shown in FIG. 25 , and which has the designated document structure, using the aforementioned three monitor field designation data, as shown in FIG. 27 .
In this embodiment, the user's monitor field designation change request contains the identification information of a document structure (e.g., “address book”), and information indicating old and new components to be set as monitor fields (in this case, information that designates a change from “address book/member” to “address book/member/name”, “address book/member/mail”, and “address book/member/office”), and the monitor field designation generation unit 134 generates monitor field designation data (e.g., “monitor_field=address book/member/name”, “monitor_field=address book/member/mail”, and “monitor_field=address book/member/office”) on the basis of the information which is contained in the monitor field designation change request and designates old and new components to be set as monitor fields. However, the present invention is not limited to such specific process. For example, the user's monitor field designation change request may contain the identification information of the document structure and new monitor field designation data themselves (e.g., “monitor_field=address book/member/name”, “monitor_field=address book/member/mail”, and “monitor_field=address book/member/office” in the above case). In such case, the monitor field designation generation unit 134 need not generate any monitor field designation data, and need only register the received new monitor field designation data in the correspondence table 17 , and re-set new monitor fields in field-designated document data, from which attribute information “monitor_field=“true”” has been deleted, on the basis of the received new monitor field designation data.
(Detailed Description of Process of Document Write Unit Upon Receiving a Plurality of Write Requests)
For example, assume that two users A and B have read out identical field-designated document data shown in FIG. 7 , and edited the readout data using their terminals 2 .
Assume that user A has rewritten “Taiyo Tusin” in the fifth line in FIG. 7 to “Taiyo Tusin K.K.” in the edit process. FIG. 20 shows a write request generated in this case.
On the other hand, assume that user B has rewritten “yamada@taiyo-tusin.com” in the fourth line in FIG. 7 to “yamada@taiyo-communicate.com”, rewritten “hanako@kanagawa-gass.co.jp” in the ninth line to “hanako@yokohama-gass.co.jp”, and rewritten “Kanagawa Gas” in the 10th line to “Yokohama Gas” in the edit process. That is, user B has made an edit process across two monitor fields. In this case, a total of two write requests are generated in correspondence with monitor fields as write objective fields, as shown in FIGS. 21A and 21B .
Assume that the write request for reflecting the edit result in the field-designated document data storage unit 12 has arrived from user A at “2001/3/3 11:10”, and the write requests for reflecting the edit result in the field-designated document data storage unit 12 have arrived from user B at “2001/3/3 12:10”. That is, the write request from user A has arrived earlier than that from user B.
The last write time as attribute information of a monitor field in the write content information, which is contained in the write request from user A, is “2001/3/3 10:23”, as indicated by the eighth line in FIG. 20 . On the other hand, the last write time as attribute information of a monitor field, which is detected as the write objective field in step S 25 in FIG. 17 and is designated by the write objective field information in the designated field-designated document data stored in the field-designated document data storage unit 12 , is “2001/3/3 10:23”, as indicated by the second line in FIG. 7 . Hence, these two times are equal to each other. Therefore, the write request ( FIG. 20 ) from user A is executed, and the field-designated document data which is stored in the field-designated document data storage unit 12 and shown in FIG. 7 is rewritten, as shown in FIG. 22 . In FIG. 22 , the value of the last write time as attribute information of the rewritten monitor field is rewritten to “2001/3/3 11:10”.
The write requests from user B arrive while the field-designated document data shown in FIG. 22 is stored in the field-designated document data storage unit 12 . The two write requests come from user B, and the last write times as attribute information of monitor fields in the write content information contained in the two requests are equal to each other, i.e., “2001/3/3 10:23”, as indicated by the eighth lines in FIGS. 21A and 21B .
The write request in FIG. 21A is a rewrite request for a monitor field from the second to sixth lines in FIG. 22 (i.e., the monitor field from the second to sixth lines in FIG. 22 is a write objective field), and the write request in FIG. 21B is a rewrite request for a monitor field from the seventh to 11th lines in FIG. 22 (i.e., the monitor field from the seventh to 11th lines in FIG. 22 is a write objective field).
The last write time as attribute information of the monitor field in the write content information, which is contained in the write request in FIG. 21A , is “2001/3/3 10:23”, as indicated by the eighth line in FIG. 20 . On the other hand, the last write time as attribute information of the write objective field detected in step S 25 in FIG. 17 is “2001/3/3 11:10”, as indicated by the second line in FIG. 22 . Hence, conflict can be determined in step S 26 in FIG. 17 , and the write request in FIG. 21A is denied.
On the other hand, the write request in FIG. 21B is executed.
In the above example, users A and B have issued data write requests associated with “Taro Yamada” for component “office” (user A), and component “mail” (user B). Since these two users have issued write requests for different components, if no monitor field is designated, conflict between the write requests from users A and B cannot be detected.
Components in a monitor field have dependency; a monitor field is set so that components have dependency. For this reason, if a plurality of write requests for monitor fields having the same last write time are received, the contents of these write requests are likely to be inconsistent. Therefore, of a plurality of write requests for monitor fields having the same last write time, only a write request that has arrived earliest must be permitted, and other write requests must be defined.
(Description of Process in Step S 17 in FIG. 12 : Terminal Y Allowed to Make Limited Edit Processes of Document Data)
For example, field-designated document data of “member address_book” information shown in FIG. 23 will be exemplified below. The document data shown in FIG. 23 has a document structure in which component (node) “address book” has a plurality of child components “member”, each component “member” is made up of child components “name”, “mail”, and “company”, and component “company” is made up of child components “company_name” and “department_name”. Identification information of this document structure is “member address book”.
A monitor field is set for each of components “name”, “mail”, and “company”.
Assume that there are two different terminals X and Y.
Terminal X is granted permission to browse and edit all components “name”, “address”, “company_name”, and “department_name”. Terminal Y is granted permission to browse and edit components “name”, “address”, and “company_name”, but is not granted permission to edit component “department_name” although it can browse that component.
In order to impose such limitation on terminal Y, for example, terminal Y preferably pre-stores information that designates a browse-only, non-editable component name corresponding to the above document structure (“browse-only component: (identification information of document structure: component)”). For example, in the above example, the document data edit unit 23 pre-stores data “browse-only component: (member address book: department name)”.
When the user reads out the document data shown in FIG. 23 at terminal Y, terminal Y writes attribute information “browse-only=“true”” that indicates a browse-only, non-editable component in component “department_name” before the user browses or edits the readout data at the document data edit unit 23 .
A case will be examined below wherein a given person in the “member address book” information has switched companies, and the value of component “company_name” must be changed in an environment where both terminals X and Y are used. At this time, since terminal Y cannot edit component “department_name”, the value of component “department_name” cannot be changed from terminal Y.
However, after an edit process for rewriting the value of component “company_name” is done at terminal Y, if the rewritten document data is browsed at terminal X, the value of component “company_name” has been changed, but the value of component “department_name” remains old. This readily causes misunderstanding.
Hence, when a write request is issued from terminal Y, incorrect data is preferably deleted rather than leaving it undeleted.
Components in a monitor field are dependent on each other, and if one of components in the monitor field has been changed, other components are likely to be changed accordingly.
However, a browse-only component in that monitor field cannot often be edited due to limitations on a terminal like terminal Y. For this reason, such browse-only component is preferably deleted rather than leaving inconsistent data undeleted.
Therefore, if the field comparison unit 224 of the difference document generation unit 22 finds as a result of comparison in a given monitor field that a given component has been changed, and a component with attribute information “browse-only” is present in the identical monitor field, it generates a difference document for deleting that component.
For example, assume that “yamada@taiyo-tusin.com” in the fourth line of the document data shown in FIG. 23 has been rewritten to “yamada@nihon-tusin.com”, and “Taiyo Tusin” in the sixth line has been rewritten to “Nihon Tusin” in the edit process at terminal Y.
In this case, since the edit process has been made for two monitor fields, i.e., monitor fields of components “mail” and “company”, two difference documents are generated. In a difference document for the monitor field of component “company”, since component “department_name” is given attribute information “browse-only=“true””, no tag “department_name” is present as items of the change contents in the difference document (see FIG. 24 ). This is because that tag is deleted upon generating the difference document in step S 17 in FIG. 12 for the above reason.
As a result of execution of a write request generated based on the difference document shown in FIG. 24 , the document data shown in FIG. 23 stored in the field-designated document data storage unit 12 is rewritten such that the value of component “company_name” in the sixth line in FIG. 23 is changed to “Nihon Tusin”, and component “department_name” in the seventh line below “company_name” is deleted.
As described above, according to the above embodiment, a monitor field for controlling write accesses from a plurality of users is set for each field consisting of at least one component on the basis of the dependency of components in each of different document structures, and write accesses from the plurality of users are controlled for each monitor field of a structured document having the document structure set with such monitor fields. Hence, write requests from a plurality of users to each of a plurality of structured documents with different document structures can be efficiently and flexibly controlled in accordance with the document structure of each structured document.
When monitor fields are to be changed while the system is running, the monitor field designation change unit 23 can change the monitor fields of field-designated document data without suspending system operation.
In the above embodiment, a monitor field is set for each data range (partial document) made up of at least one of a plurality of components in a document structure. Furthermore, a plurality of monitor fields, which are designated as independent ones in a single structured document, can be combined into one monitor field. For example, in this case, after data ranges where monitor fields are set are designated as in the description of the above embodiment, identifiers are assigned to respective monitor fields. Upon assigning the identifiers, an identical identifier is assigned to a plurality of monitor fields to be combined into one monitor field (according to user's designation). Then, write control as in the above embodiment can be done while monitor fields with an identical identifier are considered as one monitor field.
A detailed explanation will be given taking as an example the following document data that describes the same “address book” information as in FIG. 29A in XML.
<address_book>
<member>
<name>Taro Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>045-522-
5300</telephone_number>
</member>
<member>
<name>Hanako Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>045-522-
5300</telephone_number>
</member>
<member>
<name>Kensuke Suzuki</name>
<address>Yokahama-shi Kohoku-ku
2-chome</address>
<telephone_number>044-233-
2200</telephone_number>
</member>
</address_book>
A case will be examined below wherein a monitor field is set for each component “member”, i.e., each data range made up of components present below component “member” in the above document data, and the monitor fields made up of first and second components “member” from the top of data are combined into one monitor field. Attribute information “monitor 13 field=“identifier”” is set in the start tag of each component “member” to indicate a monitor field. That is, an identifier of that monitor field is given as an attribute value. As a result, the monitor field designation unit 112 generates the following field-designated document data based on the above document data:
<address_book>
<member monitor_field=“A”>
<name>Taro Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>045-522-
5300</telephone_number>
</member>
<member monitor_field=“A”>
<name>Hanako Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>045-522-
5300</telephone_number>
</member>
<member monitor_field=“B”>
<name>Kensuke Suzuki</name>
<address>Yokahama-shi Kohoku-ku
2-chome</address>
<telephone_number>044-233-
2200</telephone_number>
</member>
</address_book>
By setting the monitor fields with those identifiers, the monitor fields can be set more finely. Hence, even when two tuples to which “Taro Tanaka” and “Hanako Tanaka” belong are to be changed to one monitor field since “Taro Tanaka” and “Hanako Tanaka” are married and live under the same house, as shown in FIG. 29A , such change can be easily done.
Furthermore, a monitor field can also be set by independently designating components to be monitored as one monitor field. In this case, an identical identifier of a monitor field is assigned to a plurality of components to be monitored as one monitor field.
For example, in case of the above field-designated document data, even when “Taro Tanaka” and “Hanako Tanaka” are married and live under the same house, one may want to register a home telephone number, and the other may want to register a portable phone number. In this manner, two components “telephone number” as child components of two components “member” assigned with identifier “A” may have no dependency with components “address”. Therefore, components “telephone number” as child components of two components “member” assigned with identifier “A” can be set as monitor fields independent from those with identifier “A”. That is, in this case, “C” and “D” are assigned to two components “telephone number” as identifiers of monitor fields, and the following field-designated document data is generated:
<address_book>
<member monitor_field=“A”>
<name>Taro Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number monitor_field=“C”>045-522-
5300</telephone_number>
</member>
<member monitor_field=“A”>
<name>Hanako Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number monitor_field=“D”>090-000-
0000</telephone_number>
</member>
<member monitor_field=“B”>
<name>Kensuke Suzuki</name>
<address>Yokahama-shi Kohoku-ku
2-chome</address>
<telephone_number>044-233-
2200</telephone_number>
</member>
</address_book>
In this way, when monitor fields for write control are set for respective components of the document structure (i.e., a monitor field is set for each data range (partial document) made up of at least one component, a plurality of monitor fields are combined into one monitor field, and a monitor field is independently set for each component), monitor fields consisting of components with dependency can be finely and flexibly (variably) set. Therefore, when write control is made for respective monitor fields which are set delicately in this way, inconsistency (conflict) of the rewritten contents of document data can be perfectly prevented.
In the above embodiment, attribute information is assigned to set monitor fields in a document structure. However, the present invention is not limited to such specific case, but a monitor field range may be designated using tags. More specifically, a data range (partial document) to be set as a monitor field can be bounded by tags (e.g., tags “monitor field”) used to designate the monitor field range. As in the above description, identifiers are assigned to respective monitor fields, and an identical identifier may be assigned to partial documents and components to be monitored as one monitor field. In such case, the identifier of each monitor field may be given as attribute information of component “monitor field”. For example, in the following description example, attribute information “id=“identifier of monitor field”” is described in the start tag of each monitor field.
<address_book>
<monitor field id=“A”>
<member>
<name>Taro Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>045-522-
5300</telephone_number>
</member>
</monitor field>
<monitor field id=“A”>
<member>
<name>Hanako Tanaka</name>
<address>Kawasaki-shi Saiwai-ku
3-chome</address>
<telephone_number>0450-522-
5300</telephone_number>
</member>
</monitor field>
<monitor field id=“B”>
<member>
<name>Kensuke Suzuki</name>
<address>Yokahama-shi Kohoku-ku
2-chome</address>
<telephone_number>044-233-
2200</telephone_number>
</member>
</monitor field>
</address_book>
The method of the present invention described in the above embodiment may be stored in a recording medium such as a magnetic disk (floppy disk, hard disk, or the like), an optical disk (CD-ROM, DVD, or the like), a semiconductor memory, or the like, as a program that can be executed by a computer, and such recording medium can be distributed. More specifically, respective units of the field-designated document data management apparatus 1 except for the field-designated document data storage unit 12 and correspondence table 17 , and respective units of the terminal 2 can be implemented as a program that can be executed by the computer.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A write control method of exclusively controlling write requests from a plurality of user terminals to an identical structured document is disclosed. The identical structured document includes a plurality of elements each containing document content. A monitor field is set in units of the elements within the identical structured document. Upon accepting one write request from one user terminal, it is determined if the one write request is directed to the document content under monitoring by referral to the monitor field. Then, the one write request is handled to reject overwriting of the document content despite the one write request if the document content has been rewritten by another write request from another user terminal in advance. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to floor and wall covering tiles. More particularly, it relates to a tile system that does not require a grout compound to be applied to the tiles after installation.
[0003] 2. Description of Related Art
[0004] Ceramic tiles are widely used as a floor and wall covering in both residential and commercial applications. Tile is very versatile, and has been in use as a floor and wall covering for centuries. Tiles are available in a nearly unlimited color palette and may be installed in an equally unlimited number of designs. Tile is often a top choice for floor and wall coverings because of its great durability and aesthetic qualities. While many tiles are manufactured from ceramic compositions (baked clay), they may be made of a variety of natural or synthetic materials including, but not limited to, granite, quartz, marble, soapstone, plastic, wood, or a other suitable material.
[0005] Tile provides a durable surface and may be coated to be substantially impervious to water and other liquids. When tiles are installed, they are generally laid side by side on a surface such as a floor or wall. Typically, an adhesive compound is used as a base to attach the tiles to a surface and then grout is spread over and between the tiles to further bind the tiles to the surface and to fill spaces between adjacent tiles. While not impervious to water and moisture, the grout provides a barrier to reduce moisture between and behind the tiles. This step of grouting the tiles is labor intensive and represents a significant portion of the labor involved in a typical tile installation.
[0006] Due to the time and labor involved in tile installation, it is typically quite costly to have tile professionally installed. Accordingly, many homeowners desire to install tile in their own homes. Unfortunately, this is an extremely tedious process, and many homeowners do not wish to spend the time necessary for a satisfactory installation.
[0007] In recent years, manufactures have attempted to produce do-it-yourself tile solutions that are easier to install. One such attempt is described in United States Publication Number US 2004/0031226 entitled “Pre-glued Tongue and Groove Flooring” by Miller et al. Disclosed therein is a laminated “tile” that uses a pre-applied glue for fastening the tiles together. While this system is easier to install than traditional tiles, it still requires a separate grout to be applied and uses a laminate material rather than a solid tile. A laminate material is not likely to be as durable as more traditional materials such as ceramic or stone tiles. Additionally, because the this tile system makes use of a laminated structure that is susceptible to moisture damage, the installer is required to apply a messy grout composition to the tiles as part of the installation process.
[0008] A previous attempt to produce an easy to install tile is described in U.S. Pat. No. 2,693,102 entitled “Interlocking Wall Tile.” The '102 patent describes a synthetic wall tile system that snaps together. Unfortunately, this tile is not practicable with substantially ridged materials, such as ceramic, granite, or marble. The Luster et al. tiles are molded into a uniform structure of a single material and rigid materials could not be formed into an operable tab structure as taught in the patent. Such a limitation severely limits the aesthetic qualities available for the tiles and thereby reduces the marketability of the system.
[0009] Accordingly, there is a need in the art for a tile system that is simple to install.
[0010] Additionally, there is a need in the art for a tile system that does not require a grout to be applied to the tiles after installation.
[0011] Further, there is a need in the art for an easy to install tile system that makes use of durable tile materials.
[0012] In addition, there is a need in the art for a tile system that primarily utilizes traditional tile materials, but eliminates the need for grout.
BRIEF SUMMARY OF THE INVENTION
[0013] Briefly, described herein is a tile having at least one coupling member that cooperatively engages a coupling member of an adjacent tile, such that adjacent tiles can be reasonably secured to one another without the use of grout. In one exemplary embodiment, cooperative coupling members are a male-type coupling members and female-type coupling members that are designed to secure adjacent tiles.
[0014] In exemplary embodiments, a wide variety of tiling systems may be used. For example, in one exemplary tiling system individual tiles may include all male-type or all female-type coupling members. In another example, the individual tiles may include two male-type coupling members and two female-type coupling members located on either adjacent or opposing edges of the tiles. In yet another example, the individual tiles may have another combination of male-type and female-type coupling members disposed on one or more of the edges of the tiles. The above examples are only intended as illustrations and are not intend to be limiting in anyway, on the contrary a wide variety of alternative exemplary embodiments would be understood to a person of ordinary skill in the art.
[0015] Disclosed herein is a groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; a first coupling member disposed on an edge of the substrate; and a second coupling member disposed on an opposing edge of the substrate, wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and the second coupling member of the groutless tiles are operable for coupling adjacent groutless tiles, and wherein the substrate maintains spacing between the durable surfaces of adjacent groutless tiles.
[0016] Also disclosed herein is a groutless tile including: a durable surface disposed on a substrate; a first coupling member disposed on an edge of the substrate; and a second coupling member disposed on an opposing edge of the substrate, wherein the first coupling member and the second coupling member of the substrate extend beyond the durable surface, wherein the first coupling member and the second coupling member of the groutless tile are operable for coupling the groutless tile to an adjacent groutless tile, and wherein at least a portion of the substrate extends vertically to form a substantially continuous surface with the durable surface.
[0017] Further disclosed herein is a method for making a groutless tile including: providing a durable surface; molding a substrate to receive at least a portion of the durable surface; affixing the durable surface to the substrate; and milling at least a portion of the substrate to create a first coupling member on an edge of the substrate and a second coupling member on a opposing edge of the substrate.
[0018] Still further disclosed herein is a floor covering consisting of floor elements including at least a synthetic support structure and a decorative element selected form the group consisting of natural stone, terracotta, ceramic tile and synthetic stone; the decorative element being supported, either directly or indirectly, by the support structure and at least partially defining the upper side of the floor element; the support structure at least at a first pair of two opposite sides including coupling parts, which are realized substantially as a male coupling part and a female coupling part, which are provided with vertically active locking portions, which, when the coupling parts of two of such floor elements cooperate with each other, effect a locking in a vertical direction and also are provided with horizontally active locking portions, which, when the coupling parts of two of such floor elements cooperate with each other, effect a locking in horizontal direction whereby the coupling parts are of the type allowing that two of such floor elements can be connected to each other at the sides by engaging one of these floor elements with the associated male coupling part, by means of a rotational and/or planer motion, in the female coupling part of the other floor element; wherein the male coupling part projects at least partially beyond the upper edge of the concerned side. In a preferred embodiment said horizontally active locking portion, in a coupled condition of two such floor elements or tiles, is located vertically under a durable surface of at least one of said tiles. Said durable surface is preferably formed by said decorative element. In another or the same preferred embodiment said vertically active locking portions can substantially have the shape of a tongue and a groove, which in a coupled condition of two of such floor elements or tiles, preferably, wholly or partially, engage vertically under a portion of the synthetic support structure or substrate, whereby this portion of the substrate extends horizontally beyond said durable surface or said decorative element of at least one of said tiles. It is possible that contact surfaces are formed between the tongue and the groove, said contact surfaces preventing or limiting vertical motion of two tiles or floor elements in a coupled condition thereof. At least one of said contact surfaces, being located at the top side of the tongue, is preferably located in a plane, e.g. a horizontal plane, which intersects the decorative element forming said durable surface. Instead of being located in a plane, the concerned contact surface might also show a point of contact which is located the closest to the durable surface and which is located in a horizontal plane which intersects the decorative element forming said durable surface.
[0019] Also disclosed herein is a method for manufacturing floor elements including at least a synthetic support structure and a decorative element selected from the group consisting of natural stone, terracotta, ceramic tile and synthetic stone; the decorative element being supported, either directly or indirectly, by the support structure and at least partially defining the upper side of the floor element; the support structure having edge portions; the edge portions at least at two opposite sides of the support structure having coupling parts; wherein the method at least includes the following two successive steps: the step of providing a semi-finished product including at least the aforementioned support structure and the aforementioned decorative element; the step of performing a machining treatment on at least an edge portion of the already formed semi-finished product, more particularly on the edge portions of the support structure of the semi-finished product, in order to manufacture at least part of the coupling parts to be formed therein.
[0020] These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The subject matter that 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 objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0022] FIG. 1 is a perspective view illustration of a tile in accordance with an exemplary embodiment of the present invention;
[0023] FIG. 2 is a cross-sectional view illustration of another tile in accordance with an exemplary embodiment of the present invention;
[0024] FIG. 3 is a cross-sectional view illustration of two adjacent tiles in accordance with an exemplary embodiment of the present invention; and
[0025] FIG. 4 is an illustration of a method for making a tile in accordance with an exemplary embodiment of the present invention.
[0026] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0027] As used herein, the term “disposed” generally means located either at or upon. Additionally, the term disposed is intended to include an element integrally or detachableably connected to another element as well as object simple placed on another element. Furthermore, it will be understood that when an element is referred to as being “disposed on” another element, it can be directly on the other element or intervening elements may be present there between. In contrast, when an element is referred to as being “disposed directly on” another element, there are no intervening elements present.
[0028] Referring now to FIG. 1 , a groutless tile in accordance with an exemplary embodiment of the present invention is generally depicted as 100 . The groutless tile 100 includes a durable surface 102 that is disposed on a substrate 104 . In exemplary embodiments, the durable surface 102 may be affixed to the substrate 104 using a wide variety of methods such as the use of an adhesive. The durable surface 102 may be a ceramic composition (baked clay), or it may be made of a variety of natural or synthetic materials including, but not limited to, granite, quartz, marble, soapstone, plastic, wood, or another suitable material. Likewise, the substrate 104 may be a made of a suitable polymeric material. In exemplary embodiments, the substrate 104 may be made constructed of a suitable material that is chemical resistant, stain resistant, non-porous, and formable to within sufficient precision. While the groutless tile 100 is depicted in a square shape, it will be clear that alternate shape groutless tiles such as hexagon, octagon, or the like are also contemplated.
[0029] In exemplary embodiments, the substrate 104 is designed to have larger dimensions than the durable surface 102 such that the durable surface 102 may be disposed within a groove defined by the substrate 104 . In one embodiment, the top surface of the durable surface 102 and the top surface of the substrate 104 may form a continuous surface. The substrate 104 includes a flange portion 106 that is disposed along the edges of the substrate 104 . The flange portion 106 of the further includes a first coupling member 120 and a second coupling member 140 , which may be disposed on opposing or adjacent sides of the groutless tile 100 . The first coupling member 120 and the second coupling member 140 are designed such that they are operable for coupling together one or more adjacent groutless tiles 100 .
[0030] In exemplary embodiments, the groutless tile 100 may include an underlayment layer that may act as a moisture or sound barrier. Additionally, the underlayment may serve a surface leveling function. Further, the underlayment may serve as an adhesive for attaching the tiles to an installation surface, such as a floor or a wall. The composition of the underlayment layer may depend upon the intended purpose of the underlayment layer. In exemplary embodiments, the underlayment layer may be a multilayered layment composed of several distinct layers each designed to perform a specific function. The underlayment may be secured to substrate 104 of the groutless tile 100 through the use of an adhesive or another suitable means.
[0031] In an exemplary embodiment, at least a portion of the flange portion 106 , may be of polymeric material and preferably is a polyurethane material, such as ELASTOCASTr70654 by BASF®. ELASTOCASTr70654 is an unpigmented, 77 to 79 Shore D urethane elastomer designed for cross-sections up to three inches, which has some inherent tackiness. It is also contemplated that another polymeric material may be used in flange portion 106 . The following data may be helpful in producing the material used in a flange portion 106 in accordance with an exemplary embodiment. This data is provided for example only, and is not intended to limit the scope of the invention. Other compositions may also be used to fabricate the flange portion 106 .
[0000]
Mix Ratio @ 105 index:
100 parts of ELASTOCASTr7065R Resin
771. parts of WUC 3192T ISOCYANATE
Specific Gravity:
Resin 1/048 f/cc, 8.72 lbs./gal. @ 77° F.
Iso 1.22 g/cc, 10.2 lbs./gal. @ 77° F.
Viscosity:
Resin 1220 cps @ 77° F.
Iso 200 cps @ 77° F.
Typical Reactivity:
Hand mixed at 86° F. at 105 index
Gel time: 180 to 240 seconds
Recommended processing
Component temperatures:
Resin 75–95° F.
conditions:
Iso 75–95° F.
Mold temperature:
130–160° F.
Demold time:
10–20 minutes
[0032] Alternatively, other polymer variations, such as polyamides, vinyl polymers and polyoletins may be used. Preferably, the flange portion 106 may be made, but is not so limited, from a material that is chemical resistant, stain resistant, non-porous, and formable to within sufficient precision. Additionally, it may be desirable for the flange portion 106 to have sealing qualities so as to impede the intrusion of moisture between and behind the tiles and adherence qualities so as to minimize or present movement or displacement of the tiles.
[0033] Turning now to FIGS. 2-3 which illustrate the coupling of a first groutless tile 200 with a second groutless tile 300 . A first coupling member 220 and a second coupling member 340 function to connect the first groutless tile 200 and the second groutless tile 300 . The first coupling member 220 of the first groutless tile 200 includes a first bendable portion 222 and a groove 224 . The second coupling member 340 of the second groutless tile 300 includes a tongue 346 and a body portion 348 . The groove 224 of the first coupling member 220 is designed to receive the body portion 348 and the tongue 346 of the second coupling member 340 . Once positioned inside the groove 224 of the first coupling member 220 the body portion 348 and the tongue 346 contacts the first bendable portion 222 and the groove 224 , respectively. In one embodiment, the tongue 346 and the first bendable portion 222 are designed to bend at least the first bendable portion during the coupling of the groutless tile 200 and the second groutless tile 300 . Additionally, the tongue 346 and the first bendable portion 222 are designed such that at least the first bendable portion 222 returns to or towards its normal unbent position once the groutless tile 200 and the second groutless tile 300 are coupled in order to prevent the tiles from separating. A contact surface between said tongue 346 and said groove 224 is also formed at the top side of said tongue 346 , whereby said contact surface is located in a horizontal plane, which intersects the decorative element forming said durable surface 102 .
[0034] Continuing with reference to FIG. 3 , the first bendable portion 222 includes an enlarged portion on its distal end that has an inclined inner surface. Additionally, the body portion 348 of the second coupling member 340 also includes an inclined surface on its proximal end. The inclined inner surface of the first bendable portion 222 is designed to have a substantially complimentary angle to that body portion 348 of the second coupling member 340 . The first bendable portion 222 is designed to slideably contact the body portion 348 during the coupling of the groutless tile 200 and the second groutless tile 300 . Furthermore, the inclined surfaces of the first bendable portion 222 and body portion 348 are operable for properly positioning and the groutless tile 200 and the second groutless tile 300 during coupling. In exemplary embodiments, the inclined surfaces of the first bendable portion 222 and the body portion 348 function to keep the groutless tile 200 and the second groutless tile 300 properly positioned while the tiles are coupled to one another. Said inclined inner surfaces of both said body portion 348 and said enlarged portion 342 form horizontally active locking portions, which in a coupled condition are located vertically under a durable surface 102 of at least one of said tiles 200 - 300 .
[0035] In exemplary embodiments, the tongue 346 is located at the distal end of the second coupling member 340 and extends substantially horizontally and outwardly from the second groutless tile 300 . Said tongue 346 of said second coupling member 340 and said groove 224 of the first coupling member 220 are vertically active locking portions and wholly engage vertically under a portion of the synthetic support structure or substrate 104 , whereby this portion of the substrate 104 extends horizontally beyond said durable surface 102 or said decorative element of at least one of said tiles 200 - 300 .
[0036] In exemplary embodiments, the first groutless tile 200 may be coupled to the second groutless tile 300 by snapping or pushing the second coupling member 340 of the second groutless tile 300 into the first coupling member 220 . In one embodiment, a lateral or horizontal is necessary to properly couple the first groutless tile 200 and the second groutless tile 300 . Furthermore, during the coupling of the groutless tile 200 and the second groutless tile 300 the second coupling member 340 of the second groutless tile 300 may be locked into position once inserted into the groove 224 of the first coupling member 220 . Additionally, during the coupling of the first groutless tile 200 and the second groutless tile 300 the first bendable portion 222 may be bent to accommodate the insertion of the first body portion 348 into the groove 224 . After the first groutless tile 200 and the second groutless tile 300 are coupled the first bendable portion 222 returns to or towards its normal unbent position and remains in contact with the body portion 348 . In exemplary embodiments, the first groutless tile 200 and the second groutless tile 300 may be separated from one another by pivotally disengaging the first groutless tile 200 from the second groutless tile 300 , preferably without damaging the respective tiles and their coupling members. It is noted that in a completely coupled condition of the respective groutless tiles 200 - 300 , it is possible that the first bendable portion 222 is bent out of the level under surface of said tiles 200 - 300 . Such bending out might create an extra firm coupling especially in the horizontal direction, thereby strongly preventing separation of two coupled tiles in said horizontal direction.
[0037] Turning now to FIG. 4 , an illustration of a method for making a tile in accordance with an exemplary embodiment of the present invention is generally depicted as 400 . During the first step in the method 400 , a durable surface 402 is provided and inserted into a mold 404 . Once the durable surface 402 has been positioned in the mold 404 a substrate 406 may be formed around a portion of the durable surface 402 . In one embodiment, the substrate 406 may be a plastic material that is injection molded or reaction injection molded (RIM) around the durable surface 402 . The substrate 406 forms around the durable surface 402 to create the groutless tile 408 . Next the groutless tile 408 is processed through a series of tools 410 that are used to create one or more flanges 412 around the edges of the tile 408 . In one embodiment, the tools 410 may perform a milling process with one or more milling cutter that are positioned at different positions and angles with respect to the groutless tile 408 . As shown in FIG. 4 , the flanges 412 including the first and second coupling members may extend the entire length of one side of the substrate 406 thereby simplifying the milling process.
[0038] While the exemplary embodiments of the invention have been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements, which fall within the scope of the claims that follow. These claims should be construed to maintain the proper protection for the invention first described. | A groutless tile system including: a plurality of groutless tiles, wherein each groutless tile includes: a durable surface disposed on a substrate; and a first coupling member disposed on an edge of the substrate; wherein at least a portion of the substrate extends beyond the durable surface, wherein the first coupling member and a second coupling member of an adjacent tile are operable for coupling adjacent groutless tiles, and wherein the substrate prevents the durable surfaces of adjacent groutless tiles from contacting one another. | 4 |
FIELD OF INVENTION
[0001] This invention relates to a method for manufacturing a drive shaft with a drive coupling thereon. In particular, this invention relates to a method for forming a coupling on an end of a power transmission shaft and a power transmission shaft made by the method.
BACKGROUND OF INVENTION
[0002] Power transmission shafts, such as drive shafts, are commonly fitted with a yoke. The yoke is part of a universal type of coupling. The yoke is manufactured separately from the power transmission shaft. The yoke will have a shaft portion that is inserted into the end of the power transmission shaft and then circumferentially welded in place. The shaft is then machined to rotationally balance the shaft. Examples of power transmission shafts having a welded yoke include U.S. Pat. Nos. 5,230,658; 5,716,276; and publication no. WO 98/48186.
[0003] The prior art shafts produce suitable results. However, improvements can be had in providing the yoke assembly directly onto the end of the shaft.
SUMMARY OF INVENTION
[0004] The disadvantages of the prior art may be overcome by providing a method for forming a yoke structure directly on an end of a power transmission shaft.
[0005] It is desirable to provide a method for forming a yoke structure on the end of shaft which reduces manufacturing steps, improves a rotational balance and reduces weight of the power transmission shaft.
[0006] According to one aspect of the invention, there is provided a method including the steps of a tubular shaft having an open end. Forming a driving configuration at the end. Closing the open end with a cap. Casting a coupling structure on the closed end in driving engagement with the shaft.
[0007] According to another aspect of the invention, there is provided a drive shaft formed by the method of the present invention.
DESCRIPTION OF THE DRAWINGS
[0008] In drawing which illustrate embodiments of the present invention,
[0009] [0009]FIG. 1 is a perspective view of a power transmission shaft having a coupling structure formed thereon according to the present invention;
[0010] [0010]FIG. 2 is a perspective view of a power transmission shaft in an initial stage;
[0011] [0011]FIG. 3 is a perspective view of a power transmission shaft in an intermediate stage;
[0012] [0012]FIG. 4 is a perspective view of a cap according to the present invention;
[0013] [0013]FIG. 5 is a side elevational view of the cap of FIG. 4; and
[0014] [0014]FIG. 6 is a side sectional view of a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring to FIG. 1, a power transmission shaft 10 embodying the present invention is illustrated. The power transmission shaft 10 is preferably a drive shaft for a motor vehicle. The drive shaft 10 can be either a conventional one piece drive shaft that has a yoke or coupling structure on each end thereof or a conventional two piece drive shaft connect by a slip joint. The yoke or coupling structure is provided on opposite ends of the shaft components of the drive shaft.
[0016] Referring to FIG. 2, a tubular shaft 20 is provided. Preferably, the shaft 20 is steel. However, it is also contemplated that aluminum tubing could be employed. The tubular shaft 20 is optionally provided with a series of circumferentially spaced longitudinally extending splines 222 . An end 24 has a yoke diameter 26 . Yoke diameter 26 is slightly less than the shaft diameter 28 . Tubular shaft 20 is manufactured in accordance with known methods.
[0017] Referring to FIG. 3, end 24 undergoes a forming operation to form a driving configuration in the form of a non-circular cross-sectional configuration 25 . In the preferred embodiment, the non-circular cross-sectional configuration is octagonal and formed by a swaging operation. However, it is readily understood that other non-circular shapes, such as hexagonal, rectangular would provide suitable results. Additionally other forming operations such as stamping could also be utilized with similar results.
[0018] Referring to FIGS. 3 and 4, a cap 30 of the present invention is illustrated. The cap 30 is preferably made of aluminum. The cap 30 is cup shaped having an outline complementary with the non-circular cross-sectional configuration 25 of end 24 . The cap 30 is sized to frictionally fit within driving configuration 25 . The cap 30 can be inserted from the near end wherein the lip 32 will engage the end edge of the shaft 22 . Optionally, cap 30 has a lip 32 that will fit within the shaft 22 when the cap 30 is inserted from the distal end thereof in the direction of arrow A. Cap 30 will close the open end of the shaft 22 at the near end or at a point spaced from the near end of the shaft 22 .
[0019] With the end 24 closed, the end 24 of shaft 22 is placed in a casting mold. The casting mold has a cavity complementary to the shape of the coupling or yoke structure 40 . A yoke structure 40 is then cast directly onto the end 24 of the shaft 22 .
[0020] Yoke structure 40 generally has two legs 42 and 44 extending from a bight portion 46 . Optionally, ribs 48 are provided to improve structural strength of the yoke structure 40 .
[0021] The next step for processing the power transmission shaft 10 of the present invention is to machine or bore transversely extending apertures 50 in each of the legs 42 , 44 .
[0022] The present invention has been described in terms of casting a single yoke structure 40 on an end of a shaft 22 . However, it is readily apparent to one skilled in the art that multiple yoke structures could be cast on ends of multiple shafts by designing a multi-cavity mold. Additionally, on a single drive shaft, yoke structures on opposite ends thereof could be cast simultaneously.
[0023] Referring to FIG. 6, a second embodiment of the present invention is illustrated. The second embodiment is particularly useful for single tube drive shafts. In single tube drive shafts, it not convenient to insert an end cap at both ends if the end cap is inserted from the opposite end. The end 124 of tube 122 is first formed into a driving configuration by swaging the end 124 to expand the diameter thereof and forming at least one transverse aperture 123 therein. Preferably 2 or more apertures 123 are formed in the end 124 . As is apparent to those skilled in the art, the apertures 123 can be formed by any conventional process, such as piercing, lancing, drilling, laser cutting, etc., either before or after the swaging step.
[0024] A cup shaped cap 130 is inserted from the near or swaged end 124 into the tube 122 . The rim 132 of the cap 130 has an outer diameter that is less than the diameter of end 124 but greater than the original diameter 128 of tube 122 . The rim 132 will frictionally engage the inside surface of the tube 122 preferably at the transition between diameters to seal the end of the tube 122 . Once inserted, the cap 130 closes the end of the tube 122 and the yoke structure 140 can be cast thereon. The cap 130 limits the extent to which the yoke structure 140 extends into the end 124 . As is apparent, the cast material will flow between the inside and outside of the tube 122 through aperture 123 . Once solidified, the yoke structure 140 will have a dowel structure to provide a driving connection with the tube 122 .
[0025] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is understood that the invention is not limited to the disclosed embodiments but, on the contrary, it intended to cover various modifications in the arrangements as defined in the attached claim. | A method for forming a coupling structure ( 40, 140 ) on an end of a drive shaft and a drive shaft ( 10 ) made by the method. The method includes the steps of providing a tubular shaft ( 22, 122 ) having an open end. Forming a driving configuration at the end. Closing the open end at a point spaced from the open end. Casting a coupling structure ( 40, 140 ) on the closed end in driving engagement with the shaft ( 22, 122 ). | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 35 USC §371 application of International Application No. PCT/US2005/00388 filed Feb. 7, 2005, designating the United States, which claims priority to U.S. Application No. 60/543,236 filed Feb. 9, 2004, both of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The invention pertains to methods for extraction, isolation, and purification of triptolide and related molecules, such as tripdiolide and 16-hydroxytriptolide, from Tripterygium wilfordii.
REFERENCES
Z. Cheng et al., “Research on extraction technology of Tripterygium”, Chinese J. of Pharmaceuticals 21(10):435-436 (1990).
S. M. Kupchan et al., “Triptolide and tripdiolide, novel antileukemic diterpenoid triepoxides from Tripterygium wilfordii”, J. Am. Chem. Soc. 94(20):7194-7195 (1972).
S. M. Kupchan et al., U.S. Pat. No. 4,005,108 (1977).
P. E. Lipsky et al., U.S. Pat. No. 5,580,562 (December 1996).
K. Ren et al., U.S. Appn. Pubn. No. 20040018260 (January 2004).
T. T. Wiedmann et al., U.S. Pat. No. 5,843,452 (December 1998).
C. P. Zhang et al., “Studies on diterpenoids from leaves of Tripterygium wilfordii”, Acta Pharmaceutica Sinica 28(2): 110-115 (1993).
BACKGROUND
Compounds derived from the Chinese medicinal plant Tripterygium wilfordii (TW) have been identified as having useful therapeutic properties, particularly immunosuppressive activity and anticancer activity. These compounds include triptolide, tripdiolide and 16-hydroxy triptolide. Synthetic derivatives and prodrugs of these compounds have also shown therapeutic activity, often in combination with improved pharmacological properties. See, for example, U.S. Pat. No. 5,468,772 (Tripterinin compound and method), U.S. Pat. No. 5,648,376 (Immunosuppressant diterpene compound), U.S. Pat. No. 5,663,335 (Immunosuppressive compounds and methods), U.S. Pat. No. 5,759,550 (Method for suppressing xenograft rejection), U.S. Pat. No. 5,843,452 (Immunotherapy composition and method), U.S. Pat. No. 5,962,516 (Immunosuppressive compounds and methods), U.S. Pat. No. 6,150,539 (Triptolide prodrugs having high aqueous solubility), U.S. Pat. No. 6,294,546 (Uses of diterpenoid triepoxides as an antiproliferative agent), U.S. Pat. No. 6,537,984 (Uses of diterpenoid triepoxides as an antiproliferative agent), U.S. Pat. No. 6,548,537 (Triptolide prodrugs having high aqueous solubility), U.S. Pat. No. 6,569,893 (Amino acid derivatives of triptolide compounds as immune modulators and anticancer agents), U.S. Pat. No. 6,599,499 (Uses of diterpenoid triepoxides as an antiproliferative agent), and U.S. Pat. No. 6,620,843 (Anticancer treatment using triptolide prodrugs), each of which is incorporated herein by reference.
Isolation of the native compounds from the plant material has, to date, typically required laborious extraction and purification procedures. Kupchan et al. (1972, 1977) describe a method in which the root material is extracted with ethanol, the solid extract is dissolved in ethyl acetate and partitioned with water, and the ethyl acetate fraction is chromatographed on silica gel. Cheng et al. (1993) describe a method in which the first extraction employs hot water, followed by addition of ethanol, filtration, removal of the ethanol, partitioning with chloroform, and chromatography on silica gel. The method described by Lipsky et al. (1996) employs subsequent extractions with chloroform, methanol, and toluene, with removal of solvent between each extraction, followed by chromatography on alumina and then on silica gel. Wiedmann et al. (1998) describe a method in which the root material is extracted with refluxing aqueous ethanol, the solid extract is partitioned between dichloromethane and water, and the dichloromethane phase is concentrated and chromatographed on silica gel. Ken et al. (2004) describe a method in which the root is extracted repeatedly with ethanol, and the extracts are concentrated and extracted repeatedly with chloroform, followed by chromatographic purification.
In isolation methods to date, the extraction steps generally produce an extract which retains large quantities of undesired materials, which then must be removed chromatographically, requiring large investments of time and materials. In view of the therapeutic utility of these compounds, higher efficiency methods for isolation and purification are desired.
SUMMARY OF THE INVENTION
The invention provides an improved method of isolating triptolide and related compounds, e.g. tripdiolide and 16-hydroxytriptolide, from Tripterygium wilfordii (TW) plant material. In accordance with the method, an extract of Tripterygium wilfordii plant material containing these compounds is formed and then purified. The extract is initially formed by
(a) extracting TW plant material, preferably root material, with aqueous ethanol, and concentrating to obtain a residue; and
(b) forming a slurry of this residue in an organic solvent, preferably a chlorinated hydrocarbon solvent, such as chloroform, methylene chloride, dichloroethane, or mixtures thereof; partitioning the slurry with water for a period of about 10 mins-10 hours; and then removing the water.
Typically, the extracting of step (a) includes three extractions with refluxing ethanol, each preferably using 4-5 mL of ethanol per g of plant material, followed by pooling of the extracts; the slurry formed in step (b) comprises 8-12 volumes of organic solvent relative to the residue; and the partitioning of step (b) employs ½ to 2 volumes of water relative to the slurry.
The subsequent purification comprises the steps of:
further partitioning the slurry with an aqueous solution of base, removing the aqueous solution of base, and removing at least a portion of the organic solvent from the slurry;
washing the residue with a lipophilic solvent; and
eluting the residue from a silica gel adsorbent.
In one embodiment, this purification comprises, following steps (a) and (b) above:
(c) partitioning the slurry with an aqueous solution of base, then removing the aqueous solution, and then removing the organic solvent, to obtain a further residue;
(d) washing the further residue with a hydrocarbon solvent, to obtain a solid product; and
(e) purifying the solid product by silica gel chromatography.
In another embodiment, this purification comprises, following steps (a) and (b) above:
(c) partitioning the slurry of the residue with an aqueous solution of base, removing the aqueous solution, and removing a portion of the organic solvent, to obtain a concentrated slurry;
(d) adding silica gel to the concentrated slurry, in an amount effective to adsorb the triptolide and related compounds;
(e) washing the residue and silica gel with a hydrocarbon solvent; and
(f) eluting the triptolide and related compounds from the silica gel.
In a further embodiment, this purification comprises, following steps (a) and (b) above:
(c) removing the organic solvent from the slurry of the residue;
(d) washing the residue with a hydrocarbon solvent;
(e) forming a further slurry of the washed residue in an organic solvent selected from chloroform, methylene chloride, dichloroethane and mixtures thereof;
(f) partitioning the further slurry with an aqueous solution of base, then removing the aqueous solution, and then removing the organic solvent, to obtain a solid product; and
(g) purifying the solid product by silica gel chromatography.
In the aqueous solution of base, the base is preferably a water soluble hydroxide, carbonate or bicarbonate having a counterion selected from lithium, sodium, potassium, cesium, ammonium, and tetraalkylammonium, where alkyl is preferably C 1 -C 4 alkyl. Suitable bases include, for example, NaOH, KOH, NaHCO 3 , KHCO 3 , Na 2 CO 3 and K 2 CO 3 . The solution may be selected, accordingly, from 0.1N-2.5N aqueous NaOH, 0.1N-2.5N aqueous KOH, 10%-15% aqueous NaHCO 3 , and 12%-18% aqueous KHCO 3 . The base partitioning is generally carried out for about 2 days, following a brief (e.g. 5-20 minutes, typically about 10 minutes) period of stirring. Optionally, following the removal of the aqueous solution of base, and prior to the removal of all or a portion of the organic solvent, the organic solvent is washed with a dilute aqueous acidic solution.
The lipophilic solvent is preferably a hydrocarbon solvent selected from linear, branched and cyclic hydrocarbons having 5-7 carbon atoms, and mixtures thereof; examples include hexane and cyclohexane. In one embodiment, the hydrocarbon solvent is hexane. The silica gel chromatography preferably employs a mobile phase comprising a nonpolar solvent, such as hexane, in combination with a more polar solvent, such as ethyl acetate.
DETAILED DESCRIPTION OF THE INVENTION
I. Overview
The invention provides a procedure for purifying an extract of Tripterygium wilfordii (TW) plant material containing triptolide and related compounds, such as tripdiolide and/or 16-hydroxytriptolide, and isolating these compounds. Other useful related compounds such as triptriolide, tripchlorolide, and triptonide may also be isolated.
As described further below, the method includes treatment of an initial organic extract with aqueous base, which removes a significant amount of impurities at an early stage of the process, thereby increasing yield and reducing production costs. The base treatment effectively removes acidic or weakly acidic compounds (e.g. celastrol, triptoquinone A, triptoquinone G, 3-hydroxyoleanolic acid, polpunonic acid, tripterygic acid A, and phenolic compounds such as triptonoterpene, hypolide, triptophenolide, and triptonodial) from the organic TW extract. The base treatment also remove “oily” impurities from the extract via saponification and/or hydrolysis. This step has been found to remove about 70% of the undesired impurities from the extract, including oily materials whose removal typically generates a large majority of the cost of subsequent purification using prior art methods.
The method of the invention also includes an extraction with a lipophilic solvent, such as cyclohexane or a similar hydrocarbon-based solvent, e.g. hexanes, pentanes, petroleum ether, etc., to remove less polar impurities from the extract. This step further simplifies the subsequent chromatographic purification steps, by removing components which would otherwise typically be removed chromatographically.
II. Extraction Procedure
The Tripterygium wilfordii (TW) extract is initially formed by (i) extracting ground, chopped or otherwise finely divided TW plant material with aqueous ethanol, and concentrating the liquid extract to obtain a residue; (ii) forming a slurry of this residue in an organic solvent, preferably a chlorinated hydrocarbon solvent, typically selected from chloroform, methylene chloride, dichloroethane and mixtures thereof; (iii) partitioning the slurry with water for a period of about 10 mins-10 hours; and (iv) removing the water from the slurry.
The plant material may include the roots, stems, and leaves of Tripterygium wilfordii ; preferably, the root material is used. The TW plant is found in the Fujiang Province and other southern provinces of China; TW plant material can generally be obtained in China or through commercial sources in the United States.
Preferably, the ethanol extraction (i) includes three extractions with refluxing ethanol, each using 4-5 mL of ethanol per gram of plant material, followed by pooling of the extracts. The amount of organic solvent used, typically chloroform or dichloroethane, used in step (ii) is generally about 8-12 times the volume of the residue from step (i). The partitioning step (iii) generally employs ½ to 2 volumes of water relative to the volume of slurry.
As used herein, “partitioning” of a mixture of two immiscible fluids generally refers to a short period of stirring, e.g. about 10-30 minutes, more typically 10-15 minutes, followed by settling of the mixture, typically for a period of hours or days. In this case, the organic slurry and water are first stirred together, i.e. for about 10 minutes, and allowed to settle over a period of about 10 mins-10 hours, preferably about 2 hours.
III. Purification Procedure
In accordance with the method of the invention, the slurry obtained following step (iv) above is partitioned with an aqueous solution of base. In this process, the slurry and solution are first stirred together, i.e. for about 10 minutes, and allowed to settle over a period of about 10 mins-10 days, preferably about 1-4 days, more preferably about 2 days. The base is preferably a water soluble hydroxide, carbonate, or bicarbonate having a counterion selected from lithium, sodium, potassium, cesium, and ammonium. Suitable bases include, for example, NaOH, KOH, NaHCO 3 , KHCO 3 , Na 2 CO 3 and K 2 CO 3 . In preferred embodiments, the aqueous solution of base is selected from 0.1-2.5N aqueous NaOH, 0.1-2.5N aqueous KOH, 10%-15% aqueous NaHCO 3 , and 12%-18% aqueous KHCO 3 .
