description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/053,410, filed Feb. 7, 2005, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/542,514, filed Feb. 6, 2004, both of which are incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the use of surface modified biocompatible materials to promote the attachment of bone or bone-like cells to an implant surface. The surface of the biomaterials, which may include hydrogels, when modified in accordance with the description herein, directs the cells that migrate to the implant site to differentiate into cells that attach and lay down bone or bone-derivative material, or cartilage or cartilaginous material further enhancing the biocompatibility of the implanted device.
[0004] 2. Background Art
[0005] Materials used in the construction of implantable medical devices must be nontoxic, nonantigenic, and noninflammatory. Hydrogels are a preferred type of polymeric material for implantable devices. Because of their high water content, analogous to living tissue, they are superior in biocompatibility to non-hydrous polymeric materials.
[0006] U.S. Pat. No. 5,981,826, issued to Ku et al., describes the preparation of polyvinyl alcohol hydrogels (PVA-H) by physically crosslinking an aqueous solution of polyvinyl alcohol (PVA) to produce a gel. The crosslinking is accomplished by subjecting the aqueous PVA solution to multiple cycles of freezing and thawing. One limitation of the prior art is that the hydrogels produced are relatively nonporous and the pore size and degree of porosity, that is the density of the pores within the hydrogel, cannot vary independently of the mechanical properties or stiffness of the hydrogel.
[0007] Methods for producing certain porous hydrogels also exist in the art. U.S. Pat. No. 6,268,405,0 issued to Yao et al., describes methods for creating porous PVA-Hs by including immiscible materials in the polymerization process. After the hydrogel is polymerized, the included immiscible materials are washed out of the hydrogel by an appropriate solvent, yielding pores which are broadly distributed throughout the hydrogel. Controlling the size and density of the pores is accomplished by varying the molecular weight of the immiscible materials. A disadvantage of Yao et al. is that the range of attainable pore sizes is limited. Moreover, the invention of Yao et al. is limited in that it can only produce hydrogels whose pores extend throughout the hydrogel. The pores in Yao et al. are intended to create vascularization of the hydrogel in soft or non-load bearing tissue. A further disadvantage of Yao et al. is that the pore sizes are broadly distributed about the average pore size.
[0008] In addition to crosslinking by physical means, hydrogels may be chemically crosslinked using, for example, methods similar to those described by Müller in U.S. Pat. No. 5,789,464. Similarly, chemical crosslinking or polymerization methods may also be used to adhere hydrogels to surfaces, including biological tissues. U.S. Pat. No. 5,900,245, issued to Sawhney et al., describes applications of these techniques. These and other methods for the crosslinking or further polymerization of hydrogels are derived from methods used in the polymer industry and are well known in the art.
[0009] Artificial discs intended for the replacement of a damaged intravertebral disc have been described. These are typically articulated devices comprising two rigid metal plates adhered to opposite ends of an elastomeric core. In use, the artificial disc is placed in the intervertebral space and the metal plates are secured to the surfaces of adjacent vertebrae. Various embodiments of artificial discs of this type are described in U.S. Pat. Nos. 5,674,296 and 6,156,067, issued to Bryan et al., U.S. Pat. No. 5,824,094, issued to Serhan et al., U.S. Pat. No. 6,402,785, issued to Zdeblick et al. More recent embodiments, e.g. U.S. Pat. No. 6,419,704, issued to Ferree and U.S. Pat. No. 6,482,234, issued to Weber et al., include descriptions of elastomeric cores that may be formed from materials with different elasticities to better mimic the native structure of spinal discs.
[0010] The disadvantages of the artificial disc devices of the prior art are numerous. These prior art devices require the mechanical attachment of rigid artificial materials, such as titanium, directly to the bone with screws, staples, nails, cement, or other mechanical means. These rigid materials are only minimally compatible with natural, living bone and separation of the implant from the bone is often observed over long-term implantation. In addition, materials used in artificial discs of the prior art have physical and mechanical properties distinctly different from those of natural spinal, discs and thus, inadequately duplicate the desired properties of native spinal discs.
[0011] Vertebral fusion is still the most commonly performed procedure to treat debilitating pain associated with degenerative spinal disc disease or disc trauma, despite the fact that the procedure has many drawbacks. Vertebral fusion increases stress and strain on the discs adjacent to the fusion site, and it is now widely accepted that fusion is responsible for the accelerated degeneration of adjacent levels. Current multicomponent spinal disc prosthesis designs, elastomeric cores with metal plates on both the upper and lower surfaces, are susceptible to problems with interfacial bonding and wear. These designs have shown spontaneous device detachment due to retraction of bone tissue from the metal surface.
[0012] Bone ingrowth and attachment in the art has often required the use of bone promoting growth factors. For example, U.S. Pat. No. 5,108,436, issued to Chu et al., describes using a porous implant for use in load bearing bone replacement which is used in combination with an osteogenic factor such as TGF-β.
[0013] Biomedical devices which are implanted in or around bone often fail because of fibrinogen encapsulation of the implant instead of cellular attachment to the implant itself. This encapsulation is a defensive reaction attempting to minimize contact between the body and the implant and is considered a sign of implant incompatibility.
[0014] Moreover, the art of bone ingrowth to implantable surface contains a multitude of examples relating to porous directed ingrowth where bone essentially grows into and around channels of the implant. For example, U.S. Pat. No. 4,911,720, issued to Collier et al., discusses the ingrowth of bone into interconnecting pores which essentially locks bone into place. This method is disadvantageous in that bone does not actually attach to the material, instead bone attaches to other bone around the implant. In the unfortunate event that an implant must be removed, this type of Collier ingrowth results in large amounts of disruption to the surrounding bone tissue.
SUMMARY OF THE INVENTION
[0015] The present invention describes a biomaterial for implantation into the body. The biomaterial, which can be a hydrogel, possesses a textured surface which is comprised of superficial surface pores. Stated differently, the pores on the surface of the hydrogel substrate do not extend throughout the hydrogel but instead remain within a region near the surface. The hydrogel substrate can be comprised of two or more pore sizes. Specifically, the pores of the first size each have a diameter of between 3 and 1000 micrometers, preferably between 10 and 300 micrometers, and preferably between 30 and 100 micrometers. Further, the pores of the second size would each have a diameter of between 0.5 to 20 micrometers, preferably between 1 to 10 micrometers, and preferably between 2 and 5 micrometers. One embodiment of the present invention provides the second, smaller pores disposed within the first, larger pores. The superficial pores of the present invention extend into the hydrogel substrate less than 1 millimeter, preferably 500 micrometers, and preferably 200 micrometers, from the surface. The hydrogel substrate of the present embodiment can comprise polyvinyl alcohol having a water content of at least 5% and preferably at least 30%.
[0016] The present invention is also drawn to a hydrogel substrate comprising a hydrogel surface having thereon a plurality of first substantially uniform superficial pores and a unique plurality of second substantially uniform superficial pores. This hydrogel can possess two different yet substantially uniform superficial pore sizes grouped into a first, larger pore size and a second, smaller pore size. The pores of one size are substantially uniform in diameter relative to the other pores of the same size. Specifically, the first pores have an average diameter of between 2 and 600 micrometers, preferably between 5 and 200 micrometers, and preferably between 20 and 60 micrometers. Further, the second pores have an average diameter of between 0.1 and 10 micrometers, preferably between 0.2 to 5 micrometers, and preferably between 0.5 to 2 micrometers. The superficial pores of the present invention can be arranged so that the smaller, second pores are within the larger, first pores. The superficial pores of the present invention extend into the hydrogel substrate less than 1 millimeter, preferably no more than 500 micrometers, and preferably no more than 200 micrometers. The hydrogel substrate of the present embodiment can be made up of polyvinyl alcohol having a water content of at least 5% and preferably at least 30% w/w of the overall hydrogel.
BRIEF DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a spinal disc replacement device made in accordance with one embodiment of the present invention.
[0018] FIG. 2 is an example of a superficial surface pore construct exemplary of one embodiment of the present invention.
[0019] FIG. 3 are multiple types of superficial surface pores embodied by the present invention.
[0020] FIG. 4 is a graph of cell proliferation seen on the surfaces of FIG. 3 .
[0021] FIG. 5 is a graph of increased bone or bone-like cell markers resulting from exposure to the surfaces of FIG. 3 .
[0022] FIG. 6 is an image of a substrate which has been generated in accordance with the present invention. The upper image is a further magnification of the image in the lower portion of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present invention is drawn to a biomaterial substrate which may comprise a hydrogel surface having thereon a plurality of first substantially uniform superficial pores and a unique plurality of second substantially uniform superficial pores. Specifically, the pores of the first size preferably each have a diameter of between 3 and 1000 micrometers, preferably between 10 and 300 micrometers, and preferably between 30 and 100 micrometers, including without limitation, pores with a cross-section of 30, 40, 50, 60, 70, 80, 90, and 100 micrometers. Further, the pores of the second size preferably each have a diameter of between 0.5 to 20 micrometers, preferably between 1 to 10 micrometers, and preferably between 2 and 5 micrometers, including without limitation, pores with a cross-section of 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and 20 mircometers. It should be readily apparent to one of ordinary skill in the art that the use of the term diameter also would encompass the cross-section of the pore when not a perfect circle. In fact, the term “pore” should not be read to be limited to circular or spherical shapes. Squares, polygons, triangles, octagons, quadrahedrens, or any other geometric or amorphic structure would perform the function for the invention if properly positioned and sized. One embodiment of the present invention provides the second, smaller pores within the first, larger pores. The invention provides that third, fourth, fifth, and greater substantially uniform pore sizes can be on the hydrogel surface. By substantially uniform it is meant that the pore sizes of a particular class (e.g., first, second, etc.) do not vary more than 10%, preferably the pore sizes of a particular class vary less than 5%, 4%, 3%, more preferably less than 2%, and preferably less than 1% or 0.5%.
[0024] The superficial pores of the present invention would extend into the hydrogel substrate no more than 1 millimeter, preferably 500 micrometers, and preferably 200 micrometers, from the surface. The hydrogel substrate of the present embodiment can comprise polyvinyl alcohol having a water content of at least 5% and preferably at least 30% w/w of the overall hydrogel.
[0025] The present invention is also drawn to a hydrogel substrate comprising a hydrogel surface having thereon a plurality of first substantially uniform superficial pores and a unique plurality of second substantially uniform superficial pores. This hydrogel substrate can possess two different yet substantially uniform superficial pore sizes grouped into a first, larger pore size and a second, smaller pore size. The pores of one size are substantially uniform in diameter relative to the other pores of the same size. Specifically, the first pores have an average diameter of between 2 and 600 micrometers, preferably between 5 and 200 micrometers, and preferably between 20 and 60 micrometers. Further, the second pores have an average diameter of between 0.1 and 10 micrometers, preferably between 0.2 to 5 micrometers, and preferably between 0.5 to 2 micrometers.
[0026] The superficial pores of the present invention can be arranged so that the smaller, second pores are within the larger, first pores. The superficial pores of the present invention can extend into the hydrogel substrate preferably no more than 1 millimeter, preferably no more than 500 micrometers, and preferably no more than 200 micrometers. The hydrogel substrate of the present embodiment can be made up of polyvinyl alcohol having a water content of at least 5% and preferably at least 30% w/w of the overall hydrogel.
[0027] In one embodiment of the invention, the superficial pores of the substrate described herein can be arranged in a regular repeating fashion. Such a patter or waffle structure can be used in embodiments of varying pore size as well as in embodiments where the smaller superficial pores are within the area of the larger superficial pores.
[0028] A method provided by the present invention of making a hydrogel substrate possessing a textured surface required by the present invention comprises using an extremely accurate etching technology to generate a mold, pouring a liquid solution of the hydrogel into the mold, allowing the liquid hydrogel to polymerize and/or crosslink while in the mold, and removing the solid hydrogel substrate from the mold. The extremely accurate etching technology can be MEMS technology or its equivalent. Also, the hydrogel substrate made from this method could be a polyvinyl alcohol hydrogel having a water content of at least 5% and preferably at least 30% w/w of the overall hydrogel.
[0029] The present invention also includes a method for making a hydrogel substrate by contacting solid objects with a liquid hydrogel, allowing the hydrogel to polymerize and crosslink while the solid objects are at least partially immersed in the hydrogel, and removing those solid objects from the polymerized and crosslinked hydrogel to form superficial pores therein. The solid objects used to impart the superficial pores may be made of polystyrene beads. Also, the solid objects used to impart the superficial pores may be grit, sand, silicon, silica, and ultra-fine particulate matter. The solid objects used to create the superficial pores can have a diameter of between 3 and 1000 micrometers, preferably between 10 and 300 micrometers, and preferably between 30 and 100 micrometers.
[0030] The solid objects used to create the superficial pores of this invention can be removed by use of an organic solvent or other washing means. This hydrogel can be comprised of polyvinyl alcohol possessing a water content of at least 5% w/w of the overall hydrogel.
[0031] Accordingly, the present invention is directed to an implantable hydrogel substrate product, a method of making that product, and a method of using that product which substantially improves upon the limitations existing in the art. The invention provides methods of selectively promoting cellular residence and/or differentiation over a surface as described herein. To achieve these and other advantages in accordance with the purpose of the invention, as embodied and broadly described herein, the invention includes a load bearing biocompatible hydrogel for medical implantation that promotes bone attachment. The hydrogel consists of a surface component which has been optimized for implantation. This is accomplished through pores on the surface having a controlled range in distribution of size. The surface pores are superficial and do not extend throughout the hydrogel.
[0032] Hydrogels are materials whose state is between that of a solid and of a liquid. Gels consist of polymeric, i.e. long chain, molecules linked together to form a three-dimensional network and are embedded in a liquid medium. In the case of hydrogels, the liquid medium comprises water. The polymer backbone of hydrogels is formed by hydrophilic monomer units and may be neutral or ionic. Examples of neutral and hydrophilic monomer units are ethylene oxide, vinyl alcohol, (meth)acrylamide, N-alkylated (meth)acrylamides, N-methylol(meth)acrylamide, N-vinylamides, N-vinylformamide, N-vinylacetamide, N-vinyl-N-methylacetamide, N-vinyl-N-methylformamide, hydroxyalkyl (meth)acrylates such as hydroxyethylmethacrylate, vinylpyrrolidone, (meth)acrylic esters of polyethylene glycol monoallyl ethers, allyl ethers, of polyethylene glycols, and sugar units such as glucose or galactose. Examples of cationic hydrophilic monomer units are ethyleneimine (in the protonated form), diallyldimethylammonium chloride and trimethylammonium propylmethacrylamide chloride. Examples of anionic monomer units are (meth)acrylic acid, crotonic acid, maleic acid, fumaric acid, itaconic acid, 2-acrylamido-2-methylpropanesulfonic acid, vinylsulfonic acid, vinylphosphonic acid, 2-methacryloyloxyethanesulfonic acid, 4-vinylbenzenesulfonic acid, allylsulfonic acid, vinyltoluenesulfonic acid and vinylbenzenephosphonic acid.
[0033] From the example listing above, a hydrogel for use in the present invention may be selected based upon its biocompatibility and stability at various hydration states. For the purposes of the present invention, a suitable hydrogel will have a moisture content of at least 5% w/w of the overall hydrogel, preferably at least 10%, 15%, 20%, 25%, 30%, 35%, 40%, 50%, 60%, 70%, or 80% w/w of the overall hydrogel.
[0034] Initial events following implantation of a biomaterial in an orthotopic surgical site include rapid adsorption of serum constituents onto the implant surface. The first cells that are likely to come into contact with the surface are polymorphonuclear cells, platelets, monocytes, and macrophages. These cells release bioactive factors that promote mesenchymal cell migration to the wound site. In addition to these natural factors associated with wound healing, surgeons frequently use bone graft and bone graft substitutes to improve bone formation. Such materials include osteoinductive agents such as demineralized bone matrix and bone morphogenetic protein. If appropriate signals are present mesenchymal cells with an osteoprogenitor phenotype will continue to differentiate into osteoblasts; of these a subset will become osteocytes. Ultimately, the newly formed bone will be remodeled via osteoclastic resorption. The invention provides that physical stimulation of cells via a controllably textured surface contributes to desired cellular differentiation, adhesion, and acceptance of the implant. The present invention also provides that well-known grafting agents may be incorporated into the hydrogel composition, which include, but are not limited to growth factors, angiogenic agents, antibiotics, and the like.
[0035] Chemically modified or polar surfaces are generally known to be able to produce more reactive protein adsorption to the implant surface than unmodified or non-polar surfaces. The increased reactivity of the proteins adsorbed onto the polar surface is thought to promote cellular adhesion to that surface. Therefore, the invention provides that the hydrogel composition can possess chemically modified or polar surfaces.
[0036] In general, many materials are well-tolerated in bone, but the success of long-term or chronic implantation often depends on the intimacy of the interface between the material surface and the bone. Microarchitecture of the surface is an important determinant of cell response. It has been observed that osteoblast phenotypic expression is surface-dependent. As described herein, specific surface characteristics enhance osteoblast differentiation while permitting proliferation, leading to optimal cell response to the implantation. Likewise, cartilage or cartilage-derivative cells show enhanced differentiation based on surface microarchitecture. Since both bone and cartilage cells are derived from mesenchymal stem cells and have as a common ancestor, osteoprogenitor cells, the present invention refers to bone and bone-like cells to encompass that branch of the differentiation pathway. Stated differently, the present invention provides for the differentiation of bone cells (for example osteocytes, osteoblasts, osteoclasts) as well as bone-like cells (for example chondrocytes or related cartilaginous tissue producing cells).
[0037] The mechanical properties of the material must be appropriate for the application. When the mechanical properties of the material are similar to the mechanical properties of the tissue adjacent to the implant, tissue tolerance of the artificial material is enhanced. Polymeric and elastomeric biomaterials can be fabricated with a wide range of mechanical properties, making them suitable for many applications as implantable devices. Because of their high water content, similar to that of living tissue, hydrogels are superior in biocompatibility to non-hydrous polymeric materials. Polyvinyl alcohol (PVA) is an example of a polymer that can be used to form hydrogels, and has been studied extensively for its potential in biomedical applications. Polyvinyl alcohol hydrogels (PVA-Hs) are biologically well tolerated and compatible with living cartilage tissue.
[0038] PVA-Hs can be produced from solution via repeated freezing and thawing cycles that increase the order of the microcrystalline regions, changing the dissolution properties, mesh size, and diffusion properties of the polymer. Also, PVA-Hs can be produced from solution via a slow and sustained transition through the freezing point of the solution. The mechanical properties of PVA-Hs can be varied over a wide range, and stable PVA gels can easily be produced to have an elastic modulus ranging from a few MPa, such as articular cartilage, to about 50 MPa, such as the stiffest portion of the annulus of spinal discs. Increasing the stiffness of a hydrogel can also be achieved through chemical crosslinking. Examples of chemical crosslinker groups are vinyl groups, allyl groups, cinnamates, acrylates, diacrylates, oligoacrylates, methacrylates, dimethacrylates, oligomethacrylates, or other biologically acceptable groups.
[0039] Increasing the porosity of a hydrogel substrate produces decreased mechanical strength. When porous hydrogels are used to provide the requisite surface of the present invention, it is advantageous that the porosity not extend throughout the hydrogel, but be limited to a relatively shallow depth below the surface. The thickness of the porous portion of the hydrogel is preferably less than 1 millimeter, less than 500 micrometers, and most preferable less than or equal to 200 micrometers.
[0040] The porosity of the hydrogel surface embodied in this invention may be realized in a variety of ways. Molds may be constructed with patterning on the appropriate surfaces of the cavities in the mold. Alternatively, the porosity can be produced by abrasion of a smooth hydrogel surface after molding. Abrading the surface can result in a surface textured such as desired in this invention. Techniques for applying and using abrasives are well known to those of skill in the art.
[0041] Using extremely accurate surface building or etching techniques, one can generate extremely intricate surfaces to use as a mold for a surface envisioned by the present invention. Solid free-form fabrication methods offer several unique opportunities for the construction of medical devices. Solid free-form fabrication methods can be used to selectively control composition within the build plane by varying the composition of printed material. This means that unconventional microstructures, such as those with complicated porous networks or unusual gradients, can be designed at a computer-aided design (CAD) terminal and built through a solid free-form process such as three-dimensional printing or MEMS micro-fabrication techniques.
[0042] In one embodiment of this invention the molds for casting the hydrogels are created using MEMS micro-fabrication techniques to produce materials with precise repetitive arrays. The microfabrication process uses commercially available, epoxy-based photoresist and standard photolithography masks and techniques to produce the specified surface architecture. The dimensions of features in the x-y plane of the surface are specified by the photomask. The height of the features is dictated by the thickness of the photoresist layer prior to exposure and development. Multiple photoresist layers may be cast and exposed with different masks to build up very complex structures. An example of one such complex feature, with a pseudofractal architecture is shown in the “snowflake” pattern, seen in FIG. 2 .
[0043] Photolithography is the process of transferring geometric shapes on a mask to the surface of a silicon wafer. The steps involved in the photolithographic process are wafer cleaning; barrier layer formation; photoresist application; soft baking; mask alignment; exposure and development; and hard-baking.
[0044] There are two types of photoresist: positive and negative. For positive resists, the resist is exposed with UV light wherever the underlying material is to be removed. In these resists, exposure to the UV light changes the chemical structure of the resist so that it becomes more soluble in the developer. The exposed resist is then washed away by the developer solution, leaving windows of the bare underlying material. The mask, therefore, contains an exact copy of the pattern which is to remain on the wafer.
[0045] Negative resists behave in just the opposite manner. Exposure to the UV light causes the negative resist to become polymerized, and more difficult to dissolve. Therefore, the negative resist remains on the surface wherever it is exposed, and the developer solution removes only the unexposed portions. Masks used for negative photoresists, therefore, contain the inverse (or photographic “negative”) of the pattern to be transferred.
[0046] MEMS fabrication of hydrogel mold surfaces for use in this invention may, for example, involve standard photolithography techniques and epoxy-based photoresists (SU-8 2000 series, MicroChem, Newton, Mass.) in a Class 10 cleanroom facility. Photolithography masks can be designed, for example, using a CAD program, or its equivalent, and supplied to order (DuPont Photomasks, Inc., Round Rock, Tex.).
[0047] One embodiment of this invention is an artificial intevertebral disc, comprising one or more hydrogels shaped substantially similarly to a natural intevertebral disc. The upper and lower surfaces of the hydrogel, or assembly of hydrogels, are constructed to have a textured surface with a defined level of porosity. That porosity depends primarily upon the size and number of the surface features of the mold used to create the surface texture.
[0048] Another embodiment of this invention is a substrate used to repair tissue that has been damaged either chronically or acutely. This substrate can be implanted at a damaged area such as knee cartilage, shoulder bursa repair, or other damaged area one skilled in the art would forsee.
[0049] FIG. 1 shows a spinal disc replacement envisioned by the present invention. The spinal disc has an upper portion 1 and a lower portion 2 . It is the surfaces of the upper portion 1 and lower portion 2 which possess the textured surface envisioned by the present invention. The upper portion 1 and lower portion 2 will be less elastic and more rigid than the inner region 4 which seeks to mimic the nucleus pulposus. Likewise, the spinal disc may have an intermediate region of elasticity 3 which further aids in the function of the spinal disc. The intermediate region of elasticity 3 may or may not differ from the elasticity of either the inner region 4 or the upper portion 1 or lower portion 2 .
[0050] The size of the pores comprising the textured surface of the hydrogel can aid in promoting adhesion of one cell type over the other. For example, bone cells can show better attachment and results on textured surfaces where the pores are larger than the pores on a textured surface where cartilage cells attach. The ability to promote bone cells to attach to a given surface as compared to cartilage cells can be considered in the design of an implant. For example, a biomedical implanted device which needs a more rigid attachment to the native bone might require the attachment of bone cells as opposed to cartilage cells, requiring using a surface with larger pores. Likewise, a different implant may need to induce cartilage development on the surface of the implant and would instead use the textured surface composed of overall smaller pores to enable that selection. Other factors such as the age, sex, and pre-existing medical condition of the patient would be considered depending upon the circumstances.