The aqueous solution of base is removed, and then, optionally, the organic solvent is washed with a dilute aqueous acidic solution, e.g. 1% HCl. At least a portion of the organic solvent is then removed from the slurry.
The residue obtained, which may be substantially solid or a concentrated slurry, is then washed with a lipophilic solvent, followed by elution from a silica gel adsorbent. Preferably, the lipophilic solvent is a hydrocarbon solvent, preferably a saturated hydrocarbon, selected from linear, branched and cyclic hydrocarbons having 5-7 carbon atoms, and mixtures thereof. In one embodiment, the solvent is cyclohexane.
Note that in variations of the procedure, as described below, the order of certain treatment steps in the purification process may be altered.
Elution from a silica gel adsorbent (i.e. silica gel chromatography) preferably employs a solvent mixture, or mobile phase, comprising a non-polar solvent, such as a hydrocarbon, alkyl ether, or mixture thereof, in combination with a more polar solvent, such as an ester or ketone solvent. Such non-polar solvents include, for example, hexane, cyclohexane, petroleum ether, or THF. Such polar solvents include, for example, ethyl acetate, acetone, or methyl ethyl ketone (MEK). In one embodiment, the solvent mixture comprises cyclohexane and ethyl acetate. Solvent gradients may be used, in accordance with known methods.
IV. Variations on the Purification Procedure
In one embodiment, substantially all of the organic solvent is removed from the slurry following removal of the aqueous base, to give a solid or substantially solid residue. This residue is then washed with the lipophilic solvent to obtain a solid product, which is then purified by silica gel chromatography, as described above.
In another embodiment, only a portion of the organic solvent is removed from the slurry following removal of the aqueous base, to give a concentrated slurry. Silica gel is then added to the concentrated slurry, in an amount effective to adsorb triptolide and related compounds (e.g. tripdiolide and/or 16-hydroxytriptolide). The resulting mixture is then washed with the lipophilic solvent, and the triptolide and related compounds are then eluted from the silica gel.
In a further embodiment, extraction with the lipophilic solvent precedes the base treatment. Accordingly, prior to partitioning with base, the organic solvent is removed from the slurry obtained following step (iv) above, and the residue is washed with the lipophilic solvent. A further slurry of the washed residue is then formed, again in an organic solvent selected from chloroform, methylene chloride, dichloroethane and mixtures thereof, and this slurry is then partitioned with an aqueous solution of base, as described above, for a period of about 10 minutes to 10 days, preferably about 2 days. The aqueous base solution is removed, and substantially all of the organic solvent is then removed, to obtain a substantially solid residue, which is then purified by silica gel chromatography.
V. Exemplary Procedure
Following is an exemplary isolation procedure in accordance with one embodiment of the invention. This procedure is intended to illustrate and not to limit the invention.
A. Extraction
1. Dried TW biomass is ground into pieces (1×0.1 cm-5×0.5 cm (length×diameter) for root core and stem; 0.1-2.0 cm in size (chip shape) for root bark. The ground TW biomass is refluxed with 50-95% (preferably 90%) ethanol for 2-5 (preferably 3) hours, 2-5 (preferably 3) times, at a weight/volume ratio of solid/ethanol of 1:4-6 (preferably 1:5) for the first extraction and 1:3-5 (preferably 1:4) for the subsequent extractions. 2. The extracts are pooled, and the is ethanol removed under reduced pressure to give a dark slurry.
B. Isolation (Including Base Treatment and Hydrocarbon Extraction)
1. The slurry is suspended in 8-12, preferably 10, volumes of dichloroethane or chloroform. 2. Water is added, in an amount of ½-2 volumes, preferably ½ volume, to the suspension. The mixture is stirred for about 10 minutes and allowed to settle over a period of 1-10 hours, preferably 2 hours. 3. The water layer is removed, and ½-1 volume, preferably ½ volume, of 0.1-2.5N, preferably 0.5 N NaOH or KOH solution, or 10-15% NaHCO 3 , is added to the organic phase. The mixture is stirred gently for about 10 minutes, then left for 1-10 days, preferably 4 days, to allow the layers to separate. 4. The aqueous phase is removed. 5. Water is added, in an amount of ¼-1 volume, preferably ¼ volume, relative to the organic phase. The mixture is stirred for about 10 minutes and left for 1-3 hours. Optionally, the mixture is washed twice at this stage with 1% HCl. 6. The aqueous phase is removed, and a drying agent, such as Na 2 SO 4 or MgSO 4 (3 g/100 mL), is added to the organic phase. The mixture is stirred and then filtered to remove the drying agent. 7. The organic solvent is removed completely under reduced pressure. 8. Cyclohexane is added to the resulting solid, and the mixture is stirred, e.g. for about 10 minutes, to suspend the solid. 9. The solid is removed by filtration and dried under reduced pressure at 40-60° C. to obtain an intermediate product as a yellow powder.
C. Further Purification (Silica Gel Chromatography)
1. The powder is dissolved in 1:1 cyclohexane:ethyl acetate at a concentration of 0.5-1.0 g/mL, preferably 0.75 g/mL. 2. The dissolved material is loaded onto a pre-equilibrated silica gel column (200-300 mesh, 100×1-20 cm), using about 10 g of silica gel per 1-3 g, preferably per 2 g, of the powder intermediate. 3. The product is eluted using the same solvent mixture at a flow rate of 10-30 ml/hr, preferably 18 ml/hour. Triptolide-enriched fractions are collected, monitoring with TLC or HPLC. 4. Triptolide-enriched fractions are pooled and the solvent removed.
Typically, triptolide and/or related compounds are crystallized from the obtained product by temperature adjustment and/or solvent (e.g. acetone or ethyl ether) adjustment. Optionally, column chromatography and/or crystallization are repeated. | Methods for extraction, isolation, and purification of therapeutically useful compounds from Tripterygium wilfordii are described. Extraction steps employing aqueous base and a hydrocarbon solvent, respectively, are found to increase the efficiency of the process and reduce the amount of material that must be removed by chromatography. | 0 |
This application is a continuation-in-part of the application for patent on Wafer Cushions for Wafer Shippers, Ser. No. 08/471,641 filed Jun. 6, 1995 now U.S. Pat. No. 5,586,658 and is also a continuation-in-part of the application for patent on WAFER SHIPPER AND PACKAGE, Ser. No. 08/276,096, filed Jul. 15, 1994 now U.S. Pat. No. 5,575,394.
BACKGROUND OF THE INVENTION
This invention relates to containers and packages for shipping semiconductor wafers and similar objects.
Semiconductor wafers are subjected to numerous steps in their processing. The wafers are subjected to various process steps in various machines and at various locations. The wafers must be transported from place to place and stored over a period of time in order to accommodate the necessary processing. A number of types of transport and shipping devices have been previously known for handling, storing and shipping wafers.
A principal component of the shipping devices is a means for cushioning the wafer to protect against physical damage from shock, vibration, abrasion, and the like. Such shipping containers and cushioning means have been previously known as disclosed in U.S. Pat. Nos. 4,043,451; 4,171,740; 4,248,346; 4,555,024; 4,574,950; 4,557,382; 4,718,549; 4,773,488; 4,817,779; 4,966,284; 5,046,617; 5,253,755; 5,255,797 and 5,273,159. These shipping and transport devices utilize various means on the covers for engaging and cushioning to protect the wafers from physical damage, however, such containers do not provide for accommodation of the inherent flexing of the shipping device covers due to the presence of the wafers.
A desirable feature of shipping and transport devices is to have a top cover that provides a hermetic or near hermetic seal to prevent entry of contaminants.
The use of more flexible plastics for covers, such as polypropylene and Hytrel®, provide for better sealing but the greater flexing of the top cover creates an uneven and inconsistent engagement of the individual wafers. This is because the top covers will bow, that is, the center of the top cover flexes outwardly more than near the edges.
Attempts to deal with the problem of the flexing of the covers have been by way of trying to prevent the bowing of the top cover by adding exterior ribs, changing the top cover structure or using more rigid materials.
SUMMARY OF THE INVENTION
The present invention is a shipping container for safely storing articles such as semiconductor wafers. The shipping container has two sidewalls sealingly connected to two end walls to form a generally rectangular interior wafer confinement area. A top cover and a bottom cover are removably attached to the container to protect the wafers during shipping and storage and provide access to the wafers for processing. The wafers are securely held in place in the carrier by a cushioning means for accommodating flexing of the covers to prevent damage to the wafers. Furthermore, the wafers are locked into place to prevent contamination by the wafers generating particles in the wafer confinement area by rubbing against the carrier. The cushioning means for accommodating the flexing of the cover utilizes the flexing of the cover to support and suspend the wafers in the wafer confinement area. The cushioning means comprises structure in the top cover and a plurality of wafer engagement portions extending inwardly into the container. The wafer engagement portions each have edge portions which are aligned in a convex arcuate shape with respect to a centerline of the carrier. The arcuate shape may also be formed by an initial arcuate shape in the cover of the shipping device or an arcuate shaped fin extending from the cover of the shipping device. The cushioning means has a configuration to compress when engaged by the wafer to secure the wafer while spacing it from the top cover. The cushioning means may have a continuous wafer engaging edge along the length of the fin or it may be separated into wafer engaging tabs or fingers, each tab or finger individually engaging a wafer. The bottom cover may also have a cushioning means engaging and spacing the wafers from the bottom cover. The structure of the cushioning means on the bottom cover is designed to bend outwardly to lock the wafers from rotating in the shipping device.
An object of the present invention is to provide a shipping container with a near hermetic seal on the top cover and having a cushioning means for accommodating flexing of the covers and which utilizes the flexibility of the covers of the shipping container for safely storing and shipping semiconductor wafers to minimize the likelihood of wafer damage or contamination.
A feature of the present invention is a wafer carrier comprising a container with side and end walls, a removable top cover defining a top wall and a removable bottom cover defining a bottom wall. Wafer separating ribs are positioned on the side walls for holding the wafers in a spaced relation to each other.
Another feature of the present invention is a cushioning means on the top cover. The cushioning means comprising a plurality of fins disposed longitudinally along the top cover and extending radially into the wafer confinement area.
Another feature of the present invention is each fin may have a continuous wafer engaging edge along the length of the fin.
Another feature of the present invention is that each fin may be a row comprising a plurality of separately extending cushioning tabs having a slot between each pair of adjoining tabs forming a discontinuous wafer engaging edge having a substantially convex arcuate shape with respect to the centerline of the carrier. Each cushioning tab having a wafer engaging edge.
Another feature of the present invention is a structure in each fin on the top cover designed to resiliently indent along a radius of the wafer at the wafer engagement portion.
Another feature of the present invention is a second cushioning means on the bottom cover having a wafer engaging edge. The cushioning means on the bottom cover supporting the wafers and spacing the wafers from the bottom cover while accommodating flexing of the bottom cover due to the weight of the wafers.
Another feature of the present invention is the cushioning means in the top or bottom cover may have a structure, such as a fin or row of engaging members, which is designed to be more compressible at either end of the container and less compressible in the middle portion of the container to accommodate and utilize the flexing of the cover of the shipping device.
Another feature of the present invention is the positioning of the fins on the top cover to maximize the cushioning effect on the wafers. A top fin may be located along the center of the top cover.
Another feature of the present invention is the fin may be formed integral with the cover to minimize manufacturing costs.
Another feature of the present invention is the slot between tabs allows each tab to flex individually when engaging a wafer and prevent the flexing of one tab from effecting the alignment or engagement of other tabs with their respective wafers.
Another feature of the present invention is each fin may have the form of a bead extending longitudinally on the inside of the cover.
Another feature of the present invention is that the edge of the fin or engagement portions may take the form of a point, a bead or a flat surface.
Another feature of the present invention is the wafer engaging edge is spaced from the center line of the carrier by a radial distance. The radial distance progressively increasing from the middle portion of the fin to the portions of the fin adjacent to the end walls.
Another feature of the present invention is the cushioning means on the bottom cover may have the form of a pair of fins running longitudinally along the bottom cover. A structure of each fin on the bottom cover designed to resiliently bend to lock the wafer in place restraining rotation of the wafer.
Another feature of the present invention is the wafer engaging edge on the cushioning means on the bottom cover having an arcuate convex shape toward the centerline of the carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a plastic shipping container.
FIG. 2 is a perspective view of the shipping container in exploded condition to show the three principal parts.
FIG. 3 is a sectional view through the shipping container, taken on a broken line as indicated at 3--3 of FIG. 1, and wherein the break is taken at the centerline indicated by dot-dash lines in FIG. 3 particularly indicating the tabs and elevation.
FIG. 3A is a sectional view through the shipping container taken on a broken line as indicated at 3--3 of FIG. 1 particularly indicating the radial alignment of the fins in the top cover.
FIG. 4 is an enlarged detail section view taken at approximately 4--4 of FIG. 2.
FIG. 5 is a sectional view taken at approximately 5--5 of FIG. 14.
FIG. 5A is a sectional view taken at approximately 5--5 of FIG. 14 showing an alternative embodiment of the wafer cushioning means.
FIG. 5B is a sectional view taken at approximately 5--5 of FIG. 14 showing an alternative embodiment of the wafer cushioning means.
FIG. 5C is a sectional view taken at approximately 5--5 of FIG. 14 showing an alternative embodiment of the wafer cushioning means.
FIG. 5D is a section view taken at approximately 5--5 of FIG. 14 showing an alternative embodiment of the wafer cushioning means.
FIG. 6 is an enlarged detail section view taken at approximately at 6--6 of FIG. 5.
FIG. 6A is an enlarged detail section view taken at approximately 6--6 of FIG. 5 illustrating a bead configuration of the fin.
FIG. 6B is an enlarged detail section view taken at approximately 6--6 of FIG. 5 illustrating a knife-shaped wafer engaging edge.
FIG. 6C is an enlarged detail section view taken at approximately 6--6 of FIG. 5 illustrating a flat wafer engaging edge.
FIG. 6D is an enlarged detail section view taken at approximately 6--6 of FIG. 5 illustrating a rounded wafer engaging edge.
FIG. 7 is an enlarged detail section view taken at approximately 6--6 of FIG. 5 showing the tab bendingly engaging a wafer.
FIG. 8 is a section view taken at approximately 8--8 of FIG. 2.
FIG. 9 is an enlarged detail section view taken at approximately 9--9 of FIG. 8.
FIG. 10 is a perspective drawing illustrating the wafer cushioning means on the top cover engaging a wafer and crushing along a radius of the wafer.
FIG. 11 is a perspective view taken at approximately 11--11 of FIG. 5D.
FIG. 12 is a perspective view of the wafer cushioning means on the bottom cover engaging a wafer and bending outwardly.
FIG. 13 is an elevational view of a shipping container having a side entry with horizontal orientation of the wafer.
FIG. 14 is a perspective view of a top cover.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, the shipping container is indicated in general by numeral 15 and comprises a wafer carrier 16, a top cover 17 and a bottom cover 18.
The wafer carrier 16 is preferably molded of a substantially rigid and transparent plastic material, such as polycarbonate, although the wafer carrier might be molded of other comparable or equivalent plastics. The top cover 17 and bottom cover 18 are both molded of a substantially stiff but resiliently and flexibly yieldable plastic material, such as a thermoplastic elastomer known by its trademark Hytrel®, a registered trademark of DuPont. The bottom cover 18 forms a bottom wall of container 15. The Hytrel thermoplastic elastomer, in all of its grades, are block copolymers, consisting of a hard (crystalline) segment of polybutelyne terephthalate and a soft (amorphous) segment based on long-chain polyether glycols. The particular material used in the top and bottom covers 17 and 18 has a hardness, durometer D in the range of 45 to 55 to 63, and the material is elastic and has a sticky tack at the surface, providing for maximum grip and minimum creep of material and a high abrasion resistance. In addition, the stiff but resiliently yieldable material in the top and bottom covers resists deterioration from many industrial chemicals, oils and solvents.
The wafer carrier 16 comprises four encompassing walls specifically identified as sidewalls 19 and 20 and end walls 21 and 22. The sidewalls 19 and 20 and end walls 21 and 22 are molded integrally of each other so that the plastic wafer carrier 15 is in one piece. The upper edge portions 19.1, 20.1, 21.1 and 22.1 of the sidewalls and end walls are in substantially linear relation to each other with respect to each other, lying in a plane and defining the top opening 23 of the carrier facilitating loading the wafers W into the wafer carrier and unloading the wafers from the wafer carrier 15. The wafers W may be of the type used in semiconductor manufacturing or magnetic memory storage systems such as disk platters.
Referring to FIGS. 2 and 3, the sidewalls 19 and 20 have a multiplicity of upright ribs or teeth 24 and 25 formed integrally thereof and defining pockets or slots 25.1 therebetween for receiving and retaining the semiconductor wafers W in spaced relation with each other. The transparent polycarbonate of the sidewalls 19, 20 facilitate viewing the wafers to determine their presence and location. The sidewalls 19 and 20 also have rounded offset portions 26 and 27 shaped to conform generally to the shape of the wafers W to be carried therein. The offset portions have additional wafer separating lugs 28 and 29 for maintaining the wafers W in spaced relation to each other and in quiet relation with respect to each other.
The sidewalls 19 and 20 also have depending and parallel foot panels 30 and 31 defining the lower edge portions 32 and 33 of the sidewalls 19 and 20, respectively.
End walls 21 and 22 are both substantially flat or planar and have lower edge portions 34 and 35 which are arranged generally in the same plane as the lower edge portions 32 and 33 of the sidewalls 19 and 20. The interconnected lower edge portions 32, 33, 34 and 35 of the sidewalls and end walls cooperate to define the bottom opening 36 of the carrier between the foot panels 30 and 31 in order to provide access to the wafers W at the bottom of the carrier 16.
The sidewalls 19 and 20 have outwardly protruding tabs 37 and 38 molded integrally of the upper edge portions 19.1 and 20.1 of the sidewalls, and the tabs 37 are elongate and extend longitudinally along the sidewalls, substantially midway between the ends of the sidewalls, substantially as illustrated in FIG. 1. Sidewall 19 has lower tab 39 and sidewall 20 has a lower tab (not shown). These lower tabs protrude outwardly from the lower edge portions 32 and 33 of the sidewalls and specifically from foot panels 30 and 31 thereof. The lower tab on sidewall 20 is a mirror image of tab 39 on sidewall 19.
The upper edge portions 19.1, 20.1 of the sidewalls and the upper edge portions 21.1, 22.1 of the end walls define enlarged and outwardly flared upper rim portions 41, 42 on the sidewalls 19, 20 and rim portions 43, 44 on the end walls 21, 22, respectively. The enlarged upper rim portions 41-44 connect with each other and accordingly provide rim portions extending around the entire periphery of the carrier 16, i.e., along both sidewalls and end walls. The peripherally extending rim portions 41-44 lie substantially in a plane.
The sidewalls 19 and 20 and the end walls 21 and 22 also define enlarged and outwardly flaring lower rim portions 45, 46, 47 and 48, respectively, which join together and effectively provide lower rim portions around the entire periphery of the carrier 16. These lower rim portions lie substantially in a plane.
Each of the foot panels 30 and 31 has an indexing notch 49 formed therein to cooperate with indexing ribs or media in a processing machine for accurately locating the wafer carrier 16 in such a processing machine. The two lower rim portions 45 and 46 on the foot panels 30 and 31 of the sidewalls 19 and 20 diverge upwardly as at 50 and pass over the indexing notch 49. The shape of portion 50 illustrated in FIG. 2 may be defined by an arc passing over indexing notch 49 and extending almost the entire length of lower rim portions 45 and 46.
It is to be particularly recognized that all portions of the end walls 21 and 22 are of substantially uniform height, and of the same height as the sidewalls 19 and 20. The end wall 22 has a pair of widely spaced support bars 51 and 52 formed integrally thereof and extending into close proximity with the upper and lower edge portions 22.1 and 35, respectively, of the end wall 22. The support bars 51 have coplanar outer edges 53 to lie on a plane surface of a processing machine for the purpose of accurately locating the wafer carrier and the wafers relative to other equipment in the processing machine. The end wall 22 also has an indexing crossbar 54 formed integrally thereof, and is sometimes referred to as an "H-bar", extending transversely of the support bars 51, 52. The indexing crossbar 54 accurate locates the wafer carrier 16 in a processing machine by cooperating with the locating mechanism thereof. While the crossbar 54 is shown to extend entirely to the support bars 51, 52, but may extend only partially across the end wall 22 between the support bars.
It is to be particularly noted that both end walls 21 and 22 have the full height which is the same as the height of the sidewalls 19, 20; and the end walls 21 and 22, as well as the sidewalls, have the enlarged upper and lower rim portions which effectively extend around the entire periphery of the carrier 16. The end wall 22 in particular has panel portions 55 and 56, which respectively extend upwardly from the indexing crossbar 54 to the enlarged upper rim portion 44, and downwardly from the indexing crossbar 54 to the enlarged lower rim portion 48, respectively. Both of the panel portions 55 and 56 fill the entire spaces between the support bars 51, 52, which are formed integrally of the end wall 22.
Both the top cover 17 and the bottom cover 18, when applied to the upper and lower portions of the carrier to respectively close the top opening 23 and bottom opening 36 thereof, establish a substantially hermetic sealing relations with respect to the carrier to essentially prevent migration of air, moisture and contaminating particles either into or out of the open interior 57 of the carrier wherein the wafers W are stored. In addition, because both the top cover 17 and bottom cover 18 are formed or molded of a substantially stiff, but resiliently flexibly yieldable plastic material, these top and bottom covers 17, 18 may be flexed slightly during removal thereof so as to essentially peel the covers off the carrier by initially lifting one corner of the cover off the carrier and then progressively disengaging the remainder of the cover from the carrier.
The top cover 17 comprises a partially cylindrical panel or retainer portion 58 having the curvature substantially the same as the shape of the edges of the wafers W to be stored in the container 15. In one successful example of the container, the wafers may have a diameter of approximate eight inches (20.3 cm) and the curvature of the panel 58 appropriately substantially follows the curvature of the edge of panels of such size. The container 15 is also suited to store 6 inch (15 cm), twelve inch (30 cm) or larger wafers by making the container an appropriate size. The partially cylindrical panel 58 has a convex inner surface 59 facing the open interior 57 of the wafer carrier.
The top cover 17 also has substantially flat and planar side edge portions 61, 62, 63, 64. It will be recognized that the side edge portions 61, 62, adjacent the carrier sidewalls 19 and 20, provide springiness in the cover, and are substantially wider than the end edge portions 63, 64 which are adjacent the end walls 21, 22 of the carrier. The side edge portions 61-64 lie directly on the upper edge portions 19.1, 20.1, 21.1. and 22.1 of the carrier and contribute to maintaining the substantially hermetic seal between the carrier and the top cover.
Referring to FIG. 5, the cushioning means 130 for accommodating the flexing of the top cover 17 is illustrated as comprising a plurality of fins 131, each fin having a noncontinuous wafer engaging edge 104 comprising a row 100 of resiliently flexible tabs 102 extending longitudinally along the partially cylindrical inner surface 59. As illustrated in FIG. 5, the rows 100 extend longitudinally along the top cover 17 and of the panel 58 so as to overlie and engage each of the wafers W with a wafer-engaging edge 104. The rows 100 are spaced from each other. A center row 100 is mounted centrally of the top cover. The spacing of the rows 100 accommodate the flats of the wafers W. Each of the rows 100 of tabs 102 has two end portions 106 and a middle portion 108. Each row 100 is substantially linear and attached to panel 58 along inner surface 59. The outer edge of each row 100 is generally indicated by numeral 103 and its shape is defined by the wafer-engaging edges 104 of adjacent tabs 102.
Referring to FIG. 3A, each fin 131 protrudes radially toward the centerline 134 in the open interior 57 of the container 15 to engage wafers W (shown in outline). Each fin 131 engages each wafer W and structurally yields to support the wafers W and maintain a spaced relation between each wafer W and the panel 58. (see also FIGS. 7 and 10) It should be understood, the fins 131 illustrated as the tabs 102 of FIG. 5, are resiliently flexible and will bend (FIG. 7) or compress axially along the tab axis A without substantial bending where engaged with a wafer W (FIG. 10). The tab 102 will quickly regain its original shape to maintain contact with the wafer W and accommodate flexing of the top cover 17 to cushion the wafer W during shipment and storage.
Referring to FIG. 5, the tabs 102 are generally rectangular and have a width extending into the container 57. Each tab 102 has a length extending along the row 100 and is separated from adjacent tabs 102 by a slot 105. The length of each tab 102 along the row 100 is defined by the slot 105 (see also FIG. 4) and calibrated to allow each tab 102 to engage a single wafer W with a contact portion 132 on the wafer-engaging edge 104. The slot 105 allows each tab 102 to engage a wafer W independently of adjacent tabs 102. The wafer-engaging edge 104 is spaced from the cover 58 to engage and cushion wafers W that may be stored in container 15.
Continuing to refer to FIG. 5, the width of the tabs 102 measured from the panel 58 to the wafer engaging edge 104, may progressively increase and decrease along the row 100. The tabs 102 in the middle portion 108 are generally wider than tabs 102 located in the end portion 106. Tabs 102 in the middle portion of the row 108 are approximately 0.100 inches wide. Tabs 102 located at the end portion 106 are approximately 0.050 inches. These measurements are intended to illustrate the relative width of tabs along the middle 108 and end 106 portions of the row, they are not meant to limit the scope of the invention.
Continuing to refer to FIG. 5, tabs 102 located along the middle portion of the row 108 may be wider to allow the top cover 17 to flex and bow from the weight of wafers in the container 15 and the restraining force of the tabs 102 pressing against the wafers W. The wider tabs 102 located in the middle portion of the row 108 allow the top cover 17 to flex while maintaining contact with each wafer W by a independent wafer engaging edge 104. Under some conditions, it may be necessary for the width of tab 102 to increase in a nonlinear fashion along the row 100 from the middle portion 108 to each end portion 106.
Referring to FIG. 3A, the shape of the outer edge 103 of each fin 131 with respect to the centerline 134 of the container 15 is very important to maintaining contact each wafer W as the top cover 17 flexes. Each fin 131 is symmetrically formed around the radius 150. The outer edge 103 along each fin 131 defines a convex arcuate shape with respect to the centerline 134 of the container 15. The convex arcuate shape is further defined by a radial distance 136. The radial distance 136 is measured from the centerline 134 of the container 15 to wafer engaging edge 104 of each fin 131. It should be understood the wafers are aligned with the centerline 134 of the container 15. A radius of a wafer is therefore aligned with the radius 150 of the container 15. The radial distance 136 progressively increases from a point proximate to the middle portion 108 (FIG. 5) of each fin to a larger radial distance 136 adjacent each end portion 106 (FIG. 5) of each fin 131.
As illustrated in FIG. 5, the cushioning means 130 for accommodating flexing of the top cover 17 has an outer edge 103. The shape of the outer edge 103 is defined by the wafer engaging edges 104 of adjacent tabs 102 along a row 100. The tabs 102 may have a common fin-like base as shown in FIG. 5.
Referring to FIG. 5A, the cushioning means 130 for accommodating flexing of the top cover 17 may further comprise a convex arcuate shape of the panel 58 with respect to the centerline 134 of the container 15 forming the convex arcuate shape along the outer edge 103 of each row 100. In this embodiment, each tab 102 may be approximately the same width. The tabs 102 may individually extend from the panel 58 without the common fin-like base as shown in FIG. 5. The darken line 135 in FIGS. 5A, 5B and 5C shows the portioning of the panel 58 when engaged with the wafers.
Referring to FIGS. 5 and 5A, each tab 102 is separated from adjacent tabs 102 along the row 100 by a slot 105. The slots 105 and wafer engaging edges 104 of adjacent tabs define a discontinuous arcuate shaped outer edge 103 along each row 100.
Referring to FIG. 3A, a plurality of rows 100 of tabs 102 may be distributed across the top cover 17 along the inner surface 59. A single row 100 may be centered along the inner surface 59 between the sidewalls 19 and 20. Rows 100 of tabs 102 may also be displaced between the center row 100 and the side portions 61, 62 of the top cover 17. As illustrated in FIG. 6 and 7, fins 131 may be integrally molded with the top cover 17 to minimize manufacturing costs.
As illustrated in FIG. 5, a set of corresponding tabs is labeled 102 for reference. Each set of corresponding tabs 102 will engage and cushion a particular wafer W. The relative width of the tabs 102 in each of the respective rows 100 may vary from row to row to accommodate different shape covers 17 and different amounts of flex in the top cover 17. A row 100 centered along panel 58 may have tabs which are shorter than the corresponding tabs of rows 100 displaced between the center row 100 and the side portions 61, 62 to accommodate for a difference in the radius of the wafers W and the radius of the cylindrical inner surface 59.
Referring to FIGS. 5B and 5C, the cushioning means 130 for accommodating flexing of the top cover 17 may comprise a plurality of fins 131 comprising a continuous strip 138 extending from the inner surface 59 of panel 58. The continuous strip 138 has a wafer engaging edge 104 spaced a radial distance 136 from the centerline 134 (FIG. 3A) of the container 15 to form a convex arcuate shape as described above. This convex arcuate shape accommodates flexing of the top cover 17 due to the wafers W bearing against the cushioning means and forcing it outwardly. As illustrated in FIG. 5B, the panel 58, along the base of the fin 131, may have a cylindrical shape being substantially parallel to the centerline 134 of the container 15 (FIG. 3A). The width of the fin 131 progressively decreases from the middle portion 108 to the end portion 106 to form the convex arcuate shape of the outer edge 103 with respect to the centerline 134 of the container 15 (FIG. 3A).
As shown in FIG. 5C, the cushioning means 130 for accommodating flexing of the top cover 17 may include the panel 58 formed having a convex arcuate shape with respect to the centerline 134 of the container 15 (FIG. 3A) when in a first unflexed position. As illustrated in outline in FIG. 5C, the panel 58 may be substantially parallel to the centerline 13 (FIG. 3A) when the container 15 is loaded with wafers W in a second flexed position.
Referring to FIG. 5D, the cushioning means 130 for accommodating the flexing of the top cover 17 may comprise a fin 131 and the panel 58 formed substantially parallel to the centerline 134 (not shown in this view). In this embodiment, the flexing of the top cover 17 is accommodated by changing the structure of the fin 131 from the middle portion 108 to the end portions 106. In this embodiment, the compressibility of the fin 131 may be changed by varying the structure or the thickness of the fin 131. The cushioning means 130 for accommodating the flexing of the top cover 17 may also comprise changing the thickness of the panel 58. The panel 58 may have a thickness which progressively decreases from adjacent the middle portion 108 of each fin 131 to a smaller thickness adjacent each end portion 106 of each fin 131.
Referring to FIG. 10, the fin 131 in the top cover 17 will axially compress to engage the wafer W at the wafer engaging portion 132.
As shown in FIG. 11, the thickness of the fin 131 may vary from a larger thickness along the middle portion 108 of the fin 131 to a smaller thickness along each end portion 106 of the fin 131. The compressibility of the fin 131 along the length of the fin 131 may be varied in a manner by changing the structure to a modified I-beam or removing material in steps. The structural accommodation of the flexing of the top cover 17 by changing the compressibility along the fin 131 may be used regardless of whether the fin 131 is a continuous strip 138 or a row 100 of tabs 102.
Referring to FIG. 6, the cross section of the fin 131 is shown having a tapering shape. The fin is shown having a wide thickness adjacent the inside surface 59 of the panel 58 and a more narrow thickness spaced from the inside surface 59. It should be understood, the fin 131 is directed inward along a radius 150 of the container 15 extending from the centerline 134 (FIG. 3A).
Referring to FIG. 6A, the fin 131 is shown having a bead shape 140. The bead shape 140 is symmetrical along the radius 150 (FIG. 3A). The bead shape 140 has a wafer engaging edge 104 illustrated as a curved surface 142.
Referring to FIG. 6B, the fin 131 is shown having a sharp knife edge 144 at the wafer engaging edge 104.
Referring to FIG. 6C, the wafer engaging edge 104 is shown as a flat surface 146 on the end of the fin 131 directed radially inward into the container 15 along radius 150 (FIG. 3A). The fin 131 is symmetrical around the radius 150 (FIG. 3A) and the flat surface 146 is generally perpendicular to the radius 150 (FIG. 3A) to accommodate crushing of the fin 131 a radius of the wafer to resiliently engage and support the wafer W.
Referring to FIG. 6D, the wafer engaging edge 104 is shown as a rounded edge 142 spaced from the inner surface 59 of the panel 58. The fin 131 is symmetrically formed around the radius 150 (FIG. 3A).
The top cover 17 also has a multiplicity of deformations or stacking offsets 65 formed in the panel 58 to facilitate stacking of the containers one upon another.
The top cover 17 also has enlarged top cover rim portions extending around the entire periphery of the top cover and more specifically, the top cover has inwardly protruding enlarged top cover rim portions 66, 67 extending along the side edge portions 61, 62 of the top cover; and has enlarged top cover rim portions 68, 69 extending along the end edge portions 63, 64. When the top cover 17 is applied onto the carrier 16, the rim portions 66-69 engage and embrace the rim portions 41-44 of the carrier 16 in substantially hermetic sealing relation. The rim portions 66-69 of the top cover 17 and rim portions 41-44 of the carrier provide a snap fit for securing the top cover 17 onto the carrier 16. The interfitting rim portions 66-69 on the cover and the rim portions 41-44 on the carrier 16 provide the sole means by which the top cover 17 is anchored onto the carrier 16, i.e., there is no other latching device for holding the top cover 17 onto the carrier 16.
Top cover 17 also has a pair of tab portions 70, 71 which protrude outwardly from the rim portion 67 and extend longitudinally along the rim portion 67 and side edge portion 62 adjacent the ends of the top cover to be in offset relation with respect to the adjacent tab 38 on the carrier 16. The tabs 70, 71 are useful in completing closing of the top cover 18 onto the carrier 16. In the final stages of applying the top cover, the tabs 70, 71 may be manually squeezed toward the tab 38 on the carrier to assure that application of the bottom cover is completed, and that the snap fit has been finished. Top cover 17 may also have symmetrically located tabs on rim portion 66.
Although technicians using the container 16 may devise various procedures of applying and removing the top cover 17, it has been found to be successful to first place the top cover 17 upon the upper edge portions of the side and end walls. The two corners of the top cover may be pressed, initially, onto the rim portions of the side and end walls using the palm or heel of the person's hands. Then the side edge portions 61, 62 of the top cover are progressively pressed onto the rim portions 41, 42 at the sidewalls of the carrier, until the entire rim portions 66-69 of the cover have achieved and completed the snap fit onto the adjacent rim portions 41-44 of the carrier.
For removing the top cover 17, a corner portion, such as adjacent rim portions 67 and 69, are lifted off the adjacent rim portions 42, 44 of the carrier, and the corner portion of the top cover is flexed upwardly. The rim portions are progressively separated by lifting on the top cover until the cover is free of all of the rim portions 41-44 of the carrier.
The particular materials from which the carrier 16 and top cover 17 are formed are highly resistant to abrading and scuffing and accordingly, the generation of particulate is minimized as the cover is lifted off or applied onto the carrier.
The bottom cover 18 has side edge portions 72 and end edge portions 73 which respectively underlie the lower edge portions 32, 33 and 34, 35 of the carrier and engage the lower edge portions of the end walls and sidewalls of the carrier to contribute materially to a substantially hermetic sealing relation between the bottom cover 18 and the carrier 16.
The bottom cover 18 also has a bottom cylindrical panel 75 having an inner surface 76 defining the bottom of the interior wafer confinement area 57. A cushioning means 130 is formed on the inner surface 76 of the bottom cover 18 to support and space the wafers from the bottom cylindrical panel 75.
Referring to FIG. 3A, a second cushioning means 130.1 for accommodating flexing of the bottom cover 18 may comprise a bottom fin 148 extending longitudinally of the bottom cover 18. In the embodiment shown in FIG. 10, two bottom fins 148 are formed on the bottom cover 18 and have a shape (FIG. 12) designed to bend outwardly when engaged by the wafer to support the wafer W and prevent the wafer from rotating. Each bottom fin 148 on the bottom cover 18 has a wafer engaging edge 114 which is spaced from the centerline 134 of the container 15 by a radial distance 136. Each bottom fin 148 on the bottom cover 18 may, alternatively, be of similar shape to the fin 131 on the top cover 17. The bottom fin 148 on the bottom cover 18 may have a wafer engaging edge 114 of a similar shape as the fin 131 on the top cover 17. The wafer engaging edge 114 on the bottom fin 148 may have a flat shape 146 (FIG. 12) or may have a knife edge shape (not shown) or a rounded edge 142 (FIG. 3A) as discussed above.
Continuing to refer to FIG. 3A, the bottom fin 148 on the bottom cover 18 may be a continuous strip 149 or a noncontinuous row 110 of resiliently flexible tabs 117 as illustrated in FIG. 8. The second cushioning means 130.1 on the bottom cover 18 is illustrated in FIG. 8 as a plurality of fins 148 having a noncontinuous wafer engaging edge 114 forming a row 110 of resiliently flexible tabs 117. The tabs 117 on the bottom cover 18 are substantially similar to the tabs 102 on the top cover 17. Continuing to refer to FIG. 8, each fin 148 on the bottom cover 18 has two end portions 116 and a middle portion 118. Each fin 148 has a wafer engaging edge 114 which may have a convex arcuate shape for accommodating flexing of the bottom cover 18 as discussed above with respect to the centerline 134 (FIG. 3A).
Continuing to refer to FIG. 3A, the second cushioning means 130.1 for accommodating flexing of the bottom cover 18 may be formed of a structure similar to the cushioning means 130 for accommodating flexing of the top cover 17 as discussed above. The radial distance 136 from the centerline 134 of the container 15 to the wafer engaging edge 114 of the bottom fin 148 on the bottom cover 18 progressively decreases from the middle portion 118 to each end portion 116 (FIG. 8). This progressively changing radial distance 136 may be formed by an arcuate shape of the bottom fin 148 with respect to the bottom cover 18 or an arcuate shape of the bottom cylindrical panel 75 with respect to the centerline 134 of the container 15. As discussed above with respect to the top cover 17 illustrated in FIG. 5D above, the bottom cover 18 may have a bottom cylindrical panel 75 which has a thickness progressively decreasing from adjacent the middle portion 118 of each bottom fin 148 to the portion of the bottom cylindrical panel 75 adjacent each end portion 116 of the bottom fin 148 on the bottom panel 18.
Continuing to refer to FIG. 3A, the second cushioning means 130.1 for accommodating flexing of the bottom cover 18 may also include a structure on the bottom fin 148 on the bottom cover 18 to change the compressibility of the fin 131 from a highly compressible design adjacent the middle portion 118 and a less compressible design adjacent each end portion 116. The bottom fins 148 on the bottom cover 18 work with the fins 131 on the top cover 17 to suspend the wafers in the container 15 between the wafer engaging edges 104, 114 during shipment and storage while equally distributing the retaining force across all the wafers W and allowing for bowing or flexing of either or both of the covers 17, 18.
Referring to FIG. 3A, it should be understood as the bottom cover 18 is applied to the carrier 16, the wafer engaging edge 114 of each fin 148 on the bottom cover 18 will engage each wafer W and lift it from its resting position along the sidewalls 19 and 20. The wafer W will be suspended between the bottom fins 148 on the bottom cover 18 and the fins 131 on the top cover 17.
Referring to FIG. 8, the second cushioning means 130.1 for accommodating flexing of the bottom cover 18 may also comprise reinforcing on the bottom cover 18 to resist flexing of the bottom cover 18 as the bottom cover 18 is applied to the carrier 16. The bottom cylindrical panel 75 may have a thickness which varies from adjacent the middle portion 118 of each fin 148 to adjacent each end portion 116 of each fin 148 on the bottom cover 18. Alternatively, the bottom cover 18 may have a plurality of supporting ribs 112 on outside panel 75. These support ribs 112 extend downwardly from the bottom cover 18 and outwardly from the container 15. Each supporting rib 112 is parallel to a fin 148 on the bottom cover 18. This rib 112 strengthens the bottom cover 18 to reduce bowing or flexing when wafers W are inserted into the container 15 and engaged with the cushioning means 130 for accommodating flexing of the cover.
Referring to FIG. 12, each bottom fin 148 has an outside wall surface 152 formed substantially vertical from the bottom panel 75. Each bottom fin 148 also has an inside wall surface 154 formed at an acute angle to the vertical outside wall surface 152. The inside wall surfaces 154 on the two bottom fins 148 are opposing to each other. The wafer engaging edge 114 on the bottom fin 148 extends between the outside wall surface 152 and the inside wall surface 154 to engage the wafer. This structure of the bottom fin 148 allows the wafer engaging portion 132 to force the bottom fin 148 to bend outwardly over the outside wall surface 152. This outwardly bending locks the wafer W from rotating in the container 15 while spacing the wafer W from the bottom panel 75 and accommodating flexing of the bottom cover 18.
The bottom cover 18 also has rim portions extending around the entire periphery of the bottom cover and more specifically, the bottom cover comprises enlarged rim portions 78, 79 extending along the side edge portions 72 of the bottom cover and embracing the rim portions 45, 46 of the sidewalls 19, 20 of the carrier. The bottom cover also enlarged bottom cover rim portions 80, 81 extending along the end edge portions 73 of the bottom cover and embracing the enlarged rim portions 47, 48 of the end walls of the carrier 16. The rim portions 78, 79, 80 and 81 lie substantially in a plane and embrace the rim portions 45, 46, 47 and 48 of the wafer carrier in a snap fit and in a substantially hermetic sealing relation to retain the bottom cover on the wafer carrier. The rim portions 78-81 of the bottom cover and the rim portions 45-48 of the wafer carrier comprise the sole means by which the bottom cover is retained on the wafer carrier, i.e., there need be no supplemental latching means for holding the bottom cover on the carrier.
The substantially hermetic seal between the carrier 16 and the top and bottom covers 17, 18 prevents movement of air, other gases, moisture and particles into and out of the container 15, and prevents the carrier from burping or sucking as atmospheric pressures change.
The bottom cover 18 also has a pair of elongate tab portions 82, 83 extending longitudinally along one of the side edge portions 72 and adjacent the rim portion 79 of the bottom cover. The tab portions 82, 83 lie adjacent, but in offset relation, with respect to the adjacent tab 40 on the lower side edge portion of the wafer carrier so as to facilitate a person simultaneously engaging and squeezing both of the tab portions 83 and 40 and assuring that the snap fit has been completed in applying the bottom cover onto the carrier. Ordinarily the bottom cover 18 is applied to the carrier by laying the bottom cover 18 on a support table, then the carrier 16 is placed upon the bottom cover and pressed so as to secure the carrier 16 and cover 18 together in a snap fit. If the wafers W are already in the carrier, the wafers will be lifted by the bottom cover 18 off the offset portions 26, 27 of the sidewalls 19, 20. Bottom cover 18 may also have a pair of symmetrically located tabs on the side edge portion 72 opposite tab portion 82 and 83.
In removing the bottom cover 18 from the wafer carrier, one corner portion of the bottom cover is flexed, as above described in connection with the top cover, and the bottom cover 18 may thereby be progressively disengaged from the enlarged lower rim portions 45-48 of the wafer carrier for removing the bottom cover. The rim portions 78-81 of the bottom cover engage and embrace the rim portions 45-48 of the wafer carrier and establish a substantially hermetic sealing relation between the bottom cover 18 and the wafer carrier to prevent migration of air, moisture and particulate into or out of the interior 57 of the wafer carrier. Whereas the bottom cover rim portions 78-81 lie substantially in a plane, portions 78.1, 79.1 of the rim portions 78, 79 extending along the side edge portions 72 of the bottom cover, are diverted out of the plane of the remainder of the bottom cover rim portions to conform to the shape of the portions 50 of the rim portions 45, 46 which diverge out of the planes of the rim portions on the wafer carrier and pass over the index notches 49 in the foot panels 30, 31 of the wafer carrier.
The bottom cover 18 also has outwardly protruding lip portions 84 protruding outwardly all around the periphery of the bottom cover except at the tabs 82, 83 to add strength to the bottom cover. Similarly, the top cover 17 has outwardly protruding lip portions 85 protruding outwardly from the edge portions of the top cover all the way around the periphery of the top cover except at the tabs 70, 71 to provide additional strength to the top cover.
Referring to FIG. 13, the container 15 is intended to be used with its end wall 22 with the H-bar 54 engaged with an interface on processing equipment. The top cover 17 thus in use may have different orientations than that shown in FIG. 1 such as where the top cover 17 and bottom cover 18 are vertically positioned as in FIG. 13. In this orientation the wafers (not shown) are horizontally orientated and the top cover 17 is functionally a side cover 17.1.
The use of the terms top, end, bottom, and side in the claims are used only for purposes of showing the relative positioning of the elements of the invention with respect to each other and are not to be interpreted to restrict the scope of the claims with respect to differently oriented containers 15.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention. | The present invention is a shipping container for safely storing articles such as semiconductor wafers. The shipping container has two sidewalls sealingly connected to two end walls to form a generally rectangular interior wafer confinement area. A top cover and a bottom cover are removably attached to the container to protect the wafers during shipping and storage and provide access to the wafers for processing. The wafers are securely held in place in the carrier by a cushioning means to prevent damage to the wafers. Furthermore, the wafers are locked into place to prevent contamination by the wafers generating particles in the wafer confinement area by rubbing against the carrier. The cushioning means for accommodating the flexing of the cover supports and suspends wafers in the wafer confinement area. The cushioning means extends from the top cover and has a plurality of wafer engaging edges. Each edge is formed in a convex arcuate shape with respect to a centerline of the carrier. The arcuate shape may be formed by an initial arcuate shape in the cover of the shipping device or an arcuate shaped fin extending from the cover of the shipping device. The cushioning means has a configuration to compress when engaged by the wafer to secure the wafer while spacing it from the top cover. The cushioning means may have a continuous wafer engaging edge along the length of the fin or it may be separated into wafer engaging tabs or fingers, each tab or finger individually engaging a wafer. The bottom cover may also have a cushioning means engaging and spacing the wafers from the bottom cover. The structure of the cushioning means on the bottom cover is designed to bend outwardly to lock the wafers from rotating in the shipping device. | 7 |
This application is a continuation of application Ser. No. 07/612,849 filed Nov. 14, 1990, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor sensor such as semiconductor acceleration sensors, semiconductor flow sensors and semiconductor micro-valves, and a method of making the same.
2. Description of the Related Art
In semiconductor sensors such as semiconductor acceleration sensors, semiconductor flow sensors and semiconductor micro-valves, a silicon semiconductor substrate is selectively etched to provide a thin portion or a penetrating aperture therein. As a technique of etching such a silicon semiconductor substrate, there has been employed an electrolytic etching method using caustic potash, which utilizes a difference in electrolytic potentials due to the conductivity types of the semiconductor substrate. FIG. 1 shows etching characteristics obtained when N-type and P-type silicon semiconductor substrates having a (100) plane are electrolytically etched using the caustic potash. In FIG. 1, the ordinate indicates the electric current, and the abscissa the voltage, respectively. As is apparent from FIG. 1, in the case of the N-type semiconductor, the etching proceeds until the voltage reaches about 2 V. When the voltage exceeds 2 V, the etching is stopped. On the other hand, in the case of the P-type semiconductor, the etching proceeds until the voltage rises to about 4 V, but the etching stops when the voltage exceeds 4 V. Thus, if the voltage is set at 3 V, the N-type semiconductor is not etched, while the P-type semiconductor is etched.
By means of this anisotropic etching, the thin portion or penetrating aperture is formed in the silicon semiconductor substrate, thus providing a semiconductor sensor. FIG. 2 shows a structure of a conventional semiconductor acceleration sensor, which comprises a P-type silicon semiconductor substrate 11, an N-type semiconductor region 13 serving as a thin portion (diaphragm) and formed in a major surface of the P-type semiconductor substrate 11, a P-type semiconductor region 14 serving as a resistor and formed in the N-type semiconductor region 13, an electrode wiring layer 15 formed on the P-type semiconductor region 14 through an insulating layer 12, a funnel-shaped cavity 16 made from the bottom surface of the semiconductor substrate 11 to form the thin portion, and a funnel-shaped aperture 17 penetrating in the thickness direction of the substrate 11 so as to surround both side surfaces of the thin portion.
The funnel-shaped aperture 17 is formed by etching the bottom surface of the semiconductor substrate 11 so as to penetrate the substrate 11. The angle between the bottom surface of the semiconductor substrate 11 and the wall defining the aperture 17 is about 60°. Thus, as is shown in FIG. 3, when the thickness of the semiconductor substrate 11 is given by h, the diameter of the funnel-shaped aperture 17 becomes 1.2 h. As a result, it is not possible to reduce the size of the semiconductor sensor.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a semiconductor sensor for eliminating the disadvantage of the prior art.
Another object of the present invention is to provide a method of making a semiconductor sensor, wherein a funnel-shaped penetrating aperture and a diaphragm are simultaneously formed.
According to an aspect of the present invention, there is provided a semiconductor sensor with a compact structure, which comprises a semiconductor substrate, a semiconductor diaphragm integrally formed with the semiconductor substrate, and a penetrating aperture formed in the semiconductor substrate so as to surround desired sides of the diaphragm. The aperture has a first funnel-shaped aperture and a second aperture joined to the first funnel-shaped aperture. A cavity for defining the diaphragm is provided when the semiconductor substrate is subjected to electrolytic etching to form the second funnel-shaped aperture therein.
According to another aspect of the present invention, there is provided a method of making the semiconductor sensor according to the design incorporated in the first aspect of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel and distinctive features of the invention are set forth in the claims appended to the present application. The invention itself, however, together with further objects and advantages thereof may best be understood by reference to the following description and accompanying drawings in which:
FIG. 1 is a graph showing etching characteristics obtained when a silicon semiconductor substrate is electrolytically etched, using an electrolytic etching solution of caustic potash;
FIG. 2 is a cross-sectional view showing a conventional semiconductor acceleration sensor;
FIG. 3 is an enlarged cross-sectional view showing a funnel-shaped penetrating aperture in the conventional semiconductor acceleration sensor;
FIG. 4 is an enlarged cross-sectional view showing a semiconductor acceleration sensor according to an embodiment of the present invention;
FIG. 5 is a plane view of the semiconductor acceleration sensor;
FIGS. 6A to 6D are cross-sectional views illustrating a process of making the semiconductor acceleration sensor according to the embodiment of the invention;
FIG. 7 is an enlarged cross-sectional view showing a funnel-shaped penetrating aperture in the semiconductor acceleration sensor according to the embodiment of the invention; and
FIGS. 8A to 8C are enlarged cross-sectional views showing various types of funnel-shaped penetrating apertures in the semiconductor sensors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A semiconductor acceleration sensor according to an embodiment of the present invention will now be described with reference to FIGS. 4 and 5.