[0051] Conversely, the present invention provides for a hydrogel substrate that can be implanted which possesses multiple regions on that substrate capable of promoting the differentiation and attachment of both bone and bone-like cells such as, for example, osteocytes and chondrocytes. Such a surface would, after the migration of mesenchymal stem cells, promote the differentiation of the mesenchymal stem cell into the osteoprogenitor cell and ultimately into bone and cartilage cells on each type's respective region. Stated differently, the present invention provides for a single hydrogel substrate that has both bone cell promoting regions and cartilage, or bone-like cell, promoting regions.
[0052] Osteoblasts assume distinct morphologies depending on the architectural features of their substrate. On microrough surfaces, as long as the peak-to-peak distance is less than the length of the cell body, the cell bodies become more cuboidal, and anchor themselves to the surface through long dendritic filopodia. In contrast, on smoother surfaces osteoblasts flatten and spread, resulting in a fibroblastic appearance. The cell morphology correlates with the physiological behavior of the cells. On smooth surfaces, prostaglandin synthesis is low, TGF-β1 levels are low, alkaline phosphatase specific activity is low, and osteocalcin levels are low, whereas proliferation rates are relatively high in comparison with cells cultured on rougher surfaces. That is, a greater number of cells may be present on smooth surfaces, but the cells on textured surfaces show greater tendency to proliferate into bone or bone-like cells.
[0053] Responsiveness to the surface also depends upon the state of maturation of the cell in the osteoblast lineage. Examinations of numerous cell lines and primary cell cultures from the multipotent fetal rat calvarial cells to the osteocyte cell line MLO-Y4 have occurred. These experiments indicate that as cells become more mature, the stimulatory effect of the microrough surface on differentiation becomes attenuated. It is, however, only on textured surfaces and only in the presence of bone morphogenic protein-2 (BMP-2), that fetal rat calvarial cells are able to establish three dimensional nodules that form mineral in a physiological relevant manner. The results support in vivo observations that a mineral can affect cells directly on the surface as well as distal to the biomaterial indicating that the extracellular signaling factors released by the cells in direct contact with material are sensed by other cells in the microenvironment, and potentially systematically as well.
[0054] The surface texture is created by the distribution of pores which do not continue throughout the hydrogel, or stated differently, are superficially located on the hydrogel substrate. These pores can be broken into at least two size groups: large pores and small pores. The large pores can range in size from 3 to 1000 micrometers in diameter. Preferably, the large pores can range in size from 10 to 300 micrometers in diameter. And preferably, the large pores can range in size from 30 to 100 micrometers in diameter. The small pores are smaller in diameter. For example, the small pores can range in size from 0.5 to 20 micrometers in diameter. Preferably, the small pores can range in size from 1 to 10 micrometers. And preferably, the small pores can range in size from 2 to 5 micrometers. The present invention also provides for third, fourth, fifth, and greater numbers of pore sizes on the hydrogel substrate.
[0055] FIG. 2 depicts a superficial pore 20 as envisioned by the present invention. The superficial pore contains a large pore 10 and a small pore 15 . The small pores 15 are located within the large pore 10 . The small pores 15 , in this embodiment, are equally spaced from one another by one diameter and are positioned in a hexagonal layout.
[0056] The pores on the textured surface in this embodiment enable the surface to resemble native bone which has undergone osteoclastic resorption. Increasing the porosity of a PVA-H generally reduces the mechanical strength of the implant. When surface textured hydrogels are used to provide the requisite surface texture, it is advantageous for the pores not to extend throughout the hydrogel, but instead be limited to a relatively shallow depth below the textured surface. The thickness of the porous portion of the hydrogel is less than 1 millimeter, preferably less than 500 micrometers, and preferably less than or equal to about 200 micrometers.
[0057] In order to measure differentiation of cells into bone or bone-like cells four markers are known in the art. The presence of alkaline-phosphatase, TGF-β1, PGE 2 , and osteocalcin function as reliable indicators of cellular differentiation into bone or bone-like cells. Specifically, it has been shown that MG63 osteoblasts, NHOst cells, and fetal rat calvarial cells will attach to surfaces and then differentiate into secretory osteoblasts that exhibit increased levels of alkaline phosphatase activity and osteocalcin. As surface microroughness increases, levels of PGE 2 in the conditioned medium also increase. PGE 2 stimulates osteoclastic activity at high levels, but is required to be present at low levels for osteoblastic activity to occur. It has been previously shown that the elevated prostaglandin levels that are seen in cultures grown on rough microtopographies appear to be required for enhanced osteogenesis since inhibition of prostaglandin production by indomethacin blocks the increase in osteoblast phenotypic expression on these substrates.
[0058] TGF-β1 levels are also surface dependent. The amount of TGF-β1 produced by osteoblasts cultured on surfaces is modulated in a surface dependent manner by factors that regulate osteogenesis and subsequent bone resorption. Regulation of TGF-β1 is important to bone formation for a number of reasons. This growth factor stimulates proliferation of mesenchymal cells and enhances the production of extracellular matrix, particularly of type 1 collagen.
[0059] Osteocalcin is the most abundant non-collagenous protein in bone, comprising almost 2% of total protein in the human body. It is important in bone metabolism and is used as a clinical marker for bone turnover, but its precise function remains elusive. With no known enzyme activity, osteocalcin's function depends on its structure. That structure reveals a negatively charged protein surface that places five calcium ions in positions complementary to those in hydroxyapatite, the structural mineral component of bone. In addition to binding to hydroxyapatite, osteocalcin functions in cell signaling and the recruitment of osteoclasts and osteoblasts, which have active roles in bone resorption and deposition, respectively.
[0060] The hydrogels of the present invention may contain bioactive factors to further stimulate cell growth or differentiation. These factors, for instance attachment peptides, such as RGD containing peptides, and growth factors such as bone morphogenic proteins, insulin-like growth factor, platelet derived growth factor, fibroblast growth factor, cartilage-derived growth factor, transforming growth factor-beta, and parathyroid hormone related peptide, as well as other regulatory chemicals such as statins, prostaglandins, and mineral ions are well known in the art. These factors may be included in the hydrogels of this invention singly or in combination, and they may be included with or without their respective binding proteins.
[0061] The hydrogels of the present invention may also contain bone or cartilage forming cells (osteoblasts or chondrocytes) or precursor cells to bone and cartilage forming cells such as mesenchymal stem cells or osteoprogenitor cells. These precursor cells have the capacity to differentiate into bone and/or cartilage forming cells. Cells may be included in the hydrogels of the present invention alone or in combination with bioactive factors to further stimulate cell growth or differentiation.
[0062] Natural intervertebral discs have a tough outer fibrocartilaginous ring called the annulus fibrosus and a soft, inner, highly elastic structure called the nucleus pulposus. The artificial discs of the present invention may contain an inner core constructed to mimic the physical and mechanical properties of the natural nucleus pulposus, surrounded by an annular region constructed to mimic the physical and mechanical properties of the natural annulus fibrosus.
[0063] In one embodiment, these regions comprise hydrogels whose water content, degree of polymerization, and degree of crosslinking are routinely adjusted to produce the requisite physical and mechanical properties. The hydrogel comprising the inner core has a higher water content and/or a lower degree of polymerization and/or a lower degree of crosslinking to produce a relatively soft and elastic hydrogel. The hydrogel comprising the outer annular region has a lower water content and/or a higher degree of polymerization and/or crosslinking to produce a relatively hard outer hydrogel which mechanically is tough and stiff. The hydrogels comprising the upper and lower surfaces may substantially resemble the hydrogel comprising the annular region in terms of physical and mechanical properties, water content, and degrees of crosslinking and polymerization. The additional requirement, however, for the surfaces to be textured may allow or require a different combination of physical and mechanical properties in these hydrogels compared to the hydrogel comprising the outer annular region.
[0064] In yet another embodiment of the present invention, the hydrogel substrate can be a load bearing patch which can be used in the repair of partially or predominately damaged tissue. For example, the hydrogel substrate bearing the textured surface of the present invention can be relatively thin and small in diameter. That hydrogel substrate can then be placed where deteriorated, either acutely or chronically, cartilage was removed.
[0065] In yet another embodiment of the present invention, the hydrogel substrate can be assembled outside the body in a malleable form. The malleable form of the hydrogel substrate can then be placed in the intended area, be it a spinal disc replacement, knee cartilage replacement, shoulder bursa repair, or other use one skilled in the art would foresee. Once in the proper position, the malleable hydrogel substrate could be hardened or polymerized via photopolymerization. Radiation curing or photopolymerization (photo-induced free radical polymerization) has become an important and useful technique for applying and curing coatings, inks and adhesives. Radiation-curable compositions typically comprise as essential components one or more radiation-curable monomers and a photoinitiator. The compositions are applied as a coating to various articles and surfaces and the monomers are polymerized to form a film by exposing the coating of the radiation-curable composition to radiation, typically ultraviolet (UV) or electron-beam radiation. Examples of chemical crosslinker groups are vinyl groups, allyl groups, cinnamates, acrylates, diacrylates, oligoacrylates, methacrylates, dimethacrylates, oligomethacrylates, or other biologically acceptable photopolymerizable groups.
[0066] In yet another embodiment of the present invention, the biocompatible material used in implantation is selected from the group of polymers, ceramics, metallics, organo-metallics, or other known biocompatible materials. To be used as described herein, the materials need to be castable, formed by the use of molds, in order to have rendered upon the surfaces of the materials the necessary forms embodied in this invention. Castable ceramics would be a preferred selection as the materials are often formed in manners which resembled native bone or bone structures. Likewise, biocompatible metallic components could be fashioned using the various embodiments of this invention such to direct cellular attachment and proliferation at the surface of the implant.
EXAMPLES
Example 1
[0067] A simple mold surface pattern in accordance with this invention, for example, is an array of cylinders which are 5 μm in diameter and 5 μm in height. To construct a mold surface with this pattern, a 4-inch diameter silicon wafer is coated with a 5 μm thick layer of SU-8 2005 by spin coating at 3000 rpm for about 30 seconds. The wafer is then placed on a hotplate at 65° C. for about 1 minute and then at 95° C. for about 2 minutes. The wafer is then exposed to UV light through a photomask defining the array of cylinders using, for example, a mask aligner (Karl Suss MA-6). The exposure time is calculated to give an exposure energy of 75 mJ/cm at a wavelength of 365 nm. The exposed areas of the photoresist are then crosslinked by heating the wager on a hotplate at 65° C. for about 1 minute and then at 95° C. for about 1 minute. The unexposed areas of the photoresist are then dissolved away by immersing the wafer in solvent (SU-8 Developer, MicroChem, Newton, Mass.) for about 1 minute with continuous gentle agitation. The completed wafer is then rinsed, for example, with isopropyl alcohol and dried in a stream of nitrogen. Profilometry measurements and evaluation by scanning electron microscopy can be used to verify that the desired surface pattern is produced.
Example 2
[0068] A more complicated pattern for a hydrogel mold surface, in accordance with the present invention when generated could for example, consist of an array of cylinders 100 μm in diameter and 100 μm in height. Each cylinder is topped with a smaller array of cylinders, 5 μm in diameter, and 5 μm in height. The construction of such a mold requires two layers of photoresist and two separate exposures of those layers. First, a 4-inch diameter silicon wafer is coated with a 100 μm thick layer of SU-8 2050 by spin coating at 1700 rpm for about 30 seconds. The wafer is then placed on a hotplate at 65° C. for about 4 minutes and then at 95° C. for about 1 minute. The wafer is then exposed to UV light through the photomask defining the array of large cylinders, using, for example, a mask aligner (Karl Suss MA-6). The exposure time is calculated to give an exposure energy of 450 mJ/cm 2 at a wavelength of 365 nm.
[0069] The exposed areas of the photoresist are then cross-linked by heating the wafer on a hotplate at 65° C. for about 1 minute and then at 95° C. for about 9 minutes. Without developing the first layer, the wafer was coated with a 5 μm thick layer of SU-8 2005 by spin coating at 3000 rpm for about 30 seconds. The wafer is then placed on a hotplate at 65° C. for about 1 minute and then at 95° C. for about 2 minutes. The wafer is then exposed to UV light through the photomask defining the array of small cylinders using, for example, a mask aligner (Karl Suss, MA-6). The exposure time is calculated to give an exposure energy of 75 mJ/cm 2 at a wavelength of 365 nm. The exposed areas of the photoresist are then crosslinked by heating the wafer on a hotplate at 65° C. for about 1 minute and then at 95° C. for about 1 minute. Finally, the unexposed areas of both photoresist layers are then dissolved away by immersing the wafer in solvent (SU-8 Developer, MicroChem, Newton, Mass.) for about 9 minutes with continuous gentle agitation. The completed wafer is then rinsed with, for example, isopropyl alcohol and dried in a stream of nitrogen. Profilometry measurements and evaluation by scanning electron microscopy can be used to verify that the desired surface pattern has been produced.
Example 3
[0070] Under the methods of this invention, enhanced differentiation of cells into bone or bone-like cells is seen. Specifically, experiments were run using the PVA-H of this invention in multiple forms. This description references FIGS. 3-5 for clarity. As shown in FIG. 3 there were seven conformations of the surface topography taught by this invention used in this experiment—one being smooth hydrogel. Specifically, conformation is described using a two number nomenclature system such as PVA-H 10/2. PVA-H 10/2 refers first to the size of the large pore on the surface. As described above, the large pore can exist in a complex structure resembling a snowflake. The number 10 in the first position represents a large pore of 100 μm in diameter. The number in the second position of the nomenclature system refers to the size and arrangement of the small pores superimposed on the large pore surface. The second position numbers of 2, 5, and 10 refer to a diameter of 2 μm, 5 μm, and 10 μm, respectively. The spacing and orientation of the small pores on the large pore surface follows a hexagonal grid with a spacing between the small pores of twice the diameter of the small pores.
[0071] Moving clockwise through FIG. 3 , surfaces are shown possessing a 100 μm large pore with a 2 μm small pore (10/2) 50, a 100 μm large pore with a 5 μm small pore (10/5) 55, a 100 μm large pore with a 10 μm small pore (10/10) 60, no large pore with 10 μm small pores (0/10) 65, no large pore with 5 μm small pores (0/5) 70, and no large pore with 2 μm small pores (0/2) 75. Not shown is smooth PVA-H which would receive the 0/0 designation in the above described nomenclature.
[0072] FIGS. 4 and 5 when taken together indicate that while tissue culture plastic provides for the greatest amount of cellular proliferation, textured PVA-Hs promote increased differentiation into bone or bone-like cells. MG63 cells were cultured in conditioned media on the surfaces. Specifically, the cells cultured on the 10/10 conformation 60 showed the greatest level of secreted osteocalcin. The next highest amount of osteocalcin secretion was seen in the 10/5 conformation 55. This indicates the enhanced ability to generate differentiation into bone or bone-like cells by the mimicking of native osteoclastic resorption sites on PVA-H by the use of the present invention.
[0073] FIG. 6 is an image of the surface of a substrate manufactured in accordance with the present invention. The image shows the surface of a hydrogel that was cast in a mold similar to those depicted in FIG. 3 . It should be noted that the substrate could have been generated with this pattern out of any of the materials described herein.
Example 4
[0074] Solid polystyrene objects having complex shapes may be fabricated from uniform polystyrene beads by chemically attaching beads of different sizes. This is illustrated by the following example.
[0075] To a suspension of carboxyl-modified polystyrene beads (20.3 μm+/−0.43 μm diameter, Bangs Laboratories) in 20 mM MES, pH 4.5 is added a 10-fold excess of water-soluble carbodiimide, 1-Ethyl-3-(3-dimethylaminopropyl) carbodiimide hydrochloride. After 15 minutes at room temperature, the beads are washed twice by centrifugation and suspension in 20 mM HEPES, pH 7.5 and then resuspended in the same buffer. This suspension is added to a stirred suspension of a sufficient amount of amino-modified polystyrene beads (3.10 μm +/−0.06 μm diameter, Bangs Laboratories) to give a 25-fold molar excess of amino groups over carboxyl groups, in the same buffer. After 3 hours at room temperature, the unreacted excess smaller beads are removed. Microscopic examination shows substantially monodisperse particles composed of 20-μm beads having the majority of their surface covered with a single layer of 3-μm beads.
[0076] The polystyrene objects of the foregoing example may be used as a template to fabricate a mold for providing the desired porous surface of the hydrogels of the present invention. This may be accomplished by making a metallic replica of a surface comprising a plurality of polystyrene objects using sputtering and/or metal plating techniques and the like, all of which are well known to those skilled in the art. The metallic replica thus produced may be replicated again and reinforced with further metal or other components, again using methods well known to those skilled in the art. The result is a mold suitable for producing the complex surface texture of the hydrogels of the present invention.
[0077] Although the invention has been described with reference to a particular preferred embodiment with its constituent parts, features and the like, these are not intended to exhaust all possible arrangements, mechanical and electrical equivalents, or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art. | Implantable biomaterials, particularly hydrogel substrates with porous surfaces, and methods for enhancing the compatibility of biomaterials with living tissue, and for causing physical attachment between biomaterials and living tissues are provided. Also provided are implants suitable for load-bearing surfaces in hard tissue repair, replacement, or augmentation, and to methods of their use. One embodiment of the invention relates to an implantable spinal disc prosthesis. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a vehicle structure and, in particular, to a railway coach body and the method of manufacturing such a body.
A coach body, which is produced in a winding process and has an inner wound layer with partly molded-in, projecting and encircling stiffening ribs, a wound-in stiffening rib of metal and cut-outs between the inner and the outer wound layer for the reception of ventilation, heating, electrical installations, illumination and sanitary equipment, is shown in the British patent specification GB 1 490 575. The simple sandwich buildup of an inner wound layer, intermediate insulation and an outer wound layer forms the self-supporting structure of the coach body.
The U.S. Pat. No. 5,362,345 describes a similar process for the production of a coach body by a winding technique. In addition to a reinforcing rib, special longitudinal profiles are positioned at the upper and lower corners and are wound into the body. Also, blank covers corresponding to window and door openings to be cut out later are wound into the body. This self-supporting lightweight structure includes a thin first inner insulation layer as well as a second outer insulation layer which is of the thickness of the reinforcing profiles.
In both of the above described known processes, the insulation layers are interrupted by partial thermal bridges in the form of the wound-in metallic reinforcing parts. Furthermore, the coupling of basically different materials entails the risks of wound layer detachment and corrosion as a consequence of expansion forces arising in the case of temperature fluctuations. Moreover, a reinforcing rib to be produced separately represents a conceptional foreign body which disturbs or makes impossible a continuous sequence of the manufacturing process.
SUMMARY OF THE INVENTION
The present invention concerns a method of manufacturing a self-supporting lightweight railway coach body. The method includes the steps of: a. winding a fiber reinforced synthetic material as an inner wound layer about a longitudinal axis of the body; b. applying an inner insulation layer over the inner wound layer; c. forming grooves in the inner insulation layer; d. inserting cable channels in the grooves; e. winding a fiber reinforced synthetic material as a middle wound layer over the inner insulation layer and the cable channels; f. placing ceiling ventilation channels on the middle wound layer at an upper wall of the body; g. mounting windows and longitudinal stiffening members for the absorption of buffer forces on the middle wound layer at side walls of the body; h. applying an outer insulation layer over the middle wound layer; i. winding annular frame elements over the middle layer adjacent the windows; and j. winding a fiber reinforced synthetic material as an outer wound layer over the outer insulation layer and the annular frame elements. After the winding is completed, the portions of the inner and outer wound layers covering the windows are removed and the window openings are finished by inserting a reinforcing frame on the outer wound layer and an angle frame on the inner wound layer.
The method according to the present invention results in a vehicle structure in the shape of a cylindrical longitudinal body formed of a plurality of layers of fiber reinforced synthetic materials wound about a longitudinal axis of the body; a plurality of cable channels and ventilation channels positioned between adjacent ones of the wound layers; and a plurality of annular frame elements positioned between adjacent ones of the wound layers at spaced apart positions and wound about the longitudinal axis of said body. The body also includes windows positioned between the outer and the middle wound layers. The windows can be formed with an inner frame surrounded by an outer frame, the inner and outer frames being connected by a glued joint. The reinforcing frame bears on adjacent ones of the annular frame elements, rests on the outer layer and covers the window inner and outer frames and the joint. The angle frame rests on the inner wound layer and covers the window inner frame and the joint. The annular frame elements are formed as a hollow profile having an inner frame element web, a frame element core positioned over a portion of the inner frame element web, a frame element flange positioned on either side of the frame element core and over the inner frame element web and an outer frame element web positioned over the frame element core and the frame element flanges.
It is an object of the present invention to enable the economical production of a coach body structure.
Advantages of the present invention are that the build-up of the self-supporting structure consists of materials of like kind, the effort for installing the window assembly is reduced and the thermal insulation of the coach body is improved.
Further advantages are that the strength of the vehicle structure can be adapted to the respective requirements by the method steps and the selection of material and that the strength of the structure can be influenced still further by means of external and internal reinforcing elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a fragmentary perspective view of a coach body in accordance with the present invention;
FIG. 2 is an enlarged fragmentary cross-sectional view of the coach body shown in the FIG. 1 with a window and an annular frame element installed;
FIG. 3 is an enlarged fragmentary cross-sectional view of the coach body shown in the FIG. 1 outside the window region with an annular frame element installed;
FIG. 4 is a view similar to the FIG. 2 with the window surfaces exposed;
FIG. 5 is a view similar to the FIG. 4 with an angle frame and a reinforcing frame installed;
FIG. 6 is a perspective view of the coach body shown in the FIG. 1 in an initial fabrication stage with glued-on windows;
FIG. 7 is a perspective view similar to the FIG. 6 after further fabrication steps; and
FIG. 8 is a perspective similar to the FIG. 7 upon conclusion of the manufacturing method according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the FIG. 1, there is shown a vehicle, structure 1, such as a railway coach body, produced by winding techniques. The structure 1 is wound about its longitudinal axis L on a form (not shown) such as the mandrel shown in the U.S. Pat. No. 5,362,345. An internal surface of the vehicle structure 1 is formed by an inner wound layer 5. An inner insulation layer 6 is applied over an outer surface of the inner wound layer 5 and has grooves 6.1 formed therein into which cable channels 6.2 are inserted. Superposed on the cable channel 6.2 is an apparatus connection 16 which is mounted in one side wall of the layer 5. Covering an outer surface of the inner insulation layer 6 is a middle wound layer 7. Formed above an upper side of the layer 7 are ventilation ceiling channels 2 in the form of a one-piece synthetic material profile. The channels 2 and 6.2 can be formed of the same or similar material to that used for the wound layers 5 and 7. A coach window opening W can be formed in the side wall through the layers 5, 6 and 7. An outer insulation layer 8 is positioned over an outer surface of the middle layer 7. An outer frame element web 12 of a wound-in annular frame element is positioned between the windows openings W. An outer wound layer 13 forms the outer skin of the vehicle structure 1. The window openings extend through the layers 8 and 13, but are closed by prefabricated windows 3.
The FIG. 2 is an enlarged section through the window region of the vehicle structure 1 shown in the FIG. 1. The first or inner wound layer 5 can have a thickness of, for example, two to five millimeters. It preferably consists of resin-impregnated glass fiber layers in the form of rovings and fleeces. The inner insulation layer 6 which is laid and glued onto the outer surface of the inner wound layer 5, is a few centimeters thick and can be made of a synthetic foam material of stable shape, elastic in bending and stiff to pressure. In this inner insulation layer 6, the grooves 6.1 are formed, cut or milled out, and then equipped with the cable channels 6.2. Cables are run through the cable channels 6.2 which are preferably open in the direction towards the inner wound layer 5 and closed in the direction to the middle wound layer 7. The depth of the cable channels 6.2 corresponds to the thickness of the inner insulation layer 6 for the purpose of obtaining a planar bearing surface for the middle wound layer 7. With the addition of the middle wound layer 7, a first sandwich build-up of the vehicle structure 1 is concluded.