A semiconductor acceleration sensor 20 includes a P-type silicon semiconductor substrate 21, an N-type semiconductor region 23 serving as a thin portion (diaphragm) in a major surface of the P-type semiconductor substrate 21, P-type semiconductor regions 24 in the N-type semiconductor region 23 and serving as resistor layers, electrode wiring layers 25 above the P-type semiconductor regions 24 through an insulating layer 22, and a funnel-shaped cavity 26 integrally connected with the bottom surface of the semiconductor substrate 21 and defining the thin portion. A funnel-shaped aperture 27 penetrating the substrate 21 in the thickness direction so as to surround the thin portion includes an upper aperture 127 formed from the top surface of the semiconductor substrate 21 and a lower aperture 227 formed from the bottom surface of the substrate 21. As is shown in FIG. 5, in the semiconductor acceleration sensor 20, four P-type semiconductor regions 24 serving as resistor layers are provided in the N-type semiconductor region 23 serving as the diaphragm in order to provide a bridge circuit. Though not shown, bonding pads are formed at an end portion of the semiconductor substrate 21. The bonding pads are connected to end portions of the resistor layers 24 through the electrode wiring layers 25.
A method of making the semiconductor acceleration layer 20 will now be described with reference to FIGS. 6A to 6D.
As is shown in FIG. 6A, a P-type silicon semiconductor substrate 21 having a thickness of 300 microns and having a (100) or (110) crystal plane is prepared. Oxide films 122 and 222 are formed on both surfaces of the semiconductor substrate 21. An N-type impurity is selectively introduced into the semiconductor substrate to provide an N-type semiconductor region 23 having a thickness of 60 to 80 microns therein. Then, a P-type impurity is introduced into the N-type semiconductor region 23, thereby forming a plurality of P-type semiconductor regions 24 serving as resistors. For example, each of the P-type semiconductor regions 24 has a depth of about 3 microns, a length of about 80 microns, and a width of about 20 microns.
As is shown in FIG. 6B, after an opening with a predetermined size is formed in the oxide film 122, electrolytic etching with use of an electrolyte of caustic potash is carried out to form an upper funnel-shaped aperture 127 in the substrate 21. In this case, the depth of the funnel-shaped aperture 127 is set so as to be equal to the thickness of the N-type semiconductor region 23.
Subsequently, as is shown in FIG. 6C, the oxide film 122 on the P-type semiconductor region 24 is selectively removed to provide electrode wiring layers 25 at both end portions of the P-type semiconductor region 24.
Then, as is shown in FIG. 6D, openings of predetermined sizes are made in the oxide film 222 formed on the bottom surface of the semiconductor substrate 2 at positions corresponding to the funnel shaped aperture 127 and the N-type semiconductor region 23. In the same manner as mentioned above, the exposed semiconductor substrate 21 is selectively removed by the electrolytic etching, thereby forming a lower funnel-shaped aperture 227 and a cavity 26 therein. In this case, the funnel-shaped apertures 127 and 227 are connected with each other, and a penetrating aperture 27 is formed. In addition, a diaphragm or a thin portion (corresponding to the N-type semiconductor region 23) is formed by the cavity 26. As a matter of course, in the described etching steps, the semiconductor substrate 21 is coated with an etching mask such as wax materials.
As is clear from FIG. 6D, the angle between the bottom surface of the semiconductor substrate 21 (having a length of about 6 mm) and the wall defining the aperture 227 is about 60°. The diameter of the opening of the aperture 127 is about 0.35 mm, that of the opening of the aperture 227 is about 0.5 mm, and that of the opening of the cavity 26 is about 1 mm, respectively.
FIG. 7 is an enlarged cross-sectional view showing the penetrating aperture 27 consisting of the funnel-shaped apertures 127 and 227 shown in FIG. 6D. When the depth of the aperture 127 is given by h/4 (h: the thickness of semiconductor substrate 21), the diameter of the opening of the funnel-shaped aperture 227 becomes 0.9 h. Thus, the size of the penetrating aperture 27 can be reduced, as compared with the prior art shown in FIG. 3 wherein only the bottom surface of the substrate is etched to form the funnel-shaped aperture.
The funnel-shaped apertures 127 and 227 formed at both side portions of the diaphragm serve as buffers against mechanical and thermal shock.
Furthermore, as is shown in FIGS. 8A to 8C, penetrating apertures provided by upper and lower funnel-shaped apertures 127 and 227 having various configurations, which are different in the diameter and depth may be formed in the semiconductor substrate, and diaphragms having the different thickness, that is, the different depth may also be provided.
As has been described above, since the penetrating aperture in the semiconductor substrate is provided by upper and lower funnel-shaped apertures which are formed from both surfaces of the substrate by means of etching, the size of the penetrating aperture can be reduced, and the lower funnel-shaped aperture and the cavity can be simultaneously formed with high precision. In addition, by changing the etching amount of the top and bottom surfaces of the substrate, the thickness of the diaphragm can be controlled. Therefore, high sensitivity semiconductor sensors with the small size can be obtained with a high yield.
It is further understood by those skilled in the art that the foregoing description is preferred embodiment of the disclosed device and the method and that various changes and modifications may be made in the invention departing from the spirit and scope thereof. | A semiconductor sensor with a compact structure is provided, which comprises a semiconductor substrate, a semiconductor diaphragm integrally formed with the semiconductor substrate, and a penetrating aperture formed in the semiconductor substrate so as to surround desired sides of the diaphragm. The aperture has first and second funnel-shaped aperatures whose intersecting conic sections open toward opposite directions. A cavity for defining the diaphragm is provided when the semiconductor substrate is subjected to electrolytic etching to form the second funnel-shaped aperture therein. | 6 |
FIELD OF INVENTION
The invention relates to the assessment and clean up of soil and ground water contamination and specifically to an improved method for construction of ground water monitoring and remediation wells.
BACKGROUND OF THE INVENTION
Contaminants released at the ground surface migrate downward through unsaturated soils (also known as vadose soils) until they reach the water table (the top of the saturated zone). In migrating downward the contaminants usually encounter horizontally-oriented distinct soil horizons or strata that, because of varying hydraulic conductivities, greatly affect the rates and directions of contaminant movement. These stratigraphic variations also affect contaminant movement in the saturated zone. Removal or remediation of soil and/or ground water contaminants is extremely difficult, and is made more so if the contaminant distribution is complicated by variable stratigraphy.
Contaminant Assessment Techniques: Contaminant distribution in unsaturated sediments is usually accomplished by the drilling of boreholes in the area in and around a suspected chemical release and the collection and subsequent chemical analysis of soil samples to determine the amounts, if any, of the released chemical at the location of the borehole (Fetter, 1988). Ground water contamination is usually assessed or characterized by installing sections of perforated PVC or steel pipes and filter material known as ground water monitoring wells into boreholes that extend below the water table, and then collecting and analyzing ground water samples from the monitoring wells. Because the migration of contaminants dissolved into ground water is greatly controlled by the physical and chemical characteristics of the soil strata, it is essential that individual permeable or transmissive saturated soil strata (known as water-bearing zones when they are limited in thickness and areal extent) be sampled by a well constructed only in the zone of interest (Fetter, 1988). If more than one zone is intersected by the monitoring well screen, then two common problems result: 1) it is difficult to accurately assess the concentration of the contaminant in that particular zone because the long well screen allows water from an overlying or underlying clean zone to dilute the water from the contaminated zone, and 2) the longer screen allows the contaminant to migrate down (or up) the wellbore, thereby contaminating a previously clean zone.
Contaminant Remediation Methods: Contaminants can often be removed in-place or "in-situ". In-situ remediation techniques usually rely on drawing out or extracting contaminants from saturated or unsaturated soils or by injecting contaminant-degrading substances (most often biological agents) into soils. Similar to contaminant assessment techniques, it is extremely important that the extraction or injection be focussed on individual soil strata that contains the contaminants. Otherwise, significant resources are expended in treating clean zones. For this reason, most remediation programs use extraction wells made of short sections of perforated conduit placed into carefully selected individual soil horizons.
Highly specialized techniques are used to extract contaminants from both unsaturated and saturated sediments. Techniques used to clean up saturated sediments are known as "ground water" remediation techniques and those used to treat unsaturated sediments are known as "soil" remediation techniques. Typical ground water remediation approaches for treating organic contaminants are Ground Water Extraction" (GWE) in which pumps are installed in wells and are then used to withdraw contaminated ground water, "Air Sparging", which combines air injection into saturated soil and air withdrawal above the air injection point, and "Bioremediation" which promotes the growth of contaminant-degrading microorganisms in the contaminated strata. One of the most common soil remediation techniques is Soil Vapor Extraction (SVE), (see U.S. Pat. No. 4,593,760 and Grasso, 1993) whereby a high powered vacuum blower connected to a vadose-zone well and is used to remove vapor-phase contaminants from unsaturated soils. All of these techniques are most effectively applied using short-screen extraction or injection wells that are constructed to focus on individual contaminated zones.
Removal of Contaminants from Multiple Horizons: Although occasionally subsurface contaminants are confined to only one narrow soil horizon, more commonly the contaminants are distributed in multiple horizons that each exhibit differing hydraulic properties. For this reason, site assessments and remediations typically require installation of several sets of vertically displaced or "nested" monitoring and extraction wells that allow the contaminants in each individual zone to be individually assessed and remediated. Current industry practice constructs nested wells in one of two ways: 1) each zone is penetrated by an individual borehole, a single perforated screen is then placed into the borehole to intersect only the zone of interest, and the next deeper (or shallower) horizons are then assessed with an entirely separate borehole and well located within a few feet of the initial well (see Boyle, 1991), or 2) a single large-diameter borehole that is typically a minimum of 4 inches and a maximum of 24 inches, but more likely 6 inches to 12 inches, is drilled through the entire thickness of contaminated strata and individual, vertically offset well screens are then placed into the large-diameter borehole, with the interval between screens sealed with clay or cement to prevent cross-contamination or leakage between the screened sections.
Disadvantages of Current Practices: The two methods described above present significant disadvantages. The principal disadvantage of Method 1--unique boreholes for each screened interval--is cost. The largest portion of the cost of any well installation effort is in the time and material needed to drill the borehole. The need for a unique borehole for each screened interval dramatically increases costs. A second disadvantage of this approach is the increased amount of ground surface area needed to drill multiple wells. Not only does the need for a larger surface area complicate the placement of the wells (since most contaminated sites are industrial or commercial properties and are densely improved with structures, machinery or other surface obstructions), but it also increases costs due to the need for oversized vaults or for duplicated well head improvements.
The primary disadvantage of using Method 2--multiple, side-by-side completions in a single, large diameter borehole--is the potential for this approach to produce cross-contamination. Placement of two or more casings side-by-side in a single borehole requires the installation of a sealant between the screened intervals to prevent pressure leaks or fluid migration from one screened section to the other(s). It is very difficult to effectively place these seals because 1) borehole walls are typically unstable allowing sidewall slough to either block placement of the seals or to create high permeability sections within a sealed interval, and 2) it is very difficult to ensure that an adequate seal is placed between the side-by-side well casings. To further describe this second problem, it is equally as important to place the sealant between the individual casings as it is to place it between the casings and the borehole wall. It is virtually impossible to prevent the casings from coming into contact with one another as they are placed into the borehole and as they are being sealed. Even when using spacers between the casings, most installations cause the dual casings to spiral downward into the borehole, resulting in a "helix-like" configuration that allows substantial contact between the individual casings. Casings that are in contact with each other cannot provide adequate sealing over the interval that they touch because the sealants must typically occupy at least a 2 inch-thick area around the individual casings to provide an adequate barrier to fluid flow. For this reason, most governmental authorities charged with overseeing well installation activities require at least a 2 inch thick seal. Because of the high liabilities associated with remediation of hazardous material releases, the potential for cross contamination caused by the poor sealing characteristics of side-by-side-casing nested wells is a major drawback to their use.
SUMMARY OF THE INVENTION
The objects of this invention are to provide a device that allows the withdrawal or injection of fluids into or out of geological stratum at lower cost, with less area needed for installation and with improved borehole seal integrity than is available using current industry practices. These objects are further described below.
Reduced Cost: Using a coaxial construction technique reduces cost because: 1) only a single, smaller borehole that ranges from 4 to 18 inches in diameter, but more commonly 6 to 12 inches in diameter is needed rather than multiple individual boreholes or a larger diameter single borehole. Cost is further reduced compared to the multiple borehole approach because the well heads can be manifolded with simple fittings and because all well head improvements can be contained in a single vault, placed either above or below ground surface. Cost is also reduced using this device because the construction procedures are much simpler than those for traditional side-by-side nested well construction. By lowering individual well casings sequentially over the previously installed casings the device allows greater separation between the single casing and the borehole wall. This greater separation prevents the borehole sidewall failure or entanglements between the multiple casings that often accompany the construction of traditional side-by-side wells.
Reduced Installation Area: The coaxial installation requires significantly less surface area for the well vault compared to the multiple borehole technique because all the casings are contained in a single borehole, allowing use of a small (often 8 by 36 inch but more commonly 16 by 24 inch) well head vault or a single above-ground completion commonly known as a "stovepipe" completion. The small surface area needed allows coaxial wells to be used in highly congested areas.
Improved Borehole Seal Integrity: The greatest advantage to the use of the co-axial construction is the easier and more secure well sealing it allows between screened intervals. Seals are placed around co-axial wells in a manner identical to that used for traditional single-completion wells, with the sealing material only needing to fill a single, uninterrupted void space between the well casing and the borehole wall. Since only the space between the outer conduit of a co-axial well and the borehole wall needs to be filled with sealant, (traditional side-by-side nested wells require this space as well as the gap between the individual casings to be sealed) co-axial wells are much more likely to maintain their integrity and to prevent cross-contamination between zones compared to traditional nested wells.
In accordance with the above objects and those that will become apparent below, the device comprises:
an inner conduit with an outer surface and a distal first end and a proximal second end, a seal closing the distal first end and a plurality of perforations adjacent to the distal first end, said inner conduit positioned axially within a borehole with an inner wall traversing an upper sub-surface stratum, and at least part of a lower stratum, each stratum with an upper and a lower border. Said conduit positioned such that the distal first end and adjacent perforations are located within the lower stratum;
a distal granular filtration material surrounding the perforated interval of said inner conduit and extending adjacent to the proximal border of the most distal stratum, said filtration material extending axially from the outer surface of the inner conduit to the inner wall of the borehole;
a distal barrier plug affixed to the outer surface of the inner conduit and distal from the distal end of the inner conduit and adjacent perforations and proximal to the proximal border of the most distal stratum, said barrier plug extending from the proximal border of the aforementioned filtration material to the distal border of the proximal geologic stratum and axially from the outer surface of the inner conduit to the inner wall of the borehole and plugging the borehole thereby;
an outer conduit positioned concentric with and surrounding the inner conduit, the outer conduit having an outer surface, a distal end and a proximal end, a seal attached to the distal end of the outer conduit surrounding the inner conduit and closing the distal end of the outer conduit, and a plurality of perforations adjacent to the distal end, the outer conduit projecting such that the distal end and adjacent perforations traverse an adjacent stratum above the lower traversed stratum;
a second granular filtration material surrounding the perforated interval of said outer conduit and extending adjacent to the proximal border of the most proximal stratum, said filtration material extending axially from the outer surface of the outer conduit to the inner wall of the borehole;
a second barrier plug affixed to the outer surface of the second conduit and distal from the distal end and adjacent perforations and proximal to the upper border of the upper stratum, said barrier plug extending axially from the second conduit to the inner wall of the borehole and plugging the borehole thereby; and,
the proximal ends of both conduits adapted to accept pumping remediation devices.
Further objects and advantages of this invention will become apparent from a consideration of the drawings and ensuing description.
DESCRIPTION OF DRAWINGS
For a further understanding of the objects and advantages of the present invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings in which like parts are given like reference numerals and wherein:
FIG. 1 is a cross-sectional diagram drawn parallel to the longitudinal axis of the device showing the main components of a device constructed in accordance with the principals of the present invention.
FIG. 2 is a cross-sectional diagram drawn through line A-A' of FIG. 1 perpendicular to the longitudinal axis of the device showing the relationships between the conduits and sealants adjacent to the proximal portion of the device.
FIG. 3 is a cross-sectional diagram drawn through line B-B' of FIG. 1 perpendicular to the longitudinal axis of the device showing the relationships between the conduits and the sealants adjacent to the distal portion of the device.
FIG. 4 is a perspective drawing showing the seal that separates the distal and proximal conduits.
DETAILED DESCRIPTION OF THE INVENTION
The device consists of the following components:
A borehole 1 with a diameter between 4 and 36 inches but more typically between 8 and 12 inches, drilled using any one of a wide variety of drilling techniques, penetrates the ground surface 2 to the distal limit of the most distal geologic stratum of interest 3.
A first inner conduit 4 that ranges in size from 1/2 inch to 18 inches, but is typically between 1 and 3 inches, occupies the approximate center of the borehole. The portion of this first conduit that is most distal from the ground surface contains a plurality of perforations 5 that penetrate the entire thickness of the conduit, allowing fluids or gases to move through the conduit wall. A sealing device 6 encloses the distal end of the conduit 4, adjacent to the perforations 5. The sealing device is attached to the conduit by 1) either sliding over the outer surface of the distal end of the conduit such that friction between the inner surface of the sealing device and the outer surface of the conduit maintains the position of the sealing device and prevents fluid or gas from entering the conduit, or by 2) typical helical male/female screw threads, with the distal end of the conduit containing either the male portion of the set and the sealing device the female, or the opposite.
A granular filtration material 7 surrounds the perforated interval of the conduit and extends a short distance, which is often between 2 inches and 20 ft but more typically between 4 and 24 inches, beyond the most proximal of the conduit perforations.
A first solid or semi-solid barrier seal 8 occupies the space between the conduit and the inner surface of the borehole wall in the area between the most proximal limit of the filtration material and the distal limit of the more proximal geologic stratum, sealing the borehole between.
A second larger diameter conduit 9 that can range in size from 1 inch to 48 inches, but is typically between 2 inches and 16 inches, or even more commonly ranges from 3 to 8 inches in diameter, concentrically surrounds the first inner conduit immediately above the most proximal end of the first barrier seal. The distal portion of this conduit is penetrated by a plurality of perforations 10 that penetrate the entire thickness of the conduit. The perforations are positioned adjacent to the proximal geologic stratum of interest 11.
A second sealing device 12 seals the distal end of this second and proximal conduit. This second sealing device is sealingly connected to both the first, distal conduit and to the second, more proximal conduit. The sealing device contains a nominally round hole that is slightly larger in diameter than the outer surface of the first or inner conduit, allowing it to seal frictionally against the inner conduit. It seals either frictionally or with helical male/female screw threads against the second or outer conduit.
A second granular filter 13 surrounds the perforated interval of the more proximal conduit and extends a short distance, which is often between 2 inches and 20 ft but more typically between 4 and 24 inches, beyond the most proximal of the second conduit perforations.
A second solid or semi-solid barrier seal 14 occupies the space between the second conduit and the inner surface of the borehole wall in the area between the most proximal limit of the second filtration material and the ground surface.
Device Fabrication Procedure: The procedure used to construct the device consists of the following main tasks, described sequentially:
1) A first small diameter conduit 4 is assembled at the ground surface. The conduit ranges in size from 1/2 inch to 18 inches (but is typically between 1 and 3 inches), and is composed of either metal, plastic, Polyvinyl chloride (PVC), Teflon, or other malleable, flexible synthetic material. A second section of conduit 5 containing a plurality of grooves or perforations that penetrate the entire thickness of the conduit, allowing fluids or gases to move through the conduit wall (3 on FIG. 1) is then attached to one end of the first conduit using friction or screw threaded male/female couplings. The length of this perforated section coincides with the thickness of the most distal geologic stratum of interest 3 traversed by the borehole. The perforation are often between 0.005 and 0.5 inches in thickness, but are more commonly between 0.01 and 0.3 inches in thickness. A sealing device 6 is attached to the open end of the perforated section of conduit, such that the sealing device seals the distal end of the conduit from the atmosphere, and once it is inserted into the borehole, from the earth. The sealing device is attached to the conduit by 1) either sliding over the outer surface of the distal end of the conduit such that friction between the inner surface of the sealing device and the outer surface of the conduit maintains the position of the sealing device and prevents fluid or gas from entering the conduit, or by 2) typical helical male/female screw threads, with the distal end of the conduit containing either the male portion of the set and the sealing device the female, or the opposite.
A second larger diameter conduit 9 that can range in size from 1 inch to 48 inches, but is typically between 2 inches an 16 inches, or even more commonly ranges from 3 to 8 inches in diameter (6 FIG. 1), is also assembled at the ground surface. A section of larger diameter conduit 10 containing a plurality of grooves or perforations that penetrate the entire thickness of the conduit has also been previously attached to the distal portion of the larger diameter conduit using friction or screw threaded male/female couplings. The length of this perforated section has been previously determined to coincide with the thickness of the next most proximal geologic stratum of interest 11 transversed by the borehole. A second sealing device 12 is also sealingly attached to the distal end of this second or more proximal conduit either frictionally or with helical male/female screw threads. This second sealing device is composed of either metal, plastic, rubber, PVC, Teflon or other material and contains a nominally round hole that is slightly larger in diameter than the outer surface of the first or inner conduit.
2) A borehole 1 with a diameter between 6 and 48 inches but more typically between 8 and 12 inches, is drilled to the distal limit of the most distal geologic stratum of interest 3. Drilling techniques that are typically used include, but are not limited to, augering and rotary. Augering involves spinning a solid or hollow pipe, that has flat blades arranged in a helical screw configuration around its outer surface, into the ground. The helical blades cut into the underlying soils and then transport them to the ground surface. Rotary techniques create a borehole by circulating either air or a viscous drilling fluid through a leading cutting head attached to a hollow inner pipe that is advanced into the earth. The air or fluid is pumped into the hollow interior of the drill pipe to lubricate the cutting head as it advances and to transport the soil or rock particles removed during the drilling process to the ground surface.
3) Once the borehole is open and stable, the inner small diameter conduit 4 and 5 is placed into the approximate center of the borehole such that the distal end of the conduit is positioned adjacent to the distal limit of the most distal geologic stratum of interest 3.
4) A granular filtration material 7 is then placed to surround the perforated interval of the conduit and to extend a short distance, which is often between 2 inches and 20 ft but more typically between 4 and 24 inches, beyond the most proximal of the conduit perforations.
5) A liquid with chemical properties that cause it to progressively harden to a solid or a semi-solid is then pumped or placed into the space between the conduit and the inner surface of the borehole wall in the area between the most proximal limit of the first filtration material and the distal limit of the more proximal geologic stratum of interest. Once this liquid hardens it will form the first or most distal solid or semi-solid barrier seal 8. A layer of clay or expansive material may be placed on top of the granular filter 7 before the sealing liquid is placed to prevent the liquid from penetrating into the granular filter.
6) The second larger diameter conduit 9 is then placed into the borehole such that it concentrically surrounds the first inner conduit 4, with its distal end immediately above the proximal end of the distal barrier seal 8. The distal portion of the conduit is penetrated by a plurality of perforations and the sealing device 12 attached to the distal end of the outer conduit now abuts the outer surface of the inner conduit, thereby sealing the interior of the outer conduit from the earth.
7) The more proximal granular filter material 13 is next placed to surround the perforated interval of the outer conduit 10 and extend a short distance, which is often between 2 inches and 20 ft but more typically between 4 and 24 inches, beyond the most proximal of the outer conduit's perforations.
8) A liquid with chemical properties that cause it to progressively harden to a solid or a semi-solid is then pumped into the space between the outer conduit and the inner surface of the borehole wall in the area between the most proximal limit of the second filtration material and the ground surface 2. Once this liquid hardens it forms the more proximal solid or semi-solid barrier seal 14.
USE OF THE INVENTION
Remediation--Vadose Zone Only: The device can be used as a remediation well to remove volatile contaminants from two or more distinct unsaturated geologic horizons. The contaminants are removed by attaching an air moving device, commonly referred to as a "vacuum blower", to each of the conduits protruding from the top of the borehole using a manifold that allows either individual sampling and control of flow rates from each conduit or uncontrolled removal from both conduits. The blower is then activated causing circulation of clean air through the mass of contaminated soil and then up and out of the casings. The vapor-phase contaminants in the circulating air are either removed from the air stream using one of many available techniques commonly known to those in the industry or are discharged to the atmosphere. Extraction of contaminated soil vapor using the device allows the flow out of individual geologic stratum transverse by the perforated portions of the device to be individually controlled.
Remediation--Ground Water Only: The device can be used to remediate or cleanup contaminated ground water by inserting or attaching pumping devices to the proximal portions of both conduits and then activating the pumping devices such that contaminated ground water in drawn into the conduits through the perforated portions of the conduits and then up and out of the conduits. The removed ground water is either treated at ground surface using any one of a wide variety of treatment methods commonly known to those in the industry or is discharged without treatment. Extraction of contaminated ground water using the device allows the flow out of individual geologic stratum transverse by the perforated portions of the device to be individually controlled.
Remediation--Vadose Zone and Ground Water Simultaneously: The device can be used to remediate or cleanup contaminated soil and ground water simultaneously by constructing the device with the distal perforated section below the water table and the proximal perforated section above the water table. In this configuration the inner or distal conduit can be used to either withdraw water as described above or to inject clean air into the contaminated geologic stratum. Injecting clean air in this manner removes or degrades contaminants in the water and bound to the soil through volatilization or through increasing the rates of contaminant-degrading biological processes. Volatilization of contaminants occurs when the clean air comes in contact with the contaminated soil or water, there by inducing a concentration gradient that draws the contaminant out of the water or soil and into the air. The now-dirty air rises through buoyancy to above the water table where it either migrates away without treatment of is captured by an air stream induced by a simultaneous vapor extraction effort described below. Contaminated soils are cleaned by attaching a vacuum-inducing device to the proximal, outer conduit, and thereby inducing air circulation through the contaminated soils. The contaminant vapors in the soil (and the additional contaminant vapors generated by the volatilization mechanism described above) are removed through the proximal outer conduit and are either discharged to the atmosphere of are treated above ground. Use of the device in this manner allows the flow out of or flow into individual geologic stratum transverse by the perforated portions of the device to be individually controlled.
Ground Water Monitoring/Assessment: The device can be constructed to determine the quality of the ground water transverse by the individual saturated geologic stratum. The only modification to the device described above is the placement of at least one of the perforated sections below the water table and the installation of a third sampling conduit into the space between the inner and outer conduits. The distal portion of the third conduit is perforated to allow infiltration of water. The inner most distal conduit is sampled by inserting or attaching a purging device to the proximal end of the inner conduit, and then activating or using the purging device to remove an appropriate volume of water, which is then collected for analysis in accordance with standard industry procedures. Similarly the outer or proximal conduit can be used for assessing water quality if the perforated section of the upper conduit is wholly or partially submerged below the water table. In this application the third conduit installed between the inner and outer conduit described above is used to collect the sample. It is also possible, although more problematic, to collect water samples from the outer conduit without the use of the third conduit.
CONCLUSION, RAMIFICATIONS AND SCOPE OF INVENTION
While the above description contains many specifications, these should not be construed as limiting the scope of the invention, but rather as only one application of the invention. Many variations are possible. For example numerous variations and applications are easily achieved by changing the size, placement, materials or use of the device. Accordingly, the scope of the invention should not be determined by the illustrated embodiments, but rather by the appended claims and their legal equivalents. Examples of variations to the embodiment illustrated above include:
Multiple Completions: The device can be constructed with an unlimited number of conduits. However, restrictions imposed by drilling technologies and the difficulty of transporting fluids through small annular openings makes installation of more than three to four conduits in a single borehole difficult.
Drilled Borehole with Pushed Drive Point: Combination drilling techniques can be used to install multiple completion wells co-axially. Using this approach, the borehole is first drilled to the depth of the distal end of proximal geologic stratum of interest. A steel rod whose distal portion contains perforations is then placed into the open borehole and is hydraulically advanced to the desired position beyond the distal portion of the proximal geologic stratum of interest. The distal portion of the borehole is then sealed using a progressively hardening liquid and a larger diameter upper conduit is then lowered over the inner conduit and is sealed in place with a granular filter pack and a solid or semi-solid sealant.
Angled and Horizontal Completion: The device can also be installed in a horizontal or angled configuration similar materials and procedures.
Retrofitting a Single Completion Well Into a Multiple-completion Coaxial Well: A traditional single completion vadose zone or ground water monitoring well can be easily converted into a double or multiple completion well by performing the following procedures:
1) Drilling a small hole in the bottom cap of the existing well. The hole diameter should be slightly larger than the diameter of the inner drive rod to be inserted into the middle of the existing well.
2) Placing a steel drive point inside the drilled hole and then hydraulically pushing the drive point to the desired position beyond the distal limit of the existing well.
3) Removing the drive rods and sealing the distal portion of the existing well with a barrier seal. | A device for use in remediation of a multiplicity of adjacent subsurface geologic strata is described. The device comprises co-axially or concentrically positioned conduits installed in a borehole with an inner conduit extending below an outer conduit through a seal attached to the distal end of the outer conduit. The distal ends of both the outer, upper and the inner, lower conduits are perforated to allow the flow of liquids or gases through the conduits between ground surface and the geologic stratum adjacent to the perforated sections of both conduits. The annular spaces between the borehole wall and the unperforated portions of both the inner and outer conduits are sealed with impermeable barrier plugs to prevent flow parallel to the borehole axis between the borehole wall and the outer surface of the conduits. The annular spaces between the perforated sections of both conduits and the borehole wall is filled with a permeable granular filtration material. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is claims priority to U.S. Provisional Application No. 61/585,035, filed on Jan. 10, 2012. The entire disclosure of the prior application is incorporated by reference herein in its entirety.
BACKGROUND
1. Field of the Invention
This invention relates generally to fiber-reinforced polymer composites, preferably containing natural fibers, more preferably coconut coir fibers.
2. Description of Related Art
Fiber-reinforced polymer composites containing synthetic or natural fibers have been used as construction materials in the past. Plastics reinforced with synthetic fibers possess high strength, but are expensive to produce. Unlike synthetic fibers, natural fibers are readily available. However, natural fibers are hydrophilic, which causes them to be incompatible with many hydrophobic polymers, including polyvinyl chloride (PVC) and polyolefins.
Coir is a natural fiber obtained from coconut husks. Coir fibers are strong, lightweight, and abundant. In the past, coir fibers have been used as reinforcement in polymeric composite materials. However, raw coir is normally hydrophilic, rendering them incompatible with polyolefins and PVC. Specifically, raw coir as used in the prior art include coir fibers and coconut pith. While coir fibers are comparatively hydrophobic, pith is very hydrophilic and is incompatible with polyolefins and PVC. Complete separation of coir and pith by physical processes has not been achieved in the prior art.
To overcome incompatibility between coir and a polymer matrix, coir-reinforced composites have been made using hydrophilic resins, including epoxy resins and polyurethanes. In many cases, epoxy resins and polyurethanes have reactive sites, such as epoxide or isocyanate functionalities, which can react with hydrophilic sites on the coir fibers.
Composites made from hydrophilic fibers and/or polymers present the difficulty that they have a tendency to absorb water, rendering them unsuitable for use in outdoor construction. Attempts to overcome this have been made by using polyolefins as matrix polymers in coir-reinforced materials. However, since coir used in the past is hydrophilic, this material has been found to be incompatible with hydrophobic polymers. As a result, coir-reinforced polyolefin composites of the prior art use chemically modified coir. Coir, as used in these composites, has been modified to incorporate hydrophobic groups into the coir structure, increasing compatibility between the coir and the polyolefin.
The current disclosure relates to fiber-reinforced polymer composites containing natural coir fibers and a hydrophobic matrix polymer. Compatibility between the coir fibers and the hydrophobic matrix polymer is increased without requiring chemical modification of the fibers.
SUMMARY
In light of the present need for improved reinforced polymer composites containing natural fibers, a brief summary of various embodiments is presented. Some simplifications and omissions may be made in the following summary, which is intended to highlight and introduce some aspects of the various exemplary embodiments, but not to limit the scope of the invention.
Various embodiments disclosed herein relate to composite boards manufactured from hydrophobic polymers, i.e., PVC or polyolefins, and hydrophobic coconut coir fibers which have been treated to remove coconut pith therefrom. In various embodiments, the composite board is manufactured without any step of chemically modifying coconut coir fibers. In various embodiments, the coconut coir fibers have been treated to remove at least a portion of the coconut pith therefrom. In various embodiments, the coconut coir fibers have been treated to remove substantially all of the coconut pith therefrom.
In certain embodiments, the composite board is manufactured by removing at least a portion of the coconut pith from coconut coir fibers using a cyclonic separator; combining coconut coir fibers with a hydrophobic polymer to form a mixture; and extruding the mixture to form a composite board. In some embodiments, the composite board is manufactured by removing substantially all of the coconut pith from coconut coir fibers using a cyclonic separator; combining coconut coir fibers with a hydrophobic polymer to form a mixture; and extruding the mixture to form a composite board.
Various embodiments relate to a process of preparing a composite board by removing at least a portion of the coconut pith from coconut coir fibers; combining the coconut coir fibers with a polymer to form a mixture, and extruding the mixture to form a composite board. Removal of at least a portion of the coconut pith from coconut coir fibers may be done by abrading the coir fibers to release pith from the coir fibers, entraining the coir fibers and pith in a high-velocity stream of heated air, and separating coir fibers from the air stream in a cyclonic separator. Coir fibers may be collected in a hopper or vessel beneath the cyclonic separator while a high-velocity air stream exiting the cyclonic separator carries the lightweight pith. The hydrophobic polymer may be an olefin homopolymer, an olefin copolymer, polyvinyl chloride, polyvinylidine chloride, polystyrene, or a mixture thereof. The polymer may be virgin polymer, recycled polymer, or regrind polymer. The polymer is preferably polyethylene or polypropylene. The polymer is preferably either virgin polymer or recycled polymer, such as virgin polyethylene, recycled polyethylene, virgin polypropylene or recycled polypropylene.
In various embodiments, the polymer is combined with the coconut coir fibers and mixed in an extruder. The mixture of the coir fibers and the polymer is mixed in the extruder, and the resulting coir fiber-polymer mixture is extruded to form a composite product. The composite product may be a composite board. Alternatively, the composite product may be a plurality of pellets.
Pellets formed from the mixture by extruding may be supplied to a second extruder, and melted in the second extruder. The molten pellets may then be extruded to form a composite board.
Various embodiments of the current disclosure are directed to a composite board which has been manufactured from coconut coir fibers which have been treated to remove at least a portion of the coconut pith therefrom; and a polymeric matrix comprising a polymer selected from the group consisting of olefin homopolymers, olefin copolymers, polyvinyl chloride, polyvinylidine chloride, polystyrene, and mixtures thereof. Preferably, the coconut coir fibers have not been chemically modified. Preferably, the coconut coir fibers have been treated to remove substantially all of the coconut pith therefrom.
In some embodiments, the polymer matrix may include additives which do not chemically modify the fiber structure. These additives may include colorants, i.e., pigments or non-reactive dyes, or plasticizers.
In various embodiments, the polymer matrix for the composite board comprises a thermoplastic material, i.e., polyethylene or polypropylene, in combination with coconut coir fibers treated for removal of pith. The polymer matrix may contain an optional organic filler selected from the group consisting of ramie fibers, bamboo fibers, rice hulls, wheat husks, linen, jute, bagasse, corn husks, and sawdust. The polymer matrix may also contain an optional inorganic filler such as glass fibers, carbon fibers, mineral fibers, silica, alumina, titania, carbon black, nitride compounds, and carbide compounds.
In various embodiments, the polymer matrix for the composite board contains UV stabilizers which reduce the likelihood of the composite board undergoing degradation from exposure to ultraviolet light. Such UV stabilizers include organic light stabilizers, such as benzophenone light stabilizers, hindered amine light stabilizers, and benzotriazoles; and inorganic light stabilizers, such as barium metaborate and its hydrates.
In various embodiments, the polymer matrix for the composite board contains antifungal agents which increase resistance of the board to mold and other organisms. The antifungal agents may be incorporated into the binder of the composite board. Useful antifungal agents include copper (II) 8-quinolinolate; zinc oxide; zinc-dimethyldithiocarbamate; 2-mercaptobenzothiazole; zinc salt; barium metaborate; tributyl tin benzoate; bis tributyl tin salicylate; tributyl tin oxide; parabens: ethyl parahydroxybenzoate; propyl parahydroxybenzoate; methyl parahydroxybenzoate and butyl parahydroxybenzoate; methylene bis(thiocyanate); 1,2-benzisothiazoline-3-one; 2-mercaptobenzo-thiazole; 5-chloro-2-methyl-3(2H)-isothiazolone; 2-methyl-3(2H)-isothiazolone; zinc 2-pyridinethiol-N-oxide; tetra-hydro-3,5-di-methyl-2H-1,3,5-thiadiazine-2-thione; N-trichloromethyl-thio-4-cyclohexene-1,2-dicarboximide; 2-n-octyl-4-isothiazoline-3-one; 2,4,5,6-tetrachloro-isophthalonitrile; 3-iodo-2-propynyl butylcarbamate; diiodomethyl-p-tolylsulfone; N-(trichloromethyl-thio)phthalimide; potassium N-hydroxy-methyl-N-methyl-dithiocarbamate; sodium 2-pyridinethiol-1-oxide; 2-(thiocyanomethylthio)benzothiazole; and 2-4(-thiazolyl)benzimidazole.
The polymer matrix for the composite board may contain additives which help provide strength and scratch resistance to the board surface. Additives which help increase scratch resistance to the board surface include lubricants and very hard mineral fillers, including carbide and nitride ceramics.
The board surface may also include inorganic pigments, organic pigments, or dyes as colorants. The board surface may be embossed with a decorative pattern, i.e., wood grain or imitation stone.
The current disclosure also relates to a method of producing hydrophobic coconut coir fibers by chopping coconut husks to produce raw coconut coir; releasing hydrophilic coconut pith from the coconut coir by abrading the coconut coir; separating the hydrophilic coconut pith from the coconut coir fibers in a cyclonic separator; and recovering hydrophobic coconut coir fibers from the cyclonic separator.
In certain embodiments, hydrophobic coconut coir fibers are prepared by chopping coconut husks to produce raw coconut coir; releasing hydrophilic coconut pith from coconut coir fibers by abrading the coconut coir; drying the coconut pith and the coconut coir fibers in an air stream, preferably a heated air stream; separating the coconut pith from the coconut coir fibers in a cyclonic separator; and recovering hydrophobic coconut coir fibers from the cyclonic separator.
Various embodiments disclosed in the current disclosure relate to building materials prepared using coir fibers having low pith content or no pith content, contained in a matrix binder. In various embodiments, the matrix binder is a thermoplastic or thermosetting polymeric binder. The matrix binder may be a thermoplastic binder. The thermoplastic binder may be a polyester, a polycarbonate, a polyolefin, polystyrene, a copolymer of at least one olefin having from two to twelve carbon atoms and a second vinyl monomer, i.e., styrene, a vinyl ester, a vinyl halide, or an ester of an unsaturated acid; polyvinyl halide, or polyvinylidine halide. The thermoplastic binder is preferably a polyolefin, polyvinyl halide, or polyvinylidine halide, more preferably polypropylene, polyethylene, high density polyethylene, low density polyethylene, linear low density polyethylene, or medium density polyethylene. Composites with thermoplastic binders may be prepared by extrusion molding.
The thermosetting binder may be a phenol-formaldehyde resin, an epoxy resin, or a urea-formaldehyde resin. In various embodiments, coir fiber may be used in a composite having a cement, plaster, or other mineral binder. According to various embodiments, composites with thermosetting binders or mineral binders, i.e., cement binders, may be prepared by compression molding in a press to form large sheets or to form planks or boards.
In various embodiments, the current application is directed to building materials prepared using a composition containing from 5% to 70% by weight of coir fibers prepared by the process described herein; optionally various processing additives, including colorants, i.e., dyes or pigments; fillers; plasticizers, and other additives; with the balance of the composition being a thermoplastic, thermosetting, or mineral matrix binder.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better understand various exemplary embodiments, reference is made to the accompanying drawings, wherein:
FIGS. 1-4 show mills suitable for grinding coir chunks into coir fibers and pith;
FIG. 5 shows a mechanism for entraining coir fibers and pith in an air stream, which may be a heated air stream;
FIG. 6 shows a first embodiment of a cyclonic separator for separating coir fibers from pith;
FIG. 7 shows a second embodiment of a cyclonic separator for separating coir fibers from pith;
FIG. 8 shows an extruder for mixing coir fibers and polymer and extruding the resulting mixture to form pellets; and
FIG. 9 shows an extruder for melting pellets of coir fibers and polymer and extruding the molten pellets to form a board.
DETAILED DESCRIPTION
Referring now to the drawings, in which like numerals refer to like components or steps, there are disclosed broad aspects of various exemplary embodiments.
The present disclosure relates to a composite board manufactured using coconut coir fibers. Coconut coir, in its raw state, includes coconut coir fibers, which are comparatively hydrophobic natural fibers, and coconut pith, which is hydrophilic. The present disclosure uses coconut coir, preferably dry coconut coir, more preferably coconut coir having a moisture content of between 2% and 8%, most preferably coconut coir having a moisture content of 6%. The coconut coir may be dried in a rotating drum heater, preferably a rotating drum natural gas fired heater.
The current disclosure describes an improved method of separating coir fibers from pith. In a first step, coconut husk is chopped to produce coir chunks. In certain embodiments, the chopping step is carried out in a knife mill.
In certain embodiments, the knife mill has a rotor powered with an engine, i.e., a gasoline or electric engine, and a plurality of straight knife blades bolted to the periphery of the rotor. In various embodiments, coconut husk is added to a knife mill by a conveyer belt. The conveyer belt may include a slotted orienter to control orientation of coir chunks as they enter the knife mill; control of coir chunk orientation allows preparation of coir fibers having consistent lengths. In other embodiments, coconut husk is added to a knife mill by a hopper. The conveyer belt may include a magnet to prevent wrenches or other loose equipment from killing or damaging the knife mill.
When coconut husk is added to the knife mill, rotation of the rotor chops the aligned coconut husk into small pieces or chunks comprising consistent length coconut coir fibers and coconut pith. The coir and pith are not easy to separate from these coir chunks. The chopping step is preferably carried out on dry coir, preferably coconut coir having a moisture content of between 2% and 8%, more preferably coconut coir having a moisture content of 6%. Alternatively, the chopping step may be carried out on coir having a higher moisture content. If chopping is carried out on wet coir, the resulting coir chunks may be dried prior to further processing.
To release pith from coir chunks, coir chunks are abraded in a mill. In certain embodiments, wet or dry coir chunks are abraded in a contra-selector mill, as seen in FIG. 1 . The contra-selector mill includes a rotating screen basket 81 . Coir chunks 82 are deposited into the basket from inlet 83 . An impellor 84 having blades 85 rotates simultaneously with rotation of the basket 81 . The impellor 84 and the screen basket 81 may rotate in the same direction, or the impellor 84 and the screen basket 81 may rotate in opposite directions. Preferably, the impellor 84 and the screen basket 81 rotate in opposite directions to produce fibers. As the impellor 84 and the screen basket 81 rotate, coir chunks are ground or abraded between the blades 85 and grinding elements on the inner surface of the basket 81 . As the coir chunks are ground, centrifugal forces cause the ground particles to pass through openings in the screen basket 81 . The fiber size may be controlled by adjusting the rotation speed of the impellor 84 and the screen basket 81 , and/or the size of the openings in the screen basket 81 . The ground particles comprise coir fibers and coconut pith, and fall into a trough or hopper where they are collected after passing out of the screen basket.
According to various embodiments, wet or dry coir chunks are abraded in a contra selector mill. Abrasion of the coir fiber bundles in the mill opens the pith pockets. In certain embodiments, coir is collected in a wet state, and then the coir is stored inside for days before processing. As a result, the coir is partially dried prior to abrasion in the contra selector mill. Ground particles comprising coir fibers and coconut pith received as an output from the contra selector mill are sent to a rotating drum drier. In the rotating drum drier, the drying and rotating action of the drier causes dry pith particles to be released from the coir fibers.
In an alternative embodiment, coir chunks may be ground or abraded in a ball mill in the presence of spherical grinding media 101 , as seen in FIG. 2 . The ball mill has a hollow body 100 . A high speed air stream may be passed through the ball mill. As the ball mill grinds the coir chunks into individual coir fibers and pith particles, the coir fibers and pith particles are entrained in the air stream and exit the ball mill through screen 102 . Screen 102 retains grinding media 101 in the ball mill. The size of the coir fibers and pith particles is controlled by the size of the openings in the screen.
Alternatively, coir chunks may be ground or abraded in a hammer mill, as seen in FIG. 3 . Coir chunks are deposited in feed hopper 201 , and pass into mill chamber 202 . The coir chunks are reduced in size by impact with rotating hammers 204 mounted on a rotor 203 . The impact between the hammers 204 and the coir chunks shatters the coir chunks, releasing pith from coir fibers. As the coir chunks are reduced in size to the desired degree, forming pith particles and coir fibers, the pith particles and coir fibers 207 pass through a screen 205 into the bottom of the hammer mill and are collected in a container or hopper 206 , and then sent to a rotating drum drier.
Coir chunks may also be ground or abraded to release coir fibers and pith particles in an oscillating granulator, as seen in FIG. 4 . Coir chunks are placed in a hopper 300 . Below the hopper is an oscillating bar 301 which contacts a woven wire screen 302 . Coir chunks are abraded by shear between the oscillating bar 301 and the woven screen 302 as the bar oscillates back and forth. Coir fibers and pith particles pass through the wire screen 302 , and are collected in a container or hopper, and may then be sent to a rotating drum drier.
Other devices for abrading or milling large particles may be used to reduce the size of coir chunks and release pith particles from coir fibers.
Next, dry coir fibers and pith particles recovered from abrasion or milling of dry coir chunks, optionally followed by drying in a rotating drum drier, are entrained in a heated air stream. If abrasion or milling is performed in a ball mill, this step is preferably accomplished by passing a stream of high velocity heated air through the ball mill, as seen in FIG. 2 . If abrasion or milling is performed in a contra-selector mill, hammer mill, or oscillating granulator, then the venturi effect is used to entrain the coir fibers and pith particles in a heated air stream, as seen in FIG. 5 . The coir fibers and pith particles 401 are loaded into a hopper or tank 402 with a small hole 403 at its lower end. This hole 403 opens into a tube 404 carrying a high velocity air stream. As the air stream passes the hole 403 in the hopper or tank 402 , producing a partial vacuum in the hole 403 in the hopper or tank, coir fibers and pith particles from the hopper or tank are sucked into the high velocity air stream. The high velocity air stream carries the coir fibers and pith particles into a cyclonic separator, discussed below. The cyclonic separator separates heavy coir fibers from the air stream, producing an air stream with entrained lightweight pith particles. It is important to note the importance of drying coir prior to introducing coir fibers and pith particles into the cyclonic separator. If the coir is not properly dried, the pith particles will be wet and heavy, and will not properly separate from the heavy coir fibers. The coir fibers recovered after separation from pith have a length of from 0.1 to 5 mm, preferably 0.2 to 2.5 mm, more preferably 1 to 2 mm.
FIG. 6 shows a cyclonic separator 501 for separating coir fiber from coconut pith. Cyclonic separator 501 includes a tubular body 502 having an opening at each end. The lower end 503 of body 502 is conical, while the upper end of body 502 is cylindrical. Cyclonic separator 501 includes an inlet 504 for a stream of air containing entrained coconut coir fibers and lightweight coconut pith. Inlet 504 injects the airstream tangentially relative to the wall of the cylindrical portion of cyclonic separator 501 , establishing a helical flow of air inside the cyclonic separator. Particles entrained in this helical air flow are subjected to centrifugal force, directing the particles radially outward toward the wall of body 502 , and to a buoyant force, in which the air in the helical air stream supports the particles. The buoyant force opposes the centrifugal force. The position of a particle in the helical air stream is controlled by a balance between centrifugal and buoyant forces. In general, a particle in the cyclone moves toward either the wall of the cyclone, or the central axis of the cyclone until the buoyant and centrifugal forces are balanced. Denser particles, i.e., heavy coir fiber particles, move to the outer wall of body 502 , and lighter pith particles move toward the axis of the cyclone. As the dense coir fibers move toward the wall of body 502 , they strike the outside wall, and fall to the bottom of the cyclone where they can be removed through an opening in the bottom of conical end 503 .
The pith is lightweight, and continues to be entrained in the helical air flow until it reaches the junction of the cylindrical portion of body 502 and the conical portion 503 of body 502 . This junction interrupts the helical air flow. The air then exits the cyclone in a straight stream through the center of the cyclone and out opening 505 in the top of body 502 . The coconut pith is still entrained in the air stream, and is also removed through opening 505 .
FIG. 7 shows an alternate embodiment of a cyclonic separator for separating coir fiber from coconut pith. Cyclonic separator 510 includes a tubular body 511 having an entrance 512 at one end, and an exit 517 at the other end. Entrance 512 injects an airstream containing air and entrained coir fibers and pith particles axially into the center of the tubular body 511 of cyclonic separator 510 . Entrance 512 includes a means 513 for establishing a helical flow to the airstream as it exits entrance 512 , establishing a helical flow of air in the direction of arrow B inside the cyclonic separator. Means 513 may take the form of stationary spinner vanes in entrance pipe 512 . Particles entrained in this helical air flow in the direction of arrow B are subjected to centrifugal and buoyant forces, directing the particles radially outward toward the wall of body 511 . Denser particles, i.e., heavy coir fiber particles, move toward the outer wall of body 511 , and lighter pith particles move toward the axis of the helical airflow B.