During the next method step, the prefabricated windows 3 are laid onto the middle wound layer 7 and fixed in their final position. The windows 3 consist of an outer frame 3.1, an inner frame 3.3 connected to the outer frame by a glued joint 3.2 and a double glazing 3.4 inserted into the inner frame. The outer surfaces and the inner surfaces of the windows 3 are each covered by an easily removable protective foil material 4. The surface above and below the windows 3 is filled out, as illustrated in the FIG. 3, all around the vehicle structure 1 by the outer insulating layer 8 of the same thickness as the outer window frames 3.1
In the next method step, an annular frame element 17, which reinforces the structure 1, is wound into the now encircling free channel of constant width of a window post. As a first element of the annular frame element 17, an inner frame element web 9 is wound into the channel base in the shape of a multi-layer winding. In the middle of the inner frame element web 9, a frame element core 11 is then inserted, the width of which, for example, is half of the channel width and which consists of a light core material of stable shape. The height of the frame element core 11 is a few millimeters less than the thickness of the windows 3. Frame element flanges 10 are wound into the channels on either side of and to the same height as the frame element core 11.
The outer frame element web 12 is wound as a concluding part of the annular frame element 17 onto the insulating layer core 11 and both of the lateral frame element flanges 10. The annular frame element 17 forms a rectangular profile reinforcing the structure 1 by a stiffening core of great strength. A strength comparable with a metallic annular frame element is achieved through the appropriate choice of material. For example, carbon fibre webs impregnated with special resin are processed as high-strength material for the annular frame element 17. The wound-in annular frame element 17, together with the outer insulating layer 8 and the outward side of the windows 3, forms a uniform planar surface as a base for the outer wound layer 13 terminating the structure.
There is shown in the FIG. 4 a detail of how the windows 3, which are covered over by the outer wound layer 13 after the conclusion of the winding operations, are exposed by cutting out the outer wound layer. After removal of the protective foil 4 and installation of a terminating joint 3.5, the outer side of the structure 1 is finished to a large extent. On the inner side, the structure layers 5, 6 and 7 must be severed through to the facing surface of the inner frame 3.3 to form the window opening W to coincide with the outline of the window 3 or extend flush with the inward edge of the outer frame 3.1 in order to expose the inwardly facing side of the window from which the protective foil 4 can be removed.
An angle frame 14, which covers the inner wound layer 5 by a few centimeters, is shown in the FIG. 5 as being inserted on the inner side of the structure 1 for covering the cut surfaces of the severed-through structure layers 5, 6 and 7, the outer angle 3.1 and the glued joint 3.2. A reinforcing frame 15 is inserted on the outer side of the structure 1 at the window 3 as an additional element. Increased demands in respect of strength and finish of the outer skin of the vehicle structure 1 can be fulfilled by the reinforcing frame 15.
In the FIG. 6 there is shown the vehicle structure 1 in an intermediate stage essential for the method according to the present invention. Here, the first sandwich structure consisting of the inner wound layer 5, the inner insulation layer 6 and the middle wound layer 7 is present. The prepared shaped profile with the ceiling channels 2 is placed onto the upper wall and the windows 3 are mounted in their final position on the side walls. If the vehicle structure 1 is for use as a coach body of a rail vehicle, prefabricated longitudinal stiffening elements 18 are fastened on each side wall at the height of a buffer plane. Through these longitudinal stiffening elements 18, one obtains the pressure strength which is required for a rail vehicle parallel to the longitudinal direction of the vehicle. The longitudinal stiffening elements 18 are in terms of material and process similar to the annular frame elements 17 and for that reason also display the same mechanical strength. The elements 18 are constructed substantially as wound hollow rectangular profiles or extrusion profiles with a foamed filled cavity, each displaying the length of a window 3 and abutting at the ends the annular frame elements 17. The longitudinal stiffening elements 18, if needed, are inserted in longitudinal direction at other locations between the annular frame elements 17 such as, for example, in the floor region and the ceiling region and at the comer portions of the vehicle structure 1. The vehicle structure 1, with the contiguous reinforcing framework which is incorporated during the winding process and consists of the annular frame elements 17 and longitudinal stiffening elements 18, the inserted windows 3 with the reinforcing frame 14, the ceiling channels 2, the three wound layers 5, 7 and 13 and the insulating layers 6 and 8, displays a very great stiffness and strength with a high quality of the thermal and acoustic insulation.
In the FIG. 7, the intermediate spaces between the windows 3 and the longitudinal stiffening elements 18 are filled in by the outer insulating layer 8 and two of the three annular frame elements 17 are wound in. At the front end (left side of the FIG. 7) of the structure 1, the empty, recessed channel for a third one of the annular frame elements 17 is visible. For reasons of space, only a partial length portion of a vehicle structure 1 is illustrated in the FIGS. 6 to 8. Annular frame elements 17 are inserted not only between the windows 3, but additionally where a structural reinforcement is sensible and necessary such as, for example, at door posts to be used as a carrier element for the door mechanism and as rim stiffening at coach body ends for the attachment of end walls and driver cabins. In the FIG. 8, there is shown the finished vehicle structure 1 with the inserted reinforcing frame 15 and angle frame 14.
The result of the method according to the present invention is a double sandwich structure with the inner insulating layer 6, which incorporates the cable channels 6.2 and is closed off by the inner wound layer 5 and the middle wound layer 7, and the outer insulating layer 8, which receives the stiffening annular frame elements 17 and the longitudinal stiffening elements 18 as well as the windows 3 and the ceiling channels 2, and which is finally covered by the outer wound layer 13. The cable channels 6.2 can be drilled from the inner side at predetermined locations and the apparatus connections 16 can be constructed to include, for example, illumination and audio devices and electrical outlets for passenger carded devices such as razors, personal computers, dictating machines, typewriters and so forth. In case of need, the above described reinforcing frames 15 can be inserted at the outward side of the windows 3. The inner portion of the frame 15 projecting into the glued joint absorbs additional longitudinal forces in force-locking connection with the annular frame elements 17 and the external visible portion results in an aesthetically and mechanically satisfactory covering of the frame portion of the window 3 and of the cut-out in the outer wound layer 13.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A method for producing vehicle structures such as railway coach bodies includes winding layers and integral annular frame elements of like material. The resulting body is free of metal can include additional longitudinal stiffening elements inserted between the annular frame elements. Windows covered by protective foils are installed in an insulating layer between the wound layers during the winding process. At the conclusion of the winding process, the portions of the inner and outer wound layers covering the windows are removed and the window openings are finished by inserting a reinforcing frame on the outer wound layer and an angle frame on the inner wound layer. | 1 |
RELATED APPLICATIONS
[0001] This application claims priority to a provisional patent application, Application No. 60/398,101, filed Jul. 25, 2002, entitled, “Method and System for Providing Filtered Advertisements Over the Internet,” still pending.
FIELD OF THE INVENTION
[0002] This invention relates to systems for and methods of filtering and masking advertising over a system of distribution partners over the Internet.
BACKGROUND OF THE INVENTION
[0003] Many content-based Internet sites enter exclusive advertising arrangements with a specific advertiser, so that the Internet site is precluded from also distributing or displaying advertisements for competitors of that specific advertiser. The specific advertiser usually pays a premium to the Internet site for such exclusivity rights. The content-based Internet site generally enters these relationships with long-term advertisers who are valuable customers of the Internet site. However, an Internet site generally generates revenue from advertising and usually would like to generate as much revenue as possible from placing other non-exclusive advertisements on its Internet site.
[0004] Over the Internet, one way for a website to generate advertising revenue without having to develop its own advertising infrastructure is to receive advertisement listings from a listings provider, such as one that maintains the infrastructure to place and rank advertisement listings. Such arrangements present problems for the content-based Internet site because the ads received from the listing provider could violate its exclusivity arrangement(s).
[0005] This problem may preclude the listings provider from being able to sell its services to some Internet sites and similarly may preclude an Internet site from being able to utilize the listings server to generate revenue for its site. These and other drawbacks exist with current systems and methods.
SUMMARY OF THE INVENTION
[0006] Various embodiments of the present invention relate to methods and systems that allow an Internet distribution partner of an advertisement listings provider to receive filtered and/or masked listings for display on the website of the Internet distribution partner. This system and method allows the Internet distribution partner to define characteristics of advertisement listings to be received by the Internet distribution partner in one or more filters. The characteristics may specify the features of the advertisement it desires, the features of advertisements to be excluded or various combinations thereof. Once the characteristics of advertisement listings are defined, the advertisement listings provider system applies those characteristic(s) to the listings in its database and identifies matches and/or excludes matches depending on the characteristic(s) specified. The advertisement listings provider may then send the Internet distribution partner advertisement listings based on the application of one or more filter(s) selected by the distribution partner. Thus, the advertisement listings provider and the Internet distribution partner are able to generate additional revenue without risking the Internet distribution partner's valuable relationships with its exclusive advertisers and without jeopardizing the Internet advertising distribution partner's relationships with its end users.
[0007] Also, each distribution partner may specify several filters and may, on its own, alter the filter to be applied by the advertising listings partner based on time of day, experimenting to determine effectiveness of different filters, the source page where the listings are to be provided and any other factor it chooses. Moreover, in current systems, distribution partners request the listings through HTTP “GET” command. Through one embodiment of the present invention, a filter identification code (e.g., an alphanumeric code) is supplied with the parameters of the GET command, resulting in a minimal addition to the size of its request and requiring little reprogramming of the distribution partner's website to request that the filter be applied.
[0008] Many advantages of such a system are achieved. Particularly, for an advertising listing provider that is open to all advertisers and whose advertisers may be constantly changing, it would be virtually impossible to have a human monitor outgoing advertisements to distribution partners to ensure that any exclusivity arrangements are not going to be violated. The system of the present invention allows the advertising listings provider to preclude such violations without regard to changes to the advertisements in its database.
[0009] Aside from violating exclusivity arrangements, many other reasons exist for why a distribution partner's website may wish to exclude certain advertisements or only include certain advertisements from a rapidly changing database of advertisement listings. Operators of one website may believe that its readers are predisposed to be offended by certain advertisements and may therefore create a filter to exclude offensive advertisement by “keyword” exclusion. Operators of another website may believe that only advertisements related to a specific topic may be of interest and may thus create a filter accordingly. Various combinations may be selected, such as excluding all advertisements containing keyword A and requiring that all advertisements include keyword B.
[0010] The filters created may be keyword-based, URL based, topic-based or any other metric known about an advertisement in the source database from which advertisements are generated from the advertisement listings provider system.
[0011] In addition to filters, the advertisement listings provider may define a plurality of masks that mask out advertisements in predetermined categories. An Internet advertising distribution partner may thus specify masks, filters, or combinations thereof to ensure that it receives the advertising content that best suits its purposes. According to one embodiment, a mask may be subject matter based and each advertisement listing recorded in the advertising database provided by the advertisement listings provider may be specified as to whether it falls within one of those predetermined categories. For example, five different masks may be defined—a vice ad mask, an adult/sexual ad mask, a gambling ad mask, a non-FDA drug ad mask and a psychic ad mask. By specifying one or more of those mask values, the advertising distribution partner may indicate that they do not wish to receive any advertisements that relate to any type of a vice (e.g., smoking, drinking, gambling, sex, etc.), adult or sexual advertisements, gambling, non-FDA drugs, or ads relating to psychics, respectively.
[0012] Other advantages of the various embodiments of the present invention will be appreciated from a review of the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic diagram of a system of providing filtered advertisement listings to at least one Internet advertising distribution partner in an embodiment of the present invention.
[0014] [0014]FIG. 2 is an example of a database containing multiple advertisement filters defined by Internet advertising distribution partners according to an embodiment of the present invention.