Simultaneously with introduction of an airstream containing air and entrained coir fibers and pith particles through entrance 512 , a secondary air stream enters chamber 515 through inlet 514 . Secondary air nozzles 516 inject air at high speed tangentially into body 511 , creating a second helical airflow along the inner wall of body 511 , in the direction of arrow A. Helical airflow A surrounds airflow B, and moves toward entrance 512 while airflow B moves toward exit 517 . Helical airflow A entrains coir fiber particles exiting airflow B due to centrifugal force. Airflow A prevents damage to the inner wall of body 511 from impact with coir fibers, and moves coir fibers in the direction of entrance 512 . Near entrance 512 , airflow A strikes baffle 519 , stopping the helical airflow. At this point, air from airflow A begins to flow toward exit 517 in the direction of arrow C. Air moving in the direction of arrow C and airflow B combine and exit the body 511 through exit 517 , along with entrained pith. When airflow A strikes baffle 519 , entrained coir fibers are released and are carried into hopper 518 for recovery.
Other embodiments of cyclonic separators are known in the art, and may be used to separate coir fibers from pith particles.
Within the cyclonic separator, air flow and collisions further separate the pith from the coir fibers. The fibers that fall to the bottom of the cyclone may also still have some coir chunks included. The coir chunks are separated from coir fibers by a vibrating or oscillating screen separator. Separated coir fibers go through the screen separator, while coir chunks are caught and returned to the conveyer leading to the knife mill for further processing. Typically, less than 10% of the output of the cyclonic separator consists of chunks that need further processing.
FIG. 8 shows an extruder 520 for blending a polymer with coir fibers recovered from a cyclonic separator according to FIG. 1 or FIG. 2 . The extruder 520 includes a tubular body 521 with at least one helical screw 522 rotatably mounted inside. Screw 522 is driven by a motor (not shown). Screw 522 has a helical thread 525 thereon. Extruder 520 can be an extruder with a single screw, or a dual screw extruder.
Extruder 520 includes a hopper or other inlet 523 for receiving pellets of a polymer. The polymer is preferably a hydrophobic polymer; more preferably an olefin homopolymer, an olefin copolymer, polyvinyl chloride, polyvinylidine chloride, polystyrene, or a mixture thereof; still more preferably an olefin homopolymer, an olefin copolymer, polyvinyl chloride, or polyvinylidine chloride; most preferably polyethylene or polypropylene.
Extruder 520 includes a second hopper or other inlet 524 for receiving coir fibers. The interior of the screw is heated sufficiently to melt the polymer pellets. Screw 522 rotates, causing the thread 525 to knead the molten polymer and mix the molten polymer with the coir fibers. The mixture of coir fibers and polymer is extruded from extruder 520 through die plate 526 , forming a strand of molten polymer 529 . A cutting device having, for example, a knife blade 528 reciprocating in the direction of arrow C, cuts the strand 529 at regular intervals, forming pellets 527 . Again, it is important to note the importance of drying coir early in the process disclosed herein; if the coir is not properly dried prior to separating the coir fibers and the pith, the resulting coir fibers will be wet. Preferably, the coir fibers are dried prior to their introduction into the cyclonic separator; more preferably, the coir fibers are dried to a moisture level of between 2% and 8% after grinding in a mill, i.e., a contra selector mill, but prior to their introduction into the cyclonic separator. Wet coir fibers have poor compatibility with hydrophobic polymers, when compared to dry coir fibers.
FIG. 9 shows an extruder 530 for extruding a blend of a polymer and coir fibers. The extruder 530 includes a tubular body 531 with at least one helical screw 532 rotatably mounted inside. Screw 532 is driven by a motor (not shown). Screw 532 has a helical thread 535 thereon. Extruder 530 can be an extruder with a single screw, or a dual screw extruder.
Extruder 530 includes a hopper or other inlet 533 for receiving pellets 527 , as produced by extruder 520 of FIG. 8 . Pellets 527 are melted in extruder 530 . Extruder 530 also optionally includes a second hopper or other inlet 534 for receiving colorants, i.e., pigments or non-reactive dyes; plasticizers; or other additives, preferably additives which do not react with reactive sites on the coir fiber, i.e., hydroxyl groups. Screw 532 rotates, causing the thread 535 to knead the molten pellets and, if necessary, mix the molten pellets with the additives. The mixture of molten pellets and additives is extruded from extruder 530 through die plate 536 , forming a strand of molten polymer 539 .
In certain embodiments, die plate 536 has a die with a rectangular hole, so that strand 539 has a width that is greater than its thickness. However, die plate 536 is not limited to a die with a rectangular hole. In some embodiments, die plate 536 has a die with a complex profile, so that strand 539 has a complex cross section. Strand 539 may be extruded as a hollow rectangular board with one or more support struts formed therein. Strand 539 may be extruded as a hollow or solid board with slots or notches formed therein, where the slots or notches allow multiple boards to be linked together. A cutting device having, for example, a knife blade 538 reciprocating in the direction of arrow D, cuts the strand 539 at regular intervals, forming boards 537 .
The process described herein produces boards that are strong, due to the reinforcing fibers. The boards may be produced in lengths of up to 25 feet and used as load-bearing materials, i.e., flooring for decks. The boards are environmentally friendly, and water resistant. The boards are also resistant to mold. The coir fibers and polyethylene are not readily digested by termites or other insects, so the boards are resistant to termite infestation.
As an alternative to coir fibers, the process disclosed herein may be carried out using ramie or bamboo fibers to reinforce polymeric products. In some embodiments, the process disclosed herein may be carried out using coconut coir fibers in combination with ramie or bamboo fibers to reinforce polymeric products. Ramie and bamboo fibers are readily available and inexpensive materials. Ramie and bamboo fibers are renewable and resemble wood. Coconut coir fibers are also renewable; however, coconut coir fibers are more expensive than ramie and bamboo fibers. Coconut coir fibers have distinct advantages over ramie and bamboo fibers. Coconut coir fibers have longer fibers with a greater aspect ratio than either ramie or bamboo fibers, and are therefore able to provide composite boards with greater strength than composite boards reinforced solely with ramie and bamboo fibers.
In various embodiments, a composite board is produced comprising a polymer binder and coconut coir fibers as a reinforcing additive. In various embodiments, a composite board is produced comprising from 3% to 100% by weight of coconut coir fibers and from 0% to 97% by weight of bamboo or ramie fibers, based on the total weight of the fibers, and a thermoplastic resin matrix. In various embodiments, the composite board comprises from 35% to 100% by weight of coconut coir fibers and 0% to 65% by weight of bamboo fibers, based on the total weight of the fibers, and a thermoplastic resin matrix. In various embodiments, the composite board comprises from 40% to 60% by weight of coconut coir fibers and 40% to 60% by weight of bamboo fibers, based on the total weight of the fibers, and a thermoplastic resin matrix. The precise ratio of coconut coir fibers to bamboo or ramie fibers may be adjusted to obtain a desired board strength at a desired cost/unit length. Specifically, the cost/unit length decreases as the ratio of coconut coir fibers to bamboo or ramie fibers decreases; however, the board strength increases as the ratio of coconut coir fibers to bamboo or ramie fibers increases.
In various embodiments, the composite board comprises from 20% to 80% by weight of a mixture of coconut coir fibers and an optional filler, based on the total weight of the mixture, and from 20% to 80% by weight of a thermoplastic resin. In some embodiments, the composite board comprises from 20% to 50% by weight of a mixture of coconut coir fibers and the optional filler, based on the total weight of the mixture, and from 20% to 50% by weight of the thermoplastic resin.
In cases when the practitioner wishes to produce a composite board, i.e., a particle board, having coir fibers and a thermosetting binder matrix, i.e., a phenol-formaldehyde, urea-formaldehyde, melamine, or epoxy resin matrix, the board may be prepared by mixing liquid polymer precursors and coir fibers. Coir fibers are mixed with a thermosetting resin, and the mixture is formed into a sheet. The mixing step may be carried out by spraying the resin onto the coir fibers.
Once the resin has been mixed with the particles, the liquid mixture is made into a sheet. The sheets formed are then compressed under pressures between two and three megapascals and temperatures between 140° C. and 220° C. This process sets and hardens the thermosetting resin. The resulting boards are then cooled, trimmed and sanded.
In cases when the practitioner wishes to produce a composite board having coir fibers and a mineral matrix, i.e., cement or gypsum, the board may be prepared by mixing liquid polymer precursors and coir fibers. Coir fibers are mixed with a mineral binder, i.e., gypsum, and the mixture is formed into a core sheet, which is sandwiched between facing sheets of paper or a nonwoven material. The core is allowed to set and dry until it is strong enough for use as a building material.
Composite boards made using coir fiber prepared as described herein and a thermoplastic resin binder or a thermosetting matrix binder having important advantages over composite boards made using raw coir, or other natural cellulosic materials, i.e., sawdust or other wood fillers. Composite boards made with coir fiber material as described herein may, in some circumstances, possess one or more of the following advantages:
The composite boards have high strength, due to coir fibers giving the material high flexural toughness and rigidity;
The composite boards are low in cost, due to the ready availability of raw coir and the lack of any need for chemical processing of coir after removal of pith;
The composite boards are low in moisture absorption, because coir fiber are hydrophobic;
Resistant to mold;
Resistant to termites and other wood eating bugs; and
Fire retardant, because coir fibers are denser and more self-extinguishing than wood fillers.
In composite boards containing wood, mold tends to grow on wood/plastic composite surfaces because the wood filler promotes mold growth. Coir fibers have a lower tendency than wood to promote mold growth; therefore, boards containing coir fiber as a reinforcing material are more resistant to mold growth than boards containing wood fillers. Also, coir fibers are resistant to termites and other insects, as they are harder for insects to digest.
Example 1
A series of composite boards were produced by extruding a composition containing 35% by weight recycled polyethylene as a binder, and 65% by weight of vegetable fibers. The vegetable fibers contained a mixture of coconut coir fibers and bamboo fibers; or coconut coir fibers in the absence of bamboo fibers. A comparative composite board was produced by extruding a composition containing 35% by weight recycled polyethylene as a binder, and 65% by weight of bamboo fibers, in the absence of coconut coir fibers. The composite boards were subjected to testing using test methods in accordance with ASTM D7032-10, “Standard Specification for Establishing Performance Ratings for Wood-Plastic Composite Deck Boards and Guardrail Systems,” and ASTM D6109-10, “Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastic Lumber and Related Products.” The testing was conducted at a relative humidity of 50%±5%, and a temperature of 52° C. The test results were used to determine the maximum distance that a board having a cross section of 8″ by 1.25″ between two joists can safely span. The results are reported in Table 1. The coconut coir fibers were prepared by removing substantially all of the coconut pith from coconut coir fibers by abrading the coir fibers to release pith from the coir fibers, entraining the coir fibers and pith in a high-velocity stream of heated air, and separating coir fibers from the air stream in a cyclonic separator.
As seen in Table 1, the maximum joist span at a relative humidity of 50%±5%, and a temperature of 52° C., increases from 16 inches at a coconut coir fiber content of 0-5% by weight of the board to 36 inches at a coconut coir fiber content of 65% by weight of the board. The maximum joist span at a relative humidity of 50%±5%, and a temperature of 52° C., was 30 inches for a board having a coconut coir fiber content of 45-55% by weight of the board, and a bamboo fiber content of 10-20% by weight. Use of a coconut coir fiber content of 33% by weight of the board and a bamboo fiber content of 33% by weight increases the maximum joist span by 50%, when compared to a board having only bamboo fibers.
TABLE 1
Impact of Coconut Coir Fiber Content on Joist Span Capability.
TEST INFO
DECK/DOCK
BOARD FORMULAE
JOIST SPAN
COIR
BAMBOO
RECYCLED
CAPABILITY
FIBER %
FIBER %
Polyethylene
(INCHES)
% CHANGE
0%
65%
35%
16
BASELINE
5%
60%
35%
16
100%
25%
40%
35%
24
150%
33%
33%
35%
24
150%
45%
20%
35%
30
188%
55%
10%
35%
30
188%
65%
0%
35%
36
225%
Although the various embodiments have been described in detail, it should be understood that the invention is capable of other embodiments and its details are capable of modifications in various obvious respects. As is readily apparent to those skilled in the art, variations and modifications can be affected while remaining within the spirit and scope of the invention. Accordingly, the foregoing disclosure, description, and figures are for illustrative purposes only and do not in any way limit the invention, which is defined only by the claims. | A composite board is manufactured from hydrophobic coconut coir fibers which have been treated to remove at least a portion of coconut pith therefrom; and a hydrophobic vinyl polymer, such as a polyolefin. The composite board is manufactured without any step of chemically modifying coconut coir fibers. The composite board is manufactured by removing at least a portion of coconut pith from coconut coir fibers using a cyclonic separator; combining coconut coir fibers with a hydrophobic polymer to form a mixture; and extruding the mixture to form a composite board. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates to a wire rope clip. In particular, the present invention is directed to a two-piece bolt and saddle for wire rope clips, which will grip and secure to the exterior surface of a rope or cable.
2. Related Art.
Previously existing wire rope clips have been forged and comprised of two identical clamps, each having a long threaded leg and an orifice for receiving a threaded leg of the corresponding clamp. The forged pieces were designed to be assembled together for clamping a wire rope. An example of such a wire rope clip is a FIST GRIP® clip manufactured by The Crosby Group, Inc.
Another example of a wire rope clamp is shown in U.S. Pat. No. 3,333,303 to St. Pierre. The St. Pierre wire rope clamp is constructed of two identical forgings secured together by a pair of conventional bolts. The St. Pierre wire rope clamp eliminates the need to forge a long leg on the clamps by replacing the leg with a standard bolt that passes through apertures formed within the clamps. The clamps are provided with a sunken hexhead socket for making the bolt heads non-rotatable. Although the sunken hexhead provided on the forged piece prevents rotation of the bolt, the sunken hexhead does not secure the bolts within the apertures of the unassembled clamps. Since the bolts are free to slide in or out of a clamp, difficulties arise in assembling the completed wire rope clamp.
SUMMARY OF THE INVENTION
Consequently, it is desirable to provide a wire rope clamp having identical clamps or saddles for securing a wire rope therebetween.
It is a further object to provide a wire rope clamp wherein no long leg is forged thereon, but instead is replaced by a bolt.
It is an additional object to provide a wire rope clamp wherein a bolt is non-rotatable and is removably secured in a respective saddle so that the wire rope saddle may be assembled with greater ease without the difficulties associated with unintentional bolt disengagement from the saddle.
The wire rope clip of the present invention includes a first and second bolt each having a head, a threaded end and a plurality of splines. The splines are fashioned on the bolts proximate the head. The first bolt is received in a first orifice fashioned in a first saddle. The second bolt is received in a first orifice fashioned in a second saddle. The bolts are preferably press fit into the orifices whereby the splines on the bolts engage the walls of the first orifices so that the bolts are removably secured therein. The splines not only prevent rotation of the bolts, but also keep the bolts secured into their respective saddles.
Additionally, each saddle has a second orifice fashioned therein. The second orifice of the first saddle is for receiving the threaded end of the second bolt. The second orifice of the second saddle is for receiving the threaded end of the first bolt. The saddles are secured together by means of a first nut and a second nut that bias against the base of the second saddle and the base of the first saddle, respectively. Both the first saddle and the second saddle have a rope engaging surface fashioned between their respective first orifice and second orifice. Each rope engaging surface is fashioned on the surface opposite the base of each saddle. The wire rope clip is preferably constructed such that the first orifice on the first and second saddles are provided with a chamfered recess proximate the base of each respective saddle for receiving bolts having countersunk heads. By constructing the wire rope clip in this manner, the heads of the first and second bolts are flush with the base of the first and second saddles.
By constructing the two identical saddles, and securing the saddles together by means of the first bolt and the second bolt, a wire rope may be securely clamped by the wire rope clip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a side elevation view of a first saddle and first bolt of a wire rope clip of the present invention.
FIG. 2 an exploded side elevation view of a wire rope clip.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail. FIG. 1 illustrates a preferred embodiment of first saddle 10 and first bolt 12 of the wire rope clip. First saddle 10 is provided with first orifice 14 and second orifice 16. Additionally, first saddle 10 is provided with rope engaging surface 18 and base 20 formed on an opposite side thereof.
In the preferred embodiment, first orifice 14 is formed having a chamfered recess 22 in base 20. First orifice 14 receives first bolt 12. First bolt 12 is preferably provided with head 24, threaded end 26 and splines 28. The splines 28 in the present embodiment are parallel to the axis of the first bolt. The head 24 is preferably countersunk to correspond with chamfered recess 22. Splines 28 or ribs engage wall 30 of first orifice 14. The splines 28 interfere with or dig into wall 30 of first orifice 14 for preventing first bolt 12 from rotating within first orifice 14 and for securing first bolt 12 within first orifice 14.
Although FIG. 1 displays first saddle 10 and first bolt 12, it is to be understood that, in the preferred embodiment, a second saddle and a second bolt are identical thereto and function in the same manner.
Referring to FIG. 2, an exploded side elevation view of a wire rope clip is provided. First saddle 10 is shown with first bolt 12 affixed thereto. First bolt 12 preferably is press fit within first orifice 14. It is noted that chamfered recess 22 receives countersunk head 24 as shown in FIG. 1, thereby resulting in flush surface 32. Opposite first saddle 10 is second saddle 34. Second saddle 34 is shown with second bolt 36 affixed thereto. Second bolt 36 is preferably press fit within first orifice 38 formed in second saddle 34. Additionally, second orifice 40 is provided in second saddle 34.
Second saddle 34 is provided with rope engaging surface 42 on one side and base 44 on an opposite side. Similar to first saddle 10, second saddle 34 also has a chamfered recess for receiving a countersunk head of second bolt 36. Second bolt 36 includes a threaded end 46 and splines or ribs, similar to first bolt 12. The union of the chamfered recess of second saddle 34 and the corresponding countersunk head of second bolt 36 result in flush surface 48 on base 44 of second saddle 34.
Threaded end 26 of first bolt 12 passes through second orifice 40 of second saddle 34 and engages first nut 50. Similarly, threaded end 46 of second bolt 36 passes through second orifice 16 of first saddle 10 for engaging second nut 52. First nut 50 biases against base 44 of second saddle 34 and second nut 52 biases against base 20 of first saddle 10. Therefore, rope engaging surface 18 of first saddle 10 is positioned opposite rope engaging surface 42 of second saddle 34. Rope engaging surfaces 18 and 42 are designed to engage a wire or other type of rope therebetween to secure the rope therein.
By utilizing the wire rope clip of the invention, first nut 50 and second nut 52 can be installed in such a way as to enable an operator to swing a wrench in a full arc for fast installation.
In practice, first bolt 12 is press fit or forced within first saddle 10 and splines 28 engage wall 30 within first orifice 14 of first saddle 10. Splines 28 prevent first bolt 12 from rotating within first saddle 10. Additionally, splines 28 removably secure first bolt 12 within first orifice 14. A similar assembly is constructed with respect to second saddle 34 and second bolt 36. By providing splines 28 for engaging wall 30 of first orifice 14 and for engaging the wall of second orifice 38 of second saddle 34, an operator is not inconvenienced by accidental disengagement of first bolt 12 from first sadole 10 and/or accidental disengagement second bolt 36 from second saddle 34.
First saddle 10 is positioned such that rope engaging surface 18 engages a wire rope and positions second saddle 34 such that threaded end 26 of first bolt 12 passes through second orifice 40 of second saddle 34. Additionally, second saddle 34 is positioned such that rope engaging surface 42 also engages a wire rope. First nut 50 is then threaded over threaded end 26 of first bolt 12 and second nut 52 is threaded onto threaded end 46 of second bolt 36. In this manner, two pieces of wire rope may be securely clamped by the wire rope clip of the present invention.
The wire rope clips may be utilized on turnback loops formed from a single piece of cable or to splice two pieces of wire rope together. It is to be understood that the wire rope clips may also be utilized for other applications where traditional wire rope clips have been utilized.
Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. | A wire rope clip comprising a two-piece bolt and saddle. The clip comprises first and second bolts, each having a head, a threaded end, and a plurality of splines fashioned proximate the head. The clip further comprises first and second saddles, each having a base, a first orifice and a second orifice. A first nut engages the threaded end of the first bolt and a second nut engages the threaded end of the second bolt. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sight apparatus used for aiming projectiles and more specifically to enhanced visibility sights for projectile launching apparatus such as slingshots, bows, and the like.
2. Description of the Prior Art
Sights have been used for a very long time on apparatus used to launch projectiles, such as firearms, bows, and slingshots. For example, the slingshot apparatus that is shown and described in the U.S. patent application Ser. No. 08/666,000, by H. Ellenburg et al., filed on Jun. 12, 1996, which is incorporated herein by reference, includes a pair of pivotal sights mounted on the fork branches of a slingshot to extend into the field of vision for the path of a projectile to be launched by the slingshot and which pivot out of the projectile long path as the sling strap is released. Such sights are quite effective and easy to use, but they do require a certain degree of concentration by the user, who has to see not only the sight in the near field of vision, but also the target in the far field of vision, while holding the slingshot, stretching the sling straight rearwardly and aligning the sights with the target while taking into account the distance and likely drop in the projectile path and sometimes movement of the target. Such parameters are not unique to slingshots, however. Shooting a bow and arrow, for example, requires similar considerations and concentration.
Sight visibility has been enhanced with fluorescent fiber optics in some projectile launching apparatus recently, such as the bow sights manufactured by Toxonic Manufacturing Co., of 1324 Wolmer Road, Wentzville, Mo. 63385. Essentially, a length of optical fiber with a core that is doped with fluorescent pigment material is used to gather some amount of energy, usually nonvisible and visible electromagnetic radiation such as ultraviolet and visible light, to produce colored visible light and guiding that colored visible light to one or more points on the sight. The colored visible light emanating from the optical fiber enhances visibility of the sight and reduces concentration needed for the rear vision field, thereby allowing more concentration on the target in the far vision field. However, such optical fibers are somewhat delicate and fragile, thus vulnerable to breakage or damage in a rough use environment, such as hiking and packing in back country or simply use by juveniles, who may not always be as careful in their youthful enthusiasm as an adult. Therefore, while such fluorescent optical fibers are known to enhance visibility of sights, more rugged mounting structures that protect the optical fibers while not inhibiting energy gathering capability are needed to make such fiber optically enhanced sights feasible for projectile launchers, especially launchers such as slingshots, bows, and the like, that are used often by juveniles or in other rough use environments.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to enhance visibility of sights on slingshots and other projectile launching apparatus.
A more specific object of this invention is to improve ruggedness and durability of optical fiber enhanced sights, especially for slingshots and other projectile launching apparatus.
A still more specific object of this invention is to provide improved support and protection for optical fibers in sight applications while not inhibiting energy gathering capability of the optical fiber.
Additional objects, advantages, and novel features of the invention shall be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by the practice of the invention. The objects and the advantages may be realized and attained by means of the instrumentalities and in combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects and in accordance with the purposes of the present invention, as embodied and described herein, the fiber optic sight marker apparatus may include, but is not necessarily limited to, an elongated sight bar, an elongated fluorescent optical fiber with at least one of its ends extending transversely through the sight bar, and a support block with a groove in its surface to receive and support the length of optical fiber while leaving a substantial portion of the peripheral surface of the optical fiber exposed to ambient visible and invisible light energy. The support block can have a semicircular shape so that both ends of the optical fiber can extend through the sight bar toward the user's eye.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the preferred embodiments of the present invention, and together with the descriptions serve to explain the principles of the invention.
In the Drawings:
FIG. 1 is an isometric view of a slingshot equipped with the fluorescent fiber optic sight markers of this invention;
FIG. 2 is a top plan view of the slingshot equipped with the fluorescent fiber optic sight markers of this invention;
FIG. 3 is a rear elevation view of the slingshot equipped with the fluorescent fiber optic sight markers taken along line 3--3 of FIG. 2;
FIG. 4 is a right side elevation view of one of the fluorescent fiber optic sight markers of this invention taken along line 4--4 of FIG. 3;
FIG. 5 is a cross-sectional view of one of the fluorescent fiber optic sight markers of this invention taken along line 5--5 of FIG. 3;
FIG. 6 is an enlarged view of the fluorescent optical fiber in right side elevation illustrating diagrammatically the visible and invisible light energy capturing and transmitting function of the fluorescent optical fiber in this invention;
FIG. 7 is a fragmenting cross-sectional view of the support block and fluorescent optical fiber mounting of the present invention taken along line 7--7 of FIG. 4;
FIG. 8 is a fragmentary cross-sectional view similar to FIG. 7, but with a triangular-shaped groove cross-section;
FIG. 9 is another fragmentary cross-sectional view similar to FIG. 7, but with a square-shaped groove cross-section;
FIG. 10 is an isometric view of an alternate embodiment fluorescent fiber optic sight marker according to this invention mounted on the sight strut of a slingshot; and
FIG. 11 is a cross-sectional view from an orientation similar to FIG. 5, but showing the cross-section of the FIG. 10 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A slingshot 10 equipped with fluorescent fiber optic sight markers 60 according to this invention is shown in FIG. 1. Each fluorescent optical fiber 62, 64, 66, 68 captures ambient light--some visible, but mostly invisible--and converts the captured light energy to visible light, which it then channels to respective ends 72, 73, 74, 75, 76, 77, 78, 79, where it is emitted to make the ends 72, 73, 74, 75, 76, 77, 78, 79 glow brightly as compared to the ambient lighting. Such glowing ends 72, 73, 74, 75, 76, 77, 78, 79 serve as sight markers that enhance visibility of the sight bars 82, 84, 86, 88 in which they are mounted
As general background, the fluorescent fiber optic sights 60 can be used or easily adapted to be used on any slingshot or other projectile launching device. For purposes of illustration, but not for limitation, slingshot 10 shown in FIG. 1 can be similar to the slingshot shown and described in the patent application Ser. No. 08/666,000, of H. Ellenburg et al., filed on Jun. 12, 1996, which is incorporated herein by reference. A detailed description of such a slingshot structure is shown and described in that patent application, and additional details of such a slingshot can be seen in U.S. Pat. No. 4,250,861, which is also incorporated herein by reference. For purposes of this invention, suffice it to say that the slingshot 10 has a Y-shaped frame comprised generally of two breaches 12, 14 of a yoke extending upwardly and outwardly from a handle or hand grip 16, two elastic or rubber sling straps 18, 20 connected at their proximal ends 19, 21 to the respective yoke branches 12, 14 and connected at their distal ends 81, 83 to a pouch 22, and a wrist brace 24 comprising rearwardly extending rigid members 26, 28 and a traverse end member 30 covered by a cylindrical cushion 322. Two sight struts 41, 51 extend generally toward each other from respective pivotal connectors 40, 50, which pivot on respective yoke breaches 12, 14, as indicated by arrows 13, 15 when the projectile (FIG. 2) is launched from pouch 22.
Referring now primarily to FIGS. 4 and 5 in combination with FIGS. 1-3, the fluorescent optical fiber 66 and support block 106 is typical of the structures of the other optical fibers 62, 64, and 68 and respective support blocks 102, 104, and 108 of this invention. Essentially, the support block 106 according to a preferred embodiment of this invention has a substantially semicircular shape and extends forwardly from the sight bar 86. The elongated fluorescent optical fiber 66 has a midportion 110 that is positioned in a groove 112 in the surface of the support block 106. It also has a first end portion 114 adjacent end 76 and a second end portion 116 adjacent end 77. The first end portion 114 of fluorescent optical fiber 66 extends through a first transverse hole 115 adjacent end 118 of the sight bar 86. The second 116 of fluorescent optical fiber 66 extends through a second hole 117 adjacent end 119 of the sight bar 86. The respective ends 76, 77 can, but do not have to, extend slightly through the sight bar 86 to form the sight markers 76, 77 as discussed above. The optical fluorescent fiber 66, when positioned with its midportion 110 in the groove 112, still has a substantial portion of its elongated cylindrical peripheral surface 120 exposed to ambient visible and nonvisible light energy, as indicated diagrammatically by representative rays 122. In most circumstances, the ambient light energy will be mostly diffuse light, although some direct sunlight might also be captured. The illustration in FIG. 4 shows diffuse light energy rays incident on four points 124, 125, 126, 127 being captured by the midportion 110 peripheral surface 120 of fluorescent optical fiber 66 and channeled or transmitted to the ends 76, 77, where the energy is emitted as visible light, as indicated by visible light rays 128, 129, respectively. Actually, the light energy 22 is incident on an infinite number of points on exposed peripheral surface 120, of which points 124, 125, 126, 127 are only representative. Not all incident rays 122 are captured, of course, as some are reflected immediately, absorbed, or lost during transmission. However, enough visible and nonvisible light rays 122 are captured over the entire exposed portion of the surface area 120, converted to visible light radiation by fluorescence in the optical fiber 66, and transmitted by the fluorescent optical fiber 66 to ends 76, 77 to make the ends on sight markers 76, 77 appear to glow brighter than the surrounding ambient visible light and natural environment.
Light energy captured by the fluorescent optical fiber 66 is illustrated diagrammatically in FIG. 6, which is a simplified explanation, certainly not sufficient for manufacture of fluorescent optical fibers, but sufficient for purposes of understanding this invention. A simple fluorescent optical fiber 66 may comprise a step index (SI) structure, as illustrated in FIG. 6, wherein a core 132 has a uniform, but much higher index of fraction N 2 of a cladding 134 that surrounds the core 132. If the core index of refraction varies with the core radius, the fiber would be a graded-index (GI) fiber, and there are many core and cladding shapes and variations that need not be discussed here. The core 132 contains fluorescent dopants, which absorb light energy--some visible light energy, but mostly nonvisible electromagnetic radiation, such as ultra-violet light energy--and in response emit visible light in a fluorescence spectra or radiation frequencies that are characteristic of the fluorescent dopants used. The dopants can be selected from fluorescent pigments that emit the visible light desired colors, i.e., wavelengths or frequencies, such as red or green fluorescent optical fibers suitable for this invention, such as the "OptiBright"™ Scintillating Fibers manufactured by Poly-Optical Products, Inc., of Irvine, Calif. 92614, are readily available and easily obtainable. Essentially, for a given ratio of N 1 to N 2 , there is a critical light entrance angle to the fiber axis, below which virtually all light entering the optical fiber will be transmitted. Curving the optical fiber 66 as is shown in FIG. 6 adds to some loss of light, but not enough to defeat the effectiveness of the fiber 66 for purposes of this invention. The diagram in FIG. 6 indicates how some incident light rays 22 are refracted or bent initially upon entering the cladding 134 (going from air--a low index of infraction into the cladding--a higher index of refraction N 2 ), and then refracted again upon entering the core 132 (a much higher index of refraction N 1 ). In the core 132, the captured light energy, especially the nonvisible light energy, which is comprised mostly of ultra-violet light, excites the atoms or molecules of the fluorescent dopants in the core to emit visible light in a characteristic frequency or color. Those rays of emitted visible light that have a low enough effective angle of entrance in the core are then reflected at core/cladding interfaces to confine such emitted visible light to the core until it reaches the ends 76, 77, where it is emitted as visible light rays 128, 129. In reality, some of the emitted visible light may leak into the cladding 134 and escape or be reflected back, or it may even be transmitted by the cladding 134, depending on angles and indices of refraction. Overall, however, enough energy from incident visible and nonvisible light rays 122 is captured over the exposed peripheral surface 120 of optical fiber 66, converted by fluorescence to visible light radiation, and transmitted to ends 76, 77, to give a glowing appearance to ends 76, 77 as explained above. Fluorescent optical fibers 66 can be obtained with fluorescent pigment dopants in several color emitting varieties, so they produce and transmit mostly only light of one color, such as red or green, so the ends 76, 77 glow either red or green.
Referring now to FIG. 7, the support block 106 has a groove 112 sunk into its end surface 113 to receive and retain the fluorescent optical fiber 66. In a preferred embodiment, the groove 112 has a semicircular cross-section with about the same or only slightly larger radius as the fluorescent optical fiber 66, so that the fluorescent optical fiber 66 is well supported and protected laterally as well as transversely when nested in the groove 112, yet with about one-half of the diameter of the fluorescent optical fiber 66 extending radially outward from the end surface 113 to expose about one-half of the peripheral surface 120 to the incident light rays 122.
An alternative embodiment support block 106 shown in FIG. 8 is similar to the support block 106' in FIG. 7, but the groove 112' has a triangular rather than semicircular shape. Another embodiment support block 106" shown in FIG. 9 has a groove 112" with a square cross-section. In both the 106' and 106" support block embodiments, it is still preferable to protect the fluorescent optical fiber 66 while leaving sufficient peripheral surface 120 exposed to capture incident light rays 122. Therefore, about 30 percent to 70 percent of the diameter of the fluorescent optical fiber 66 may protrude radially beyond the end surface 113, but preferred to be about 50 percent.
While the curved support block 106 and trough 112 of the embodiments described above have the advantages of increasing probability of capturing direct light from some angle as well as providing two sight markers 76, 77 with one fluorescent optical fiber 66, another embodiment with a straight trough 112, thus straight fluorescent optical fiber 66 nest and less light loss due to no curvature, is shown in FIGS. 10 and 11. This FIGS. 10 and 11 embodiment still shows one end 76 of fluorescent optical fiber 66 extending transversely through a hole 115 in the sight bar 86, but the other end 77' is anchored in a hole 142 in the block 156 that is an axial extension of the straight trough 152. It is still desirable to have about 30 to 70 percent, preferably about 50 percent, of the diameter of the fluorescent optical fiber 66 protrude outward beyond the end surface 154 of the block 136 to protect and support the fluorescent optical fiber 66 while exposing a substantial portion of the peripheral surface 120 to incident light 122. In this embodiment, a reflective surface 156 at the end of hole 142 can be provided to reflect emitted visible light back into the end 77' of the fluorescent optical fiber 66 to reduce light loss.
Of course, other curvature configurations of support block surfaces and troughs can also be used, such as one-quarter circle instead of the semicircle or straight embodiments described above or any extent over or under those configurations while still providing the fluorescent optical fiber nesting for protection while capturing light energy for fluorescent illumination of the sight markers according to this invention.
The foregoing description is considered as illustrative only of the principles of the invention. Furthermore, since a number 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 process shown described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow. | An enhanced sight marker apparatus for slingshots, bows, and other projectile launching devices includes a support block with a trough for mounting and retaining an elongated, fluorescent optical fiber. The trough is deep enough to receive a substantial portion of the fluorescent optical fiber for support while leaving some portion of the peripheral surface of the optical fiber unshielded by the support block for exposure to ambient electromagnetic radiation, and the support block also leaves at least one end of the fluorescent optical fiber exposed and visible so that light transmitted in the core of the optical can be propagated from the exposed end to a user's eye. | 5 |
TECHNICAL FIELD
The present invention relates generally to intervertebral implants and more particularly, to providing stability to such spinal implants when they are inserted between vertebrae to replace vertebral discs.
BACKGROUND
The human spine is a biomechanical structure with thirty-three vertebral members, and is responsible for protecting the spinal cord, nerve roots and internal organs of the thorax and abdomen. The spine also provides structural support for the body while permitting flexibility of motion. A significant portion of the population will experience back pain at some point in their lives resulting from a spinal condition. The pain may range from general discomfort to disabling pain that immobilizes the individual. Back pain may result from a trauma to the spine, be caused by the natural aging process, or may be the result of a degenerative disease or condition. Similarly, neck pain may occur in related ways, i.e., from injury, aging or disease.
The intervertebral disc functions to stabilize the spine and to distribute forces between vertebral bodies. A normal disc includes a gelatinous nucleus pulposus, an annulus fibrosis and two vertebral end plates. The nucleus pulposus is surrounded and confined by the annulus fibrosis.
It is known that intervertebral discs are prone to injury and degeneration. For example, herniated discs are common, and typically occur when normal wear, or exceptional strain, causes a disc to rupture. Degenerative disc disease typically results from the normal aging process, in which the tissue gradually looses its natural water and elasticity, causing the degenerated disc to shrink and possibly to rupture. These conditions often are treated with the use of intervertebral implants.
In particular, areas of the cervical spine and the lumbar spine are particularly prone to the need for intervertebral implants, or artificial disc implants because they are areas where the spine is particularly dynamic. Thus, the implants that are used often are dynamic or motion-preserving implants. There are challenges, however, with dynamic implants and when there are problems, comes poor performance. For example, maintaining the stability of dynamic implants in the disc space, or merely preventing such dynamic implants from backing-out of the disc space after they are surgically inserted are some such challenges.
There, therefore, is a need to increase the stability of dynamic implants in the disc space and also a need to prevent backing-out of such devices after they have been implanted. Further, there is a need to do so without the use of anchors or flanges on the disc and the need for extra preparation of the endplates of the vertebrae for such extra features.
SUMMARY
An intervertebral implant system for positioning between an upper vertebra and a lower vertebra is provided. The implant system comprises an intervertebral implant and a staple. The implant comprises an inferior plate and a superior plate, while the superior plate has a vertebral surface facing the upper vertebra and the inferior plate has a vertebral surface facing the lower vertebra. There are two grooves on at least one vertebral surface extending at an angle outward from a centerline on the vertebral surface as they extend from the anterior portion of the plate toward the posterior portion of the plate. When in use, the staple is associated with the two grooves for maintaining stability of the intervertebral implant and preventing backing out of the intervertebral implant. The staple also has two arms and has a generally rectangular shape prior to use.
The end of each arm of the staple is pointed. In some versions, the grooves are wider at the anterior portion of the plate than at the posterior portion of the plate. Also, the implant further comprises a stop situated on the anterior side of at least one of the plates such that the at least one plate does not move too far into the disc space. The implant further comprises a screw for fastening the staple into the at least one plate to which the staple is inserted. In some versions, the intervertebral implant system further comprises a second staple for fastening the staple into the other of the superior or inferior plate such that both the superior and inferior plates each have a single staple helping to maintain stability of the intervertebral implant and to prevent backing out of the intervertebral implant. With the intervertebral implant system of the present invention, it is preferred that the two grooves on the at least one vertebral surface extend at an angle outward from the centerline on the vertebral surface in the range of 10 degrees to 15 degrees from the anterior portion of the plate toward the posterior portion of the plate.
A different embodiment of the intervertebral implant system of the present invention comprises an intervertebral implant as described above and a staple, wherein the staple has a left half and a right half. Other than this difference, the characteristics of this embodiment are similar to that of aforementioned embodiments, i.e., for example, the shape of the staple, having stops, pointed ends and angles of the arms of the staple.
Additional aspects and features of the present disclosure will be apparent from the detailed description and claims as set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top isometric view of a spinal implant of the present invention.
FIG. 2 shows a front view of the spinal implant of FIG. 1 .
FIG. 3 shows an isometric view of the first or third embodiments of the V-shaped staple of the present invention.
FIGS. 4A and 4B shows isometric views of the procedure for implanting the first embodiment of the V-shaped staple of the present invention.
FIG. 5 shows an isometric view of the second embodiment of a spinal implant of the present invention.
FIG. 6A shows the V-shaped staple that cooperates with the second embodiment of the spinal implant.
FIG. 6B shows the second embodiment of the V-shaped staple inserted in a spinal implant.
FIGS. 7A , 7 B and 7 C shows top views of the procedure for implanting the second embodiment of the V-shaped staple into the superior plate of the spinal implant of the present invention.
FIG. 8 shows the second embodiment of the V-shaped staple in cooperation with both the superior and inferior plates of an intervertebral disc.
FIGS. 9A and 9B shows top views of the procedure for implanting the third embodiment of the V-shaped staple into the superior plate of the spinal implant of the present invention.
FIG. 10 shows the third embodiment of the V-shaped staple of the present invention in cooperation with both superior and inferior plates of an intervertebral disc.
DETAILED DESCRIPTION
For the purpose of promoting an understanding of the principles of the present disclosure, reference is made to the specific embodiments illustrated in the drawings, and specific language is used to describe the embodiments. It is nevertheless understood that no limitation of the scope of the present disclosure is intended. Any alterations and further modifications of the described embodiments, and any further applications of the principles of the present disclosure as described herein, are fully contemplated, as would occur to one skilled in the art to which the invention relates.
As mentioned above, there is a need to increase the stability of dynamic implants in the disc space and also prevent backing-out of such devices after they have been implanted. Moreover, there is a need to do so without the use of anchors or flanges on the disc and the need for extra preparation of the endplates of the vertebrae for such extra features.
FIG. 1 shows a top isometric view of an artificial disc or spinal implant 15 of the present invention. In particular, FIG. 1 shows a superior plate 20 and an inferior plate 10 , which cooperate together with articulating surfaces. Shown on the superior plate 20 , however, are grooves 30 and 32 . At the anterior portion 22 of the plate 20 , the groove 30 is relatively wide and it narrows as it extends toward posterior portion of the disc 15 or plate 20 . Thus, at the posterior portion of the plate 20 , the groove is labeled 32 as it is relatively narrow. Also shown in FIG. 1 is a stop 23 , which will be discussed below. Located in or around the stop 23 is a hole 21 , which also will be discussed below.
FIG. 2 shows a front view of the spinal implant 15 of FIG. 1 . In particular, FIG. 2 shows a ball-and-socket or ball-and-trough type mechanism 12 of the spinal implant 15 , which allows the plates or plates 10 and 20 to articulate, which thereby allows the adjacent vertebrae to which they have been affixed to have motion after the artificial disc 15 is implanted. Located in or around stops 23 and 13 , are holes 21 and 13 , respectively, which will be discussed below.
FIG. 3 shows a V-shaped staple 40 , which is part of the first embodiment of the present invention. The V-shaped staple 40 comprises two arms 44 , and each arm 44 has an end 48 which is pointed (or sharp) for penetrating the endplate of each vertebrae to which the plates 10 or 20 are being affixed. The overall shape of the staple 44 before use can be described as generally rectangular. V-shaped staples of the present invention may be made from materials including titanium, titanium alloys such as nickel-titanium, stainless steel and cobalt chromium, PEEK, PEEK-carbon composites and/or any combination of the above.
In isometric views, FIGS. 4A and 4B demonstrate the procedure, and specifically the beginning and end stages, for implanting the V-shaped staple 40 into the superior plate 20 of the spinal implant 15 of the present invention. In FIG. 4A , the V-shaped staple 40 is introduced to the implant 15 and the vertebra (not shown). The V-shaped staple 40 can simply be hammered or power-driven through the vertebra that lies above the superior plate 20 , while the V-shaped staple 40 moves through the grooves 30 and 32 . That is, because of the material of the V-shaped staple 40 and the shape of the groove 30 , the V-shaped staple 40 will yield to the groove 30 and change shape from a generally rectangular shape of FIG. 3 to the V-shaped staple of FIGS. 4B . That is, the angle α of each arm 44 of the V-shaped staple 40 from centerline CL (which also can be described as an angle outward from the centerline it moves from the anterior portion to posterior) is in the range of ½ degree to 15 degrees. Such an angle will both allow for the V-shaped staple 40 to enter the vertebrae and groove 30 , and also allow for the staple 40 to achieve the purpose of the invention, which is to provide stability to the spinal implant, particularly transverse stability, while also preventing backing out of the implant. Further, note that the relatively narrow grooves 32 toward the posterior end of the plate 20 work to fix or lock the staple 40 in the final position. Also note that for the second embodiment of the V-shaped staple of the present invention, a different range of angle α, is preferred.
FIG. 4B also shows the stop 23 on the superior plate 20 . The stop 23 helps prevent the V-shaped staple 40 from causing the plate 20 from moving too far into the disc space. After the V-shaped staple 40 is fully inserted into place, a screw 42 is inserted through hole 41 in staple 40 and into stop 23 and/or partially or directly into plate 20 , i.e., depending on the location of hole 41 . Specifically, screw 42 maintains stability between the V-shaped staple 40 and each respective plate 10 or 20 of the spinal implant 15 . Note that this present procedure and spinal implant 15 is described with reference to the superior plate 20 for illustrative purposes only. That is, it is preferred that a V-shaped staple (in any embodiment described herein) is used on both the superior and inferior plates 20 and 10 , respectively, for maximum stability and results, e.g., to prevent backing out.
FIG. 5 shows an isometric view of a second embodiment of a spinal implant 115 of the present invention. In particular, FIG. 5 shows a superior plate 120 and an inferior plate 110 , which cooperate together with articulating surfaces such as a ball-and-socket mechanism of FIG. 2 . Shown on the superior plate 20 , and as opposed to the embodiment 15 of FIG. 1 , the grooves 130 are relatively narrow and of the same width throughout their length. Similar to the embodiment 15 , however, implant 115 also contains a stop 123 on its superior plate 120 . Located in or around the stop 123 is a hole 121 for a screw 142 (shown in FIG. 6B ) to be inserted.
FIG. 6A shows the V-shaped staple 140 that cooperates with the second embodiment of the spinal implant 115 . The V-shaped staple 140 comprises two halves or parts 144 and 146 , instead of the two arms 44 , and like V-shaped staple 40 , each end 148 is pointed for penetrating the endplate of each vertebrae to which the plates 110 or 120 are being affixed.
FIG. 6B shows V-shaped staple 140 already inserted in spinal implant 115 . FIG. 6B also shows both the superior 120 and inferior 110 plates of the spinal implant 115 , as well as the fastening screw 142 of the V-shaped staple 140 . As compared to V-shaped staple 40 , V-shaped staple 140 is shaped more like a “V” prior to use (as well as during use) from the start, and as shown in FIGS. 6A and 6B , V-shaped staple 140 can be stiffer than V-shaped staple 40 in that it does not need to bend to accommodate insertion in the grooves of the plates. The two parts or halves of V-shaped staple 140 allows one half 144 to be inserted, and then the next half 146 to be inserted thereafter, allowing for each part to be relatively rigid. Thus, the V-shaped staple 140 provides stability to the spinal implant, particularly transverse stability, while also preventing backing out of the implant in a relatively rigid manner.
In top views, FIGS. 7A , 7 B and 7 C demonstrate the procedure, and specifically the beginning, middle and end stages, for implanting the V-shaped staple 140 into the superior plate 120 of the spinal implant 115 of the present invention. In FIG. 7A , the left half 144 of the V-shaped staple 140 is introduced to the implant 115 and the vertebra (not shown). The left half 144 of the V-shaped staple 140 can simply be hammered or power-driven through the vertebra that lies above the superior plate 20 , while it moves through groove 130 . In FIG. 7B , the right half 146 of the V-shaped staple 140 is introduced into the implant 115 and the vertebra, such that the holes 141 A and 141 B in each half (shown in FIG. 6A ) line up over each other. The left half 146 of the V-shaped staple 140 can similarly be hammered or power-driven through the vertebra that lies above the superior plate 120 , while it moves through groove 130 . Then, as shown in FIG. 7C , when the halves 144 and 146 are fully in place, the fastening screw 142 can be inserted through holes 141 A and 141 B and into stop 123 to secure the V-shaped staple 140 to the implant 115 . The same angle of the halves (or arms) 144 and 146 from center (or centerline) for the first embodiment of the present invention also is preferred for this second embodiment for achieving maximum stability to the spinal implant, particularly transverse stability, while also preventing backing out of the implant.
FIG. 8 shows the second embodiment of the V-shaped staple 140 of the present invention in cooperation with both the superior and inferior plates 120 and 110 , respectively, to achieve maximum stability and results, e.g., to prevent backing out. Specifically, a V-shaped staple 140 is shown in cooperation with a superior plate 120 , and a V-shaped staple 150 is shown in cooperation with an inferior plate 110 , where plates 120 and 110 are part of the same artificial disc 115 .
A third embodiment of the present invention is illustrated and described with reference to FIGS. 3 , 5 , 9 A, 9 B, and 10 . FIG. 3 shows the third embodiment of a V-shaped staple 240 , while FIG. 5 depicts an artificial disc 115 that also can be used with V-shaped staple 240 . Like the first two embodiments, the V-shaped staple 240 is made of the same materials, but typically is of a smaller thickness. Specifically, for the first and third embodiments of the V-shaped staple, the preferred range of thickness is in the range of 0.3 mm. to 1.0 mm. for metal materials, and 0.5 mm. to 3.0 mm. for non-metal materials. For the second embodiment, although it can be thinner than the other embodiments, the preferred range of thickness is in the range of 0.3 mm. to 3.0 mm. for all materials. Similarly, for the first and third embodiments of the V-shaped staple, the preferred range for angle α from the centerline CL is ½ degree to 15 degrees. For the second embodiment, however, the preferred range for angle α from the centerline CL is ½ degree to 65 degrees, and a more preferred range for α from the centerline CL is 10 degrees to 30 degrees.
Accordingly, FIGS. 9A and 9B demonstrate the procedure, and specifically the beginning and end stages, for implanting the V-shaped staple 240 into the superior plate 220 of the spinal implant 215 of the present invention. In FIG. 9A , the V-shaped staple 240 is introduced into the implant 215 and the vertebra (not shown). With the aid of the pointed ends 248 , the V-shaped staple 240 can simply be hammered or power-driven through the vertebra that lies above the superior plate 220 , while it moves through groove 230 . Because the staple 240 is relatively thin, it can yield to the angle of the groove 230 as it enters the implant 215 , as shown in FIG. 9A . In FIG. 9B , when the V-shaped staple 240 is fully in place, the fastening screw 242 can be inserted through hole 41 and into stop 223 to secure the V-shaped staple 240 to the implant 215 . The same angle of the halves 144 and 146 (or arms) from center for the first embodiment of the present invention also is preferred for this third embodiment for achieving maximum stability to the spinal implant, particularly transverse stability, while also preventing backing out of the implant.
FIG. 10 shows the third embodiment of the present invention V-shaped plate 240 in cooperation with both the superior and inferior plates 220 and 210 , respectively, for maximum stability and results, e.g., to prevent backing out. Specifically, a V-shaped staple 240 is shown in cooperation with a superior plate 220 , and a V-shaped staple 250 is shown in cooperation with an inferior plate 210 , where plates 220 and 210 are part of the same artificial disc 215 .
Although only a few exemplary embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this disclosure. Accordingly, all such modifications and alternative are intended to be included within the scope of the invention as defined in the following claims. Those skilled in the art should also realize that such modifications and equivalent constructions or methods do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure. It is understood that all spatial references, such as “horizontal,” “vertical,” “top,” “upper,” “lower,” “bottom,” “left,” and “right,” are for illustrative purposes only and can be varied within the scope of the disclosure. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | An intervertebral implant system for positioning between an upper vertebra and a lower vertebra is provided. The implant system comprises an intervertebral implant and a staple. The implant comprises an inferior plate and a superior plate, while the superior plate has a vertebral surface facing the upper vertebra and the inferior plate has a vertebral surface facing the lower vertebra. There are two grooves on at least one vertebral surface extending at an angle outward from a centerline on the vertebral surface as they extend from the anterior portion of the plate toward the posterior portion of the plate. When in use, the staple is associated with the two grooves for maintaining stability of the intervertebral implant and preventing backing out of the intervertebral implant. The staple also has two arms and has a generally rectangular shape prior to use. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 09/969,951 filed Oct. 3, 2001.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an image-forming apparatus which is controlled to stop to avoid a situation where the adherence between toner of the image pattern α in the non-image area and a photoreceptor, intermediate transfer member or a second transfer roller increases, so as to keep the inside of the apparatus clean and to obtain clean images. Here, the image pattern α is an image which inevitably forms when an image forming operation has stopped or an image pattern created in the non-image area which comes after the image area before the image forming operation is stopped and used for optimizing the quality of the normal image by detecting the density, position, etc. of the image.
[0003] There is a well-known image-forming apparatus which forms a toner image on a photoreceptor having charging, exposing, and reversal developing means in its periphery, transfers (i.e. first transfer) the toner image onto an intermediate transfer member, and then transfers (i.e. second transfer) the toner image from the intermediate transfer member onto transfer material, such as transfer paper or the like used as recording material. This kind of apparatus uses a two-component developer which includes toner having the same charging polarity as that of the photoreceptor so as to perform reversible deposition. In order to prevent a two-component developer carrier from adhering to the photoreceptor, the developing bias is impressed before charging is started when an image forming operation starts and then the developing bias is turned off after charging has been finished when the image forming operation stops. This causes the toner to adhere to the area located before and after the charged area on the photoreceptor in a belt-like appearance. If the adhering toner (especially, the toner that has adhered when the image forming operation stopped) remains on the photoreceptor or the intermediate transfer member, the toner adherence increases causing an insufficient cleaning, which results in poor image quality when the next image is printed. Further, if the adhering toner remains sandwiched between two members or remains receiving heat from the fixing unit, etc., the adherence between the toner and a transfer member, such as an intermediate transfer member, photoreceptor, or a transfer roller, further increases causing an insufficient cleaning, which results in poor image quality. Furthermore, if the toner in the image area remains on a photoreceptor or an intermediate transfer member when transfer material, such as transfer paper or the like, jams, the same thing can happen. Especially, if the adhering toner remains sandwiched between two members or remains receiving heat from the fixing unit, etc., the adherence between the toner and a transfer member, such as an intermediate transfer member, photoreceptor, or a transfer roller, further increases causing an insufficient cleaning, which results in poor image quality. Those cases happen frequently.
OBJECT OF THE INVENTION
[0004] The main purpose of the present invention is to provide an image-forming apparatus for forming a toner image on a photoreceptor, primarily transferring the toner image on the photoreceptor onto an intermediate transfer member and secondarily transferring the toner image from the intermediate transfer member onto transfer material, such as transfer paper or the like used as recording material, which does not have the problem described above. That is to say, the main purpose of the present invention is to provide an image-forming apparatus which does not stop, when a toner image exists in the non-image area and the toner image remains sandwiched between a photoreceptor and an intermediate transfer member or the intermediate transfer member and a second transfer member, so as to prevent the adherence between each member and the toner from increasing, thereby preventing image problems which affect the creation of the next image from occurring.
SUMMARY OF MEANS FOR ACHIEVING THE INVENTION
[0005] (1) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily transferring said toner image from said intermediate transfer member onto transfer material, comprising cleaning means for removing residual toner which has adhered to the downstream-side surface of said intermediate transfer member in its rotational direction after the second transfer position, further comprising controller for controlling a first transfer voltage or current so that most of the toner image pattern α which has been formed in the non-image area on said photoreceptor is transferred onto said intermediate transfer member and stored thereon and also stopping said intermediate transfer member after the toner which adhered to said intermediate transfer member has been removed.
[0006] (2) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily transferring said toner image from said intermediate transfer member onto transfer material, comprising cleaning means for removing residual toner which has adhered to the downstream-side surface of said photoreceptor in its rotational direction before the first transfer position, further comprising controller for controlling a first transfer voltage or current so that most of the toner image pattern α which has been formed in the non-image area on said photoreceptor remains on said photoreceptor and also stopping said photoreceptor after the toner which has adhered to said photoreceptor has been removed.
[0007] (3) An image-forming apparatus, having a second transfer member, for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily transferring said toner image from said intermediate transfer member onto said transfer material, comprising controller for stopping said photoreceptor and said intermediate transfer member at a position where the toner image pattern α which has been formed in the non-image area on said photoreceptor when said apparatus was stopped is not sandwiched between the contacting parts of said photoreceptor and said intermediate transfer member.
[0008] (4) An image-forming apparatus according to means (3), comprising a roller or belt for making said second transfer member come in contact with said intermediate transfer member, further comprising controller for stopping said intermediate transfer member at a position where the toner image pattern α which has been formed in the non-image area on said photoreceptor when said apparatus was stopped is not sandwiched between the contacting parts of said second transfer member and said intermediate transfer member.
[0009] (5) An image-forming apparatus according to Means (4), comprising a roller or belt for making said second transfer member come in contact with said intermediate transfer member, further comprising controller for stopping said intermediate transfer member after the toner image pattern α which has been formed in the non-image area when said apparatus was stopped has passed the contacting parts of said photoreceptor and said intermediate transfer member and is located at a position before the contacting parts of said second transfer member and said intermediate transfer member.
[0010] (6) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily transferring said toner image from said intermediate transfer member onto said transfer material, comprising controller for controlling a first transfer voltage or current so that most of the toner image pattern α which has been formed in the non-image area on said photoreceptor before said apparatus is stopped is transferred onto said intermediate transfer member and stored thereon and also stopping said intermediate transfer member so that the toner image does not remain at a position close to a fixing unit.
[0011] (7) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily contact-transferring said toner image from said intermediate transfer member onto transfer material, comprising cleaning means for removing residual toner which has adhered to the downstream-side surface of said intermediate transfer member in its rotational direction before the second transfer position, further comprising controller for releasing the press-contact of said intermediate transfer member with a secondary contact transfer member when a paper jam has occurred, controlling a first transfer voltage or current so that most of the residual toner image is transferred onto said intermediate transfer member and stored thereon, and also stopping said intermediate transfer member after the toner which has adhered to said intermediate transfer member has been removed.
[0012] (8) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily contact-transferring said toner image from said intermediate transfer member onto transfer material, comprising controller for releasing the press-contact of said intermediate transfer member with a secondary contact transfer member when a paper jam has occurred, and then stopping said intermediate transfer member and said photoreceptor at a position where the residual toner image is not sandwiched between the contacting parts of said photoreceptor and said intermediate transfer member.
[0013] (9) An image-forming apparatus for forming a toner image on a photoreceptor having charging, exposing and developing means in its periphery, primarily transferring said toner image onto an intermediate transfer member, and then secondarily contact-transferring said toner image from said intermediate transfer member onto transfer material, comprising controller for releasing the press-contact of said intermediate transfer member with a secondary contact transfer member when a paper jam has occurred, and then stopping said intermediate transfer member so that the toner image so that the residual toner image on said intermediate transfer member does not remain at a position close to a fixing unit.
[0014] As described in Means (1) or (7), it is possible to prevent image problems by controlling an image-forming apparatus to transfer most of the untransferred toner image which has been formed in the non-image area or at a time of a jam onto an intermediate transfer member and store it thereon, and then remove the residual toner on said intermediate transfer member by a cleaning device, such as a blade, etc., and finely stop the apparatus.
[0015] In Means (8), when a jam has occurred, an image-forming apparatus is controlled to stop in a state where the toner image on an intermediate transfer member is not located on the first transfer contacting parts (i.e. the contacting parts of a photoreceptor and said intermediate transfer member) and also the press-contact of the second transfer roller has been released. Consequently, it is possible to prevent the toner adherence from increasing.
[0016] Further, as described in Means (2), it is possible to prevent image problems by keeping most of the untransferred toner image which has been formed in the non-image area or at a time of jam on a photoreceptor without transferring the image onto an intermediate transfer member and then removing the residual toner on said photoreceptor by a cleaning device, such as a blade, etc., and finally stopping the apparatus. Normally, the distance between the first transfer position and the cleaning position of the photoreceptor is shorter than the distance between the first transfer position and the cleaning position of the intermediate transfer member. Therefore, according to Means (1), the time duration for running the image-forming apparatus is shorter, which improves the durability of various components.
[0017] As described in Means (3), it is possible to prevent image problems by stopping a photoreceptor at a position where the adhering toner in the non-image area does not remain sandwiched between the contacting parts (i.e. first transfer nipping part) of an intermediate transfer member and said photoreceptor. In this case, when there is a sufficient distance between a developing part and a first transfer nipping part, stopping said photoreceptor at this position requires less time to rotate said photoreceptor, etc., which improves the durability. However, it is difficult to create a sufficient clearance between the developing part and the first transfer nipping part when the photoreceptor-peripheral area is made compact. But, it is possible to reduce the time required for said photoreceptor to rotate while making the photoreceptor-peripheral area compact by stopping an intermediate transfer member at a position which is located before, preferably right before, (i.e. on the downstream side) the first transfer nipping part (i.e. first transfer position) where the adhering toner remains. Further, when a second transfer nipping part is made by a contact transfer member, such as a transfer roller or a transfer belt, as described in Means (4), it is possible to prevent image problems by stopping the intermediate transfer member at a position where the adhering toner in the non-image area does not remain sandwiched between the contacting parts (i.e. second transfer nipping part) of said intermediate transfer member and a second transfer member. Furthermore, as described in Means (5), in addition to the structure of Means (4), by controlling the stop position of said intermediate transfer member so that it stops before the toner image on said intermediate transfer member comes to the second transfer position, it is possible to reduce the time required for rotating the photoreceptor, etc., which improves the durability.
[0018] Furthermore, when said intermediate transfer member is stopped with the adhering toner stored thereon, as described in Means (6) or (9), it is possible to prevent image problems by controlling the stop position of said intermediate transfer member so that it is not exposed to the heat mainly caused by a fixing unit, for example, high temperatures exceeding the toner's glass transition point which appear between 50° C. and 60° C. centigrade.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic diagram that illustrates an image-forming apparatus which is an embodiment of the present invention.
[0020] [0020]FIG. 2 is a conceptual diagram of controller used for an image-forming apparatus which is an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] Preferred embodiments of the present invention will be described in detail below referring to drawings.
[0022] Descriptions below are not to be construed to limit the scope of the invention or the definition of terms.
[0023] [0023]FIG. 1 is a schematic diagram of a color image-forming apparatus which relates to the present invention, and especially of an image-forming apparatus wherein an intermediate transfer belt is placed horizontally in a longitudinal direction so that monochrome and full-color images can be formed.
[0024] This embodiment comprises plural sets (i.e. four sets in this embodiment) of image forming unit 100 , for each color, each at least comprising a photoreceptor 2 used as an image forming body or an image carrier, an charging roller 1 used as charging means, an exposing optical system 14 used as image writing means, and a developing device 3 used as developing means. In the embodiment, each image forming unit 100 of yellow (Y), magenta (M), cyan (C) and black (K) is placed beginning from the right in the following order: Y, M, C, K, oppositely facing the horizontal stretching surface of an intermediate transfer belt 15 which travels in a loop. The four sets of image forming units 100 for four colors have the same structure.
[0025] The charging roller 1 electrifies the photoreceptor 2 with an electric charge which has the same polarity as the toner (i.e. negative charging in this embodiment) at each given potential in order to apply a uniform electric potential to the photoreceptor 2 .
[0026] The exposing optical system 14 is placed on the downstream side of the charging roller 1 in the rotational direction of the photoreceptor 2 and is also located on the upstream side of the developing device 3 . The exposing optical system 14 is an exposing unit consisting of exposing elements arrayed in the main scanning direction in parallel to the rotating shaft of the photoreceptor 2 , for example, an array of plural LEDs (Light Emitting Diodes), and a light convergent light transmitting body (product name: Selfoc Lens Array) used as an image-forming element. A laser optical system can be applied to the exposing optical system 14 . The exposing optical system 14 exposes an image on the photoreceptive layer of the photoreceptor 2 according to each color's image data which has been read by an image reading device installed separately and recorded in the memory, and then forms an electrostatic latent image of each color.
[0027] In the photoreceptor 2 ( 2 Y, 2 M, 2 C, 2 K), photoreceptive layers of the charge generating layer (lower layer) and the charge transporting layer (upper layer) are laminated in the described order or reverse order on the under-coating layer formed on the surface of a conductive cylindrical supporting body. A publicly known surface protecting layer, for example, an over-coating layer mainly made of thermoplastic or thermosetting polymer, may be formed on the surface of the charge transporting layer or the charge generating layer. In this embodiment, the conductive cylindrical supporting body of the photoreceptor 2 is grounded.
[0028] The developing device 3 ( 3 Y, 3 M, 3 C, 3 K) has a cylindrical non-magnetic stainless steel or aluminum developing sleeve (not shown) which maintains given clearance between the peripheral surface of the photoreceptor 2 and rotates in the same direction as that of the photoreceptor 2 . The developing sleeve contains a one- or two-component developer which includes yellow (Y), magenta (M), cyan(C) and black (K) according to each developing color (i.e. toner is negatively charged in this embodiment). In this embodiment, a two-component developer is contained. The sleeve of the developing device 3 does not come in contact with the drum surface of the photoreceptor 2 maintaining given clearance, for example, 100 to 500=|m by means of a thrust roller (not shown) or the like. A toner image is formed on the drum of the photoreceptor 2 by impressing the developing bias which superimposes the direct current voltage and the alternating current voltage on the developing sleeve thereby performing the contact or non-contact reversible deposition.
[0029] An intermediate transfer member (i.e. intermediate transfer belt) 15 is tightly stretched being circumscribed by an intermediate transfer belt drive roller 11 , intermediate transfer belt tension roller 12 , intermediate transfer belt supporting rollers 9 and 10 and a second transfer backup roller so that the intermediate transfer member (i.e. intermediate transfer belt) 15 rotates in the counter-clockwise direction. Further, a second transfer roller 7 oppositely faces a second transfer backup roller 8 via the intermediate transfer member (i.e. intermediate transfer belt) 15 . Further, a cleaning blade A 5 abuts on the intermediate transfer member (intermediate transfer belt) 15 located at the position of the drive roller 11 , a cleaning blade B 18 abuts on the second transfer roller 7 , and each cleaning blade C ( 4 Y, 4 M, 4 C, 4 K) abuts on each photoreceptor 2 , which carries images, in the counter-clockwise direction respectively. Furthermore, similarly, each first transfer roller 6 ( 6 Y, 6 M, 6 C, 6 K) for each color oppositely faces each photoreceptor 2 via the intermediate transfer member (i.e. intermediate transfer belt) 15 .
[0030] This intermediate transfer member (i.e. intermediate transfer belt) 15 is an endless belt with a volume resistance of 10 6 to 10 12 Ω·cm. For example, the intermediate transfer belt uses resin material, such as polycarbonate (PC), polyimide (PI), polyamide imide (PAI), polyvinylidene fluoride (PVDF), tetrafluoroethylene-ethylene copolymer (ETFE), etc., or rubber material, such as EPDM, NBR, CR, polyurethane, etc., which mixes conductive filler, such as carbon, etc., or contains ionic conducting material. The preferable thickness is approximately 50 to 2001 m for resin material and about 300 to 700=|m for rubber material. There is a case where a rubber layer is formed on a resin belt, or a coating layer is further formed on the surface layer.
[0031] The intermediate transfer member (i.e. intermediate transfer belt) 15 is driven by the rotation of a drive roller 11 which is driven by a drive motor (not shown).
[0032] For example, the drive roller 11 is usually made of the material which coats the peripheral surface of a conductive cored bar (no reference numeral assigned), such as stainless steel, etc., with conductive or semi-conductive material (no reference numeral assigned) which mixes rubber or resin material, such as polyurethane, EPDM, silicon, etc. with conductive filler, such as carbon, etc.
[0033] The first transfer roller 6 oppositely faces the photoreceptor 2 via the intermediate transfer member (i.e. intermediate transfer belt) 15 thereby forming a transfer area between the intermediate transfer member (i.e. intermediate transfer belt) 15 and the photoreceptor 2 . A direct current voltage which has an opposite polarity of the toner (i.e. positive polarity in this embodiment) is applied to the first transfer roller 6 to form an electric field in the transfer area. This makes it possible to transfer toner images of each color which have been formed on the photoreceptor 2 onto the intermediate transfer member (intermediate transfer belt) 15 .
[0034] The first transfer roller 6 for each color, which is first transfer means, is made, for example, by coating the peripheral surface of a conductive cored bar, such as stainless steel, etc., having an outer-diameter of 8 mm (not shown) with semi-conductive elastic rubber (not shown). The semi-conductive elastic rubber, which mixes rubber material, such as polyurethane, EPDM, silicon etc. with conductive filler, such as carbon, etc. or contains ionic conducting material, is solid or foamed sponge having a volume resistance of approximately 10 5 to 10 9 Ω·cm, a thickness of 5 mm, and a rubber hardness (Asker-C) of approximately 20 to 70°.
[0035] The second transfer roller 7 for transferring images onto the surface of transfer material oppositely faces the second transfer backup roller 8 which comes in contact with the second transfer roller 7 via the intermediate transfer member (i.e. intermediate transfer belt) 15 . A direct current voltage which has an opposite polarity of the toner (i.e. positive polarity in this embodiment) is applied to the second transfer roller 7 by a direct current power source (not shown) in order to transfer the superimposed toner image carried on the intermediate transfer member (intermediate transfer belt) 15 onto the surface of the transfer material.
[0036] The second transfer roller 7 , which is second transfer means for retransferring color toner images on the intermediate transfer member (intermediate transfer belt) 15 onto recording material, is made, for example, by coating the peripheral surface of a conductive cored bar, such as stainless steel, etc., having an outer-diameter of 16 mm (not shown) with semi-conductive elastic rubber (not shown). The semi-conductive elastic rubber, which mixes rubber material, such as polyurethane, EPDM, silicon etc. with conductive filler, such as carbon, etc. or contains ionic conducting material, is solid or foamed sponge having a volume resistance of approximately 10 5 to 10 9 Ω·cm, a thickness of 7 mm, and a rubber hardness (Asker-C) of approximately 20 to 70°. Different from the first transfer roller 6 , there is a case where the surface of the second transfer roller 7 is coated with semi-conductive fluorocarbon resin or urethane resin, etc. which has a good mold-releasing property because the second transfer roller comes in direct contact with the toner. The second transfer backup roller 8 is made by coating the peripheral surface of a conductive cored bar (not shown), such as stainless steel, etc., with semi-conductive material which mixes rubber or resin material, such as polyurethane, EPDM, silicon etc., with conductive filler, such as carbon, etc., or contains ionic conducting material, forming the coated layer to be approximately 0.05 to 0.5 mm.
[0037] The cleaning blade 4 or 5 is made by bonding a urethane rubber sheet that has a thickness of 1 to 3 mm and a JIS-A hardness of 60 to 80 onto the sheet metal holder so that the free length becomes approximately 5 to 12 mm. The load of the cleaning blade is approximately 49 to 490 mN and the blade abuts on the photoreceptor 2 and the intermediate transfer belt 15 . In some cases, the blade tip is coated with fluorine to prevent the blade from turning up or a conductive urethane rubber is used for the blade to prevent the opposing side from being charged.
[0038] Transfer material, such as recording paper, etc., is sent out one by one from a schematically shown integrating. device 35 , carried overlapping by the intermediate transfer belt 15 which is sandwiched between the second transfer roller 7 and the second transfer backup roller 8 , receives second transfer of the toner image, and sent to a fixing unit 45 , then fixed by thermal bonding and finally collected.
[0039] In Embodiment (1), the negatively charged yellow toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 Y is transferred onto the intermediate transfer belt by the first transfer roller 6 Y wherein a positive transfer voltage has been applied so that the toner can be transferred onto the intermediate transfer belt and stored thereon. After that, a positive transfer voltage is applied to the first transfer roller 6 M, 6 C, or 6 K so that the toner on the intermediate transfer belt will not be retransferred onto each photoreceptor 2 M, 2 C or 2 K. The same operations are conducted as to a negatively charged magenta (cyan, black) belt-like toner which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 M ( 2 C, 2 K). Then, controller performs the control to remove all of the four color toner image pattern a on the intermediate transfer belt by means of a cleaning blade 5 and then stop the intermediate transfer member (i.e. intermediate transfer belt) 15 .
[0040] Further, in Embodiment (1), when a jam has occurred, the press-contact of the second transfer roller is released, the toner which remains on the photoreceptor is transferred onto the intermediate transfer member (intermediate transfer belt) 15 and stored thereon by means of the first transfer roller 6 Y, 6 M, 6 C, or 6 K wherein a positive transfer voltage is applied so that the toner can be transferred to the intermediate transfer member (i.e. intermediate transfer belt) 15 and stored thereon. After that, controller performs the control to remove all the toner remaining on the intermediate transfer member (i.e. intermediate transfer belt) 15 by means of a cleaning blade 5 and then stop the intermediate transfer belt.
[0041] In Embodiment (2), the negatively charged yellow toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 Y is stored on the photoreceptor by the first transfer roller 6 Y wherein a negative transfer voltage has been applied so that the toner will not be transferred to the intermediate transfer belt. As to a negatively charged magenta (cyan, black) toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 M ( 2 C, 2 K), a negative transfer voltage is applied to the first transfer roller 6 M, 6 C or 6 K so that the same operations are conducted. After that, controller performs the control to remove all of the four color belt-like toner on each photoreceptor 2 Y, 2 M, 2 C or 2 K by means of cleaning blades 4 Y, 4 M, 4 C and 4 K and then stop the photoreceptor and the intermediate transfer belt. This system requires less time to stop the devices than the system of Embodiment (1).
[0042] For example, this system is more preferable when an image density detecting sensor is placed, oppositely facing a photoreceptor, at a position which is on the downstream side of a developing device and also on the upstream side of the first transfer position in the rotational direction of the photoreceptor so that the image density can be detected by using the image pattern a which has been intentionally formed in the non-image area coming after the image forming area. On the other hand, the system of Embodiment (1) is more preferable when an image density detecting sensor is placed, oppositely facing the intermediate transfer member, at a position which is on the downstream side of the first transfer position and also on the upstream side of the cleaning position of the intermediate transfer member in the rotational direction of the intermediate transfer member.
[0043] In Embodiment (3), the negatively charged yellow toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 Y is transferred onto the intermediate transfer member (i.e. intermediate transfer belt) 15 by the first transfer roller 6 Y wherein a positive transfer voltage has been applied so that the toner can be transferred onto the intermediate transfer belt (i.e. intermediate transfer belt) 15 and stored thereon_ After that, a positive transfer voltage is applied to the first transfer roller 6 M, 6 C or 6 k so that the toner on the intermediate transfer belt (i.e. intermediate transfer belt) will not be retransferred onto each photoreceptor 2 M, 2 C or 2 K. The same operations are conducted as to a negatively charged magenta (cyan, black) toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 M ( 2 C, 2 K). After that, controller controls the stop position of the intermediate transfer member (i.e. intermediate transfer belt) 15 so that all of the four color belt-like toner does not stop at a nipping position (i.e. first transfer position) of the first transfer part. Embodiment (4) performs the control to stop the intermediate transfer member (i.e. intermediate transfer belt) 15 at a position where the toner on the intermediate transfer member (i.e. intermediate transfer belt) 15 is not sandwiched at the second transfer position. Further, Embodiment (5) uses the position where the toner on the intermediate transfer member (i.e. intermediate transfer belt) 15 is not sandwiched at the second transfer position, described in Embodiment (4), as the upstream position of the second transfer position.
[0044] In Embodiment (6), the negatively charged yellow toner of the belt-like image pattern a which has been intentionally (or unintentionally) formed in the non-image area coming after the image forming area on the photoreceptor 2 Y is transferred onto the intermediate transfer member (i.e. intermediate transfer belt) 15 by the first transfer roller 6 Y wherein a positive transfer voltage has been applied so that the toner can be transferred onto the intermediate transfer belt (i.e. intermediate transfer belt) 15 and stored thereon. After that, a positive transfer voltage is applied to the first transfer roller 6 M, 6 C or 6 k so that the toner on the intermediate transfer belt will not be retransferred onto each photoreceptor 2 M, 2 C or 2 K. The same operations are conducted as to a negatively charged magenta (cyan, black) toner of the belt-like image pattern a which has been formed in the non-image area coming after the image forming area on the photoreceptor 2 M ( 2 C, 2 K). After that, controller performs the control to stop the intermediate transfer member (i.e. intermediate transfer belt) 15 while all of the four color belt-like toner on the intermediate transfer member (i.e. intermediate transfer belt) 15 is located on the upstream side of the second transfer position where the toner is not affected by heat caused by a fixing unit 45 . This system requires less time to stop the device than the system of Embodiment (1).
[0045] In Embodiment (7), when a jam has occurred, controller controls a voltage and current to be applied to the first transfer roller 6 so that all of the toner on the photoreceptor is transferred onto the intermediate transfer member (i.e. intermediate transfer belt) 15 at the first transfer nipping part, then removes the toner remaining on the intermediate transfer member (intermediate transfer belt) 15 by means of a cleaning blade 5 while releasing the press-contact of the second transfer roller 7 at a second transfer nipping part, and finally stops the intermediate transfer member (i.e. intermediate transfer belt) 15 .
[0046] In Embodiment (8), when a jam has occurred, controller controls a voltage and current to be applied to the first transfer roller 6 so that all of the toner on the photoreceptor is transferred onto the intermediate transfer member (i.e. intermediate transfer belt) 15 at the first transfer nipping part, and then stops the intermediate transfer member (i.e. intermediate transfer belt) 15 and the photoreceptor 2 while releasing the press-contact of the second transfer roller 7 at a second transfer part.
[0047] In Embodiment (9), when a jam has occurred, controller controls a voltage and current to be applied to the first transfer roller 6 so that all of the toner on the photoreceptor is transferred onto the intermediate transfer member (i.e. intermediate transfer belt) 15 at the first transfer nipping part, and then controls the residual toner not to remain at a position close to the fixing unit 45 while releasing the press-contact of the second transfer roller 7 at a second transfer nipping part.
[0048] As described above, an explanation has been given mainly focusing on a belt-like image pattern for detecting image density, which has been described as the image pattern a in the non-image area. Besides this, a image pattern which has been unintentionally formed according to the conditions of the image forming process, or a position detecting pattern for accurately superposing images of each color can be applied.
[0049] Further, in the above explanation, as shown in the conceptual diagram of controller in FIG. 2, controller imports various position and condition information so as to control each process as described in the embodiments.
[0050] When a toner image which has been formed when an image-forming apparatus stopped or when a jam occurred remains adhered to each member, such as a photoreceptor or an intermediate transfer member, or when the adhering toner remains contact-pressed by a first transfer member or a second transfer member, or when the adhering toner remains heated by a fixing member, the adherence between the toner and each member increases, causing blade cleaning to be impossible or a part of the toner component to remain adhered to the surface of the intermediate transfer member, which results in image problems which affect the creation of the next image. The present invention, which comprises controller for controlling to stop the photoreceptor and the intermediate transfer member (i.e. intermediate transfer belt) at a position located in the area which is not contaminated by the toner, eliminates such image problems. | An image-forming apparatus is provided which primarily transfers a toner image onto an intermediate transfer member, and then secondarily transfers the toner image from the intermediate transfer member onto a transfer material, wherein a controller controls the process so that when the image forming apparatus stops, a toner image α formed on a non-image area of a photoconductive member is preventing from causing image problems. | 6 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a railway car coupler and more particularly to a shelved coupler having an anticreep protection means operable to prevent accidental unlocking of the coupler during movement of a railway car along a track.
2. Prior Art
Conventional AAR Standard railway couplers generally have an articulated rotary locklift assembly to operate the locking mechanism of the coupler resulting from a torque applied to it by an operating rod. The articulate and rotary arrangement of the locklift assembly permits longitudinal translation as a result of longitudinal buff and draft forces occurring during the normal operation of the railway car. The mass inertia of the locklift assembly about its point of suspension can result in a vertical force to activate and release the lock. The locklift assembly is constructed and arranged to prevent accidental unlocking of the knuckle due to such inertia buff forces. This is generally accomplished by the provision of an anticreep prong structure in the locklift assembly to engage with a front face ledge of the coupler head positioned in the vertical path of movement of the anticreep prong so that vertical motion of the locklift assembly transmitted from the longitudinal forces occurring during car operation is stopped by the front face ledge and prevented to activate and release the locking mechanism.
A Standard railway coupler may include a bottom shelf means having a horizontal shelf depending below the knuckle so that the underside of a mating coupler knuckle may engage with the shelf to limit relative vertical movement between a mating coupler. This bottom shelf means is generally formed on a wall depending downwardly from the underside of the front face of the coupler. A vertical portion of the wall may lie in the path of longitudinal movement of a locklift assembly laterally displaced due to a bent, worn or a damaged operating rod mechanism so that the anticreep prong fails to engage with the front face ledge. Failure to provide anticreep protection may result in the transmission of longitudinal inertia forces to vertical forces which activate and release the locking mechanism thereby causing inadvertent uncoupling.
Representative but non exhaustive of anticreep protection device relating to couplers are U.S. Pat. Nos. 3,114,461 and 3,572,518.
SUMMARY OF THE PRESENT INVENTION
By the present invention, it is proposed to provide an improved railway car coupler which overcomes the difficulties encountered heretofore.
This is accomplished generally by the provision of a chamfered portion along one of the wall of the bottom shelf or the locklift assembly in the area of interference so as to permit engagement of the anticreep prong with the front face ledge.
In one embodiment of the invention, one of the vertical wall portion or a portion of the locklift assembly is chamfered, or beveled in the area of interference so that the locklift assembly is free to seek its own path of movement.
In another embodiment of the invention, a vertically extending and rearwardly projecting rib is formed to provide a chamfered or beveled ledge in the area of interference so that the locklift assembly is guided by the chamfered or beveled ledge to engage the anticreep prong with the front face ledge.
DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a partial and side elevational view of a coupler head having a bottom shelf embodying one of the structures of the invention;
FIG. 2 is a front elevational view of the coupler head showing the locklift assembly in a laterally displaced position;
FIG. 3 is a side elevational view of a locklift assembly embodying another structure of the invention;
FIG. 4 is a front elevational view of the locklift assembly in FIG. 3;
FIG. 5 is a partial and side sectional view of the coupler head of FIG. 2 along line 5--5; showing the locklift assembly in a free hanging position;
FIG. 6 shows, in solid lines, the position of the locklift assembly with its anticreep prong engaging with the front face ledge, and in phantom lines, the position of the locklift assembly under longitudinal shock forces;
FIG. 7 is a sectional and fragmentary view of the coupler head of FIG. 2 along line 7--7;
FIG. 8 is a sectional and fragmentary view of the coupler head showing another embodiment;
FIG. 9 is a sectional and fragmentary view of the coupler head embodying an alternate structure of the embodiment shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown a coupler head 10 embodying the structure of the invention. Coupler head 10 includes a forwardly projecting guard arm 12 laterally spaced from a knuckle 14. Knuckle 14 is supported by head 10 and pivotable about a vertically disposed pivot pin 16 between its thrown position (not shown) and its locked position (FIGS. 1 and 2). Movable with knuckle 14 toward its locked position is a knuckle thrower (not shown) positioned inside coupler head 10. A lock 35 (shown in FIGS. 5 and 6) is cooperatively associated with the knuckle thrower within head 10 in a conventional manner. A locklift assembly 18 is positioned below the coupler head and associated with head 10 and lock 35 to operate the lock between its locked, released and an intermediate lockset position.
As best illustrated in FIGS. 3 and 4, locklift assembly 18 includes a J-shaped hook 20 rotatably mounted to a transversly extending rotary shaft 22 (FIGS. 5 and 6) located at a lower portion of coupler head 10. A connector 24 having a longitudinally extending body is pivotally connected to hook 20 by rivet 26 at one end and a vertically projecting toggle 28 pivotally connected to the other end by rivet means 30. A laterally projecting lock slot trunnion 32 is formed at the end of toggle 28 to be disposed in a toggle slot 34 of the lock 35 as defined in the lower portion of the lock 35 (FIG. 5).
A portion of an operating rod 39 is releasably mounted intermediate the ends of the body of connector 24 so that a rotational movement of operating rod 39 causes connector 24 to rotate about rotary shaft 22 of the lower portion of coupler head 10.
The movement of the lock from a locked to a lockset position requires the rotation of the locklift assembly 18 about rotary shaft 22 so that lock slot trunnion 32 of toggle 28 may advance vertically within lock slot 34 and lift lock vertically to its lockset position.
The forward end of connector 24 includes a longitudinally projecting arm integrally formed with the body to define an anticreep prong 36. Anticreep prong 36 is free to travel in a vertical direction when operating rod 39 rotates connector 24 to release the lock.
It should be noted that the lock should be moved to its lockset position only when it is desired to open the knuckle. In order to prevent inadvertent movement of this nature as a result of longitudinal forces under normal operating conditions, a front face ledge 38 positioned adjacently to and perpendicular to a front face of the coupler, acts as a stop for anticreep prong 36 to prevent transmission of vertical and longitudinal forces that result in placing the lock in a lockset position. Thus it will be seen that only deliberate movement of the locklift assembly 18 will position lock in its lockset position. During normal operation of the locklift assembly 18, as an anticreep protection device, it is subject to lateral displacement due to a certain amount of tolerance inherent in the manufacture of its component parts, and lateral coupler angling towards the guard arm side restricted by a damaged or worn operating rod 39. The bottom shelf structure of a coupler may lie in the path of longitudinal movement of the anticreep means when the locklift assembly 18 is laterally displaced toward the knuckle side of the coupler due to a bent or damaged connecting operating rod 39. The present invention provides an anticreep protection means to insure the proper engagement of the prong and the front face ledge when the locklift assembly is laterally displaced.
In FIGS. 1 and 2, a horizontal bottom shelf 40 is shown depending from coupler head 10 below knuckle 14 for engagement with the underside of the knuckle of a mating coupler (not shown) so as to limit relative vertical movement of the couplers. A wall 42 of sufficient thickness is extended downwardly from coupler head front face 44 to provide structural support for the horizontal bottom shelf 40. It can be seen in FIG. 2 that support wall 42 is recessed laterally without adversely affecting the structural strength of the support wall and to provide clearance for the longitudinal movement of the connector 24 of a normal and operable locklift assembly 18. However, where the locklift assembly 18 is laterally displaced toward the knuckle side due to tolerance of parts or damaged or worn operating rod or the like, wall 42 may lie in the path of longitudinal movement of the locklift assembly and prevent the engagement of anticreep prong 36 with front face ledge 38.
In order to permit the engagement of a laterally displaced anticreep prong with the front face ledge of the coupler head, one embodiment of the invention provides for a chamfered or beveled vertical edge 46 along the upper portion of the rear edge of shelf support wall 42 to allow connector 24 to move unobstructively in its longitudinal path. FIG. 7 shows connector 24 at a free hanging position in solid line; and its laterally disposed position in phantom lines. Shelf support wall 42 includes a front face 48 opposite a rear face 50 and adjoined by a side face 52 facing the guard arm of the coupler. In practice, it has been found that the chamfering of 1/4 inch from rear face 50 and side face 52 of shelf support wall 42 along the rear edge at an angle of inclination of 45° with the longitudinal axis of the coupler head is preferable, and will provide the necessary clearance for the engagement of anticreep prong 36 with front face ledge 38. However, it should be understood that any angle of inclination is satisfactory which provides clearance for connector 24 to move freely in its path. As a result, anticreep prong 36 of connector 24 engages front face ledge 38 during buff or draft forces to provide a positive anticreep protection against inadvertent uncoupling.
In FIG. 9, there is shown a second embodiment of the invention. A partial structure of connector 24 is shown having a side face 54 toward the knuckle and adjoined to front face 56. Approximately a 1/4 inch is chamfered from side face 54 and front face 56 to form a beveled edge 58 at an angle of inclination of 45° with the longitudinal axis of the coupler head. The beveled edge 58 may contact with shelf support wall 42 when connector 24 is at its most lateral position, shown in phantom lines, so that connector 24 may be guided by shelf support wall 42 to move freely in a longitudinal direction. As a result, anticreep prong 36 of connector 24 may engage front face ledge 38 to provide a positive anticreep protection against inadvertent uncoupling.
It should be apparent that the shelf support wall 42 as well as the connector 24 may be chamfered to provide the necessary clearance for an unobstructed moving connector. This has the advantage of reducing the amount of chamfer to each of wall 42 and connector 24, and still provide the positive anticreep protection against inadvertent uncoupling as disclosed heretofore.
FIG. 8 shows a third embodiment of the invention. A rearwardly projecting and vertically extending rib 60 is formed on rear face 50 of the shelf support wall 42. Rib 60 merges with side face 52 to form a wedge-like structure having a chamfered surface 62 along the rear edge of shelf support wall 42. In practice, it has been found that when connector 24 is displaced laterally toward the knuckle side of the coupler head and contact surface 62, the angle of inclination of surface 62 tends to compel connector 24 away from wall 42 and allow connector 24 free to engage its anticreep prong with the anticreep ledge. | This invention relates to a railway car coupler having an improved anticreep protection assembly so as to prevent inadvertent uncoupling during movement of the railway car along a track. The improvement comprises the provision of a chamfered locklift connector or a chamfered coupler structure that lies in the path of movement of the connector so that an anticreep prong of the connector may be free to engage with a front face ledge of the coupler head to provide positive anticreep protection against accidental unlocking of the coupler. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to PCT Application PCT/EP2008/052390 filed Feb. 27, 2008 and also to French Application No. 0701633 filed Mar. 6, 2007, which applications are incorporated herein by reference and made a part hereof.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the present invention is that of automobile equipment relating to conductive electrical connections produced by structural combination of a number of mutually-insulated electrical connection members. Its subject matter is an auxiliary electrical socket intended to be fitted to an automobile vehicle for the occasional supply of power to an accessory provided with a complementary plug.
2. Description of the Related Art
In the automobile field, a vehicle is frequently equipped with an auxiliary electrical socket which is available to a passenger for the occasional supply of electrical power to an accessory device, such as a mobile telephone, for example. Such accessory devices are generally provided with a plug including a body of globally cylindrical shape that carries a first connecting terminal at its periphery and a second connecting terminal at its distal end.
To connect the contacts of the plug with the terminals of the electrical circuit of the vehicle that are assigned to them, the socket includes a cylindrical first conductive element for connecting it to the body of the plug, extended by a first pin. A second conductive element takes the form of a plate against which the second contact of the plug bears, extended by a second pin. The respective pins are intended to be connected to a voltage terminal and a ground terminal of the electrical circuit of the vehicle to deliver to the accessory device a low direct-current voltage, for example of the order 12 V, 24 V, even 42 V. An electrically-insulative connecting member at the distal end of the socket electrically insulates the conductive elements from each other, and can even provide a mechanical connection between the socket and the terminals. Moreover, the socket is equipped with a member for joining it to a structural element of the vehicle, such as a dashboard, console or similar structural element. This joining member is conformed as a ring, for example, intended to be introduced into a housing that the structural element comprises for this purpose. See for example the documents U.S. Pat. No. 5,044,993 (EI-HAJ et al.) and U.S. Pat. No. 4,713,017 (PESAPANE), which describe auxiliary electrical sockets of the kind referred to above.
SUMMARY OF THE INVENTION
One aim is to obtain the socket at lower cost, in particular by simplifying its structure and its production. It is desirable for the structure of the socket to simplify assembling its components and mounting it on the structural element of the vehicle. This structural simplification must not be achieved to the detriment of the reliability of the electrical connection obtained between the plug and the terminals and must not affect how strongly the socket is retained on the structural element of the vehicle. Given these requirements, there must in particular be taken into account the frequent and repetitive operations of introducing and withdrawing the plug, and the structure of the socket must be intrinsically robust, reliable and durable in such use.
The object of the present invention is to propose an electrical socket intended to be fitted to an automobile vehicle for the occasional supply of power to an accessory equipped with a complementary plug. The present invention more particularly aims to propose a socket of this kind that can be produced at lower cost and can easily be installed on a structural element, whilst being robust, reliable and durable.
The device of the present invention is an auxiliary electrical socket adapted to be fitted to an automobile vehicle for the occasional supply of electrical power to an accessory device equipped with a complementary plug. This socket includes:
a ring joining the socket to the interior of a housing of a structure element of the vehicle,
a connecting member at the bottom of the socket for nesting the latter over the terminals of an electrical circuit of the vehicle, and
a pair of conductive elements for making an electrical connection between contacts of the plug and the terminals that are assigned to them, including a cylindrical first conductive element extended by a first pin and a second conductive element conformed as a plate extended by a second pin.
The cylinder of the first conductive element is more particularly intended to cooperate with a body of the plug carrying a first contact and the first pin is intended to cooperate with the corresponding terminal of the electrical circuit of the vehicle. The plate of the second conductive element is intended to come into axial contact with a second contact carried by the body of the plug and the second pin is intended to cooperate with the terminal of the electrical circuit of the vehicle that is assigned to it. The connecting member is adapted to electrically insulate the conductive elements from each other and preferably to produce a mechanical connection between the socket and the terminals.
According to the present invention, such a socket is distinctive mainly in that it has the following features, separately or in combination:
The first conductive element consists of a unitary body consisting of a barrel nested inside the ring and adapted to receive the plug and a first connecting tongue of the first pin. The barrel is advantageously disposed radially between the ring and the plug and joins the unitary body to the ring as well as providing a cylindrical first conductive element adapted to cooperate with the plug.
The ring and the connecting member are integrated into a one-piece assembly. For a strong connection of the socket to the vehicle, the one-piece assembly is advantageously a rigid member disposed between the structural element and the terminals of the electrical circuit. This also facilitates positioning it and making the mechanical connection with the structural element and the electrical connections to the terminals of the circuit of the vehicle when mounting the socket on the vehicle.
The socket comprises means for assembling together the unitary body and the one-piece assembly. These assembly means can advantageously be of the nesting type relying on respective and cooperating integral assembly members of the unitary body and the one-piece assembly. More particularly, placing the members constituting the socket between two joined members respectively consisting of the unitary body and the one-piece assembly facilitates their assembly by nesting by means of respective and cooperating integral assembly members. As a result, the assembly means are obtained at lower cost and speed up and facilitate assembly of the components of the socket.
The socket proposed by the invention advantageously consists of a small number of components adapted to be assembled together, and in particular the unitary body, the one-piece assembly and the second conductive element. By virtue of their inherent structure, these components can be assembled and the socket mounted on the structural element of the vehicle by nesting processes without requiring attached assembly members.
These features simplify assembling the socket and mounting it on the structural element, the socket consisting essentially of the unitary body and the one-piece assembly, which have integral nesting members for assembling them to each other and for mounting the socket on the structural element of the vehicle. The second conductive element can be structurally reduced to the plate and the second pin conjointly formed from the same metal sheet, attached by nesting it over the connecting member, which includes a raised pattern provided for this purpose. These features are also such that accurate relative positioning of the terminals of the electrical circuit of the vehicle and the contacts of the plug is easily achieved by virtue of the means for assembling the unitary body and the one-piece assembly to each other. These assembly means preferably include integral radial positioning means and means for axial abutment of the unitary body against the one-piece assembly during their mutual nesting, in order to position the pins in corresponding relationship to the terminals. The connection between the plug and the terminals is obtained simply, easily and at lower cost, is robust because of the rigid nature of the one-piece assembly disposed between the structural element and the terminals, and by virtue of the assembly means achieves reliable relative positioning of the plug and the terminals.
The one-piece assembly is advantageously adapted to be produced by molding an electrically insulative plastic material. The proposed division of the structure of the socket into a unitary body and a one-piece assembly means that the ring and the connecting member can be produced in a single molding operation at lower cost and, because of the integral members for assembling them to each other, eliminates assembly operations. Eliminating all risk of inadequate electrical connection means that the connection between the plug and the terminals is not only mechanically strong but also electrically reliable.
The assembly means are advantageously of the type entailing axial nesting of the unitary body inside the one-piece assembly and advantageously combine means for radial positioning and means for axial positioning of the unitary body relative to the one-piece assembly.
The radial positioning means advantageously consist of a first window formed in the connecting member for the first tongue to nest in. This first window is in particular radially offset relative to the axis along which the unitary body is nested inside the one-piece assembly.
The means for axially positioning the unitary body inside the one-piece assembly are more particularly adapted to limit the axial travel of the unitary body toward the interior of the one-piece assembly on its introduction therein, complemented in an accessory manner by opposed axial bearing points of the unitary body on the one-piece assembly.
A first embodiment of the axial positioning means entails clipping the unitary body onto the one-piece assembly with two opposed axial bearing points. These opposed axial bearing points consist of respective and cooperating joining members integral with the unitary body and with the one-piece assembly. For example, the bottom of the unitary body bears axially against the connecting member and integrates a clip or similar member for opposed bearing against the one-piece assembly, for example against the edge of a window in the latter.
A second embodiment of the axial positioning means consists of a bent portion that includes the first tongue adapted to bear axially against the connecting member. In an accessory manner, the connecting member integrates a raised pattern to receive this bent portion so that it bears more firmly on the bottom of the connecting member.
A preferred embodiment of the one-piece assembly includes a cage formed by extending the ring as far as the connecting member. In particular this cage produces a space for the plug to pass through toward the connecting member and can even also envelope the unitary body to protect it and prevent accidental electrical contact with elements around the socket installed on the structural element. Such a cage can also and advantageously be used for assembling the unitary body and the one-piece assembly by elastic nesting (clipping) and even for clipping the one-piece assembly to the structural element of the vehicle.
To achieve tight elastic nesting of the unitary body inside the one-piece assembly, the cage and/or the unitary body are preferably elastically deformable on introduction of the unitary body into the one-piece assembly. The one-piece assembly advantageously being obtained by molding a plastic material, it can easily integrate various auxiliary members, in particular for strengthening it and improved guidance inside the housing of the structural element.
For example, the cage is advantageously provided with axial stiffeners further forming ramps for guiding introduction of the one-piece assembly into the housing of the structural element.
The second conductive element is attached by nesting it over the connecting member. For example, a second tongue of the second pin is introduced through a second window in the connecting member and the plate is placed inside the one-piece assembly, at the bottom. This window can be either coaxially oriented or radially offset relative to the axis along which the unitary body is nested inside the one-piece assembly.
The one-piece assembly is preferably provided with a polarizer for radially positioning the socket on the structural element and accurately lining up the tongues and the terminals.
The one-piece assembly is preferably clipped onto the structural element between two opposed axial bearing points provided in particular by axial bearing engagement of the one-piece assembly on respective opposite sides of a wall of the structural element including the housing to receive the socket.
For example, the ring has a shoulder for introducing it and for its bearing engagement with the front face of the wall and the cage preferably includes, in the vicinity of the area in which it is joined to the ring, opposed raised patterns bearing axially against the rear face of the wall. This leads to fast, easy, reliable and durable installation of the socket on the structural element of the vehicle from the front face thereof.
The present invention also proposes methods for producing a first conductive element of such a socket.
In a first embodiment, the first conductive element is produced by a single operation of stamping a metal blank to form simultaneously the barrel, the first tongue and the ring through which the unitary body bears axially against the connecting member.
In a second embodiment, the first conductive element is produced by cutting a metal sheet to produce a mutually orthogonal strip and blade, this cutting operation being followed by shaping the flat cut metal sheet to roll it to form the barrel and to bend it back on itself to form the first tongue and its bent portion.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The present invention will be better understood and details thereof will become apparent on reading the following description of embodiments given with reference to the figures of the appended drawings, in which:
FIG. 1 is an exploded perspective view of a socket of a first embodiment of the present invention;
FIG. 2 is a perspective view of a method of producing a conductive element of the socket represented in FIG. 1 ;
FIGS. 3 to 5 are views of a socket of a second embodiment of the present invention, respectively an exploded perspective view, an assembled perspective view and a perspective view from one end; and
FIG. 6 is a perspective view of a conductive element of the socket represented in FIGS. 3 to 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 and FIGS. 3 to 5 show a socket adapted to be fitted to a vehicle for the occasional supply of electrical power to an accessory. Such an accessory is commonly equipped with a plug comprising a cylindrical body provided with a peripheral first contact and an axial second contact. The socket is intended to be received inside a housing 1 in a structural element 2 of the vehicle, in particular a dashboard or the like, as shown diagrammatically in FIG. 1 . The socket is in particular adapted to make a reliable electrical connection between the plug that it occasionally receives and terminals of an electrical circuit of the vehicle.
The socket consists mainly of a unitary body 3 that is part of a first conductive element and a one-piece assembly 4 that carries the unitary body 3 and a second conductive element 5 . The unitary body 3 and the one-piece assembly 4 are assembled together by nesting of respective and cooperating integral members. The second conductive element 5 consists of a plate 6 , for example, placed at the bottom of the one-piece assembly 4 to cooperate with the axial second contact of the plug and provided with a tongue 7 that extends toward a corresponding terminal of the circuit. The second conductive element 5 is advantageously attached by nesting it over the one-piece assembly 4 .
The unitary body 3 consists of a barrel 8 that is extended by a first pin in the form of a first tongue 9 . The barrel 8 is adapted to be disposed between the plug and the one-piece assembly 4 on axially receiving the body of the plug and the unitary body 3 therefore constitutes both an electrical connecting member and a mechanical connecting member between the plug and the socket.
The one-piece assembly 4 is produced by molding an electrically insulative plastic material and integrates a connecting member 10 and a ring 11 for fastening the socket to the interior of the housing 1 of the structural element 2 . The connecting member 10 and the ring 11 are connected to each other by a cage 12 forming a spacer to define a space for the axial passage of the body of the plug toward the connecting member 10 . This cage 12 is stiffened by peripheral stiffeners 13 , which further constitute guides to facilitate introduction of the socket into the interior of the housing 1 . As can be seen in FIG. 1 , the ring 11 is preferably provided with a polarizer 14 adapted to cooperate with a corresponding relief 15 in the structural element 2 . These features facilitate radial positioning of the socket on the structural element 2 .
The nested assembly of the unitary body 3 and the one-piece assembly 4 positions them relative to each other both axially and radially, to line up the tongues 7 , 9 with the terminals of the electrical circuit. The one-piece assembly 4 can be disposed between the unitary body 3 and the housing 1 on axial reception of the barrel 8 inside the ring 11 and reception of the first tongue 9 in a first window 16 in the connecting member 10 , visible in FIG. 5 . The connecting member 10 also includes a second window 17 through which the second tongue 7 of the second conductive element 5 passes. It follows from this that the unitary body 3 is axially introduced into and radially positioned in the one-piece assembly. The travel on introduction of the unitary body 3 into the one-piece assembly is limited by axial positioning means.