[0015] [0015]FIG. 3 is a flowchart showing a process for an Internet distribution partner to receive filtered advertisement listings from an advertisement listings provider according to an embodiment of the present invention.
[0016] [0016]FIG. 4A is an example of outputted advertisement listings that may be delivered to an Internet advertising distribution partner without any filters applied; FIG. 4B is an example of outputted advertisement listings that may be delivered to the same Internet advertising distribution partner with filter 1 applied.
[0017] [0017]FIG. 5 is an example of listings provided to an advertising distribution partner in response to a request from an advertising listings provider according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] Various embodiments of a filter-based advertisement distribution system are described below. An overview of the system 10 is depicted in FIG. 1.
[0019] [0019]FIG. 1 is a schematic diagram of a system that enables filtered advertisement listings 100 to be provided to at least one Internet advertising distribution partner 105 in an embodiment of the present invention. In the present embodiment, at least one advertisement provider 110 submits its advertisement listings to the advertisement listings provider 120 . In the present embodiment two (2) advertisement providers 110 are shown, although it is understood that any number of advertisement providers 110 may submit advertisement listings 115 to an advertisement listings provider 120 . Moreover, an individual advertisement provider 110 may submit more than one advertisement listing 115 to advertisement listings provider 120 . An advertisement listing 115 may include all or part of the following information fields, some of which are supplied by the advertising provider and some of which are stored by the advertising provider (e.g., the advertisement ID number): the name of the advertisement provider, a title of the advertisement, a description of the goods or services advertised, a URL to be displayed in the listing, where an end user will be directed upon clicking on the advertisement, contact information, an email address, billing information, pricing information, and an advertisement identification number.
[0020] In an embodiment of the present invention, the advertising listing provider 120 may rank the advertisement listings submitted (e.g., by keyword, subject or otherwise) and store the ranked listings in a database server 125 . The rank that an advertisement listing 115 is assigned may depend upon the bid the advertisement provider 100 offers the advertisement listings provider 120 for a “click-through.” For example, the price may be a flat rate for placement or a price per end Internet user 135 who selects the advertisement, often referred to as price-per-click through. Also, the ranking may be based on a revenue model as disclosed in co-pending application No. 60/406,064, filed Aug. 27, 2002, entitled “Method and System for Providing Advertising Listing Variance in Distribution Feeds over the Internet,” the entirety of which is hereby incorporated by reference. The advertisement listing 115 may contain a hyperlink so that when an end Internet user 135 may select the advertisement, and be redirected to a predetermined website defined in the advertisement listing 115 .
[0021] An Internet advertising distribution partner 105 may maintain a website. An end Internet user 135 may access that website via an http connection. The Internet advertising distribution partner 105 may have an agreement with an entity to place its predetermined advertisement listings on its website and not to place advertisement listings of other predetermined competitors. For example, an Internet advertising distribution partner 105 such as CNN (www.cnn.com) may have an agreement with Barnes and Noble to place a Barnes and Noble advertisement listing on its website. That agreement may also require that CNN not place any advertisements for Amazon.com on its website. Thus, CNN may wish to receive supplemental advertisement listings 110 to increase its revenue without receiving any advertisements for Amazon.com.
[0022] According to an embodiment of the present invention, CNN, an Internet advertising distribution partner 105 , may send the advertisement listings provider 120 a filtered listings request 130 . The filtered listings request 130 may direct that certain predefined filters stored in the database server 125 be applied such as by using a filter identifier. Also, it should be understood that the filters may be stored in another location, or the filters may not be stored at all, but defined each time a filter listings request 130 is generated. In the latter example, the filter may identify the characteristics the Internet advertising distribution partner 105 wishes to include or exclude from the advertisement listings 115 received.
[0023] Upon receiving a filtered listings request 130 , the advertisement listings provider 120 may send a listings request 140 to the database server 125 . In one embodiment of the present invention, the filtered listings request may be a single http GET command that requests listings and requests a filter to be applied. The database server 125 may return available listings 145 . These listings 145 may or may not be ranked. The advertisement listings provider 120 may then apply the requested filter and send filtered listings 100 to the Internet advertising distribution partner 105 . The Internet advertising distribution partner 105 may then dynamically include information from the filtered listings 100 in its website content delivered to end Internet user(s) 135 .
[0024] A distribution advertising partner 105 may generally transmit a filtered listing request 130 for each request of a webpage to contain the filtered listings 100 due to the dynamically changing content of listings, rankings, etc. It should be appreciated that advertising distribution partner 105 may cache the filtered listings to reduce the number of requests to advertisement listings provider 120 . The cache may be used for minutes, hours, etc., as desired.
[0025] Internet advertising distribution partner 105 may comprise a website and any structure, software and network connections to implement that functionality. End Internet users 135 may connect using an Internet-compatible device. Similarly, advertisement providers 110 may connect to advertisement listings provider 120 using any Internet-compatible device. Database server 125 may comprise any data storage system accessible and usable with an Internet-based server system such as advertisement listings provider 120 . Variations to the systems shown in FIG. 1 may be made as known those or ordinary skill in the art, such as by enabling some of the network connections to be made over a network other than the Internet or making connections secure or non-secure as deemed appropriate. As described above, the advertisement and filters may be stored in database server 125 .
[0026] End Internet user 135 may view the filtered listings 100 on the website of the Internet advertising distribution partner 105 . In this particular embodiment, there are two (2) Internet advertising distribution partners 105 shown. However, it should be understood that any number of Internet advertising distribution partners 105 may be incorporated into the present invention. Additionally, there are two (2) end Internet users 135 shown in this embodiment. However, it should be understood that any number of end Internet users 135 may receive filtered listing from each Internet advertising distribution partner 105 .
[0027] [0027]FIG. 2 is an example of multiple advertisement filters defined by Internet advertising distribution partners and stored in a database. An Internet advertising distribution partner 105 may desire to increase revenue by adding advertisement listings onto their website. The Internet advertising distribution partner 105 may receive monetary compensation for each click-through from their website to the advertiser's website in a preferred embodiment. However, the Internet advertising distribution partner may have an exclusive arrangement with a seller of books, Barnes and Noble for example, which precludes that Internet advertising distribution partner 105 from advertising for any other sellers of books on the website. Thus, in one embodiment of the present invention the Internet distribution partner 105 may wish to receive only listings which do not include “Amazon.com” in the URL.
[0028] One example filter database, as shown in FIG. 2, may include one or more of the following fields: filter number 200 , Internet advertising distribution partner 205 , filter type 210 , affirmative/negative 215 , filter characteristic 220 , filter creator 225 . The filter number 200 may be used as a storage and identity mechanism. Each filter may have a unique filter number 200 . The Internet advertising distribution partner 205 may represent the website or advertiser where the filtered listings may be delivered. The filter type 210 may identify what section of the advertisement listing to which the filter is to be applied to. Example filter applications include the text of the advertisement, the URL displayed, the URL to which the advertisement listing will direct the Internet end user, the title of the advertisement, or a content node of specific subject matter. The affirmative/negative 215 field may store whether the filter is to include or exclude the filter characteristic 220 , respectively. The filter characteristic 220 field may be used to store the particular text to be excluded. Moreover, the filter creator field 225 may identify the source of the filter. The filter creator 225 may or may not be the same entity as the Internet advertising distribution partner 205 . Other fields may be included in this database to store information relevant to placing an advertisement listing.
[0029] For example, filter number 1 may be applied to filter the advertisement listings provided to cnn.com. In this example, CNN may have a contract with Barnes and Noble which disallows it from placing advertisements for Amazon.com. Thus, filter 1 has a filter type 210 of URL and a affirmative/negative setting 215 of negative. This indicates that advertisement listings with a filter characteristic 220 of “Amazon.com” in the URL may be excluded from the filtered advertisement listings delivered to cnn.com. Filter number 1 has a filter creator 225 of Barnes and Noble. This indicates that Barnes and Noble is the source of the exclusion. Sometimes, the Internet advertising distribution partner itself may be the source of the filter. For example, filter number 2 may be applied to requests for advertisements from abc.com and may exclude advertisements with NBC in the URL, since NBC is a competitor of the Internet advertising distribution partner itself.
[0030] There may be other motivations for filtering the listings on an Internet site. For example, an Internet advertising distribution partner, such as www.disney.com may wish to be family friendly and may therefore wish to filter any listings with the word “sex” in any of the listing's text. Thus, as shown in filter number 6 , the Internet advertising distribution partner disney.com may submit a request for filtered listings to the advertisement listings provider with a negative filter type 210 of text, a filter characteristic of “sex” and filter creator 225 of the Internet advertising distribution partner, itself. In addition to filters, it may be desirable to also provide masks that generally exclude advertisements in certain predefined categories defined by the advertisement listing provider and/or advertising distribution partners. In such an embodiment, a series of masks may be identified by mask number. So, for example, a mask may be provided to exclude vice ads, adult/sexual ads, gambling ads, non-FDA drug ads, and psychic ads. In such an embodiment, the vice ad mask may be designated with a value of 1, the adult/sexual ad mask may be designated with a value of 2, gambling ad mask may be designated with a value of 3, the non-FDA drug ad mask may be designated with a value of 4, and the psychic ad mask may be designated with a value of 5. Also, it may be desirable to provide a certain number of bits to be able to enable the selection of an ad mask based on whether the bit value is 0 or 1. Accordingly, if there are five different masks, then a five bit code may be provided with each bit designating whether or not a particular mask is to be applied. So, in this embodiment, the vice ad may be assigned bit 1 , the sexual ad may be assigned bit 2 , the gambling ad assigned bit 3 , the non-FDA drug ad mask assigned bit 4 , and the psychic ad mask assigned bit 5 . So, for example, if an advertiser wished to mask out vice ads and psychic ads, it would provide a bit mask value of 10001.
[0031] An example of an affirmative filter is shown in FIG. 2 as filter number 3 . In this example, the Internet advertising distribution partner 205 , WebMD, may request advertisement listings which contain the word “health” in the text of the advertisement listing. This filter may be desirable so that the readers of the Internet advertising distribution partner 205 receive information relevant to their interests.
[0032] It should be understood that an Internet advertising distribution partner may store as many unique filters in the database as is desired. Moreover, an Internet advertising distribution partner may indicate which filters are to be applied in each filtered advertising request. Furthermore, the actual advertisement listings received by the Internet advertising distribution partner are determined by the particular filtered listing request submitted. Thus, a particular advertisement listing which is excluded by the application of a filter to one Internet advertising distribution partner may be delivered to other Internet advertising distribution partners.
[0033] It should also be appreciated that the advertisements in the database server 125 may be categorized based on keyword or subject with which the advertisement is associated. For example, advertisers may bid on keywords or subjects and therefore, the advertisement listings provider ranks advertisements based on bids for a given keyword or subject. Advertisements distribution partners then may request advertisements using the keyword or subjects by which the advertisements are categorized. The filter may then be applied to the ranked listing. In the CNN example above, CNN may request advertisement listings for its main “Sports” page from the advertisement listings stored in the advertisement listings provider associated with a keyword “sports.” CNN may then specify a filter to exclude advertisements made by ESPN by excluding all ranked listings which contain, in its text, the keyword “ESPN.”
[0034] Similarly, in the Sprinks System operated by the assignee of the present invention, advertisement providers may bid on subjects based on an hierarchical node-based system. A distribution partner may request ranked listings from a subject in such a system but request exclusion of any advertisement from a URL of a competitor. Other combinations of category-request and filter are all possible within the scope of the present invention.