In the alternative embodiment shown in FIG. 1 , the axial positioning means consist of a bent portion 18 of the first tongue 9 adapted to abut against the connecting member 10 . Referring to FIG. 2 , the first conductive element consisting of the unitary body 3 is formed by cutting a metal sheet 19 into a strip 20 and a tongue 21 that are mutually orthogonal. The strip 20 is rolled to form the barrel 8 and the tongue 21 is bent to form the first tongue 9 and its bent portion 18 .
In the embodiment shown in FIGS. 3 to 5 , axial positioning is achieved by clipping the unitary body 3 onto the one-piece assembly 4 between opposed axial bearing points. One of these axial bearing points 22 is formed by a ring at the distal end of the unitary body 3 and is adapted to bear against the connecting member 10 . The other axial bearing point 23 is formed by a projection on the barrel 8 that bears against the edge of a window 24 in the cage 12 in the vicinity of its area joined to the ring 11 . The unitary body 3 shown in FIG. 6 is advantageously formed by stamping a metal blank to form in a single operation the barrel 8 , the axial bearing point 22 and the first tongue 9 , and even the axial bearing point 23 .
In an embodiment that is not shown, the socket of the present invention is produced by molding the one-piece assembly 4 onto the unitary body 3 .
The one-piece assembly 4 is clipped to the structural element 2 after receiving the unitary body 3 and is immobilized axially between two opposed axial bearing points. One bearing point 25 is formed by a flange of the ring 11 and the other bearing point 26 is formed by raised patterns at the periphery of the cage 12 in the vicinity of the bearing point 25 . It follows that when the socket is mounted on the structural element 2 it is positioned radially by the polarizer 14 and axially by virtue of being engaged with respective opposite sides of the wall of the structural element 2 in which the housing 1 is formed.
While the forms of apparatus herein described constitutes preferred embodiments of this invention, it is to be understood that the invention is not limited to these precise forms of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims. | An auxiliary electrical socket for automobile vehicles that includes a unitary body having a connecting tongue and a barrel adapted to receive a plug. This socket also includes a one-piece assembly that has a connecting member and a ring. The ring receives the barrel and constitutes a member for joining the socket and a structural element of the vehicle. The unitary body and the one-piece assembly include integral nesting-type assembly and positioning means. | 7 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a method and device for determine the position of an object. The exact determining the position of objects in the industrial production is a vary useful and necessary condition. The acknowledgment the coordinates of the tools and components provide increasing quality of products and decreasing production costs. For example at tightening joint screws of cylinder head must follow the right sequence to avoid stress in the cylinder head and clamp the cylinder head seal uniformly. A screw joint which has not been acceptably tightened can cause a break down of safety critical parts of a motor car.
[0002] At the moment there are several possibilities to determine the position of an object:
[0003] Mechanical, for example through turn sensors or distance sensors. The object is mounted on a movable arm. The Disadvantage of this system is that a movable arm is fixed on a device and the freedom of movement is limited.
[0004] Position determination through delay time, for example Global Positioning System or ultrasound. The disadvantage of a system based on radiowave is bad accuracy (circa 50 cm) and therefore is not sufficient. A ultrasound positioning system is disturbed by sound of pneumatic machines that are used in a production.
[0005] Position determination through a optical method with a camera. The camera searches for a pattern or an object that is deposited in the memory of the system.
[0006] This system is very disturbed for example by bad contrast, bad lightening and radiation of other light sources.
[0007] It is an object of the invention to provide a method and device for determining the position of an object precise and undisturbed. It increase the quality on objects assembled by screw joints through force the operator for removal an unacceptable tightened screw joint before he move to the next screw joint or object.
[0008] Further objects and advantages of the invention will appear from the following specifications and claims.
[0009] A preferred embodiment of the invention is described below with references to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a schematic view of an object with a light source which position will determine through a light sensor/image sensor with an optical band-pass filter and an optical lens.
[0011] FIG. 2 shows a schematic 3D plane view of an object with a light source and the light sensor/image sensor, the optical band-pass filter and the optical lens are shown as a plane.
[0012] FIG. 3 shows a similar view as FIG. 2 but illustrates two systems comprises light sensor/image sensor, optical band-pass filter and optical lens as a plane for determining the position of the object in space.
[0013] FIG. 4 shows a schematic view of a workpiece carrier carrying an object with screw joints to be tightened by a power wrench with position indicating means.
DETAILED DESCRIPTION
[0014] The schematic arrangement shown in FIG. 1 comprises an object 1 with a light source 2 , an optical band-pass filter 3 , an optical lens 4 , a light sensor/image sensor 5 , a front view of the light sensor/image sensor 9 , a pixel 10 on the light sensor/image sensor, a light beam 6 from the light source and a light beam 7 from other light source that is unwanted. Number 8 shows the side view of the optical band-pass filter 3 , optical lens 4 and the light sensor/image sensor 5 .
[0015] The arrangement in FIG. 1 describes the method of the invention for sense the light from the light source 2 to determine the position of the object 1 . The light beam 6 from the object 1 passes the optical band-pass filter 3 , the optical lens 4 and meets the light sensor/image sensor 9 . The pixel 10 that is illuminated from the light beam 6 appear as a bright pixel. All pixels that are illuminated from the light beam 6 together add up to a bright flaw. The unwanted light beam 7 can not pass the optical band-pass filter and therefore comes the bright flaw 10 on the light sensor/image sensor only from the light source 2 from the object 1 . The bandwidth of the light source 2 and the bandwidth of the optical band-pass filter 3 is attuned to each other.
[0016] In FIG. 2 there is illustrated the schematic arrangement in form of planes.
[0017] The arrangement in FIG. 2 comprises an object 12 with a light source 13 , a plane 11 of the object 12 , an optical band-pass filter 15 , an optical lens 16 , a light sensor/image sensor 17 , a pixel 18 on the light sensor/image sensor 17 , a light beam 14 from the light source 13 and a light beam 20 from other light source 19 that is unwanted.
[0018] The arrangement in FIG. 2 describes the method of the invention for sense the light from the light source 13 to determine the position of the object 12 . The light beam 14 from the light source 13 passes the optical band-pass filter 15 , the optical lens 16 and meets the light sensor/image sensor 17 . The pixel 18 that is illuminated from the light beam 14 appear as a bright pixel. All pixels that are illuminated from the light beam 14 together add up to a bright flaw. The unwanted light beam 20 can not pass the optical band-pass filter 15 and therefore comes the bright flaw on the light sensor/image sensor 17 only from the light source 13 on the object 12 . The bandwidth of the light source 13 and the bandwidth of the optical band-pass filter 15 is attuned to each other.
[0019] In FIG. 3 there is illustrated the schematic arrangement in form of planes which comprises two systems for determine the position of an object in space.
[0020] The schematic arrangement comprises an object 21 with a light source 22 , two planes from two views 28 , 29 of the object 21 , an optical band-pass filter 23 , 30 , an optical lens 24 , 31 , a light sensor/image sensor 25 , 32 , a pixel 27 , 33 on the light sensor/image sensor 25 , 32 , a light beam 46 , 47 from the light source 22 and a light beam 48 , 49 from other unwanted light source 26 .
[0021] The arrangement in FIG. 3 describes the method of the invention for sense the light from the light source 22 to determine the position of the object 21 in space. The light beam 46 , 47 from the light source 22 passes the optical band-pass filter 23 , 30 , the optical lens 24 , 31 and meets the light sensor/image sensor 25 , 32 . The pixel 27 , 33 that is illuminated from the light beam 46 , 47 appear as a bright pixel. All pixels that are illuminate from the light beam 46 , 47 together add up to a bright flaw. The unwanted light beam 48 , 49 can not pass the optical band-pass filter 23 , 30 and therefore comes the bright flaw on the light sensor/image sensor 25 , 32 only from the light source 22 on the object 21 . The bandwidth of the light source 22 and the bandwidth of the optical band-pass filter 23 , 30 is attuned to each other. Under consideration of geometrical context it is possible from the information of the light sensor/image sensor 25 , 32 to determine/calculate the position of the object 21 in space.
[0022] In FIG. 4 there is illustrated an embodiment of the invention that provides a device to control a power wrench 38 that each screw joint 40 , 41 is tightened with the right parameters. The power wrench 38 is provided with an identity providing means in the form of a light source 39 which is recognised by two stationary position scanning cameras 34 , 35 with optical band-pass filter 36 , 37 , wherein the light source 39 , the cameras 34 , 35 , the optical band-pass filters 36 , 37 and control unit/calculation unit 44 form a position sensing system. The cameras 34 , 35 with the optical band-pass filter 36 , 37 are connected to the control unit/calculation unit 44 and arranged to transfer the signals for calculation the actual position of the power wrench 38 . The control unit/calculation unit 44 is connected to the control unit 45 of the power wrench 38 and they communicate with each other.
[0023] The position sensing system is arranged to indicate continuously the position of the power wrench 38 during operations on the workpiece 42 that lies on the workpiece carrier 43 .
[0024] The control unit 45 of the power wrench 38 is programmed with target torque levels, angle and/or spend time as well as limit value for each tightening operation for each screw joint 40 , 41 . The control unit/calculation unit 44 is programmed with the right sequence of tightening screw joints 40 , 41 . That means that each tightening operation will monitor by the control unit 45 and control unit/calculation unit 44 and they together will provide an OK or NOK indicating telling whether the tightening result of each screw joints 40 , 41 is acceptable or not.
[0025] If a non-acceptable tightening result is occurred it is possible to program the control unit 45 of the power wrench 38 so, that for example the power wrench 38 can be locked until the non-acceptable tightening screw joint is corrected before moving to the next screw joint or to the next workpiece. Other possibilities for programming the control unit 45 are thinkable and are not limited after a non-acceptable tightening screw joint.
[0026] An important advantage provided by the method and device according to the invention is that no-preprogramming of screw joint positions is necessary.
[0027] It is to be observed that the embodiment of the invention are not limited to the above described examples but may be freely varied within the scope of the claims. For instance, the above mentioned method to communicate signals by wire between the control unit of the power wrench and the control unit/calculation unit of the position sensing system may be carried out by any available communication system and by wireless communication too. All communications by wire can replace through wireless communications. The control unit of the power wrench and the control unit/calculation unit of the position sensing system can be integrated to one control unit. | A method and device for determining the position of the object with a light source. The light source illuminates light with a specific range of wave length. The optical band-pass filter lets pass only the light from the light source for the most part. And the camera only sees the light from the light source which is mounted on the object. The arithmetic unit calculates the position of the light source from the data of the cameras. The position is known of the light source on the object and therefore it is possible to determine the position of the object over the position of the light source. | 1 |
CROSS-REFERENCE TO A RELATED APPLICATION
The invention described and claimed hereinbelow is also described in German Patent Application DE 10 2006 007 067 filed on Feb. 15, 2006. This German Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present invention generally relates to a linear guide device with separate circulatory units.
More particularly, the present invention relates to a linear guide device with a guide rail which extends in the guidance direction, and a guide carriage which is guided such that it is displaceable on the guide rail in the guidance direction using at least one rolling body circuit; the at least one rolling body circuit includes a circulatory channel and a large number of rolling elements which circulate in the circulatory channel; the circulatory channel includes a running channel which is bounded by a rolling body circuit formed in the guide rail and by a load-bearing wall section of the guide carriage, and it includes a return channel and two turnaround channels which connect the running channel with the return channel, in which the rolling elements are essentially load-free; the guide carriage includes a base unit and at least two circulatory assemblies.
A linear guide device of this type is made known, e.g., in DE 102 37 278 A1. In this case, two circulatory assemblies designed as plastic injection-moulded parts are placed on the base unit of the guide carriage, and they are connected with each other at each end of the guide carriage using an end plate. The end plate contains turnaround inserts which, since the circulatory assemblies are manufactured via injection moulding, cannot be provided integrally with the circulatory assemblies. In addition, the circulatory assemblies are installed on the base unit of the guide carriage in a force-transmitting manner using the end plate. This known linear guide device has the disadvantage that, although the circulatory assemblies can be used “as is” for guide carriages having different widths, an end plate adapted to each width must be provided.
It should be pointed out that reference is hereby expressly made to the contents of DE 102 37 278.0 and U.S. application Ser. No. 10/638,756, which was submitted with claim to the priority of this German patent application, to supplement the disclosure of the current application, in particular with regard for the basic design of the guide carriage.
An attempt is made to solve this problem using the linear guide devices made known on pages 166 through 169 of the catalog “Linearführungen, Profilschienenführungen, Laufrollenführungen, Wellenführungen” ( Linear Guides, Rail Guides, Cam Roller Guides, Shaft Guides ), publication LIF from the INA Company. The circulatory groups used there have the disadvantage, however, that, in order to provide a sufficiently stable guide, they are made of steel, and these steel circulatory groups are mounted on the base unit using screw bolts, which are difficult to install.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a linear guide device with separate circulatory units, which is a further improvement of the existing linear guide devices.
More particularly, it is an object of the present invention In contrast, the object of the present invention is to improve a generic linear guide device by ensuring that it can be easily adapted to guide carriages having different widths and lengths, but which are cost-favorable to manufacture and ensure easy installation of the circulatory groups and the guide carriage.
This object is attained according to the present invention by a generic linear guide device, with which the two circulatory groups are designed separately and are connected with each other only via the base unit, and at least four recesses are provided in the guide carriage, each of which includes an end face which extends essentially orthogonally to the guidance direction, against which one of the circulatory assemblies bears in the guidance direction; the end faces of two recesses each located on one side of the guide rail point in opposite directions.
By providing the recesses, the circulatory group of the inventive linear guide device can bear in the guidance direction against the end faces formed on the base unit, so that the force can be transferred between the circulatory group and the base unit preferably essentially entirely via this planar support. It is therefore not necessary to provide a mounting of the circulatory group on the base unit which is suitable for force transmission and which must therefore have a complex design.
According to the descriptions provided above, compared with the related art, a “base unit” is understood—per the present invention—to refer to the guide carriage without circulatory groups and end plates on the end faces. Based on this fact, among others, the circulatory groups are mounted directly on the base unit.
With an embodiment of the present invention, the recesses can be provided on both ends of the base unit; this ensures that the base unit will be particularly simple to manufacture.
In addition or as an alternative thereto, at least one recess can be provided in an essentially central region of the base unit. Several circulatory groups located one behind the other in the guidance direction can be provided on the guide carriage, for example, so that the circulatory groups of the inventive linear guide device can also be used with guide carriages having different lengths.
According to a further refinement of the inventive object, the circulatory groups are made at least partially of plastic, preferably via injection-moulding. The circulatory group can include a load-bearing wall section—made of metal—of the running channel, which bears against the base unit of the guide carriage, so that, even though the circulatory group is manufactured as a plastic part, a stable design and support of the running channel can be provided.
To ensure particularly simple mounting of the circulatory group on the base unit, it can be provided that each circulatory group includes several mounting segments which engage in openings of the base unit, and the end regions of which are deformable in order to rivet the circulatory group with the base unit. The mounting segments are preferably made of plastic.
To simplify the manufacture of a circulatory group, e.g., using injection moulding, it can be provided that each circulatory group includes a main part and two turnaround inserts.
Each of the turnaround inserts preferably bears in the guidance direction against the end face of the base unit and against a mounting segment, and/or a cover wall of the main part of the circulatory group, by way of which the turnaround inserts are fixed in position securely on the main part.
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 shows a perspective view of a guide carriage of a linear guide device according to a first embodiment of the present invention;
FIG. 2 is an exploded view of the guide carriage in FIG. 1 ;
FIG. 3 is a front view of the linear guide device of the first embodiment of the present invention;
FIG. 4 is a perspective view of the guide housing of the linear guide device in FIGS. 1-3 ;
FIG. 5 is a further perspective view of the guide carriage according to the first embodiment of the present invention;
FIG. 6 shows a perspective view of a guide carriage according to a second embodiment of the present invention; and
FIG. 7 is a sectional view of a linear guide device, which shows how the rolling element running channel rests on the base unit of the guide carriage in the manner according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment of the present invention which is shown in FIGS. 1 through 5 will be explained first.
As shown in FIG. 3 , a linear guide device 10 includes a guide housing 12 , in which two guide rails 14 a and 14 b are fixed in position by staking a dovetail segment of guide rails 14 a and 14 b in grooves 16 a and 16 b in guide housing 12 . A threaded spindle 20 is rotatably supported in guide housing 12 to drive a guide carriage 18 which is guided in guide housing 12 in a guidance direction. A counternut 22 fastened to guide carriage 18 is engaged with threaded spindle 20 . A cover plate 24 is also secured to guide housing 12 .
Guide carriage 18 includes a base unit 26 , which is typically made, e.g., of aluminium, in particular an aluminium extruded profile section, which is provided with support sections 28 for securing an object to be moved by linear guide device 10 , and legs 30 a , 30 a , each of which laterally encloses an associated guide rail 14 a , 14 b and is guided on this guide rail.
Each of the legs 30 a , 30 a of guide carriage 18 includes a rolling element circulatory assembly 32 a , 32 b . Each circulatory group 32 a , 32 b is riveted with base unit 26 using two mounting segments 34 (see FIGS. 1 and 2 ) by guiding mounting segments 34 through openings 36 in base unit 26 , and then deforming the exposed end of mounting segments 34 .
According to the present invention, guide carriage 18 and, in particular, circulatory groups 32 a , 32 b , are designed such that circulatory groups 32 a , 32 b can be provided as preassembled units, by including the rolling elements (not shown in FIGS. 1 through 5 ) which serve to guide guide carriage 12 on guide rail 14 . Each circulatory group 32 a , 32 b includes a main part 48 , which is preferably made as a plastic injection-moulded part, on which a trough-shaped element 42 is installed by being snapped into place, and two turnaround inserts 50 which are inserted in the main part such that they bear against a cover wall of main part 48 and mounting segment 34 which is integral with main part 48 .
The rolling elements circulate in a rolling element circulatory channel 38 which is formed by a running channel 39 , a return channel, and two turnaround channels. Running channel 39 is formed between guide carriage 18 and guide rails 14 a , 14 b , and is bounded by a running surface 40 on the side of guide rails 14 a , 14 b , and by a load-bearing section of a trough-shaped element 42 on the side of guide carriage 18 . In return channel 44 which forms circulatory group 32 a , 32 b , the rolling elements return, load-free, to the beginning of running channel 39 . Running channel 39 and return channel 44 are connected at both longitudinal ends in turnaround channels 46 formed in circulatory group 32 a , 32 b.
As shown in FIG. 2 in particular, lower wall sections of return channel 44 and both turnaround channels 46 are formed on main part 48 of circulatory group 32 a , 32 b . Together with a steel wire—which is indicated in FIG. 2 using a dash-dotted line—the rolling elements are therefore enclosed by circulatory group 32 a , 32 b such that circulatory group 32 a , 32 b acts as a basket or shell, out of which the rolling elements do not fall.
Trough-shaped element 42 is preferably made of steel, so that it can easily withstand the stresses placed on its load-bearing wall. In the state in which it is joined with base unit 26 , trough-shaped element 42 bears with its back side directly against base unit 26 . In this manner, the forces of the load-bearing running channel 39 to be absorbed can be transferred directly to base unit 26 .
Four recesses 52 are formed in the ends of base unit 26 , the end faces 54 of which extend essentially orthogonally to the guidance direction. As shown in FIGS. 1 and 2 in particular, circulatory groups 32 a , 32 b bear via their turnaround inserts 50 against end faces 54 such that forces acting in the guidance direction or against the guidance direction can be transferred via this planar support directly from circulatory groups 32 a , 32 b to base unit 26 .
This design makes it possible, with inventive linear guide device 10 , to install circulatory groups 32 a , 32 b —at least part of which are manufactured as a plastic injection-moulded part—directly on base unit 26 of guide carriage 18 without installing an end plate in-between, since, given that circulatory groups 32 a , 32 b bear against end faces 54 of recesses 52 , a stable transfer of force between circulatory groups 32 a , 32 b and base unit 26 is attained without placing stress on the attachment of circulatory groups 32 a , 32 b on base unit 26 via mounting segments 34 .
It is therefore possible, with the linear guide device according to the present invention, to use the same injection-moulded main parts 48 and trough-shaped elements 42 of circulatory assemblies 32 a , 32 b , which are already used, e.g., for linear guide deices made known in DE 102 37 278 A1. It is only necessary to change turnaround inserts 50 of inventive circulatory groups 32 a , 32 b as compared with the circulatory groups made known in DE 102 37 278 A1, in which case they are connected with each other via an end plate with integrated turnaround inserts. As a result, the manufacturing cost for inventive circulatory groups 32 a , 32 b is minimized.
In addition, a preload-adjustment device 56 is assigned to a leg 30 a of guide carriage 18 ( FIG. 5 ). This preload-adjustment device 56 includes several knee joints 58 which are integral with base unit 26 of guide carriage 18 . A not-shown adjustment screw bears against base unit 26 of guide carriage 18 and engages in a thread in an engagement part 60 of knee joint 58 , so that the preload of legs 30 a , 30 a against guide rails 14 a , 14 b can be adjusted by rotating the adjustment screw.
As shown in FIG. 5 , two bores 62 are formed on the end face of counternut 22 , in which a matching tool can engage in order to screw counternut 22 via its (not shown) outer thread into the (not shown) thread of base unit 26 .
FIG. 6 shows a second embodiment of the present invention, in which two circulatory groups 32 a 1 ′, 32 a 2 ′, 32 b 1 ′ 32 b 2 ′ are provided on either side of base unit 26 ′ and extend in the guidance direction. In order to support circulatory groups 32 a 1 ′, 32 a 2 ′ 32 b 1 ′, 32 b 2 ′ in the guidance direction and in the direction opposite thereto, an additional, central recess 62 ′ with two end faces 64 a ′, 64 b ′ is provided on both sides of base unit 26 ′. Each circulatory group 32 a 1 ′, 32 a 2 ′ 32 b 1 ′, 32 b 2 ′ therefore bears, via one side, against an end face 54 ′ of recess 52 ′ located on one end of guide carriage 18 ′, and via its other side against an end face 64 a ′, 64 b ′ of center recess 62 ′. As a result, circulatory groups 32 a 1 ′, 32 a 2 ′ 32 b 1 ′, 32 b 2 ′ can be used with guide carriages 18 , 18 ′ having different lengths or widths.
FIG. 6 also shows a retaining bracket 66 ′ which is mounted on a main part 48 ′ of circulatory groups 32 a 1 ′, 32 a 2 ′ 32 b 1 ′, 32 b 2 ′, which prevents rolling elements 68 ′ from falling out of the running channel when guide carriage 18 ′ is not installed on a guide rail. Instead of this retaining bracket, it is can be provided that the load-bearing wall section of the running channel formed in each circulatory group encloses the rolling elements around more than half of their circumference.
FIG. 7 shows a cross section through a linear guide device 10 ″, with which, instead of the guide rail, an arm element 14 ″ is enclosed by guide carriage 18 ″ and serves to illustrate how element 42 ″—which forms a wall of load-bearing running channel 39 ″—of circulatory groups 32 a ″, 32 b ″ bears against base unit 26 ″ of guide carriage 18 ″. As a result, the forces transferred via the running channel between guide carriage 18 ″ and guide rail 14 ″ are absorbed by base unit 26 ″ without the intermediate installation of main part 48 ″ of circulatory group 32 a ″, 32 b ″, so that, despite the fact that main part 48 ″of circulatory groups 32 a ″, 32 b ″ is designed as a plastic part, it is ensured that the guidance of guide carriage 18 ″ on guide rail 14 ″ is adequately stable.
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 type described above.
While the invention has been illustrated and described as embodied in a linear guide device with separate circulatory units, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | A linear guide device, comprising a guide rail; a guide carriage displaceable on the guide rail and having at least one rolling body circuit with a circulatory channel for rolling elements and including a running channel, a return channel and two turnaround channels. The guide carriage has a base unit and at least two circulatory assemblies with at least one rolling body circuit and configured to be separate and interconnected only via the base unit. The guide carriage also has at least four recesses with orthogonal end faces, with two end faces on each side of the guide rail pointing in opposite directions. | 5 |
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This is a non-provisional application based on U.S. Ser. No. 60/479,710, filed Jun. 19, 2003.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] The present invention is directed toward testing of specimens, and particularly toward an apparatus and method for processing specimens during testing, including adding fluids such as reagents during the processing of specimens.
BACKGROUND OF THE INVENTION
AND
TECHNICAL PROBLEMS POSED BY THE PRIOR ART
[0005] Testing sample biological specimens is commonly done, for example, to check for the presence of an item of interest, which item may be or include all or portions of a specific region of DNA, RNA, or fragments thereof, complements, peptides, polypeptides, enzymes, prions, proteins, messenger RNA, transfer RNA, mitochondrial RNA or DNA, antibodies, antigens, allergens, parts of biological entities such as cells, virons or the like, surface proteins, or functional equivalents of the above, etc. Specimens such as a patient's body fluids (e.g., serum, whole blood, urine, swabs, plasma, cerebral-spinal fluid, lymph fluids, tissue solids) can be analyzed using a number of different tests to provide information about a patient's health.
[0006] In such testing, it is imperative that the specimens be handled in a manner which prevents contaminants from being introduced to the specimens, whether from the outside environment or between specimens. For example, where the HIV virus from one specimen is inadvertently allowed to contaminate the specimen of a different patient, the resulting false positive test result could potentially have catastrophic psychological effect on the patient, even should subsequent testing later discover the error. Moreover, since such testing is highly sensitive, even the smallest amounts of contamination can cause erroneous test results. Simply put, it is imperative that the specimens be properly handled.
[0007] In such sophisticated testing, it is also imperative that the various reagents which may be used in the testing be properly handled as well, not only to avoid contaminants but also to ensure that the proper reagent in proper quantities is used at appropriate times.
[0008] Commonly, such testing is accomplished using automated devices which handle multiple specimens and fluids (typically, reagents). Such automated devices typically will use sets of pipettes to move various fluids between their original containers (usually receptacles such as open topped tubes) and containers in which the specimens are to be processed. For example, a set of 8 specimens may be contained in 8 tubes or other receptacles loaded in a rack on the device, and a head carrying 8 pipettes will, through programmed motion, move the pipettes into those 8 tubes, where a vacuum will be applied to extract a selected amount of each specimen from its tube into the pipettes. The head will then retract the pipettes from the tubes and move to another set of tubes located at a processing station, depositing the extracted amounts of each specimen from the pipettes into sets of testing tubes.
[0009] In such automated devices, racks or trays of multiple tubes are usually moved from one station to the next for different stages of processing. For example, a heating element may be provided at one station, and a magnetic element introducing a magnetic field in the tubes may be provided at another station. Further, in such situations, multiple trays of multiple tubes may be actively processed in series and simultaneously at different stations. However, such processing can result in resource contention, where one rack of tubes is delayed from being placed at a station while another rack of tubes completes its processing at that station when, as is commonly the case, the processing time at one station is different than the processing time at another station. For example, a tray of tubes which have completed processing at one station may be delayed from being processed at the next station until another tray of tubes at that next station has completed its processing there. Like a chain which is no stronger than its weakest link, such an automated device will provide an overall processing time which is a function of the processing time at the slowest station. Of course, a slow overall processing time can reduce the amount of tests which are performed during a given day, and thereby either delay the completion of tests or require significant additional investment of capital for additional devices to allow for a desired testing capacity level.
[0010] At the processing stations of such automated devices, the specimens are variously handled according to the purpose of the testing (e.g., incubated, prepared, lysed, eluted, etc.). For example, the specimens may be prepared for analyzing, as for example by separating DNA or RNA from the specimen. The specimens may also or alternatively be analyzed. Commonly, such processes involve the addition of various fluids (typically reagents) to the specimen in each tube. For example, in a first step, a reagent may be added to each of the tubes to wash the specimens, and second and third (and more) reagents may be added to the specimens in the course of carrying out other processes to, for example, unbind and/or separate the DNA or RNA of interest so that it may be extracted from the specimen in each tube for subsequent testing. Similar processes, in which the same or different reagents are added to and/or extracted from the tubes, may also occur after the specimen has been prepared as part of analyzing the prepared specimens.
[0011] In some processes, magnetic fields have been used to assist in separating analytes of interest from the fluid in the tubes. For example, analytes of interest have been bound to magnetic particles within a reagent and a magnetic field applied to pull the particles and bound analyte to one side of the tube, whereby the reagent may be drawn out of the tube to leave a concentration of the analyte therein. Where it has been necessary to adjust the magnetic field within the tubes (e.g., in order to change the location where the analytes are to be drawn), the tubes have been moved in order to accomplish the desired orientation of the magnetic field in the tubes.
[0012] The handling of the reagents and other fluids with automated devices such as described above can be problematic. Though the reagents may be automatically moved from receptacles to the specimen containing tubes in the processing station by use of the head and pipettes such as noted, it is in the first instance necessary to load the appropriate reagent into the appropriate receptacle on the device in order to ensure that the head and pipettes are adding the appropriate reagent to the appropriate specimen containing tube at the appropriate time in the process. Further, it should be recognized that it is necessary for the receptacles to be readily cleaned, whether to remove possible contaminants or to permit use of different fluids in connection with different processes. As a result of such requirements, the receptacles are typically readily removable from the apparatus for such action.
[0013] Heretofore, loading the appropriate reagent into the appropriate receptacle has been accomplished in several different ways. In one such procedure, the individual who is controlling the device manually measures and adds the reagents to receptacles, and then places those receptacles on the device. In another such procedure, the loading of reagents is automatically accomplished by the device itself, which uses some transfer apparatus (such as a head and pipette(s) as previously described) to move the reagents from bulk supplies of the reagents provided with the device.
[0014] Removing reagents from tubes is similarly accomplished, such as by use of a head which positions pipettes in the tube and vacuum draws the fluid from the tubes into the pipettes. Such a process can be time consuming, and tie up the head from other uses, particularly if prevention of contamination between tubes makes it necessary to use a new pipette with each tube. In such cases, it may be necessary to repetitively move the head to discharge, discard and pick up new pipettes every time fluid is drawn from tubes (e.g., a head carrying eight pipettes may have to be cycled six times when used with a tray of 48 tubes, where each cycle requires discharging and discarding used pipettes, and picking up new pipettes). Of course, in such situations, multiple pipettes will be consumed at some cost. U.S. Pat. No. 6,117,398 alternatively discloses drawing fluid from the bottom of a sample vessel, wherein a valve is situated between every sample processing vessel and the waste container.
[0015] The present invention is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0016] In one aspect of the present invention, a reaction vessel for testing an analyte in a fluid is provided. The vessel has an open top and a drain opening in its bottom, with the drain opening being adapted to support a selected head of fluid and to drain fluid therethrough when a selected pressure differential exists between the top of the fluid and the bottom of the vessel.
[0017] In one form of this aspect of the invention, the surface tension of the fluid supports the selected head of fluid when the pressure differential between the top of the fluid and the bottom of the vessel is less than the selected pressure differential.
[0018] In another form of this aspect of the invention, a hydrophobic frit is associated with the drain opening.
[0019] In another form of this aspect of the invention, the drain opening permits draining of the fluid only when the relative pressure between the top of the fluid and the drain opening is at least a selected amount.
[0020] In still another form, a non-wettable surface is provided around the drain opening on the outside of the vessel.
[0021] In yet another form, a drain opening protrusion extends beyond the bottom surface of the vessel.
[0022] In another aspect of the present invention, a processing zone for a specimen handling device is provided, including a support for a plurality of reaction vessels having drain openings in their bottoms, passages adapted to communicate with the bottom drain openings of supported reaction vessels, and a source of air at non-atmospheric pressure adapted to selectively drain fluid through the drain openings in supported reaction vessels. The drain openings are adapted to support a selected head of fluid in the vessels.
[0023] In one form of this aspect of the invention, the source of air at non-atmospheric pressure is a vacuum source for drawing a vacuum in the passages.
[0024] In another form of this aspect of the invention, a heater is provided for heating reaction vessels supported in the processing zone.
[0025] In still another form, the reaction vessels are adapted to selectively contain fluids having a surface tension sufficient to support a selected head of fluid without the fluid draining through the drain openings, and the source of air at non-atmospheric pressure is adapted to selectively create a relatively lower pressure at the drain opening than at the top of the fluid to overcome the fluid surface tension and selectively drain the fluid through the drain openings.
[0026] In yet another form, the support is adapted to support the plurality of reaction vessels in at least two rows, each row having a defined space from at least one adjacent row. In a further form, the defined space between rows is a generally vertical longitudinal slot, and a bar magnet extends generally horizontally and is supported for selected vertical movement in the slot. In a still further form, the support is adapted to support the plurality of reaction vessels in at least four rows and the defined space is a generally vertical longitudinal first slot between the first and second rows and a generally vertical longitudinal second slot between the third and fourth rows, with the bar magnet being a first bar magnet supported for selected vertical movement in the first slot and a second bar magnet supported for selected vertical movement in the second slot. In a yet further form, the first and second bar magnets are supported for vertical movement together.
[0027] In still another aspect of the present invention, a method of processing analytes in fluids in reaction vessels is provided, including the steps of (1) supporting a reaction vessel containing an analyte in a fluid, the reaction vessel having a drain opening in its bottom capable of supporting a selected head of the fluid in the vessel by the surface tension of the fluid, (2) drawing the analyte to a side of the vessel to concentrate the analyte clear of the drain opening, and (3) selectively creating a pressure differential between the top of the fluid and the bottom of the drain opening sufficient to overcome the fluid surface tension and drain the fluid through the drain opening.
[0028] In one form of this aspect of the invention, the selectively creating a pressure differential step includes selectively creating a vacuum beneath the drain opening.
[0029] In another form of this aspect of the invention, the drawing step includes binding the analyte to a magnetic particle, and introducing a magnetic field into the vessel which draws the magnetic particle and bound analyte to the side of the vessel. In a further form, the magnetic field is moved vertically along the height of the reaction vessel to draw the magnetic particles and bound analyte together into a pellet in the reaction vessel. In a still further form, the moving step moves the magnetic field down from an upper position near the top of the fluid in the reaction vessel to a position near the bottom of the reaction vessel whereby the pellet is formed near a bottom side of the reaction vessel.
[0030] In yet another aspect of the present invention, a processing zone for a specimen handling device is provided, including a support adapted to support a reaction vessel in a generally vertical orientation, and a magnet supported for selected vertical movement along one side of a supported reaction vessel.
[0031] In one form of this aspect of the invention, the support is adapted to support a plurality of reaction vessels in at least two rows where each row has a defined spacing from at least one adjacent row, and the magnet extends generally horizontally and is supported for selected vertical movement in the defined spacing. In a further form, the defined spacing between rows comprises a generally vertical longitudinal slot, and magnet is a bar magnet or an electromagnet. In a still further form, (1) the support is adapted to support the plurality of reaction vessels in generally parallel first, second, third and fourth rows, (2) the defined space is a generally vertical longitudinal first slot between the first and second rows and a generally vertical longitudinal second slot between the third and fourth rows, and (3) the bar magnet includes a first bar magnet supported for selected vertical movement in the first slot and a second bar magnet supported for selected vertical movement in the second slot. In a yet further form, the first and second bar magnets are supported for vertical movement together.
[0032] In yet another aspect of the present invention, a method of processing analytes in fluids in reaction vessels is provided, including the steps of (1) supporting a reaction vessel containing an analyte in a fluid, (2) binding the analyte to a magnetic particle, (3) introducing a magnetic field into the vessel which draws the magnetic particle and bound analyte to the side of the vessel, and (4) moving the magnetic field vertically along the height of the reaction vessel to draw the magnetic particle and bound analyte together into a pellet in the reaction vessel.
[0033] In one form of this aspect of the invention, the moving step moves the magnetic field down from an upper position near the top of the fluid in the reaction vessel to a position near the bottom of the reaction vessel whereby the pellet is formed near a bottom side of the reaction vessel.
[0034] In a still further aspect of the present invention, a fluid handling mechanism is provided for an analyte testing device which includes a deck with a processing zone having a plurality of reaction vessels supported therein with upwardly facing openings. The fluid handling mechanism includes a first bulk supply of a first fluid, and a dispensing head having X discharge openings selectively positionable with each of the discharge openings over the upwardly facing openings of X selected reaction vessels, wherein X is at least four. A metering pump mechanism is adapted to selectively meter X units of a selected quantity of fluid from the first bulk supply, and selectively pump X units of metered selected quantities of fluid through the discharge openings to the selected reaction vessels.
[0035] In one form of this aspect of the invention, the deck supports a plurality of reaction vessels in a repeating pattern, each pattern including X reaction vessels, and the dispensing head discharge openings are arranged in the pattern. In a further form, the repeating pattern comprises a plurality of rows of reaction vessels. In a still further form, the rows include at least eight reaction vessels, and X is at least eight.
[0036] In another form of this aspect of the invention, a second bulk supply of a second fluid is provided, and the metering pump mechanism is adapted to selectively meter the X units of the selected quantity of fluid from a selected one of the first and second bulk supplies. In a further form, the metering pump mechanism includes X piston pumps, and X valve structures are also provided, where each valve structure is associated with one of the piston pumps and selectively switchable between providing a connection to (1) a selected one of the first and second bulk supplies, and (2) an associated discharge opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 is a perspective view of a processing zone and one reaction vessel according to various aspects of the present invention;
[0038] FIGS. 2 a , 2 b , and 2 c are cross-sectional views of a processing zone supporting a plurality of reaction vessels illustrating the magnets in different positions according to one aspect of the present invention;
[0039] FIG. 3 a is a perspective, cross-sectional view of a processing zone which includes the present invention;
[0040] FIG. 3 b is an enlarged cross-sectional partial view showing two reaction vessels supported in the processing zone;
[0041] FIG. 4 a is a cross-sectional view of a reaction vessel according to one aspect of the present invention;
[0042] FIGS. 4 b , 4 c , 4 d , and 4 e are enlarged cross-sectional partial views of different reaction vessels incorporating one aspect of the present invention;
[0043] FIG. 4 f is an enlarged cross-sectional partial view of a reaction vessel used with a passive valve as usable with certain aspects of the present invention;
[0044] FIG. 4 g is an enlarged cross-sectional partial view of a reaction vessel used with an active valve as usable with certain aspects of the present invention;
[0045] FIG. 5 is a graph showing the theoretical head or height of a particular fluid which will be retained based on the diameter of the fluid bead at the drain opening;
[0046] FIG. 6 is a graph illustrating test results of the head or height of a particular fluid which will be retained in a reaction vessel having different hole diameters;
[0047] FIG. 7 is a graph illustrating the predicted time required to evacuate a 3.5 mL sample through different drain openings; and
[0048] FIG. 8 is a diagram of a fluid handling mechanism according to an aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0049] Two processing zones 20 , 22 in accordance with the present invention and usable with a suitable automated testing device (not shown) are illustrated in FIG. 1 . For simplicity of explanation of the invention, the overall testing device is not (and need not be) shown in the figures. For example, a suitable automatic testing device may be adapted for the substantial isolation of nucleic acids from biological samples, including the isolation and testing of nucleic acids from biological samples.
[0050] In a suitable automated testing device for such a use, for example, a hood may be provided to protect against contamination from the environment in which the zones 20 , 22 are located to prevent outside contaminants from entering therein as is known in the art. Such an automatic testing device may advantageously also include one or more of the following features: (1) a receptacle to hold and segregate from samples and reagents used pipette tips such that contamination from used tips is minimized, (2) aerosol control devices, for example without limitation, (a) a sample tube or reagent tube sealer, (b) electrodes for treating surfaces and/or liquids with electrical current capable of modifying nucleic acids, (c) an ultraviolet light source capable of degrading or modifying nucleic acids, (d) an apparatus for causing laminar air flow in or around the automatic testing device, and (3) an optical detector (e.g., a flourometer) for measuring the light absorbance or fluorescence of processed samples. Tecan AG manufactures a general purpose laboratory pipetting instrument with which the various described aspects of the invention may be used. However, it should be understood that many features of such instruments, though usable with the present invention, do not form a part of the invention, and therefore are not shown in the figures. Those skilled in the art who obtain an understanding of the present invention will recognize such features, such as disclosed in, for example, in U.S. Ser. No. 10/360,956 titled “Apparatus and Method for Handling Fluids for Analysis”, filed Feb. 7, 2003, U.S. Pat. No. 6,413,780, titled “Structure and Method for Performing a Determination of an Item of Interest in a Sample”, and U.S. Publication No. 2002-0127727 also titled “Structure and Method for Performing a Determination of an Item of Interest in a Sample”, the complete disclosures of which are hereby incorporated by reference.
[0051] Further, a plurality of processing zones may be used with a single testing device such as shown, including not only multiple processing zones 20 , 22 embodying aspects of the present invention such as shown in FIG. 1 , but also additional processing zones (not shown) for different types of processing or specimen handling. For example, additional handling zones can be provided wherein reaction vessels may be prepared prior to desired processing by adding specimens, etc. The multiple processing zones 20 , 22 illustrated in FIG. 1 assist in minimizing resource contention (i.e., conflicts arising where processing using one group of reaction vessels may be delayed until another group of reaction vessels has completed processing at the next required processing zone 20 .
[0052] FIG. 1 generally illustrates a processing zone 20 at which testing of specimen samples may be done. In suitable testing devices with which the processing zones 20 , 22 as discussed herein may be used, reaction vessels 26 (only one of which is shown in FIG. 1 ) containing specimens for testing may be loaded onto supports 30 , 32 at each zone 20 , 22 . The supports 30 , 32 may be support brackets or racks, for example, defining rows in which reaction vessels 26 may be supported, each with an upwardly open top. The supports 30 , 32 may serve as heat shields to protect a user from heat blocks therebeneath (as described below). Suitable movable carriers may also be used which are transportable to and from the processing zones 20 , 22 (e.g., manually or by a suitable robotic arm) to facilitate handling reaction vessels where desired.
[0053] The supports 30 , 32 illustrated in FIG. 1 will support reaction vessels 26 in a repeating pattern, with a pattern consisting of a row of eight reaction vessels 26 repeated six times, whereby a total of forty-eight reaction vessels 26 may be processed simultaneously at one processing zone 20 or 22 . Thus, in the present description, the processing may be to isolate analytes of interest from up to forty-eight specimens (e.g., DNA or RNA), after which processing the isolated analyte may be further tested according to an appropriate protocol. However, it should be understood that the present invention is not limited in any way to such processing, and could as readily be used with a device in which different processing or protocols are carried out.
[0054] In the illustrated embodiment, each of the processing zones 20 , 22 includes heat blocks 40 which may be suitably controlled to heat the reaction vessels 26 to whatever temperatures, for whatever periods of time, is required by the processing or protocol being carried out. The heat blocks 40 may be configured so as to surround the reaction vessels 26 to dissipate heat from a suitable heater 42 evenly throughout the reaction vessels 26 in the processing zone 20 , 22 .
[0055] The heat blocks 40 may also be arranged with a longitudinal, vertical slot between adjacent rows of reaction vessels 26 . For example, as illustrated in FIGS. 2 a - 2 c , there is a slot 46 between the left two rows of vessels 26 , a slot 48 between the right two rows of vessels 26 , and a slot 50 between the middle two rows of vessels 26 .
[0056] In accordance with one aspect of the invention, suitable bar magnets 60 , 62 , 64 may be supported for movement in the slots 46 , 48 , 50 between the rows of reaction vessels 26 . The bar magnets 60 , 62 , 64 are suitably supported for selected vertical movement together in the slots 46 , 48 , 50 , as by a controlled drive 68 which moves a cross-support 70 on vertical guide rods 72 . It would, however, be within the scope of this aspect of the present invention to use any structure which would suitably control vertical movement of the bar magnets 60 , 62 , 64 as described hereafter so as to move the magnetic field 76 (see FIG. 2 a ) in the reaction vessels 26 . Moreover, it would be within the scope of the present invention to use still other suitable magnets, such as electromagnets. Still further, it should be understood that it would be within the scope of some aspects of the present invention to not use magnets at all (e.g., where certain aspects of the invention are used in processing which does not magnetically separate the analytes of interest from the fluid including, as one example, non-magnetic sample preparation in which the analytes of interest are bound to silica membrane).
[0057] Specifically, during processing of a specimen within the reaction vessel 26 , the analyte of interest dispersed in the reaction vessel 26 may be suitably bound to a magnetic material or particles in a suitable manner such as is known in the art. During processing thereafter, the magnets 60 , 62 , 64 may be selectively moved vertically in the slots 46 , 48 , 50 to draw the magnetic particles (and bound analyte of interest) to one side of the vessel 26 . Morever, by selectively moving the magnets 60 , 62 , 64 along the side of the vessels 26 in the slots, the magnetic particles and bound analyte of interest within the reaction vessel 26 may be strongly drawn to the side of the vessels 26 throughout the height of the vessel 26 by essentially subjecting the vessel contents to a uniform magnetic force throughout its height. Further, by moving the magnets 60 , 62 , 64 from an upper (lyse capture) position such as illustrated in FIG. 2 c to a bottom (wash capture) position as illustrated in FIG. 2 b , magnetic particles and bound analyte of interest may not only be drawn to the side of the vessels 26 but may also then be pulled down along the side of the vessels 26 as the magnets 60 , 62 , 64 move down whereby a desired pellet of such materials is formed at the bottom corner of the vessels 26 .
[0058] While the above described structure using bar magnets with multiple vessels 26 may be particularly efficiently used, it should be understood that most broadly, aspects of the present invention could also include the use of a magnet as described with a single reaction vessel 26 , that is, moving a magnet along one side of one vessel 26 to draw the magnetic particles and bound analyte of interest to the side of the vessel 26 and down to form a pellet at a bottom corner of the vessel 26 .
[0059] FIGS. 3 a - 3 b illustrate yet another aspect of the present invention. Specifically, each processing zone 20 , 22 may include concave recesses 78 (see FIG. 3 b ) for receiving the bottoms of the reaction vessels 26 , for example, in the heat blocks 40 . A horizontal drain passageway or channel 80 may extend along the length of the heat blocks 40 beneath each row of vessels 26 , with a vertical passageway 82 connecting the horizontal passageway 80 . A suitable vacuum source (indicated schematically at 86 in FIG. 3 a ) may be applied to the passageways 80 , 82 to selectively draw/drain fluid from the vessels 26 as described below. While a vacuum source 86 is described herein, it should be understood that the significant feature is a lower pressure beneath discharge or drain openings in the bottom of the vessels 26 (as described in detail below) relative to the pressure on the fluid at the top of the vessels 26 . Therefore, it should be understood that this aspect of the invention could also be accomplished through the application, for example, of high pressure to the top of the reaction vessels 26 where the passageways 80 , 82 are at atmospheric pressure, or a combination of pressure and vacuum.
[0060] Specifically, as illustrated in FIG. 4 a , it is contemplated as an example that a reaction vessel 26 may be provided with a fluid 90 and sample having a depth (or height or head) H.
[0061] A discharge or drain opening 92 is provided in the bottom of the reaction vessel 26 , where the drain opening 92 is configured so that the surface tension of the fluid 90 in its condition at the processing zone 20 , 22 is sufficient to support the height of fluid without the fluid draining through the drain opening 92 . It should be understood that, while a single opening 92 is shown in FIG. 4 a , it would advantageously be within the scope of the present invention to define the drain opening via multiple openings through the bottom of the vessel 26 .
[0062] FIG. 4 b illustrates a reaction vessel 26 with one configuration of drain opening 92 , where fluid- 90 has passed through the drain opening 92 so as to form a bead 94 around the opening 92 . So long as the opening 92 is small enough to maintain a bead 94 which is no greater in size than the surface tension of the fluid 90 can maintain, the fluid 90 will be supported in the vessel 26 (that is, until an additional force, a relative pressure between the top and bottom of the fluid 90 , is selectively created by the introduction of a vacuum in the passageways 80 , 82 beneath the vessels 26 ).
[0063] FIG. 4 c discloses an alternative embodiment of a reaction vessel 26 a , wherein a suitable non-wettable coating or surface 96 is provided around the drain opening 92 a . Such a non-wettable coating 96 will prevent a bead from spreading out onto the coating ( FIG. 4 b illustrates a bead 94 which spreads out onto the outer surface of the vessel 26 ), such that a larger size drain opening 92 a may be used while still maintaining the ability of the surface tension of the fluid 90 to support a desired height of fluid 90 in the vessel 26 a.
[0064] FIG. 4 d discloses still another embodiment of a reaction vessel 26 b , wherein a protruding tube or flange 98 is provided around the drain opening 92 b . The flange 98 may also prevent the bead from spreading out to an area much larger than the flange 98 , thereby allowing use of a larger drain opening 92 b while still maintaining the ability of the surface tension of the fluid 90 to support the fluid 90 as described for FIG. 4 c.
[0065] FIG. 4 e discloses yet another embodiment of a reaction vessel 26 c , in which a hydrophobic frit 99 or other suitable hydrophobic porous material (such as may be obtained from Porex Corporation of Fairburn, Ga.) is associated with the vessel 26 c to define the drain opening 92 c . The hydrophobic frit 99 may be advantageously selected, based on the fluid, whereby the frit 99 will support the desired height of fluid 90 in vessel 26 c , and will allow the fluid to pass therethrough when a selected pressure differential is introduced between the top of the vessel 26 c and beneath the frit 99 /drain opening 92 c . Thus, where a fluid having low surface tension properties is used (e.g., alcohol), the porosity of the frit material may advantageously be less than the material used with fluids having higher surface tension properties to enable the desired height of fluid to be supported as desired.
[0066] The above described vessels 26 , 26 a , 26 b , 26 c are particularly advantageous inasmuch as such vessels are low cost disposables. However, it should be understood that aspects of the present invention encompass still further vessels having drain openings which will support a head of fluid 90 by other than the fluid surface tension, while allowing that fluid to be selectively drained from the vessel responsive to a selected pressure differential created (e.g., by the introduction of a vacuum in the passageways 80 , 82 beneath the vessels 26 ).
[0067] For example, a drain opening consisting of not only an opening in the vessel 26 but also a suitable passive valve may be provided to provide the desired fluid flow, where the passive valve is biased to block fluid flow unless a selected pressure differential across the valve is created. FIG. 4 f illustrates a reaction vessel 26 d having a duckbill valve 100 as one example of a suitable valve which would be pulled open by a selected pressure differential resulting from a vacuum in the passageways 80 , 82 . Those skilled in the art will recognize that many other valve structures providing such operation would be suitable, including, for example, umbrella valves, flapper valves and spring biased ball check valves, and could also be advantageously used with certain aspects of the present invention.