[0035] While various methods may be employed within the scope of the present invention, one such method is depicted in FIG. 3 for a filter that excludes results. FIG. 3 is a flowchart showing a process for an Internet distribution partner to receive filtered advertisement listings from an advertisement listings provider according to one embodiment of the present invention. In step 300 of the process, an Internet advertising distribution partner may request listings from an advertisement listings provider. In step 305 of the process, the Internet advertising distribution partner may request one or more filters on the listings to be provided. In one embodiment of the present invention, the advertisement listings provider may then generate a ranked file of listings in its database in step 310 . In step 315 the advertisement listings provider may then compare the chosen filter fields to the fields in the database and identify matches in step 320 . The advertisement listings provider may delete the listings identified as matches from the rank file, but not from the database, and provide a filtered ranked file of listings to the advertising distribution partner in step 325 . The listings provider may notify the advertisement provider whose listing has been excluded, by the requested filter in step 330 . This step in the process is optional, because performing this step may discourage advertisement providers from paying greater amounts to increase their rankings. However, performing this step may inform the advertisement provider why their advertisement would not show up on certain web sites where the advertisement provider would expect to see their listing, instead of having the advertisement provider discover the omission on their own. In step 335 , an end Internet user may view the filtered listings while accessing the Internet web site of the Internet advertising distribution partner.
[0036] To better understand how the listings may be displayed by distribution partners, one example is depicted in FIGS. 4A and 4B. FIG. 4A displays a graphical user interface (GUI) with advertisement listings that may be delivered to an Internet advertising distribution partner without any filters applied. In this GUI, the Internet advertising distribution partner 405 , www.cnn.com, shows three advertisement listings 415 , 425 and 435 . In this example, the advertisement listings may be ranked in that order as a result of the price offered for listing the advertisements. For example, Barnes and Noble may be listed first as a result of an agreement from www.cnn.com not to place advertisements for Amazon.com. www.cnn.com desires to fill openings on its website for advertisement listings and thus may request advertisement listings from an advertisement listings provider to supplement its own advertising revenue. With the advertisement listings provider, Amazon.com may have offered 9 cents per click through for placement and The Weather Channel may have offered 3 cents per click through for placement. In the example shown in FIG. 4A no filters have been applied, thus all three advertisements appear in the following order: Barnes and Noble, Amazon.com, and The Weather Channel. If FIG. 4A were generated for end Internet users, www.cnn.com appears to have violated its contractual obligations to Barnes and Noble.
[0037] [0037]FIG. 4B is a GUI with advertisement listings that may be delivered to the same Internet advertising distribution partner with filter 1 from FIG. 2 applied. This filter would exclude any advertisement listings with “Amazon.com” in the URL. Thus, FIG. 4A shows that the advertisement for Barnes and Noble remains the first listed advertisement at 410 . The Amazon.com advertisement does not appear and in the second position, the Weather Channel advertisement listing has moved up to 420 . The third position is now occupied by and advertisement for TV Guide at 430 . Thus, with filter 1 applied, www.cnn.com is able to increase its potential for generating advertising revenue by supplementing its advertisement listings without breaching its contract with Barnes and Noble.
[0038] As discussed above, in one embodiment, the filter to be applied may be stored in association with the advertising listings provider 120 and identified by an identifier supplied by an Internet advertising distribution partner 105 . FIG. 5 is an example of the listings provided to an advertising distribution partner in response to an http GET command according to one embodiment of the present invention. In this example, the get request may be “http://get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs.” The “get.about.com” portion of the request identifies the advertisement listings provider's URL and directs where to send the request. In this example, “ref=shelley” identifies the Internet advertising distribution partner, so that the advertisement listings provider knows who is making the request and where to return the results. The “type=g” and “term=dogs” identify the category of listings desired within the database server. The GET command is instructing the advertisement listings provider to return listings based on bids for the “dogs.” In this case, the returned results may be limited to a listings associated with the “dogs” (term=dogs) content site (type=g) in the listing. If the Internet advertisement distribution partner wished to send a filtered listings request, the command may be http://get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs&f=0001.” “f=0001” indicates that the Internet advertisement distribution partner wishes to filter the rank file with the predefined filter number 1 , which may be stored in the advertisement listings provider database. The advertisement listings provider may access Internet advertising distribution partner shelley's filter number 1 from its database and apply the filter to the rank file. Any listings which are matches with the filter may be deleted from the rank file and the rank file may then be distributed to shelley via an http connection. If filter number 1 were predefined, for example to exclude any listings with a URL of “poochpillows.com,” then the rank file that would be delivered to shelley would exclude the first listing shown in FIG. 5. The listing which is listing number 2 in FIG. 5 would become listing number 1 in the rank file. If the advertising distributor partner also wished to specify a mask, the get request may be as follows: http.//get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs&f=0001&m=10001. This would specify that filter 1 was being applied as well as mask value 10001 as mentioned about which could mask out the vice ads and psychic ads from the content.
[0039] It should also be appreciated that multiple filters may be selected by an Internet advertising distribution partner and may be provided by specifying multiple filter values separated by the ampersand in the get http request.
[0040] While the foregoing description includes details and specificities, it should be understood that such details and specificities have been included for the purposes of explanation only, and are not to be interpreted as limitations of the present invention. Many modifications to the embodiments described above can be made without departing from the spirit and scope of the invention, as it is intended to be encompassed by the following claims and their legal equivalents. | Methods and systems that allow an Internet distribution partner of an advertisement listings provider to receive filtered and masked listings for display on the website of the Internet distribution partner. The Internet distribution partner defines filters to be applied to ranked advertising listings provided by an advertising listing provider. The advertisement listings provider system applies the filter to the listings in its database and identify matches and/or excludes matches depending on the characteristic specified. The advertisement listings provider may then send the Internet distribution partner advertisement listings based on the application of one or more filter selected by the distribution partner. Thus, the advertisement listings provider and the Internet distribution partner are able to generate additional revenue without risking the Internet distribution partner's valuable relationships with its exclusive advertisers and without jeopardizing the Internet advertising distribution partner's relationships with its end users. | 6 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for producing water and, and more particularly, to the use of a desiccant to extract water from air and the recovery of the extracted water from the desiccant in an energy-efficient manner. The water may to treated to obtain potable water.
BACKGROUND OF THE INVENTION
In many locations there is a shortage of water such as in arid regions of the planet. In other locations there is a shortage of potable water such as in areas which have poor water treatment or areas which have experienced a natural disaster (eg. a flood) or a man made disaster (eg. a war). In many cases, however, the ambient air contains sufficient moisture that, if extracted, could provide a supply of water to these regions.
One method for extracting water from air is to compress the air to the point where water vapour condenses to form liquid water. This method requires large amounts of energy and equipment involving many moving parts including seals which must withstand high pressures. The cost and complexity of this method makes it undesirable.
Another method is disclosed in U.S. Pat. No. 4,726,817. Pursuant to this disclosure, the ambient air is canalized and cooled in a free space. The cooled air is then passed through a curtain of hygroscopic fibres where water vapour condenses into liquid water which is evacuated through a conduit. To date, no device to obtain water in useable form from the atmosphere has achieved commercial acceptance
In industry, it is sometimes necessary to remove water from air and different methods have been developed to achieve this result. For example, water may be removed from air by passing the air over a cool surface to condense out water. This technique is used in various areas of art such as to separate water from process flow streams in industry or to provide drier chilled air for climate control. U.S. Pat. No. 4,726,817 also used the concept of cooling the air to condense water vapour.
Industry has also used liquid desiccants for extracting water from air. For example, U.S. Pat. No. 4,189,848 discloses a process in which a liquid desiccant is used to dehumidify air for the purpose of drying a crop. In a closed loop portion of the process, air for drying, on leaving a drying bin, is contacted with a liquid desiccant to remove moisture from it, heated, and recirculated to the drying bin. The liquid desiccant is re-concentrated after contact with the air so that it may be re-used.
The effectiveness of liquid desiccants can be expressed in terms of their "drying efficiency" and "drying capacity". "Drying efficiency" is the ratio of total water exposed to the hygroscopic solution to the amount of water removed. "Drying capacity" is the quantity of water that a unit mass of desiccant can extract from the air.
The drying efficiency and drying capacity of a hygroscopic solution is in part dependant on the partial pressure of water vapour in the air and on the concentration of the solute, which effects the partial pressure of water vapour in the desiccant. Although other factors influence the reaction, a hygroscopic solution having a high concentration of solute, and thus a low partial pressure of water vapour, quickly adsorbs water from air having a higher partial pressure of water vapour and so its initial drying efficiency is high. As water is adsorbed in the hygroscopic solution, the partial pressure of water vapour in the solution increases and the rate of water adsorption slows down. Eventually, the hygroscopic solution and the air reach equilibrium and no more water will be adsorbed. In a regenerative process, the extracted water must therefore be separated from the hygroscopic solution to return it to its initial concentration. This regeneration step accounts for a significant amount of the energy required in a regenerative process.
The focus of the process disclosed in U.S. Pat. No. 4,189,848 is on reducing the amount of water in the relatively fixed volume of air that is recirculated to the drying bin. As the air is recirculated, increased amounts or water are removed from the air until the air reaches the required level of dryness. Any water extracted from the air is an unwanted by-product. Therefore, in designing the drying cycle to reach the required level of dryness, the drying efficiency of the liquid desiccant is a primary design criteria and the process is designed to favour the drying efficiency, and not the drying capacity, or the liquid desiccant.
SUMMARY OF THE INVENTION
The present invention discloses a novel use for desiccants, namely the use of desiccants to obtain water from air. While liquid desiccants are known, they have been used to dry a defined amount of air or product (eg crops in a bin) and processes have been designed to achieve this result. The present invention is a paradigm shift in thinking which views the water itself as the valuable end product and provides a regenerative process for separating water from air using a desiccant which, over the full cycle of the process, favours the drying capacity of a desiccant over the drying efficiency of the desiccant.
The present invention efficiently uses the drying capacity of a hygroscopic solution in a regenerative process to produce water. The external energy required to treat the water rich hygroscopic solution to remove water from is reduced by recycling energy within the process to regenerate the hydroscopic solution.
In accordance with the present invention, there is provided a regenerative process for separating water from air comprising:
(a) providing a hygroscopic solution comprising an solute in an initial concentration;
(b) contacting the hygroscopic solution with air containing water to obtain a water rich hygroscopic solution having a concentration of solute less than the initial concentration and a water lean air stream;
(c) separating the water lean air stream from the water rich hygroscopic solution;
(d) releasing the water lean air stream to the atmosphere; and,
(e) treating the water rich hygroscopic solution to obtain water and the hygroscopic solution.
In accordance with the present invention, there is also provided a regenerative process for separating water from air comprising:
(a) providing a releasable water absorption means;
(b) contacting the releasable water absorption means with air containing water vapour in a contact area to obtain a water rich releasable water absorption means and a water lean air stream;
(c) separating the water lean air stream from the water rich releasable water absorption means;
(d) releasing at least a portion of the water lean air stream to the atmosphere; and,
(e) removing water from the water rich releasable water absorption means to regenerate the releasable water absorption means and collecting the water for use.
In accordance with the present invention, there is also provided an open loop regenerative process for separating water from air comprising:
(a) contacting a desiccant with air containing water and maintaining a difference in the partial pressure of water in the desiccant compared to the partial pressure of water in the air to preferentially favour the drying capacity of the desiccant over the drying efficiency of the desiccant to obtain a water rich desiccant and a water lean air stream;
(b) separating the water lean air stream from the water rich desiccant; and,
(c) removing water from the water rich desiccant to regenerate the desiccant and collecting the water.
In one embodiment, the hygroscopic solution is treated to produce discrete droplets prior to contacting the hygroscopic solution with air containing water to obtain the water rich hygroscopic solution. Preferably, the air is induced to flow in a cyclonic path to separate the water lean air stream from the droplets of the water rich hygroscopic solution. The hygroscopic solution May be contacted with the air in a plurality of stages which are operated counter current.
In another embodiment, the hygroscopic solution is contacted with air by flowing the hygroscopic solution in sheet flow over a plate while flowing air across the plate. Alternately, the hygroscopic solution may be contacted with the air in a packed column.
In one embodiment, the water rich hygroscopic solution is treated to obtain water and the hygroscopic solution by contacting the water rich hygroscopic solution against a feed side of a membrane, collecting water from a permeate side of the membrane and withdrawing a retentate of the first hygroscopic solution from the feed side of the membrane.