[0068] Active valves may also be advantageously used with certain aspects of the present invention. FIG. 4 g illustrates a reaction vessel 26 e with a suitable connection 102 to passageways 80 ′, 82 ′ with a suitable pinch valve 104 and suitable control 106 for selectively closing and opening the passageway 80 ′ as desired for operation. A hydrophobic frit 99 ′ may also be provided in the bottom opening of the vessel 26 e . Active valves may advantageously be selected which will support the desired height of fluid and may be opened to allow fluid to drain from the vessel 26 e without assist by a pressure differential. However, it would be within the scope of certain aspects of the present invention to additionally provide a vacuum to assist in such draining when the active valves 104 are open.
[0069] Valves such as described above may be a part of the reaction vessel, or part of the vacuum passageways 80 , 82 beneath the vessel.
[0070] FIG. 5 illustrates a theoretical retention height H of the following fluid 90 , such as may be commonly encountered as one example:
Vessel Content 1 mL Plasma + 2.5 mL Buffer Solution Sample height 5 cm Temperature 50 degrees C. Sample density ρ 1 g/cc Sample surface tension σ 60 dyne/cm (est. at 50 degrees C.) Sample viscosity μ 0.87 cP (est. at 50 degrees C.)
As can be seen from the curve 106 in FIG. 5 , for such a fluid, the 60 dyne/cm surface tension would be sufficient to support a height H of fluid of 5 cm if the bead diameter is slightly less than 0.02 inches (or smaller). Thus, any drain opening 92 which will form a bead diameter no larger than slightly less than 0.02 inches will be able to retain the fluid 90 in the reaction vessel 26 until a relative pressure is introduced via the vacuum 86 .
[0072] As illustrated in FIGS. 4 b and 6 , however, the drain opening 92 as in FIG. 4 b may not be as large as the allowable bead size inasmuch as the bead may tend to spread out around the opening 92 . FIG. 6 shows the results 110 , 112 , 114 of tests using DI water at 22 degrees C. (with a surface tension σ of 72.7 dyne/cm), in which it can be seen that the actual height of supported liquid 90 (generally around 1 to 2 cm) for a given hole diameter was far below the maximum theoretical liquid retention height 118 for a bead of such water having that same diameter. Such a shortfall can be attributed in large part to the spreading of the bead (see 94 in FIG. 4 b ) around the opening 92 . As previously discussed, the FIGS. 4 c and 4 d embodiments address this issue by limiting the spreading of the bead around the opening 92 a , 92 b.
[0073] FIG. 7 illustrates the predicted time to evacuate a 3.5 mL sample (e.g., a 5 cm fluid height from a conventional reaction vessel 26 ) based on the hole diameter. Different theoretical conditions are illustrated using the FIG. 5 sample fluid (having a fluid viscosity p of 0.87 cP at a temperature of 50 degrees C.). Hole lengths of 0.040 inch and 0.080 inch, and vacuum of −10 inches Hg and −20 inches Hg, are illustrated. Specifically, the theoretical evacuation time for a hole length of 0.080 inch using a −10 inch Hg vacuum is shown at 120 , the theoretical evacuation time for a hole length of 0.040 inch using a −10 inch Hg vacuum is shown at 122 , the theoretical evacuation time for a hole length of 0.080 inch using a −20 inch Hg vacuum is shown at 124 , and the theoretical evacuation time for a hole length of 0.040 inch using a −20 inch Hg vacuum is shown at 126 .
[0074] As can be seen from the FIG. 7 curves 120 , 122 , 124 , 126 , the hole length has a theoretical minor impact on the predicted evacuation time. The amount of vacuum assist has a greater impact on the time, but that is still relatively small. Of particular significance is the indication that hole diameters which are about 0.01 inch or smaller will have significantly greater evacuation times, with holes much smaller than about 0.005 inch theoretically incapable of evacuating the fluid with the indicated vacuum levels. Since evacuation time could thus potentially significantly slow processing of samples, it should be appreciated that the larger hole diameters above 0.01 inch would provide advantageous speeding of processing over smaller hole diameters. Thus, the FIGS. 4 c and 4 d embodiments, for example, which will enable the reaction vessels 26 a , 26 b to retain the desired height of fluid 90 with larger size drain openings 92 a , 92 b such as previously described, may be particularly advantageously used with the present invention.
[0075] This manner of draining fluid 90 from the reaction vessels 26 should thus be appreciated to be fast and convenient. Further, it should be appreciated that such draining may be accomplished with minimal cost of disposable pipettes. Moreover, it should be appreciated that the use of reaction vessels 26 with bottom drain openings 92 such as described may be advantageously used with the previously described movable magnets 60 , 62 , 64 , inasmuch as the magnets 60 , 62 , 64 operate to pull the magnetic particles and bound analyte of interest to the bottom side of the vessel 26 , whereby the pellet of such material will be clear of the drain opening 92 .
[0076] FIG. 8 discloses a further aspect of the present invention, which uses a traveling head 200 connected to bulk supplies of fluid, whereby desired amounts of such fluids may be added to sets of vessels 26 (not shown in FIG. 8 ).
[0077] Specifically, the head 200 includes two sets of outlets 204 , 206 , with one outlet set 204 , for example, used for wash, and a second outlet set 206 used for wash and pipette prime. A second (or additional) outlet set 206 may be provided, for example, where a different type of discharge (e.g., a spray nozzle) may be desired. In the illustrated embodiment, the outlet sets 204 , 206 include eight outlets arranged in a row to match the pattern of the vessels 26 supported in the processing zones 20 , 22 . Thus, the head 200 may be arranged above any selected pattern row of eight vessels 26 in a processing zone 20 , 22 whereby the eight outlets of a selected set 204 , 206 will be aligned above the selected eight vessels 26 so that fluid discharged from the head outlets will enter the selected vessels 26 .
[0078] Associated with the head 200 is a suitable pump 220 which may meter desired amounts of selected fluids (as further described below) for each of the outlets in a set 204 , 206 . One such suitable metering pump 220 is illustrated in FIG. 8 as a Cavro 24V, 48V signal motor which includes eight 2.5 mL piston pumps 222 . Cavro Scientific Instruments Inc. is located at 2450 Zanker Road, San Jose, Calif., USA 95131. As described further herein, this pump 220 will meter a desired amount (e.g., 2.5 mL) of fluid from the bulk supplies for each of the X number (eight in the illustrated embodiment) outlets of each outlet set 204 , 206 . However, it should be understood that the details of this pump 220 do not form a part of the invention, and any pump and valving system which will meter a selected number (X, e.g., eight) of a selected quantity (e.g., 2.5 mL) of fluid for discharge through the outlets of a selected outlet set 204 , 206 would be suitable.
[0079] Suitable bulk supplies 230 , 232 may be provided according to the expected needs of the testing. In the illustrated example, there is a bulk supply 230 of wash and a bulk supply 230 of single step lysis buffer (SSLB). As illustrated in FIG. 8 , each bulk supply 230 , 232 may include a refillable tank 236 , 238 which is connected to a sealed dispensing tank 240 , 242 . A valve 246 , 248 may selectively connect the dispensing tank 240 , 242 to a vacuum source (vacuum reservoir 254 and vacuum pump 256 ) to assist in maintaining a desired level of fluid in the dispensing tank 236 , 238 , and to permit fluid to be drawn off the top of the dispensing tanks 240 , 242 if desired. Another vacuum valve 260 may be used to selectively draw such materials to a waste container 262 . It should be understood, however, that the illustrated bulk supply structure is merely one suitable example of a structure which may be used with this aspect of the invention, and any suitable bulk supply from which the needed fluids may be pumped by the metering pump 220 may be used with this aspect of the present invention.
[0080] The dispensing tanks 236 , 238 are suitably connected to the traveling head 200 , as by flexible hoses 270 , 272 .
[0081] A suitable valve structure is provided to enable the metering pump 220 to be selectively connected to the bulk supply of selected fluid in order to obtain X (e.g., eight) units of selected quantity (e.g., 2.5 mL), after which the X units of selected fluid may be sent to a selected set of outlets 204 , 206 for discharge into a selected set of reaction vessels 26 over which the head 200 has positioned the selected outlet set 204 , 206 .
[0082] One valve structure which would be suitable for a head 200 connected to two bulk supplies 236 , 238 and having two outlet sets 204 , 206 is the three-valve structure illustrated in FIG. 8 . One such valve structure is associated with each of the piston pumps 222 illustrated. While the illustrated embodiment may be advantageously used with this aspect of the invention, it should be recognized that this aspect of the invention may be readily practiced with different valve structures.
[0083] Specifically, the illustrated three-valve structure includes valves 280 , 282 , 284 , each of which may be selectively switched between path A and path B. During a single cycle, for example, valve 280 may be connected to path A, after which the metering pump 220 may be activated to draw 2.5 mL of wash fluid from bulk supply 230 through hose 270 into the piston pumps 222 . Valve 280 may then be switched to path B, valve 282 switched to path A, and valve 284 switched to path B, whereby the piston pumps 222 may then be operated to discharge the eight 2.5 mL units of wash fluid through the eight outlets of outlet set 284 into vessels 26 (not shown) located beneath those outlets.
[0084] When used with a processing zone 20 , 22 in which there are six rows of eight reaction vessels 26 such as previously described, the above process may be repeated six times to provide the wash fluid to all forty-eight reaction vessels 26 .
[0085] After the wash fluid has been discharged into all of the selected reaction vessels 26 , operation of the valve structure can be changed to supply a different fluid if needed based on the testing being accomplished. For example, if SSLB fluid is thereafter desired, valve 280 positioned at path B, valve 282 positioned at path A, and valve 284 positioned at path A, whereby the piston pumps 222 may then be operated to draw 2.5 mL of SSLB fluid from bulk supply 232 through hose 272 into the piston pumps 222 . Then, valve 280 may be kept at path B and valve 282 switched to path B, whereby the piston pumps 222 may then be operated to discharge the eight 2.5 mL units of SSLB fluid through the eight outlets of outlet set 284 into vessels 26 (not shown) located beneath those outlets. This processing may then be repeated as necessary to provide SSLB fluid to all of the selected reaction vessels 26 .
[0086] It should be appreciated that the FIG. 8 aspect of the invention will enable the processing zones 20 , 22 to be used efficiently and reliably. The desired amounts of fluid may be easily and reliably metered in the desired amounts. Further, this may be accomplished quickly, without the delay time which would be required by a dispensing head which travels back and forth from the processing zones and bulk supplies each time a set of reaction vessels requires such fluids.
[0087] It should also be appreciated that the various aspects of the invention described herein may be combined to provide a processing zone which may be advantageously operated to efficiently and quickly process samples.
[0088] Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained. | A reaction vessel with a bottom drain opening supporting a selected unpressured head of fluid by the surface tension of the fluid. A device processing zone includes a support for spaced rows of reaction vessels, passages communicating with their drain openings of supported vessels, and a pressure source for selectively draining fluid through the drain openings. Generally horizontal bar magnets are supported for selected vertical movement between the vessel rows. A dispensing head has X discharge openings selectively positionable over X selected reaction vessels. A metering pump mechanism selectively meters X a selected quantity of fluid a bulk supply (where X is at least four), and selectively pumps the metered selected quantities through the drain openings to the selected reaction vessels. Methods of drawing fluid from the vessels using the pressure source, and moving the magnets to form a pellet of analyte are also included. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to prefabricated fireplaces that provide both radiant heat and convection heat. More particularly, the present invention relates to using heat from a fireplace to mix with cold outside fresh air or to preheat outside fresh air used to raise the air quality in a home.
[0003] 2. Description of the Prior Art
[0004] It is known that it is possible to build heat efficient houses so tight that the air inside of a home becomes stale. There is no universal standard in all states which defines the minimum amount of make-up air required to maintain the indoor air quality.
[0005] The State of Minnesota has proposed that the air in a heated house be replaced every two hours. Minnesota has also proposed that a minimum of a set amount of cubic feet of air for each bedroom plus another set amount of air for the remainder of a house be replaced every hour. At present, all known proposed standards leave the solution to builders of custom equipment.
[0006] Heretofore, it was known that an auxiliary air pump could be installed in an old house to pull in a predetermined amount of outside fresh air to make-up or refresh the stale air in a home. Large custom air conditioning systems, if properly designed, introduce into the air conditioning system a small percentage of fresh air, however, there is no standard and the equipment is not mass-produced, thus, imposing a substantial cost to new home builders.
[0007] It would be desirable to incorporate a make-up or air quality replacement system into present mass produced, low cost, prefabricated fireplaces and combination fireplaces/forced air furnace systems and still maintain high efficiency.
SUMMARY OF THE INVENTION
[0008] It is a principal object of the present invention to introduce into a fireplace/furnace system outside fresh make-up air in a manner that does not unbalance the heating system.
[0009] It is a principal object of the present invention to mix outside fresh air into a return air duct or ducts and add the convection heat from a fireplace into the same return air duct.
[0010] It is a principal object of the present invention to introduce a predetermined amount of make-up air into a fireplace to produce heated and diluted exhaust air products that are then used in an efficient heat exchanger to preheat fresh outside make-up air being supplied to a return air plenum.
[0011] It is a principal object of the present invention to provide an efficient co-linear fireplace system having hot exhaust gases that are passed through a novel remotely located heat exchanger system for preheating outside make-up air being supplied to a return air plenum of a quality air system.
[0012] It is a principal object of the present invention to provide a novel air-to-air heat exchanger having a pair of separately controlled blower motors for universal use in fireplace/furnace duct systems to supply variable amounts of make-up air in an air quality system.
[0013] According to these and other objects of the present invention, there is provided a fireplace with a heat exchanger/exhaust system for heating or preheating outside fresh air that is then introduced into return air ducts of a forced air furnace system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a diagrammatic drawing in front elevation of a prior art direct vent fireplace with a convection heat exchanger;
[0015] [0015]FIG. 2 is a diagrammatic drawing in front elevation of a prior art direct vent fireplace with a fire tube air heat exchanger and a high-speed blower;
[0016] [0016]FIG. 3 is a diagrammatic drawing in side elevation of a direct vent fireplace adapted to deliver heat from its heat exchanger to a duct or ducts of a central heating system for distribution to all rooms in a house;
[0017] [0017]FIG. 4 is a diagrammatic drawing in front elevation of a co-linear fireplace having a quiet blower in its heat exchanger and a remote blower for supplying outside fresh air for combustion as well as excess fresh air to the heat exchanger for supplying fresh make-up air in conformance with new air quality standards;
[0018] [0018]FIG. 5 is a diagrammatic drawing in elevation of a fireplace adapted to heat room air in its heat exchanger and to deliver the heated air into the return air duct of a central heating system and is shown having a remote air pump for supplying a predetermined amount of fresh make-up air to the house;
[0019] [0019]FIG. 6 is a diagrammatic drawing in elevation of a draft-assisted or power-vented fireplace adapted to use room air for combustion and to dilute the exhaust gases; and
[0020] [0020]FIG. 7 is a diagrammatic drawing in elevation of a co-linear fireplace adapted to pass its hot exhaust gases through a remote heat exchanger used to heat room air in a house as it passes into the return air duct of a central heating system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Refer now to FIG. 1 showing a top direct vented fireplace 10 of the type having a coaxial pipe comprising an exhaust pipe 11 and a fresh intake air pipe 12 . The fresh outside air is burned in the center of the fireplace 10 in combustion chamber 13 and subsequently exhausted back out the center exhaust pipe 11 so that no inside air is required for the combustion products. Such gas fireplaces are sold by Heat and Glow Fireplace Products, Inc. of Lakeville, Minn. under Model Number 600DVT. Such fireplaces are provided with a heat exchanger which passes under the combustion chamber around the back of the combustion chamber and comes out at the top to provide an efficient convection and radiant heating system. The intake for the heat exchanger is shown at numeral 14 and the outlet of the heat exchanger is shown at numeral 15 .
[0022] Refer now to FIG. 2 showing a front elevation of a direct vent fireplace 20 having an air intake pipe 12 and an exhaust pipe 11 . The combustion gases produced in the combustion chamber 13 are passed into a plenum 16 which connects to fire tubes 17 which exits into an upper plenum 18 and then passes out through the exhaust stack 11 . To create a heat exchanger, a supply duct from the room(s) 19 is connected to the heat exchanger box and the air is heated by the hot fire tubes 17 and exits into the hot air return duct 21 with the assistance of an induced/forced draft fan or blower which, by nature of its operation and location, is noisy.
[0023] It has been found that consumers who buy prefabricated fireplaces will tolerate low speed quiet blowers in the heat exchangers of the system shown in FIG. 1, but are not quite as tolerant of a noisy high speed blower of the type shown in the prior art fireplace of FIG. 2. Another disadvantage of the FIG. 2 embodiment is that the heat exchanger system is mounted on top of the fireplace 20 and often makes the mantel or top shelf of the fireplace inordinately high and unattractive if it is provided.
[0024] Refer now to FIG. 3 showing a direct vent fireplace 30 adapted to deliver heat from its heat exchanger to a supply duct or return duct of a central heating system for distribution to all rooms or specific rooms in a house. The fireplace 30 is shown comprising an inlet 12 A for supplying fresh air into fresh air passage 24 which extends under floor 25 at burner 26 for burning gases in combustion chamber 13 which surround logs 27 . In the preferred embodiment, the intake air passage 14 and lower passageway 14 A connect into rear heat exchanger passage 23 which connects into upper passageway 15 A for supplying heated room air out of the outlet 15 .
[0025] However, when the system is employed to deliver hot air into duct 28 , damper 29 is opened and hot air can be supplied to the return duct 35 . In the preferred embodiment of the present invention, when heated room air is being supplied via duct 28 into duct 35 the blower motor 32 is not enabled or activated because the return air duct is capable of pulling the air to the central heating system not shown. In the event that the closest duct available is a supply duct, it is necessary to force the air into the supply duct using a forced draft fan 31 .
[0026] The advantage of fireplace 30 is that the blower motor 32 is a very quiet low speed motor and is only used when fireplace 30 is used in its conventional mode to take air in inlet 14 and exhaust heated air out outlet 15 . In all other modes, the motor 32 may be disabled by switches 33 or 33 A. As an alternative, it is possible to connect duct 28 to a direct duct which exits into a remote room having an induced draft fan which is actuated by controller 34 . The controller 34 may actuate the remote controller RC and used to actuate the damper 29 .
[0027] Refer now to FIG. 4 showing a co-linear fireplace 40 having a conventional heat exchanger where the inlets and outlets 14 and 15 are shown and are connected by a passageway like passageway 23 in the rear of the combustion chamber 13 . In this embodiment, a remote blower 37 is shown having an intake pipe 36 connected to an outside source of fresh air which is pumped into the fireplace 40 . The necessary amount of combustion air is supplied by supply pipe 38 and the remainder of the outside fresh air which comprises the make-up air is supplied into the heat exchanger by branch 39 . Thus, the outside fresh air being forced into the heating system is preheated by the heat exchanger and supplied directly into the same room with the heat exchanger. When the fireplace 40 is of sufficient capacity, all of the outside air is heated above room temperature so that the system operates efficiently to preheat the make-up air as well as supply diluted heated room air to the room in which the fireplace 40 is located. In this embodiment, a control 42 in fireplace 40 operates the remote blower motor 37 at a predetermined speed to supply the necessary make-up air into the chamber shown at inlet 14 , 14 A.
[0028] Refer now to FIG. 5 showing a direct vent fireplace 50 having a supply duct 43 which connects into the heat exchanger of the fireplace 50 . The duct 43 supplies room air at approximately 270 degrees Fahrenheit to the return air plenum or duct 44 which terminates at the central hot air furnace 45 . The furnace 45 is provided with a blower (not shown) and heats the air received and supplies it in the supply duct 46 to the rooms to be heated. An air conditioning coil 47 is shown connected into the supply duct 46 , but is not used during the heat season. After supplying the heated air to the rooms, the individual return ducts from the rooms are connected back into the return air plenum 44 and since there is a negative pressure provided at the central heating system 45 no additional fan is needed to pull this return air back to the central air furnace. The furnace blower is preferably on when fireplace 50 is on.
[0029] In order to supply the necessary make-up air or quality replacement air for the home, a remote air pump 48 is shown connected to an outside source of fresh air. In the preferred embodiment, the remote air pump 48 is located in a basement area. Basement air and the fresh air enter the return 44 and do not overly cool any particular isolated room. In this embodiment, the fresh air in a tight home is circulated through the duct system to the individual rooms and is preheated with the air in the return duct 44 . Further, the outside fresh air that is passed into the room in which the fireplace 50 is located passes through the heat exchanger 14 , 15 and is heated before it passes into duct 44 and the return air plenum duct 44 . Since the remote air pump 48 can produce a positive pressure in a tightly sealed house, it is preferred that a bleeder 49 be located at an area completely remote from the air pump to relieve this positive pressure inside of the house.
[0030] Refer now to FIG. 6 showing a diagrammatic drawing in elevation of a draft assist or power vent fireplace 60 adapted to use room air for combustion and for dilution of exhaust gases which in turn are passed through a novel heat exchanger. The fireplace 60 , like fireplace 30 , has a heat exchanger with two inlets 14 and 15 . The bottom grill 15 supplies stale room air for combustion in combustion chamber 13 as well as dilution of the exhaust gases. The inlet 14 supplies room air for dilution of the mixed exhaust gases which pass into the exhaust duct 11 B at approximately 270 to 500 degrees Fahrenheit, depending on the amount of excess combustion air and dilution supplied in inlets 14 and 15 . As will be explained later, this amount of dilution may be controlled in a tight house. The exhaust gases in exhaust duct 11 B are cooled to approximately no more than 220 degrees Fahrenheit before being passed into a novel cross flow air-to-air heat exchanger 51 . The arrows in the heat exchanger show the exhaust gases pass diagonally downward into in-line blower 54 and force the cooled exhaust gases out of duct 55 at approximately 118 degrees Fahrenheit. There is shown a fresh air intake duct for outside air 56 supplying air into the heat exchanger 51 via in-line blower 57 which forces the preheated outside air into duct 58 which is connected to the aforementioned plenum 44 A that serves as the supply to the central hot air furnace 45 . The furnace 45 has its own blower and heats the air which is supplied to supply duct 46 through air conditioning coil 47 into the previously explained supply duct 46 . The air conditioning system 53 is shown having a supply S and a return R even though the air conditioning coils 47 are not cooled during the heating season. The novel heat exchanger 51 is preferably made from a high heat conductivity metal such as aluminum and comprises a plurality of spaced plates sealed one from another to permit an efficient cross flow heat exchanger. Such heat exchangers made of aluminum are capable of operation as high 500+ degrees Fahrenheit in the preferred embodiment.
[0031] In this embodiment, a controller 59 preferably is capable of operating the blower motors 57 and 54 at predetermined speeds to achieve predetermined desired cubic foot displacements of make-up air and exhaust air in the system. For example, if motor 54 is run at a slower speed the exhaust gases in exhaust stack 11 B increase in temperature. The exhaust motor 54 only needs to be operated to a speed which exhausts the desired amount of make-up air plus combustion air into the system. Similarly, the blower motor 57 only needs to supply the amount of fresh air needed for combustion and make-up. It is not intended that motors 54 and 57 be operated at variable speeds over a long period of time. It is preferred that the motors be set to operate at desired displacement speeds when the fireplace 13 is on and the blower in central air furnace 45 may be operated independently of the make-up system which passes through the fireplace.
[0032] Refer now to FIG. 7 showing a diagrammatic drawing in elevation of a co-linear fireplace 70 adapted to pass its exhaust gases through the aforementioned novel air-to-air cross flow heat exchanger 51 . When the fireplace 70 is on, it takes outside fresh air in through duct 61 and burns the air in the combustion chamber 13 and passes the undiluted exhaust gas into exhaust duct 11 B at approximately 600 degrees Fahrenheit where it cools on its passageway to the novel cross flow heat exchanger 51 . The exhaust gases pass through the in-line blower 54 and are exhausted through exhaust duct 55 to the outside. In this embodiment, the blower 57 sucks in air from the house at 60 to 80 degrees Fahrenheit and passes it into the return duct 58 after being preheated in the heat exchanger 51 . The preheated house air is passed into the central hot air furnace 45 where it is heated again and forced into the supply duct 46 by air conditioning coils 47 and into the rooms.
[0033] In the preferred embodiment of this invention, it may be possible to control the blower motor 57 in a manner where it creates a negative pressure in a room or area in which it is located so that either the bleeder 49 or leaks in a loose house supply the sufficient make-up air desired for air quality. However, if the house is new and of tight construction it could be necessary to place a remote heat pump in the system as shown and described in FIGS. 4 and 5 in order to supply the deficiency of make-up air for quality air conditions. Blower 54 acts to induce outside combustion air into combustion chamber 13 .
[0034] Having explained a preferred embodiment of the present invention and modifications thereof, it will be understood that presently designed and manufactured high production fireplaces may be coupled into existing heating systems in homes that have forced air furnaces so as to create not only an efficient heating system, but a system which supplies make-up air for a quality air system in a very efficient manner. The preferred embodiment of the present invention is provided with variable speed motors and controls which allow the installers of such systems to use universal equipment to achieve precise and exacting predetermined standards for different types of houses made to different tightnesses and specifications. Thus, the present invention permits a builder of houses to select universal components that are produced at high efficiency and low cost for installation without having to engineer and manufacture a custom system.
[0035] Having explained the problem of maintaining heat efficiency in tight houses having hot air fireplaces and hot air furnaces, it will be appreciated that the introduction of a required amount of cold outside air to maintain air-quality can decidedly reduce the heat efficiency of the fireplace and/or the heating system. Accordingly, there is provided a high efficiency heat exchange system that preheats the fresh air using the hot exhaust gas from a gas fireplace and/or the fireplace heat exchanger is employed to preheat the air without unbalancing the temperature of the rooms or the system. The outside fresh is preheated in a manner which will permit easy modification of existing fireplace/furnace systems as well as the installation of the present novel system in new homes. | The need to maintain the quality of air in a home has become more of a problem in new high efficiency tight houses so that governmental regulations are being proposed for a minimum change of fresh air. If too much cold outside fresh air is introduced into such homes at a single source, the room with the fresh air is usually too cold and/or unbalanced.
The present invention avoids cooling any one room while maintaining heat efficiency. When the home has a gas fireplace, the exhaust gases are preferably directed through an air-to-air cross flow heat exchanger which preheats the quality air passing into a forced air furnace system.
In modified embodiments of the present invention, make-up quality air is mixed with the room air and heated in the heat exchanger of the fireplace. The preheated room air from the fireplace is preferably connected to the supply/return of a forced air furnace system and distributed to all rooms to provide uniform heating. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a frequency shifter and an optical displacement measuring apparatus using the same. The present invention is ideally used for performing noncontact measurement of the displacement of a moving object or fluid (hereinafter referred to as "moving body") in particular, by detecting the shift of the frequency of the scattered light which has been subjected to a Doppler shift according to the moving speed of the moving body.
2. Description of the Related Art
Hitherto, a method for modulating a signal by means of an optical frequency shifter is often used for various types of interferometers.
A laser Doppler velocimeter is known as one of the interferometers which are capable of measuring the displacement of an object with high accuracy without the need of contact.
The laser Doppler velocimeter is a device which is designed to measure the moving velocity of a moving body by radiating a laser beam to the moving body and making use of the Doppler effect in which the frequency of the scattered light shifts in proportion to the moving velocity.
FIG. 1 shows an example of a conventional laser Doppler velocimeter which has been disclosed in Japanese Patent Laid-Open No. 4-230885 and U.S. Pat. No. 5,256,885.
The laser Doppler velocimeter shown in FIG. 1 includes a laser 1, a collimater lens 2 for producing a parallel luminous flux I, a beam splitter 3 including a diffraction grating, convex lenses 5 and 6 having a focal distance f, wherein a+b=2f, "a" being the distance between the beam splitter 3 and convex lens 5, and "b" being the distance between an object 7 and convex lens 6, a condensing lens 8, and an optical sensor 9. The object 7, shown in FIG. 1, is moving in the direction indicated by the arrow shown at velocity V to be measured.
The laser beam emitted from the laser 1 is transformed into the parallel luminous flux I through the collimator lens 2. Parallel luminous flux I then enters the diffraction grating 3 and is then separated into diffracted lights I1a and I1b of plus/minus primary diffraction angle θ for emission. The luminous fluxes I1a and I1b are then turned into converged beams I2a and I2b through the convex lens 5 having the focal distance f. When the converged beams I2a and I2b pass through the convex lens 6 at a distance 2f from convex lens 5, they again become parallel luminous flux beams, identified as I3a and I3b, so that two luminous fluxes I3a and I3b are radiated to the object 7, at an incident angle θ which is identical to diffraction angle θ given by the diffraction grating 3. The scattered lights resulting from the radiation of the two luminous fluxes are detected by the optical sensor 9 via the condensing lens 8. The frequencies of the scattered lights from the two fluxes are subjected to Doppler shifts of +Δf and -Δf, respectively, in proportion to moving velocity V. If the wavelength of the laser beam is taken as λ, then Δf can be represented by expression (1):
Δf=V·sin (θ)/λ (1)
The scattered lights which have been subjected to the Doppler shifts of +Δf and -Δf interfere with each other, causing a change in the brightness on the light receiving surface of the optical sensor 9. Frequency F in this case is given by expression (2) shown below:
F=2·Δf=2·V·sin (θ)/λ(2)
From expression (2), velocity V of the object 7 to be measured can be obtained by measuring frequency F (hereinafter referred to as "Doppler frequency") of the optical sensor 9.
Further, based on a conditional formula of the diffraction by diffraction grating 3: sin (θ)=λ/d (where d is the grating interval of the diffraction grating 3), expression (3) given below can be derived:
F=2·V/d (3)
Thus, the Doppler frequencies no longer depend on laser wavelength λ. This means that the angle of diffraction and incident angle θ change to compensate for the change in laser wavelength λ.
A method has been devised for such a laser Doppler velocimeter so that it employs a frequency shifter to add a predetermined frequency fR as a bias to the Doppler frequencies in order to permit easy detection of the moving direction of a moving body and also to permit accurate detection even when the velocity of the moving body is nearly zero.
Foord et al. have disclosed a frequency shifter as shown in FIG. 2 (refer to Appl. Phys., Vol. 7, pp L36-L39 1974). The frequency shifter has an electrooptical element 10 which has electrodes provided on electrooptical crystal plates; a sawtooth voltage is applied to the electrooptical element 10 through a serrodyne driver circuit 20.
In FIG. 2, the luminous flux I having the wavelength λ is separated into two luminous fluxes Ia and Ib through the beam splitter 4 before they respectively reach electrooptical crystals 10A and 10B constituting the electrooptical element 10. At this time, the electrooptical crystals 10A and 10B are subjected to the frequency shift by the serrodyne driver circuit 20 which applies the sawtooth voltage to give plus and minus half-wavelength phase shifts. The two luminous fluxes, which have been subjected to the frequency shifts, are deflected through the lens 5 to be converged; the two luminous fluxes intersect with each other on the moving body 7. The scattered light from the moving body 7 is led into an optical sensor, which is not shown, to produce a Doppler signal.
The Doppler frequency is given by the expression shown below from velocity V of the moving body 7, intersecting angle θ of the two luminous fluxes, and difference in frequency fR between the two luminous fluxes:
F=2·V·sin (θ)/λ+fR (4)
Thus, the measurement including that of the velocity direction can be performed even when the velocity of the moving body 7 is nearly zero. This configuration is used primarily for an apparatus for measuring flow velocity.
When the electrooptical element is serrodyne-driven as stated above, the amplitude of the sawtooth voltage is relatively large and the sawtooth voltage changes steeply when it falls. This may cause a high-frequency noise which prevents proper detection of Doppler frequency F or leads to poor accuracy.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a frequency shifter and an optical displacement measuring apparatus using the same which are capable of preventing the adverse influences of the aforesaid high-frequency noise and of maintaining highly accurate measurement. Other objects of the present invention will be made apparent as the description of embodiments progresses.
According to a first aspect of the present invention, a frequency shifter for modulating the phase of luminous flux includes an electooptical element for receiving the luminous flux, a plurality of electrode components provided on the electrooptical elements, a circuit for generating a voltage to be applied to the electrooptical element via the plurality of electrode components, and a shield for electrically shielding the circuit generating the voltage and the electooptical element. The level of the voltage to be applied is variable in order to shift and frequency of the luminous flux received by the electrooptical element, and thereby modulate the phase of the luminous flux.
According to another aspect of the present invention, an optical displacement measuring apparatus for measuring displacement of an object includes a luminous flux generator for generating a measuring luminous flux, a frequency shifter for modulating a phase of the luminous flux, and a light receiving section for receiving light from the object, the object having been subjected to the measuring luminous flux, and the phase of the flux having been modulated by the frequency shifter, and thereby the displacement of the object may be measured by the light received through the light receiving section. The frequency shifter includes the features of the first aspect of the present invention described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a conventional laser Doppler velocimeter;
FIG. 2 illustrates another conventional laser Doppler velocimeter;
FIG. 3 illustrates a laser Doppler velocimeter of a first embodiment in accordance with the present invention;
FIG. 4 illustrates an optical frequency shifter employing an electrooptical element;
FIG. 5(a) is a block diagram showing an example of a serrodyne (sawtooth) driver circuit;
FIG. 5(b) illustrates a waveform 24 of a pulse used to operate discharger circuit 20B;
FIG. 5(c) illustrates a sawtooth waveform 25 produced by serrodyne driver circuit 20;
FIG. 6 illustrates the electrooptical element in detail;
FIG. 7(a) illustrates the serrodyne driver circuit of the frequency shifter;
FIG. 7(b) illustrates a waveform of the clock signal of input clock 23;
FIG. 8(a) and 8(b) illustrate comparative examples and
FIG. 9 illustrates a part of a laser Doppler velocimeter of a second embodiment in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 illustrates the configuration of the laser Doppler velocimeter of the first embodiment in accordance with the present invention. The laser Doppler velocimeter for measuring the displacement of object 1 in the drawing includes a laser diode 1, the collimator lens 2, the beam splitter 3 having a diffraction grating, the convex lenses 5 and 6, the condensing lens 8, the optical sensor 9, the frequency shifter 10, electrooptical elements 11a and 11b, electrodes 12 and 13, a serrodyne driver circuit 20, and an electric board 40.
In FIG. 3, the laser beam emitted from the laser 1 is transformed into the parallel luminous flux I through the collimator lens 2. Parallel luminous flux I then enters the diffraction grating 3 and is separated into diffracted lights I1a and I1b of plus/minus primary diffraction angle θ for emission. The luminous fluxes I1a and I1b are then converted into converged beams I2a and I2b through the convex lens 5 having a focal distance f. The electrooptical crystal 10, which includes the electrooptical crystal elements 11a and 11b, is located so as to permit the two luminous fluxes I2a and I2b through their corresponding electrooptical crystal elements 11a and 11b.
The electrooptical crystal elements 11a and 11b use uniaxial crystals such as LiNbO 3 and LiTaO 3 crystals, the electrodes thereof being arranged in the direction of a C a axis so that the polarization directions of the laser beams coincide with the direction of the C a axis. This arrangement causes the angle of diffraction θ of the diffraction grating 3 to change as the laser wavelength changes; therefore, the optical paths of the beams in the electrooptical crystals change. But, the polarization directions can be maintained in the direction of the C axis. Hence, the frequency shifter is compatible with the compensating effect which enables the Doppler frequency to be independent from the change in the laser wavelength, which has been described in relation to FIG. 1.
Taking the LiNbO 3 crystal as an example, a description will be given in conjunction with FIG. 4. A refractive index ellipsoid of the LiNbO 3 crystal under electric field E (Ex, Ey, Ez) can be expressed as follows: ##EQU1##
Where r denotes the Pockels constant (r13=10×10 -9 , r22=6.8×10 -9 , r33=32.2×10 -9 , r51=32.0×10 -9 ); no denotes the refractive index of an ordinary ray (no=2,286); and ne denotes the refractive index of an extraordinary ray (ne=2.2).
As shown in FIG. 4, the LiNbO 3 crystal is cut in the direction of the Z axis or C a axis to a thickness of d and electrodes are evaporated on both surfaces of an electrooptical crystal elements 11a and 11b. If an electric field of Ez=V/d supplied from serrodyne driver circuit 20 is applied to the electrooptical crystal elements 11a and 11b through leads 26 and 27 to electrodes 12 and 13 (Ez≠0, Ex=Ey=0), then expression (5) will be:
(1/no.sup.2 +r13Ez)(X.sup.2 +Y.sup.2)+(1/ne.sup.2 +r33Ez)Z.sup.2 =1 (6)
Because no 2 r13Ez and ne 2 r33Ez<<1, expression (6) can be simplified as: ##EQU2##
Thus, refractive indexes nx and ny of the polarized components in the directions of the X and Y axes, respectively, are given by:
nx=ny=no-1/2·no.sup.3 r13Ez.
Refractive index nz of the polarized component in the direction of the Z axis is given by:
nz=ne-1/2·ne.sup.3 r33Ez.
If the X-Y plane is selected as the propagating direction of light and the direction of the z axis is selected for the polarizing direction, then the application of electric field Ez applied in the direction of the Z axis gives refractive index N (Ez) shown below:
N(Ez)=nz=ne-1/2·ne.sup.3 r33Ez (8)
Accordingly, when a laser beam is let pass through the LiNbO 3 crystal elements 11a and 11b which have the thickness of d and a length of l, if applied voltage V is changed, then optical phase difference Γ(V) is given by: ##EQU3##
Thus, changing the applied voltage at a fixed level changes the optical phase at a fixed level, providing a frequency shifter. In practice, however, it is impossible to change the voltage at the fixed level at all times; therefore, the sawtooth (serrodyne) drive is performed. The sawtooth voltage is set for an amplitude at which the phase difference between the two luminous fluxes is equivalent to 2π so that the optical phase does not become discontinuous at the fall.
Assuming that thickness d and length l of the LiNbO 3 crystal elements 11a and 11b are 1 mm and 2 mm, respectively, the voltage amplitude at which optical phase difference Γ(V) is 2π is approximately 230 V from expression (8).
In FIG. 3, Ca and Cb of the C axis of the electrooptical crystal elements 11a and 11b, respectively, are arranged in opposite directions from each other along the Z axis; the voltage is applied to them in the same direction through the electrodes 12 and 13 via conductors 26 and 27 from the serrodyne driver circuit 20. This makes it possible to achieve the 2π optical phase difference between the luminous fluxes I2a and I2b after passing through the electrooptical element 10 at half of the voltage amplitude corresponding to 2π, i.e. the voltage amplitude for giving the π phase difference. In this case, the required voltage amplitude is approximately 115 V.
Referring back to FIG. 3, the luminous fluxes I2a and I2b, which have been modulated to have opposite phases from each other by the electrooptical element 10, are turned into the parallel luminous fluxes I3a and I3b through the convex lens 6 and they are radiated to the object 7, the displacement of which is to be measured and which is moving at velocity V, at incident angle θ which is equivalent to the angle of diffraction θ given by the diffraction grating 3. The scattered light from the object 7 to be measured is condensed to the optical sensor 9 of the electric board 40 via the condensing lens 8 and a mirror 31. The scattered light of the parallel luminous fluxes I3a and I3b has been frequency-modulated by the frequency shifter composed of the electrooptical element 10 and the serrodyne driver circuit 20; frequency F is given by the following expression:
F=2·V· sin θ/λ+fR=2·V/d+fR (10)
The electric board 40, on which the optical sensor 9 is mounted, is provided with a power line 41 for receiving the power supplied from outside, a signal line 42 for sending signals to outside, an amplifier circuit 43 for amplifying the outputs of the optical sensor, and a laser driver circuit 44 for controlling the output of the laser diode 1 at a fixed level. The lines 41 and 42 are covered with a grounded knitted shield 50.
A detected signal supplied by the optical sensor 9 is amplified through the amplifier circuit 43 and transmitted to an external signal processor (not shown) through the signal line 42. The external signal processor calculates moving velocity V of the object 7 to be measured from frequency F according to expression (10). The signal processing is known and the description thereof will be omitted.
FIG. 5(a) is a typical block diagram of the serrodyne driver circuit 20 for applying the sawtooth voltage to the electrooptical element 10. The serrodyne driver circuit 20 is constituted by a constant-current circuit 20A and a discharger circuit 20B; the constant-current circuit 20A supplies constant current i to the electrodes of the frequency shifter 10, which is considered to have a fixed capacity, so as to charge it.
The discharger circuit 20B momentarily turns ON a switch by using an extremely short pulse 24 shown in FIG. 5(b) of a fixed period to discharge instantly the electrooptical element 10 which has been charged by the constant-current circuit 20A. Thus, the serrodyne drive of a fixed cycle illustrated by sawtooth waveform 25, shown in FIG. 5(c), is achieved by repeating the charging and the instant discharging.
FIG. 6 shows the specific configuration of the electrooptical element in this embodiment.
A circuit board 16 on which the serrodyne driver circuit 20 may be surface-mounted, is arranged using spacers 15a and 15b so that it faces the serrodyne driver electrode 12 of the electrooptical element 10. The sawtooth voltage is supplied to the electrode 13 via a short lead wire 16b from a pad 16a provided on a serrodyne driver circuit board 16.
The electrooptical element 10 and the serrodyne driver circuit board 16 are shielded by the grounded electrode 12 of the electrooptical element 10 and a cover 14 which is made of a conductive material and which is provided with apertures 14a through 14d for luminous fluxes and an aperture 14e for a power cable (not shown) and a cable 14f for a clock 23 shown in FIG. 7(a) which will be discussed later.
FIG. 7(a) is the circuit diagram of the serrodyne driver circuit employed for the embodiment. The constant-current circuit 20A using a well-known arrangement of circuit elements, supplies constant current i, which has been regulated by a variable resistor VR, through the pad 16a to the electrooptical element 10 which is considered to have a fixed capacity. The discharging circuit 20B produces the extremely short pulse 24, shown in FIG. 5(b), by utilizing the delaying function of an RC circuit composed of a resistor R and a capacitor C at the fall of the clock signal received from the clock 23 of a transmitter or the like. The pulse is used to momentarily turn ON a switching transistor Q3 so as to instantly discharge the electrooptical element 10, which has been charged by the constant-current circuit 20A, nearly to the source voltage, -HV, of the switching transistor Q3. Thus, the serrodyne drive at the clock signal period of the input clock 23, whose waveform is shown in FIG. 7(b), is carried out by repeating the charging and the instant discharging.
Capacitors 21 and 22 serve to prevent high-frequency noises from leaking to power supplies Vcc and -HV, respectively, from the serrodyne driver circuit. The clock 23 is designed to smooth the waveforms through an appropriate high-frequency filter, not shown, but known in the art, to minimize higher harmonics before outputting them.
In the aforesaid circuit, 2SA1226 made by NEC, 2SA1384 made by HITACHI, and 2SK1334 made by HITACHI are respectively used for the transistors Q1, Q2, and Q3. Small surface-mounted elements such as TC74AC00F made by TOSHIBA are used for ICa through ICd. The electrooptical element 10 and the serrodyne driver circuit board 16 are piled-up and shielded by the cover 14 or the like shown in FIG. 6 to make the frequency shifter. Incorporating the frequency shifter in the optical system shown in FIG. 3 has provided a noise-free Doppler signal.
An example for comparison will now be described with reference to FIGS. 8(a) and 8(b).
In FIG. 8(a), instead of using the case shown in FIG. 6, only the electric board 40 was shielded by conductive covers 45 and 46. Cover 45 has an aperture 45a for receiving the light from the optical sensor 9. This arrangement failed to prevent high-frequency noise. The high-frequency noise could not be prevented perfectly also when the electrode 12 was grounded and the sawtooth waveform voltage was applied to the electrode 13.
In the device shown in FIG. 8(b), instead of using the case shown in FIG. 6, the cover shown in (a) was used and only the electrooptical element 10 was shielded by a conductive cover 14', which has apertures 14'a through 14'd for the luminous fluxes I2a and I2b as shown in (b), and aperture 14'e for a power cable and a cable to the clock (neither cable being shown). This arrangement also failed to completely prevent high-frequency noise. The noise was particularly conspicuous as cables 26 and 27 from the serrodyne driver circuit 20 came closer to cables 41 and 42 of the electric board 40.
The failure to prevent the high-frequency noise is considered due to the fact that, although the cables 41 and 42 of the electric board 40 are shielded by the knitted shield 50 outside the apparatus, the portions thereof for the connection to the electric board are not completely shielded against the serrodyne driver circuit inside the apparatus, and therefore they pick up high-frequency noises from the serrodyne driver circuit.
FIG. 9 illustrates a part of another embodiment in accordance with the present invention. FIG. 9 shows only the electrooptical element as shown in FIG. 6. The rest of the configuration is identical to the first embodiment; therefore, the description and drawings will be omitted.
In the second embodiment, a serrodyne driver circuit board 16' has surface-mounted elements of the serrodyne driver circuit on one surface thereof and has an electrode 16c for supplying the sawtooth voltage on the other surface. The electrode 16c has been gold-plated approximately to the size of the electrode 13 of the electrooptical element 10; it is screwed directly to the electrode 13 of the electrooptical element 10 to supply the sawtooth voltage. Thus, providing the circuit board with the plated electrode for the contact with the electrode 13 makes it possible to achieve compact design in the case and consequently a smaller apparatus incorporating it.
The electrooptical element 10 and the serrodyne driver circuit board 16 are shielded with a conductive cover 14, which has apertures for luminous fluxes and an aperture for the cable for the power and the clock 23, and the grounded electrode 12 of the electrooptical element 10 as described above.
In the above embodiments, the electric noise from the frequency shifter, which employs the electrooptical element, can be controlled by a shielding space formed by the case and the electrode. Further, an electric power supply cable to the frequency shifter and another cable of the apparatus can be combined into one and the frequency shifter can be incorporated in the apparatus in a compact manner.
The individual components shown in outline or designated by block in the drawings are all well-known in the art and their specific construction and operation are not critical to the operation of best mode for carrying out the invention.
While the present invention has been described with respect to what are presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions. | A frequency shifter is capable of controlling the adverse influences of electric noise caused by the voltage applied to electrooptical elements of a frequency shifter. The frequency shifter modulates the phase of the luminous flux entering the electrooptical elements by applying a voltage to the electrooptical elements; the shifter is provided with a shield for electrically shielding the circuit for generating the voltage to be applied to the electrooptical elements and the electrooptical elements from an external circuit. | 6 |
FIELD OF THE INVENTION
The object of the present invention is a method for making a binder by using, as the starting material, a particulate mineral material with a glassy amorphous structure, especially a waste material from mineral wool production. Such a binder is suitable for binding mineral materials, especially for use as a binder in the manufacture of mineral wool products from mineral fibres. Another object of the present invention is a method for manufacturing mineral wool products using the said binder for binding the mineral fibres.
BACKGROUND OF THE INVENTION
(Mineral fibres made by melting and centrifuging of mineral raw materials, such as stone, slag, glass, ceramics or the like,) are extensively used for the manufacture of mineral fibre mats and blankets, primarily for heat and sound insulation purposes, especially within the construction industry. Such mineral fibre products conventionally contain a binder, of which a number of different types are known.
Thus for example phenol cured insulating products are known. Phenol is a fairly inexpensive and also a rapidly curing binder. A phenol cured product resists temperatures up to 250° C., but the bonds are destroyed if the temperature is maintained above 250° C. for an extended period of time. At higher temperatures, at 400° C. and more, the binder loses its strength, the temperature increases rapidly and the product collapses. In addition, a phenol cured insulating product emits poisonous gases during burning. An additional and also major disadvantage is that the presence of phenol in the product will cause an undesired load on the environment when the binder-containing mineral wool product is to be disposed of after use.
Also water glass has been widely used as a binder. Water glass is traditionally made by melting silica sand with sodium or potassium carbonate at a very high temperature and then dissolving the finely divided solidified product in water. Thus water glass can be considered an ecologically acceptable substance to include as a binder e.g. in mineral wool products. A disadvantage is, however, that the manufacture thereof uses pure raw materials and is energy consuming.
It is also known to use a mixture of water glass and clay as a binder for mineral wool products, see e.g. SE 420 488. Such a product, although providing good water and heat resistance, has poor compression resistance, is brittle and causes dusting. The EP B 466 754 on the other hand describes the use of a binder made from slag and water glass for making a temperature and moisture resistant mineral wool product which is also capable of withstanding high temporary loads.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an easy and economically feasible method for obtaining a binder, which has excellent binding and fire resistant properties and is acceptable from a use or labour hygiene point of view. In addition, the binder according to the invention can be manufactured from inexpensive and easily available raw materials, or by-products, in a simple manner. An important advantage is that the binder made according to the invention presents no excessive ecological load on the environment, but contains only such components that are already inherently present in nature.
The object of the present invention is thus a method for making a binder comprising the steps of
(dissolving a particulate mineral material having a glassy amorphous structure in an aqueous solution to form a solution containing nucleated re-precipitated particles from the material,)
stabilizing the so obtained solution to (form a sol) having a desired particle size, and optionally
adjusting the dry matter content of the sol.
The starting material for the binder can be a mineral wool material, especially a recirculated waste material from mineral wool production, as will be described in more detail below.
Another object of the present invention is a method for the production of a mineral wool product using the binder prepared according to the invention by contacting the binder with mineral fibres in order to bind the fibres to form a mineral wool product.
DETAILED DESCRIPTION OF THE INVENTION
According to a preferred embodiment of the invention, the particulate mineral material is a waste mineral wool product obtained from mineral wool production. Such waste material is formed in large quantities, typically up to 20-30% by weight of the starting raw material, in the form of spinning waste, unused fibers of rejected fibrous products (pre-consumer products). One applicable source for the material is also different constructions which will be taken down and in which mineral wool material has been used for instance as heat insulation (post-consumer products). Such a waste material is already in finely divided, typically fibrous form and can thus be used as such, or alternatively it can also be divided to an even finer form to provide a product with a large surface area, such as 0.4 m 2 /g or larger, e.g. up to 25 m 2 /g and thus has good dissolution properties in the aqueous solution. Fibres obtained from mineral wool production typically have a diameter of 0.5 to 20, usually 2 to 15 μm, preferably 3 to 5 μm as measured with OM or SEM using a suitable method (e.g. Koenig et al, Analytica Chimica Acta 1993 280 289-298; Christensen et al, AM IND HYG ASSOC (54) May 1993), and a length of 0.5 to 50, usually 2 to 20 mm, preferably 3 to 10 mm.
The aqueous solution can be an alkaline solution, such as an alkali metal or earth alkali metal hydroxide, carbonate or hydrocarbonate solution, especially a sodium, potassium or lithium hydroxide solution, or an ammonium hydroxide solution. Such a solution is preferably 0.1 to 2 molar with respect to the alkaline agent, or has a pH of 10 to 14, in order to easily dissolve also such mineral raw materials which are poorly soluble in neutral solutions.
The aqueous solution can also be an acidic solution, such as an aqueous solution made acidic by adding an inorganic or organic acid, such as HCl, HNO 3 , H 2 SO 4 , H 3 PO 4 , formic, acetic, propionic acid or any other suitable mineralor organic acid. The pH of the solution is adjusted suitably. A low pH value results in a rapid dissolution of the mineral material and rapid gel formation, the gelling time being dependent on the pH, a lower pH resulting in a more rapid gelling than a higher pH. Good dissolution for a wide range of mineral materials is obtained at a pH of 0 to 6. The strength of the acid can be, depending on the acid used, from 0.1 to 10 M, typically 0.5 to 5 M.
According to a preferred embodiment, the dissolution of the raw material is preferably carried out at an increased temperature, such as at a temperature of 80 to 100° C., preferably while simultaneously stirring, in order to facilitate the dissolution process. Dissolution takes place within a period from 1-2 hours up to 20 hours depending on the dissolving medium and the solids content of the solution.
Preferably an amount of starting mineral material is dissolved in a solution to provide a metal oxide containing solution which advantageously contains over 1, preferably 5 to 60% by weight of dry matter, which is a suitable concentration for the subsequent use as the binder. After the dissolution is complete, the material nucleates and re-precipitates to form a sol with the desired particle size. (The subsequent stabilization of the sol is brought about by creating in the solution electrostatic repulsion between the particles. The electrostatic repulsion between the sol particles can be effected for example by providing suitable ions in the solution, or by changing the pH.) If necessary, additional water can be added or removed, e.g. by evaporation, if it is necessary, for example for adjusting the viscosity.
(Stabilization may also be achieved by using suitable surfactants and polymers, especially non-ionic ones.) Non-ionic surfactants and polymers can be preferred in some cases as they are not so sensitive to an environment which contains high concentrations of electrolytes and other chemicals, especially when the ionic strength is high. Examples of polymers are polyethylene oxide and polyethylene glycol, and examples of surfactants are nonylphenols, Tween and Span. In a typical situation, such surfactants and polymers are used in an amount of 0.5 to 2.5% by weight, calculated from the total solids of the solution.
At an alkaline pH the sol tends to be stable and an increase in sol particle size can be seen. By maintaining the sol at an alkaline pH for a suitable time, or by increasing the pH from appr. neutral to pH 10, an increase in particle size is obtained, the increase being less pronounced if the solution in addition contains salts. In the presence of sufficient quantities of salts, such as inorganic salts, e.g. sodium chloride, the sol particles tend to aggregate to form gels, which precipitate. The same gel formation will also take place by providing an acid pH to the solution, whereby a pH of appr. 2 to below 7 is suitable for gel formation.
Thus by adjusting the pH the sol state can be maintained, or the sol can be made to gel. The gel can be dispersed and stabilized by using high-shear mixing and raising the pH, and then again be brought to gelling by readjusting (lowering) the pH, or by the addition of an electrolyte.
According to the invention it is thus possible to provide sols containing predominantly silica in combination with other metal oxides stemming from the starting mineral material, such as calcium oxide, magnesium oxide, aluminium oxide, and possibly further metal oxides in smaller amounts. It is also possible to adjust the reaction conditions, such as pH, so as to obtain sols with a desired particle size. Silica sols typically can have a primary particle size of 1 to 1000 nm, whereas for the purposes of the invention a particle size of 10 to 100 nm is suitable. The sols so obtained can be made to gel either directly after sol formation, or preferably only immediately prior to application of the binder onto the mineral fibres. The sol can also be made to gel when heating or evaporating water when the final product is shaped.
When using the binder in mineral wool production, the preparation of the mineral wool product and the addition of the binder made according to the invention can take place conventionally in a conventional set of apparatuses. The binder can be added as a solution through a nozzle to the fibres in the wool chamber of a conventional machine line and distributed on the wool. The curing of the wool material carrying the binder takes place at once or later, at room temperature or at a raised temperature.
The binder solution can also contain possible additional curing, modifying, dust binding and/or hydrophobing agents, if desired or necessary.
The spraying of the binder solution and of the additives usually takes place directly after the fibre formation, preferably in the wool chamber. This is an advantage since the wool is in a virginal state at this point and is uncontaminated and has good adhesiveness.
The binder solution can be sprayed on the wool through the binder nozzles of the centrifuge, whereby it is possible to use both peripheral and central sprayers. It is also possible to use two or more different solutions to be fed onto the wool, so that possible modifying and/or additional curing agents are fed through one or more sprayers and the binder solution through a separate sprayer.
It is, however, also possible to apply the binder solution to the wool in a subsequent step of the production of the insulating material, for example by spraying it on the primary web on the conveyor, or even at a later stage. It is also possible to apply an additional binder in such a separate and later stage, thus obtaining a material with improved resistance and/or strength. Special properties can be given to the material by applying further additives to the web.
The amount of water fed to the wool with the binder is adjusted so as to provide on the one hand the correct viscosity for application purposes and on the other hand the correct moisture for the web and to prevent dusting. Any water evaporating from the wool in the wool chamber increases the viscosity of the binder applied to the fibre, whereby the primary web can retain its elasticity and curability for a long period of time.
The amount of binder generally is appr. 1 to 15, such as 1 to 5% by weight, calculated as dry substance, for a normal insulating product, but it is naturally possible to use higher and lower amounts depending on the desired product and the reactivity of the binder.
When producing insulating sheets, these are appropriately cut out from a mineral web, which has conventionally laid out by crosslapping a primary web to the desired thickness and then cured.
According to a preferred method, the mineral fibre web is cured at room temperature, for example between metal sheets. Such a sheet will acquire a better flexibility as a slowly cured fibre body is more flexible and elastic than a fibre body that has been cured at a high temperature.
According to another preferred embodiment, a secondary web having the desired thickness is taken up in an uncured state and stored in a non-curing environment, e.g. enclosed in a plastic wrapper at a suitable temperature and during a limited determined time. Such an insulating material is used in situ for insulation in places that are not easily accessable and have an awkward shape. After installation the insulation is allowed to cure at the prevailing temperature. It is relatively easy to apply an insulating material or mat having a suitable thickness onto or around various bodies which are difficult to access. The curing does not require any special measures or equipment since it takes place spontaneously at the prevailing temperature.
The method is also suitable for blow wool applications in which uncured fibre material torn into small tufts is applied and the wool cured at the prevailing temperature.
Also additional additives, such as additional curing, modifying, dust binding and hydrophobizing agents can be used.
According to the invention, an additional curing agent can consist of mineral salts and compounds, suitable acids, esters or alcohols or of combinations of these. The mineral salts can be e.g. magnesium, aluminium or calcium salts or compounds. Phosphoric acid, for instance, is a usable acid. Buffer curing agents can also be used for adjusting the storage time. The additional curing agent may be a combination of the above mentioned curing agents.
In case the binder is made by dissolving the mineral material in an alkaline solution, such as sodium hydroxide, thus providing a product of water glass type, but containing additional metal oxides, various modifying agents such as organic and inorganic polymers, cellulose and silicones, such as silicon organic polymers can be used as additives. Also monomers polymerized by e.g. a pH change or a temperature rise during the curing can be used. The said modifying agents have in common the fact of not being film forming. By means of the modifying agents one aims at increasing its adhesiveness to the fibre surface, and also improving the elastic properties, the water resistance, carbonation resistance etc. of the binder.
As dust binding agents, alcohols, polyols, film forming polymers, gelling polymers, waxes, resins, oils, fats, paraffines etc. can be used. The task of the dust binding agent is to bind together any dust or to bind it to the main matrice either physically (film forming) or chemically (surface active properties). In case high temperature curing is used, melting dust binding agents, e.g. stearates, can be used, or curing dust binders, forming a film over the matrice. A great number of the dust binding agents simultaneously have a water repellent effect.
The task of the hydrophobizing agent is to prevent water and moisture from penetrating into the product. As hydrophobizing agents, silanes, silicones, oils, various hydrophobic compounds and hydrophobic starch can be used.
A polybutene-silane composition has proved especially advantageous as a dust binding agent and a hydrophobing agent. The polybutene component acts as a dust binder and the silane component as a hydrophobing agent.
Within the various groups, compatible compounds can be mixed in advance, whereas incompatible compounds have to be mixed immediatedly before the application or applied through separate nozzles.
According to the invention it is also possible to use the binder obtained according to the invention for binding other materials, especially particulate mineral materials, especially in the manufacture of briquettes containing particulate mineral material. Such briquettes are especially suitable starting materials for mineral wool production, although also other briquettes uses are conceivable, such as any use where the excellent binding properties of the binder can be taken advantage of. Such a use can be, for example, in iron ore briquettes for iron manufacture.
The composition of the particulate mineral material to be used as raw material for making such briquettes naturally varies depending on the intended use of the briquettes. When the briquettes are to be used for mineral wool production, the particulate mineral material is chosen according to the desired chemical composition of the fibres to be produced. Suitable materials include any of the stone and other mineral materials normally used for this purpose, such as quartz sand, olivine sand, glass, basalt stone, slags, waste material from mineral wool production, lime stone, dolomite, wollastonite etc. The briquettes are made by simply mixing the mineral material with the binder, and if necessary, adding water to form a mixture of suitable stiffness. This mixture or mass can be formed into briquettes by compressionor compression vibration, using per se known techniques, and hardened in connection with the manufacturing process, or later. The hardening process can be accelerated for example by heating.
The amount of binder can easily be determined by a person skilled in the art. As an example it can be mentioned that when used as a binder in briquettes for mineral wool production, the amount of binder generally is appr. 1 to 15, such as 1 to 5% by weight, calculated as dry substance, of the dry weight of the product, but it is naturally possible to use higher and lower amounts depending on the desired product and the reactivity of the binder. When used as a binder in metal ore briquettes, a typical amount would be appr. 1 to 15, such as 1 to 5% by weight of the total weight of the batch. According to the invention, briquettes with good strength properties, including good green strength properties are obtained.
The following example illustrates the invention, without limiting the same.
EXAMPLE
The binder according to the invention can be prepared in the following way. 7.5 g of conventional rock wool fibres having a fibre diameter of 3 to 4 μm and a fibre length of 3 to 10 mm, are mixed with 100 ml of a 5M solution of formic acid. For the mixing a high-shear mixer should be used to ensure effective mixing and to speed up the dissolution process. The dissolution is usually complete in 1 to 2 hours. When the fibres are completely dissolved a small amount of polymer, such as polyethylene glycol with a molar mass of 1000 to 10000, is added, appr. 1% by weight based on the total solids content of the solution. During the addition of the polymer, the solution is constantly mixed to stabilize the formed particles. By altering the amount of polymer and the time of addition, i.e. the point of time when all fibres have dissolved, the size of the sol particles can be affected to obtain optimal gelling and binding properties. The colloidal particle sol is then kept under continuous mixing to ensure that the polymer adsorps to the surface of the particles.
When used as a binder for making mineral wool products, the binder so prepared can be applied by spraying onto mineral fibres in a conventional maner. The binder is cured and excess water is driven away by raising the temperature up to about 150° C.
The said binder can also be used as a binder in a briquette by mixing the binder with finely ground mineral raw material in a mixer, for example of Henschel type. It can be advantageous to add a small amount of water for forming the mixture in molds. Curing is obtained by raising the temperature, but also air drying is possible. | The invention concerns a method for making a binder, especially for mineral wool products comprising the steps of dissolving a particulate mineral material having a glassy amnorphous structure in an aqueous solution, nucleating and stabilizing the so obtained solution to form a sol having the desired particle size, and optionally adjusting the dry matter content of the sol. The invention also concerns a method for the production of a mineral wool product using the said binder for binding the fibers. | 2 |
BACKGROUND OF THE INVENTION
The invention concerns an apparatus for the manufacture or finishing of a fiber band, such as for a drawing frame or a carding process, wherein the fiber band is conducted between two feeler rolls. The feeler rolls are adjustable in a radial direction to achieve a preset distance of separation for the measurement of fiber band thickness, and at least one of the rolls is driven by a shaft.
An apparatus of this class, such as, for instance, the Regulier drawing frame RSB 951 of the firm Rieter Ingolstadt Spinnereimaschinenbau AG, shows for the measurement of the thickness of the fiber belt, a pair of feeler rolls, which are variable in their spatial interval, one from the other. The fiber band which is conducted through the feeler roll pair activates the distance of the one feeler roll from the other more or less in accord with the thickness of the fiber band. The rolls, which are pressed against each other by means of springs, follow the varied thicknesses of the fiber band which is between them. The fiber band thickness which has been so registered, is transmitted to the control of the machine or at least brought to a display. By means of the determination of the fiber band thickness, the manufacturing procedure can be improved, in that a fiber band with an extremely even thickness can be made, when the machine is operated in adjustment, that is, in the chosen stretch of the fiber band. Pairs of feeler rolls of this kind are found on the input side and/or on the output side of a drawing frame. At the drawing frame entrance, the thickness of the fiber band which is on the point of entering the frame is measured. In accord with this measurement, single drawing frame pairs of rolls are more or less accelerated, so that too thick a fiber band is reduced in thickness and a too thin a fiber band is less strongly stretched, whereby its thickness is increased. At the draw frame exit end, an additional pair of feeling rolls can be found, which are frequently called a pair of calender rolls. These determine the result of the drafted fiber band. At this point, a quality control operation of the extended fiber band is carried out.
These measurement based results can serve for statistic evaluation as well as also for an input to the regulation of the drawing frame.
Very often, a stationary feeler roll is arranged as one of a feeler roll pair. The second feeler roll is designed to be radially pivotable, in order that it may be disengaged in case of an uneven fiber band. The pivotable feeler plate is furthermore driven to avoid slip of the fiber band between the feeler rolls and thus, in an unfavorable case, to avoid a faulty draft of the fiber band.
In order to achieve especially good measurement results with a feeler roll pair of this description, it is important that the feeler rolls can quickly follow a fiber band of fast changing thickness. A detriment of the conventional embodiment is that the pivotable feeler plate and the drive mechanism are affixed to a pivotable bearing block. The complete assembly is relatively heavy and because of its high inertia, results in a relatively sluggish response reaction as the thickness of the fiber band changes. Even by modern equipment of this generic type and driven at very high loading rates, the changing fiber band thickness cannot be tracked with the required precision.
OBJECTS AND SUMMARY OF THE INVENTION
Thus a principal purpose of the present invention is to create a feeler roll pair, which even in the case of fast thickness changes of the fiber band, reacts with exactness and provides precise readings of the thickness of the fiber band. Additional objects and advantages of the invention will be set forth in part in the following description or may be obvious from the description, or may be learned through practice of the invention.
According to the invention, the shaft by which the feeler roll is carried is separated into a drive shaft and a feeler roll axle, and the two shaft sections are connected by a misalignment tolerant coupling. Thus, the deviation of the feeler roll occurs with a reduced weight. The feeler roll with its axle are deviated as well as the bearings thereof. A deviation then of the weight of the drive, the drive shaft, and the bearings thereof is not necessary. Thereby, a clear reduction of the moving weight is carried out by the measurement of the fiber band. Reproduceable changes of the fiber band thickness under these conditions are possible without great time delay because of large inertial forces. The measurement of the fiber band is accordingly very exact. The present invention realizes thereby a clear weight reduction of the moving components.
If the drive shaft and the feeler roll shafts are at least partially installed independently of one another, then advantageously there is no interference with the single, pivotable shafts.
If the shafts are arranged in individual, pivotable bearing blocks, then a deviation of the feeler roll is, from a technical standpoint, easily solved. By means of the pivoting of the bearing blocks, one feeler roll is radially distanced from the other. The separation occurs during the measurement of the fiber band. The magnitude of the distancing is in relation to the changing fiber band thicknesses. Advantageously, the two bearing blocks are so interconnected, that after a predetermined angular rotation of the roll bearing block, the drive bearing block likewise pivots. Thus it is assured that, for instance in the case of windup of the fiber band, that is, in an operational difficulty of the apparatus of the invention first, the roll bearing block is displaced up to a detent, whereupon the drive bearing block pivots. Damage to the feeler roll arrangement is thereby avoided, since the feeler roll can yield to the pressure of the fiber band.
Advantageously, in the case of windups of the fiber band, an eccentric thrust bar arrangement, which acts upon the drive bearing block, is released. When this occurs, the feeler roll pair becomes continually open and thereupon remains in this state. By means of the eccentric thrust bar arrangement, it is moreover possible to carry out cleaning operations or manually or to automatically feed fiber band between the two feeler rolls. Also, the feeler rolls can be opened by means of the eccentric rod and subsequently, following the insertion of the fiber band, the said rod again closes both of the feeler rolls.
It is especially of advantage if the roll bearing block is pivotably installed on the drive shaft bearing block. This leads, on the one hand, to simple construction, and on the other, to a more secure pivoting during the fiber band measurement as well as a means to open the feeler rolls upon a windup.
In order to be able to evaluate the different fiber band thicknesses, a displacement pickup is arranged on the drive bearing block. This pickup is arranged for the measurement of the pivoting of the roll bearing block.
Usually, a maximum spatial interval of 10 mm is sufficient between the feeler rolls with a corresponding pivoting allowance for said feeler roll blocks.
Sliding bearings, in which the bearing blocks are pivotally secured, bring about favorable friction relationships for the small dislocations of the measurement. This allows exact measuring of the fiber band. An adjustment of the feeler rolls is possible by means of an adjustment screw, which fixes the start point adjustment of the two feeler rolls to one another.
In order to make possible a further pivoting of the drive bearing block, it has been advantageously provided that a maximum distance between the feeler rolls of 30 mm can be reached. In order to be able to take off a windup of the fiber band from a feeler roll, 30 mm usually suffices. If the drive bearing block is pivoted to its maximum degree, then the drive bearing block acts upon a disconnect of the apparatus. In this way, it is assured, that no fiber band windup grows larger and leads to damage of the apparatus.
A design which has shown itself as simple and thus advantageous becomes evident when the bearing blocks are securable in their basic positions by means of loading springs. The basic start position means that the feeler rolls lie upon one another or show a gap therebetween of less than 0.5 mm, preferably 0.05 mm when no fiber band is present. In order to permit a deviation of the roller bearing blocks prior to the pivoting of the drive shaft bearing block, the spring acting on the roll axle block possesses a weaker characteristic curve than does the spring acting upon the drive shaft bearing block. In this way, the weaker spring expands first to its maximum extension and only after this does the stronger spring come into play.
A torsionally rigid, flexible shaft coupling between the drive shaft and the feeler roll axle has shown itself as particularly advantageous. By this means, a misalignment of the two shafts can be tolerated, but in any case torque is transferred to the feeler roll axle. Excellent results have been obtained by the use of a multiple disk coupling.
It is advantageous, for an exact measurement of the fiber band, if only small forces for the generation of a misalignment of the coupling are required. Under certain circumstances, forces which are too great react to produce a strong loading of the fiber band with subsequent erroneous measurement results. Beyond this, there are conditions within which too great an offset force would negate the savings which have been made in reducing the weight.
If the feeler roll axle is borne by needle bearings and is force fit on its axle, then a further weight reduction is brought about in regard to the pivoting components for the measurement of the fiber band, since the needle bearings are built very small and light, and by the force fit of the feeler roll on its axle, no additional constructional parts are needed.
A further reduction of the total weight of the feeler roll is achieved if the feeler axle is made hollow by axial boring. Thus, the feeler roll is designed to be extremely light. In addition, axial borings which reduce weight can be made in the feeler roll to reduce the inertia of the feeler roll and thus make possible a quick and precise measurement of the fiber band.
If the feeler roll possesses a concave, circumferential rim to accept the fiber band, then a guidance of the feeler roll is provided by the fiber band. This situation allows omitting an axial guide mechanism for the bearings of the feeler roll. Thus, at the same time, weight for the necessary components for such guidance can be eliminated.
It is particularly advantageous, if the drive shaft is driven by means of a toothed belt. This simple drive mechanism brings about a sufficiently exact speed of the feeler roll. In many applications, it is advantageous if the drive shaft is powered directly from a motor which is connected directly to the drive shaft.
An example embodiment of the invention is described in the following Figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of an apparatus in accord with the invention;
FIG. 2 is a plan view of an apparatus in accord with the invention;
FIG. 3 is a front view of an apparatus in accord with the invention;
FIGS. 4a to 4c are different disengagements of an invented apparatus; and
FIG. 5 is a view of a coupling.
DETAILED DESCRIPTION
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the figures. Each example is presented to explain the invention, and not as a limitation of the invention. In fact, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment. It is intended that the present invention include such modifications and variations.
An apparatus, in accord with the invention, shown in FIG. 1 shows a coupling 1, which joins a drive shaft 15 with a feeler roll axle 16. The drive shaft 15 is rotatably secured in a bearing block 2. Likewise, the feeler roll axle 16 is rotatably secured in a feeler roll bearing block 3. The bearing provision is made advantageously with needle bearings, which are not shown. Needle bearings possess the advantage that they can be made very small. If space allowances permit, other kinds of bearings are permissible in the drive shaft bearing block 2. The drive shaft 15 is provided on one end with a toothed belt sheave 14. By means of a power mechanism not shown, driven toothed belts act on the toothed belt sheave 14, which turns the drive shaft 15, the coupling 1, as well as the roll axle 16 which latter carries a feeler roll 6 affixed thereto. Instead of the toothed belt, the drive can possibly be carried out by means of a flat belt, a chain, or another similar drive means. Moreover, the drive can be effected directly by means of a motor, the shaft of which being flangedly affixed to the drive shaft 15.
The drive bearing block 2 is secured on a swivel axis 13. The swivel axis 13 is set in bearings 20, 20', by means of bushings 21, 21' and with a washer 23. The sliding bushings 21, 21' of the swivel axis 13, as well as the washer 23, have shown that in a small construction space, the small axial displacement of the drive bearing block 2, to be later described, can be carried out very well. Axel 13 is set in bearing block 3 by means of bushings 22 and 22'.
On the drive shaft bearing block, a carrier 24 is installed. To this carrier 24 is affixed, by means of an axle 19, an eccentric bar 18, used as a tripping device. The lever bar 18 is comprised, in part, of a spring 5. Upon a rotary movement of the drive bearing block 2 by the swivel axis 13, the spring 5 is more or less strongly compressed.
This allows, to a prescribed extent, a pivoting of the drive bearing block 2. As soon as this prescribed measurement of movement is overstepped, the eccentric bar 18 kicks out and prevents a reverse springing of the drive bearing block 2 into the start position. This is advantageous if the entire unit pivots because of a windup around the feeler roll 6. In this case, the eccentric bar 18 pivots around the axle 19 and so acts that the drive bearing block 2 as well as the feeler bearing block 3 rotate into an end position and remain there. Customarily, it is foreseen that in this position a switch 35 (FIG. 4c) is activated which shuts down the machine, blocking the delivery of anymore fiber band.
On the drive bearing block 2 as well as the carrier 24, a pivoting lever 17 is provided. On this said pivoting lever 17, a positioning screw 9 is to be found which serves for the loading of the rolls. By means of positioning screw 9, that force is applied which is required to move the feeler roll 6 away from its paired feeler roll 6' by means of the fiber band. By the adjustment of the positioning screw 9, the spring force is increased or decreased.
This has the effect that more or less force is necessary in order to move the two rolls 6, 6' away from each other. This movement occurs by means of the fiber band which has been led through the two rolls 6 and 6', and which fiber band exhibits differing thicknesses. The more the positioning screw 9 compresses the spring 4 (FIG. 2), just so much earlier will a detent of the feeler roll bearing block 3 confront the pivot lever 17. When this occurs, a deviation of the drive bearing block 2 results by means of the spring 5. In this situation, since the spring 4 is weaker than the spring 5, it follows that first the spring 4 is compressed and then, only after complete compression of the spring 4, a deviation of the spring 5 occurs.
The feeler roll 6 is affixed to a roll axle 16. The roll axle 16 is furnished in this embodiment example as a hollow shaft. In this way, an additional weight reduction in the movable roll bearing block 3 is achieved. For yet a further reduction in weight, provision is made that the feeler roll 6 is force fit by means of a collar 27 on the roll axle 16. By means of the elimination of additional material for fastening, this further reduces the weight.
Likewise, to the purpose of weight reduction of the moving parts, feeler roll 6 is provided with a recess 28 as well as web borings 26. This assures that all the components installed on the roll bearing block 3 have been designed to be especially light, whereby a quick response to changes in the fiber band thickness is made possible for the feeler roll 6 which is secured in said bearing block 3.
The coupling 1 is designed in such a way that it is easily deflected, that is, it is tolerant of a misalignment but on the other hand, the torque, which is communicated by the driving means to the drive shaft 15, is transmitted in good order. The coupling 1 must therefore be stable for transmission of torque but yet permit a lateral offset of the drive shaft 15 upon a deflection of the feeler roll bearing block 3 of the roll axle 16. By means of a minimal restoring force from the coupling 1, the advantage arises that the weight reduction achieved in the movable bearing block 3 is not counteracted by an excessively high restoration force, compelling the drive shaft 15 and the feeler axle 16 into an aligned axle position.
The flexible shaft coupling 1, which has a torque transmitting rigidity, can be provided with two multi-disk packets, which, in the connection of two shaft ends, compensate for a radial shaft offsetting. The coupling is comprised of two multi-disk packets, two collars and a transition piece. Between the toothed belt sheave 14 and the drive shaft 15, a slip clutch is provided. In the case of a blocking of the feeler roll 6, for instance because of a windup of the fiber band around the feeler roll 6, the coupling would be damaged if the drive acting upon the toothed belt sheave 14 does not stop. The coupling is advantageously arranged to act from the drive bearing block 2 upon the drive shaft 15. Otherwise, if it were to act upon the feeler roll axle 16, an additional increase of pivoting weight due to the feeler roll bearing block 3 would result.
One of the essential thoughts in the case of the arrangement in accord with the invention is that the drive of the feeler roll and the feeler roll itself are at least partially uncoupled from one another.
Thereby, a displacement of the feeler roll 6 is allowable, without carrying along those components which are necessary for the drive of the feeler roll 6. By means of this weight reduction, a very exact measurement of the fiber band is made possible.
FIG. 2 shows the apparatus in accord with the invention in a plan view. The toothed belt drive 14 is connected by means of a clutch 25 to the drive shaft 15. The coupling 1 is affixed to the drive shaft 15 as well as to the roll axle 16. The feeler roll 6 is installed on the roll axle 16. The circumference of the feeler roll is shown as a concave rim d . By means of this concave rim d, the circumstance arises that the fiber band found between the feeler roll 6 and the feeler roll 6' serves as an alignment guide for the one feeler roll 6. This allows that an axial securement of the bearing system of the feeler roll 6 may be eliminated. Thus no further components are necessary to fix the feeler roll 6 axially in its bearings. The preferably employed needle bearings for the support of the roll axle 16 can accordingly be used with very little additional weight.
A feeler plate 30 has been installed on the feeler roll bearing block 3. When the fiber band varies in its thickness between the feeler rolls 6 and 6', then the feeler roll bearing block 3 carrying the feeler plate 30 is also more or less pivoted. The pivoting works against the pressing action of the spring 4. The spring 4 is anchored on the positioning screw 9, which in turn is fastened in the pivot lever 17. By means of the adjustment of the positioning screw 9 the pressing action of the spring 4 is altered. Therewith, an influence is brought to bear on the force with which the fiber band is compressed between the two feeler rolls 6 and 6'. If there is no fiber band between the feeler rolls 6, 6', then the spring 4 presses the feeler roll bearing block 3 against a detent on the drive bearing block 2. The pivoting of the entire unit with the drive bearing block 2 and the feeler roll bearing block 3 is adjustable by means of a positioning screw 8 which presses against a spacer 29. In this way, the spatial interval between the feeler roll 6 and the feeler roll 6' is set. Usually, the adjustment is carried out in such a way, that in an empty condition, the feeler rolls 6 and 6' do not touch each other.
This is to assure that upon a long stillstand, the feeler rolls 6 and 6' do not press against one another and in this way contribute to measuring results which reflect erroneous pressure points. The detent for the position of the feeler roll bearing block 3 for the drive bearing block 2, in the state where no fiber band is found between the feeler rolls 6, 6', is planned in such a way that an offset V between the axes of the drive shaft 15 and the roll axle 16 arises, which is slightly negative. This is favorable for the restoration force of the coupling 1, since in the situation in which there is fiber band between the feeler rolls 6 and 6', the coupling 1 is less strongly pivoted, as would be the case in idling time, had no misalignment been purposely arranged.
The distance between the feeler rolls 6 and 6' is measured with the aid of the displacement pickup 7. The displacement pickup 7 is either stationarily fixed on a roll bearing housing 11 for the feeler roll 6' or is on the drive bearing block 2. By means of the turning of the feeler roll bearing block 3, the distance between the displacement pickup 7 and the feeler plate 30 changes. This change of the separating distance is proportional to the change of the thickness of the fiber band between the feeler rolls 6 and 6'.
As soon as (1) the spring 4 is completely compressed by means of a deflection of the feeler roll 6, which deflection could lead to damage of the equipment, or (2) the feeler roll bearing block 3 impinges against a detent on the drive bearing block 2, then the drive bearing block 2 itself will be deflected.
This deflection is made against the force of the spring 5. The spring 5 is of stronger design than the spring 4, so that in each case, the spring 4 is deflected for the measurement of the fiber band. By means of the deflection of the drive bearing block 2, the spring 5 is compressed. The spring 5 is integral with the eccentric bar 18, which in turn is pivotally supported by the axle 19 on the carrier 24. In the case of an extreme deflection of the drive bearing block 2, which can happen, for instance, by a windup around the feeler roll 6 or 6', the eccentric thrust bar 18 is disconnected and the entire movable component is brought into an end position wherein the feed of fiber band is halted. Only by means of manual intervention, can the drive bearing block 2 and the feeler roll bearing block 3 be brought back into their operating position by the eccentric bar 18, in which position the feed of new fiber band can be restarted.
FIG. 3 presents a front view of an embodiment of the apparatus in accord with the invention. The feeler roll 6' is immovably installed in the roll bearing housing 11. The feeler roller 6' here exhibits borings 26', which reduces the weight of said feeler roll 6'. The feeler roll 6' can be designed without the borings 26', and not endanger the functioning of the invented apparatus as well as without the recess 28'. A weight reduction in the case of the feeler roll 6' is not so important, since in this case the measurement of the fiber band thickness is not dependent on a movable feeler roll. Contrary to this, in the case of the feeler roll 6, the borings 26 and the recess 28 are advantageous, since they contribute to the weight reduction of the feeler roll bearing block 3 and hence also to a precise measurement of the fiber band 31. The measurement of the thickness of the fiber band 31 is done in that the feeler roll 6, which is supported in the feeler roll block 3, pivots around the axis 13 when a change in the thickness of the fiber band 31 occurs. The feeler plate 30 is installed on the feeler roll bearing block 3. Upon the swivelling of the feeler roll bearing block 3, the feeler plate 30 moves against the force of the spring 4. As this is done, the feeler plate 30 more or less distances itself from the displacement pickup 7. This removal distance is transmitted from the displacement pickup 7 to an (not shown) evaluation unit of the apparatus. The transmitted signal is interpreted as the thickness of the fiber band 31 and serves for the determination as to whether or not the said thickness of the fiber band 31 lies within the allowable tolerances. The displacement of the feeler plate 30 works against the force of spring 4, which is adjusted by means of the positioning screw 9. The positioning screw 9 is affixed to the pivoting lever 17, which in turn is connected with the drive bearing block 2. As soon as the extended travel stroke of the spring 4 has reached its limit, or the feeler roll bearing block 3 impinges on the detent of the drive bearing block 2, the said drive bearing block 2 likewise turns about the axis 13.
As this occurs, the entire pivotable unit, which is essentially comprised of the drive bearing block 2, the feeler roll bearing block 3 as well as the feeler roll 6, moves away from the feeler roll 6' and can stop the feed of the fiber band 31. This is possible because either damage to the invented apparatus is threatened or the allowable tolerance for the thickness of the fiber band 31 has been overstepped. A stoppage of the feed to the machine can also come about if the deflection pickup 7 determines such an overstepping of the thickness tolerance of the fiber band 31. The allowable tolerance is communicated to the control of the apparatus. Only the feeler bearing block 3 together with the feeler roll 6 are exclusively pivoted for the measurement of the fiber band 31 within the allowable thickness tolerance range. Along with this, and contrary to the conventional state of the technology, a marked reduction in weight of the moving components has been brought about whereby the thickness of the fiber band can be determined with greater reproducibility. Thus, the variance of the fiber band thickness is determined and transmitted better than previously.
The FIGS. 4a, 4b and 4c show in a schematic manner, the drive bearing block 2 and the feeler roll bearing block 3 in various positions relative to one another. In FIG. 4a, the feeler bearing block 3 and the drive bearing block 2 are shown in their start position. The feeler roll bearing block 3 lies on a detent 32 of the drive bearing block 2. This position is customarily set up when the fiber band 31 finds itself between the feeler rolls 6 and 6'. The feeler bearing block 3, which is pivotable about the axis 13 and which carries the roll axle 16, is thus in its start position. The feeler plate 30, which is on the feeler bearing block 3, is in a specified position in regard to the displacement pickup 7 which is fastened to the drive bearing block 2.
FIG. 4b shows the deflection of the feeler bearing block 3 in a normal operation. The pivoting of the feeler roll 6 bearing block 3 occurs about the pivot axis 13. The pivoting is thereby achieved, in that the (not shown in FIG. 4b) feeler roll 6 which is carried by the roll axle 16, is moved away from the feeler roll 6' by means of the fiber band 31 which runs between the said feeler rolls.
In this way, there follows a pivoting of the roll axis 34 about the pivot axis 13 to the degree of angle α. Something like 5° is seen as advantageous and sufficient for the angle α. The displacement through angle α activates a lateral offset of the roll axis 34 through the distance f. This value f represents the maximal allowable measurement range for a change in the thickness of the fiber band. The value of about 2 mm has shown itself to be sufficient. Simultaneously with the drive bearing block 2, the feeler plate 30 which is fastened thereon, is displaced and moved away from the displacement pickup 7. Therefrom is developed a measurement travel F, which corresponds to a fiber band thickness. By means of the shape and the lever relationships which arise therefrom, among axis 34, pivot point 13 and feeler plate 30, an advantageous measurement travel F has arisen showing a value of 3 to 5 mm.
In FIG. 4c, the situation is presented, in which the feeler roll 6 is rotated out of the measurement zone. In this case, the drive bearing block 2 is likewise pivoted around the axis 13. In this position, the maximum separation M of the feeler rolls 6 and 6' occurs. This offset may amount to about 7 mm which is considered sufficient. The total divergence is approximately 15°. This total divergence γ is comprised of the combined angles α and β. The angle α indicates the maximum deviation of the roll bearing block 3 in reference to the drive bearing block 2. The deviation β shows the maximum possible deviation of the drive bearing block 2. The invented apparatus finds itself in the position of FIG. 4c whenever a windup occurs about one or both of the feeler rolls 6, 6' and the entire apparatus swivels into the idling state by means of the eccentric bar 18. A position of this kind can also be of value if the feeler rolls are opened in order to insert a new fiber band.
In FIG. 5 a coupling 1 is shown. The coupling 1 is comprised of a midpiece 40, which joins flanges 41 and 42. In flange 41, the drive shaft 15 is installed. The roll axle 16 is affixed to flange 42. The connection is done respectively in a slip free manner. Between midpiece 40 and flange 41 or 42, respectively springs 43 and 44 are arranged.
These springs are connected to flange 41 and flange 42 with rods 45 in such a manner that the transmission of rotary motion can be carried out. Otherwise, an axial displacement of the flanges 41 and 42 with the respective shafts, that is, 15 and 16 is made possible. Several of the rods 45 with accompanying springs 43 or 44 are apportioned around the circumference of the flange. Some of the rods 45 are torsion tightened to the flanges 41 and 42, other rods are similarly torsionally tightened to the midpiece 40. Those rods 45 which are torsionally tightened with the flanges 41 and 42 are not secured into the midpiece, but essentially make the connection between the spring 43 or 44 with the flange 41 or 42 respectively. The other rods 45, which are connected with the midpiece 40, bind the springs 43 and 44 torsionally tightened to said midpiece 40 and are independent of the flange 41 or 42. It is by means of this arrangement that the axial displacement of the shafts 15 and 16 is made possible.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents. | In regard an apparatus for the manufacture or finishing treatment of a fiber band (31), such as, for instance, a drawing frame or a carding process, the fiber band (31) is conducted between two feeler rolls (6, 6'). The feeler rolls (6, 6') are adjustable in a radial direction to achieve a set distance of separation for the measurement of the fiber band thickness. At least one of the feeler rolls (6, 6') is driven by a shaft. The shaft is composed of a drive shaft (15) and a feeler roll axle (16). The feeler roll axle (16) is connected to the drive shaft (15) by means of a shaft misalignment tolerant coupling (1). | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hair treatment, and more particularly, to a hair treatment device for use primarily in separating and isolating individual tufts or tresses of hair and permitting selected segments of the tresses to be treated with different treating solutions. In one embodiment the hair treatment device includes a rod having a partition intermediate the ends thereof and a post on one end, with staggered apertures in the post, rod and partition for securing the device in place, the partition operating to prevent comingling of treating solutions placed on the separate segments of the wound tresses. Grooves may be provided in the rod in the area of the partition in order to provide a uniform length of curl and wave pattern in the hair as the hair strands or tresses are wound on the rod and secured in place. In another embodiment of the invention the rod may be provided with a single partition and with the grooves to provide more uniform curling of the strands.
2. Description of the Prior Art
Many devices for curling and treating hair are known in the prior art. Typical of such devices is the hair curling device disclosed in U.S. Pat. No. 3,105,503 to Albert Safianoff, which consists of a mandrel and a cooperating sleeve designed to hold a tress of hair in wound configuration on the mandrel. The device is designed to form curls in the hair as the individually wound tresses are caused to assume a curled configuration from winding on the mandrel. Another hair curling device is disclosed in U.S. Pat. No. 2,423,252 to O. R. Nemeth, which device is used for both dressing and drying hair. The Nemeth apparatus includes a hollow, cylindrical body fitted with spaced disks and holes provided in the body to permit air to be blown through the hollow interior of the body and out of the holes. Hair tresses are wound around the cylindrical body between the disks, treated as desired, and dried by application of air, for example, from a hairdryer. The tresses are then secured in place by elastic bands stretched from one end of the device to the other. Another hair curling device is disclosed by U.S. Pat. No. 2,867,223 to R. L. Anzalone, which includes a cylindrical spindle with a pair of arms pivotally mounted on the spindle and adapted to close on a hair tress or strands wound on the spindle. U.S. Pat. No. 2,536,705 to A. Teopilian illustrates a hair curler clamping bobbin having telescoping loop and an adjustable end plate.
There exists today a need in the hair treatment field for, and it is an object of this invention to provide, a hair treatment device which is characterized by at least one partition on a rod, which device is small, light in weight, easy to manipulate and anchor in the hair, capable of receiving strands, tufts or tresses of hair in isolated fashion for separate treatment and uniform curling, and which is comfortable, particularly while the user is sleeping or resting.
Another object of the invention is to provide a hair treatment device which is characterized by a grooved rod and at least one dividing partition, which rod is, in a preferred embodiment, hollow to reduce weight and is small in diameter to permit treatment of hair wound thereon very close to the scalp.
Yet another object of this invention is to provide a hair treatment and curling device primarily for use in professional shops which includes a round, partially partitioned, grooved curler rod with a post or enlargement having a flat area thereon on one end, which rod is, in a preferred embodiment, capable of receiving a single tress or tuft of hair wound thereon and separated by the partition for separate treatment of the tress segments.
Another object of the invention is to provide a new and improved hair treatment device which is shaped and grooved to receive a single hair tress or tuft, the length of which device is separated by a truncated partition to permit selective, separate treatment of the hair tress with no mixing of the treating solutions.
A still further object of the invention is to provide a new and improved hair curler and treatment device for professional use, which device is characterized by a grooved rod having at least one truncated partition and post mounted thereon, which partition and post are formed and shaped to conform to the shape of a user's head, which device can be quickly and easily secured in place by conventional pins inserted in staggered holes after a single tress or tuft of hair is wound thereon.
Another object of the invention is to provide a new and improved hair treatment device which includes a shaft or rod fitted with a pair of crossing grooves and a curved, truncated post on one end and a curved, truncated partition spaced from the post and located between the post and the opposite end of the device, with the truncated segments essentially parallel to each other, and a plurality of staggered, spaced apertures in the rod, post and partition to permit the device to be securely, yet comfortably, positioned in the hair with pins.
Yet another object of the invention is to provide an improved hair curling and treatment device which includes a round rod having an essentially semicircular shaped, truncated post on one end thereof and an essentially semicircular shaped, truncated partition spaced from the post and having the curved portion thereof extending from the rod in parallel relationship to the curved portion of the post, the truncated or flat segment of the post and partition being in essentially parallel relationship to each other, and the rod being further fitted with a pair of intersecting grooves for receiving the tuft or tress of hair and to effect uniform curling of the hair.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a hair treatment device which includes a round curler rod having at least one truncated partition intermediate the ends thereof, and, in a preferred embodiment, a truncated post secured to one end. In a most preferred embodiment of the invention, a single, curved partition with a flat or truncated edge in essentially parallel relationship to the truncated post is provided, with spaced apertures in the rod, partition and post to accommodate pins for securing the device in place against the scalp. The post and partition are preferably curved in co-extension from the curler rod, and a pair of intersecting grooves are formed in the rod diagonally across the truncated segment of the partition to facilitate uniform wave formation of a hair tress wound on the rod and in a selected one of the grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawing, wherein:
FIG. 1 of the drawing is a perspective view of a preferred embodiment of the hair treatment device of this invention;
FIG. 2 is a top elevation of the hair treatment device illustrated in FIG. 1;
FIG. 3 is a bottom elevation of the hair treatment device illustrated in FIG. 1;
FIG. 4 is a left end elevation of the hair treatment device illustrated in FIG. 1;
FIG. 5 is a top elevation of an alternative embodiment of the hair treatment device of this invention;
FIG. 6 is a bottom elevation of the hair treatment device illustrated in FIG. 5;
FIG. 7 is a perspective view of another embodiment of the hair treatment device of this invention;
FIG. 8 is a top elevation of the hair treatment device illustrated in FIG. 7;
FIG. 9 is a bottom elevation of the hair treatment device illustrated in FIGS. 7 and 8;
FIG. 10 is a right end elevation of the hair treatment device illustrated in FIG. 7;
FIG. 11 is a top elevation of still another preferred embodiment of the invention; and
FIG. 12 is a perspective view of the hair treatment device illustrated in FIGS. 5 and 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-4 of the drawing, the hair treatment device of this invention is generally represented by reference numeral 1. The device includes a round, preferably hollow rod, generally illustrated by reference numeral 2, and further characterized by end segment 3 and post segment 4, defined by a flat partition 5, the latter of which is preferably generally truncated and semicircular in shape, and is provided with spaced logitudinal apertures 11. Truncated segment 7 of partition 5 is cut such that it is coextensive with the surface of rod 2 near the center of the segment. Post 6, also preferably truncated and semicircular in configuration and provided with spaced apertures 8, is joined to one end of rod 2, or may be molded integrally with rod 2, as desired. Truncated segment 7 of post 6 is also cut so as to be coextensive with the surface of rod 2 near the center of the segment and is generally parallel to the truncated segment 7 of partition 5.
It will be appreciated that partition 5 and post 6 project from rod 2 on all sides thereof except at truncated segment 7, and partition 5 serves to divide rod 2 into two distinct segments, end segment 3 and post segment 4. Like post 6, partition 5 is preferably formed integrally with rod 2, and in a preferred embodiment of the invention both members project concentrically from the surface of rod 2 along a substantial portion of the surface of the rod and are co-extensive with rod 2 at one point at the center of truncated segment 7. As illustrated, apertures 8 are drilled through rod 2 in continuous, staggered relationship to permit one or more pins 10 to be inserted through rod 2 from top to bottom and from side to side, respectively, of hair treatment device 1. Similarly, and referring now to FIGS. 1 and 12 of the drawing, logitudinal apertures 11 in post 6 and partition 5 are aligned in spaced relationship to permit a hair tuft or tress 12 to be secured in place by a pin or pins 10. In a most preferred embodiment of the invention grooves 9 are provided in the surface of rod 2, extending from end segment 3 and diagonally crossing that portion of rod 2 which coincides with truncated segment 7, and into post segment 4. As illustrated in FIG. 12, a hair tuft or tress 12 can be initially wound on end segment 3 and positioned in the appropriate one of grooves 9, to terminate on post segment 4. Since the distance around rod 2 at the diagonal across the area on rod 2 where truncated segment 7 and rod 2 coincide is greater than the circumference of rod 2, grooves 9 serve to equalize the curl in hair tress 12. Accordingly, in a preferred embodiment of the invention grooves 9 are cut sufficiently deep in rod 2 to insure that the length of the diagonal wrap of hair tress 12 in grooves 9 and around rod 2 is substantially equal to the ungrooved circumference of rod 2. This provision insures that each curl in hair tress 12 will be substantially equal in magnitude, and provides a uniform wave pattern in the hair.
Referring now to FIGS. 5, 6 and 12 of the drawing, in another preferred embodiment of the invention rod 2 is divided into end segment 3 and post segment 4 by a flat, circular and truncated partition 5, having a truncated segment 7, as in the case of the device illustrated in FIGS. 1-4, but without a post 6. End segment 3 and post segment 4 are essentially equal in length and truncated segment 7 coincides with the surface of rod 2 at the center of the segment, as illustrated.
Referring to FIGS. 7-9 of the drawing, in yet another preferred embodiment of the invention rod 2 is provided with a partition 5 and a post 6 formed in spaced relationship on rod 2 as enlarged nodules on the rod. As in the case of the device illustrated in FIGS. 1-4, a truncated segment 7 is provided on both partition 5 and post 6, which segment coincides with a flattened area on rod 2 at the point of truncation. Grooves 9 are provided as described above in order to standardize the magnitude of curl in each hair tress wound on the rod 2, and ensure a uniform wave pattern in the hair.
Referring again to FIG. 12 of the drawing, a hair tress 12 is illustrated in wound configuration on end segment 3 and post segment 4 of rod 2 in one of the grooves 9, and isolated by partition 5. If, for example, it is desired to treat only the new growth of hair nearest the scalp and not the end segment of the hair tuft, the hair tress 12 is first wound on post segment 4, the hair strands crossed to end segment 3 in one of grooves 9 at the flat edge of partition 5, and the end portion of hair tress 12 wound on end segment 3, leaving the area of hair tress 12 adjacent the scalp concurrently isolated on post segment 4 for treatment. Partition 5 prevents the treating solution from flowing from end segment 3 to post segment 4 when the flat edge of partition 5 is secured against the scalp by pins 9. A small portion of lambs wool can be used to hold the ends of the hair tress on end segment 13, if desired.
It will be appreciated that hair treatment device 1 of this invention can be easily and comfortably utilized to curl and treat adjacent tufts or tresses of hair in the manner outlined above because of the small physical size and light weight of the device and the design of truncated partition 5 and post 6. For example, under circumstances where it is desired to "frost" the end segment of a tress or tresses of hair and otherwise treat the adjacent segment, the end portion designated for "frosting" can be wound on the end segment 3 of rod 2 after the intermediate section is wound on post segment 4. When the entire area of hair to be treated is similarly wound and secured in place by using pins 10, each respective tress can be treated as desired with little or no interaction between treating solutions, due to the barrier provided by partition 5.
While rod 2 is preferably divided into two portions, end segment 3 and post segment 4, by a single partition 5, it will be appreciated that rod 2 can be provided with additional partitions of substantially any shape and multiple sets of grooves 9 to permit multiple tress segments of hair to be wound and isolated on rod 2, as desired. The number, shape, and size of such partitions is limited only by the practicality of easily winding multiple tufts or tresses of hair on a single rod in specified segments defined by a plurality of partitions 5.
The hair treatment device of this invention can be manufactured of substantially any suitable material, but is preferably formed of plastic, rubber or fiberglass materials which are impervious to commonly used hair treating solutions, according to the knowledge of those skilled in the art. Rod 2 is also preferably hollow to facilitate comfort due to reduced weight, and in a preferred embodiment, the partition or partitions 5 and post 6 are formed integrally with the rod 2. The device can be easily formed by injection molding or other well known production methods, depending upon the type of material chosen for manufacturing. While the device is generally designed for use by professional hair stylists, it will be appreciated that it may also be used by individuals in the home as well, according to the proficiency of the user. The device is characterized by flexibility in that it can be utilized to roll the hair tress segments from the tip of the segments in, or from the scalp out, as desired, and according to the proficiency of the user.
It will be further appreciated that the extent of treatment can be varied by using a hair treatment device in which the respective diameters of end segment 3 and post segment 4 are dissimilar. For example, a stronger "set" is achieved when the hair tresses are wound in tight coils on a roller of small diameter in comparison to tresses wound on a roller of larger diameter, assuming that a like concentration of treating solution is used in both cases. Generally, a rod 2 of small diameter is preferred in the instant invention in order to achieve a good "set" and to permit treatment of hair quite close to the scalp. Accordingly, the degree of "set" can be varied in applicant's invention by varying the size of both end segment 3 and post segment 4 of rod 2, as desired. However, when a "set" of maximum uniformity is desired to achieve a uniform wave pattern, a hair treatment device which is provided with grooves 9 may be used according to the description set forth above. | A hair treatment device characterized by a round, partitioned rod having, in a preferred embodiment, a post on one end and a partition between the post and the opposite end, the post, partition and rod each having a plurality of staggered apertures for securing the device in place with pins. The rod may be provided with a single partition in another embodiment of the invention, and the partitioned design permits a length or tress of hair to be wound on the device and treated simultaneously with separate treating solutions and no comingling of the solutions. The device may also be provided with grooves traversing the partition and rod to accommodate the hair strands or tresses and effect more uniform curling. | 0 |
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