In another embodiment, water in the water rich hygroscopic solution is vaporized to obtain water vapour and the hygroscopic solution and the water vapour is subsequently condensed. The water rich hygroscopic solution may be heated by an external heat source. Alternately, or in addition, the water rich hygroscopic solution may be heated at least in part by the heat of condensation which is liberated by the condensation of the water vapour. Alternately, or in addition, the water rich hygroscopic solution may be subjected to sub-atmospheric pressure to assist in volatilizing water therefrom.
In another embodiment, the water rich hygroscopic solution may be treated to obtain water and the hygroscopic solution by:
(a) subjecting the water rich hygroscopic solution to at least one heat exchange step to indirectly heat the water rich hygroscopic solution to an elevated temperature at a first pressure;
(b) introducing the heated water rich hygroscopic solution into an area at a second pressure below the first pressure whereupon water in the water rich hydroscopic solution is evolved to produce a heated hygroscopic solution and heated water; and,
(c) using the heated water to heat the water rich hygroscopic solution.
Pursuant to this embodiment, the heated hygroscopic solution may be used to indirectly heat the water rich hygroscopic solution and produce a cooled hygroscopic solution. The cooled hygroscopic solution may be further cooled prior to contacting the hygroscopic solution with air. A motor driven fan may be used to draw air to contact the hygroscopic solution and the water rich hygroscopic solution may be heated by using the water rich hygroscopic solution to cool the motor.
In another embodiment, the water rich hygroscopic solution may be treated to obtain water and the hygroscopic solution by:
(a) dividing the water rich hygroscopic solution into a first stream, a plurality of intermediate streams and a final stream;
(b) heating the first stream to evolve a portion of the water in the first stream and condensing water evolved from the first stream to obtain water, a first heated hygroscopic solution and liberated heat of condensation;
(c) subjecting a first one of said plurality of intermediate streams to a reduced pressure and using the liberated heat of condensation from step (b) to heat the first intermediate stream to evolve a portion of the water in the first intermediate stream and condensing water evolved from the first intermediate stream to obtain water, a second heated hygroscopic solution and liberated heat of condensation and sequentially repeating step (c) for each intermediate stream; and,
(d) using the liberated heat of condensation from the last heated intermediate stream of step (c) and the heated hygroscopic solutions to heat the final stream to obtain water, a final heated hygroscopic solution and liberated heat of condensation and using this liberated heat of condensation to heat the first stream in step (b).
Pursuant to this embodiment, the final heated hygroscopic solution may be used to heat the final stream. The heated hygroscopic solutions may be combined and cooled prior to contacting the combined hygroscopic solution with air.
In one embodiment, the hygroscopic solution is contacted with the air until the concentration of the solute in the water rich hygroscopic solution is reduced to a preset level and the water rich hygroscopic solution is then treated to obtain water and the hygroscopic solution.
Preferably, the solute is selected from the group consisting of inorganic salts, such as Group 1 chloride and a Group 2 chloride, or organic compounds such as glycol, glycerine and sulphuric acid. More preferably, the solute is lithium chloride and/or calcium chloride.
In a preferred embodiment, the water is collected and treated to obtain potable water.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other advantages of the instant invention will be more fully and particularly described in combination with the following descriptions of the drawings in which:
FIG. 1 is a schematic drawing of one embodiment of the present invention;
FIG. 2 is a schematic drawing of another embodiment of the present invention;
FIG. 3A is a schematic drawing of another embodiment of the present invention; and,
FIG. 3B is a schematic drawing of an alternative to the embodiment of FIG. 3A.
DETAILED DESCRIPTION OF THE INVENTION
The regenative process may be conducted either on a continuous basis or on a batch basis. The process uses a regenerable media for absorbing and releasing water (i.e. a releasable water absorption means). Any such media known in the art may be used. The media may be a hygroscopic solution and, preferably, an aqueous solution of a hygroscopic solute. In a particularly preferred embodiment, the hygroscopic solution is a liquid desiccant such as a solution of a Group 1 and/or a Group 2 salt (preferably a chloride) in water, glycol, glycerine or sulphuric acid. Most preferably, the liquid desiccant is an aqueous solution of lithium chloride and/or calcium chloride. However, if flowable, a solid desiccant may be used.
If the hygroscopic solution is an aqueous solution of a chloride, eg. lithium chloride, then the solute may compris about 40 weight percent lithium chloride based on the total weight of the solution.
Referring to FIG. 1, a schematic drawing of a reactor 10 is shown for removing water from air in a batch process. Reactor 10 has a water absorption chamber 12, a desiccant reservoir 14, a water collection chamber 16, and a water reservoir 18. A hygroscopic solution 20 is stored in the desiccant reservoir 14.
Water absorption chamber 12 defines a contact area in which air is contacted with hygroscopic solution 20. The air and hygroscopic solution 20 are introduced into water absorption chamber 12 so that the water and hygroscopic solution 20 will contact each other and thereby water will be transferred to hygroscopic solution 20. Any technique known in industry may be used. The greater the contact time and the greater the surface area of hygroscopic solution exposed to the air, the greater the amount of water that will be absorbed into hygroscopic solution 20. The two streams may be individually introduced into the contact area but, preferably, the are introduced simultaneously so as to mix together. Various contact techniques may be used such as atomizing the hygroscopic solution, using plate contacting techniques or the use of a packed tower.
As shown in FIG. 1, a pump 22 forces the hygroscopic solution 20 from the desiccant reservoir 14 via stream 23 through a valve 24 and via stream 25 to a nozzle 26 in the water adsorption chamber 12. The force of the pump 22, in combination with the restriction of the nozzle 26, pressurizes the hygroscopic solution 20 so that it leaves the nozzle 26 in fine, discrete droplets 28 and preferably as a mist. The nozzle breaks up the water to produce a media having a very high surface area so as to increase the surface area available for adsorbing water from the air in water absorption chamber 12.
As the droplets 28 are sprayed into the water adsorption chamber 12, a fan 30 forces ambient air 32 into the water adsorption chamber 12. Ambient air 32 is preferably introduced into water absorption chamber 12 so as to flow in a cyclonic path first downwardly adjacent the inner side wall of chamber 12 and then upwardly through the centre portion of chamber 12. For example, a shroud 34 around the fan 30 and/or the shape of the water adsorption chamber 12 may cause ambient air 32 to enter chamber 12 tangentially to flow in a cyclonic path in the water adsorption chamber 12 before flowing out of the top of the water adsorption chamber 12. The cyclonic airflow of the ambient air 32 in the water adsorption chamber 12 encourages contact between the ambient air 32 and the droplets 28 of hygroscopic solution 20 but does not substantially entrain the droplets 28 in the air when it exits chamber 12. The droplets 28 of hygroscopic solution 20 contact the ambient air 32 and adsorb water contained in the ambient air 32. The hygroscopic solution 20 thus becomes a water rich hygroscopic solution 36 which may pool at the bottom of the water adsorption chamber 12. Simultaneously, the ambient air 32 is depleted of moisture and exits the water adsorption chamber as a water lean air stream 38.
Although the affinity of the hygroscopic solution for absorbing water is dependant on many factors, one significant factor is the partial pressures of water vapour in the air and in the hygroscopic solution. When the ambient air has a higher water vapour partial pressure then the hygroscopic solution, water passes from the air to the hygroscopic solution. This process stops when the partial pressures of water vapour in the hygroscopic solution and in the air are equalized. Conversely, the rate of transfer is greater when the difference in partial pressures of water vapour in the air and in the hygroscopic solution are greater.
As there is effectively an unlimited supply of ambient air 32, the water content of hygroscopic solution 20 is favoured, and is preferably maximized, over the need to minimize the moisture content of water lean air stream 38. Therefore, it is preferable if a significant proportion of the drying capacity of the desiccant is used. Since the supply of air is essentially limitless and producing dehumidified air is not an object of the invention, the drying efficiency, which is the fraction of total water input that the desiccant removes, is of little importance. Accordingly, it is preferable in the present embodiment to maintain a high difference in the water vapour partial pressure between the air 32 and the hygroscopic solution 20.
By not drying air 32 too much (eg. by maintaining a brisk flow of air through the reactor), the partial pressure of water vapour that contacts the hygroscopic solution is maintained at a high level. Thus, drying of the air in contact with the desiccant is minimized and the partial pressure of water vapour in the air remains high allowing the desiccant to adsorb water even after it is partially diluted by absorbed water. Generally, if more water can be adsorbed by a given volume of desiccant, the energy required to treat the desiccant, for a given volume of water extracted, is reduced. It is preferable therefore to keep the partial pressure of the ambient air 32 at a high level by maintaining a high degree of flow of ambient air 32 through the water adsorption chamber 12 and by releasing the water lean air stream 38 to the atmosphere. While a portion of stream 38 may be recycled through the process, preferably there is no recycle so that the air flow loop is fully open.
The water rich hygroscopic solution 36 that collects on the bottom of the water adsorption chamber 12 is conveyed back to the desiccant reservoir 14 through a return valve 40. The water rich hygroscopic solution 36 mixes with hygroscopic solution 20 in the desiccant reservoir 14 and is recirculated by pump 22 to the water adsorption chamber 12 for further contact with ambient air 32. Through recirculation and repeated contact with the ambient air 32, more of the drying capacity of the hygroscopic solution 20 may be used. Although the drying efficiency of the hygroscopic solution is lowered with each recirculation, since the supply of ambient air 32 is continually refreshed, the hygroscopic solution 20 continues to be effective in withdrawing water from the air. In the case of a lithium chloride solution, the hygroscopic solution is recirculated until the concentration of lithium chloride is reduced to from about, eg., 40 weight percent solute, based on the total weight of the solution,to about, eg., 20 to about 30 weight percent solute.
When a concentration sensor 42 determines that the solution in the desiccant reservoir 14 is at a concentration of, eg. 20 to 30 weight percent solute, the liquid in the desiccant reservoir 14 is considered to be comprised of water rich hygroscopic solution 36. At this point, a controller 44 connected to the concentration sensor 42 may shut down the fan 30. Controller 44 changes the position of valve 24 and causes the pump 22 to move the water rich hygroscopic solution 36 via stream 15 into the water collection chamber 16.
Water collection chamber 16 functions to concentrate water rich hygroscopic solution 36. Various concentration means may be utilized either alone or in combination including heating solution 36 to evolve water (which is subsequently collected), subjecting the solution to a reduced pressure (eg. flashing solution 36) and reverse osmosis. It will be appreciated that any portion of water rich hygroscopic solution 36 may be transferred to and treated in chamber 16 and that water rich hygroscopic solution 36 may be treated to obtain any desired concentration of solute in the resultant concentrated product.
Preferably all or substantially all of the water rich hygroscopic solution 36 is transferred to the water collection chamber 16, as determined by volume sensor 46. At this point, the controller 44 turns the pump 22 off and then turns on a heater 48 which heats the water rich hygroscopic solution 36 causing it to evolve water vapour. Water in the form of water vapour 50 leaves the water rich hygroscopic solution 36 and rises to upper surface 56 of the water collection chamber 16. Upper surface 56 is preferably convex in shape and may be cooled eg, by refrigeration or a chilled fluid. Preferably, a cooling fan 52 blows air through a heat exchanger 54 which in turn cools the upper surface 56 of the water collection chamber 16. Water vapour 50 which contacts the upper surface 56 of the water collection chamber 16 condenses to form water droplets 58 which flow toward the centre of the upper surface 56. The water droplets 58 then fall into a water collector 60 which collects water 62 which flows, eg. by gravity, to water reservoir 18.
Preferably, the water is for domestic use, eg. as potable water. Accordingly, water 62 may be passed to a purifier 64 which may be an ozone water purification unit. Water 62 when purified may then be collected in the water reservoir 18.
Heater 48 may be any device for heating water rich hygroscopic solution 36. Heater 48 may be a burner which burns a fossil fuel. Alternately, if electricity is available, it may be an electric heater. A further alternate embodiment utilizes solar power to heat water rich hygroscopic solution 36.
The volume sensor 46 preferably is a combined sensor which can also measure the concentration of lithium chloride. As water is removed from the water rich hygroscopic solution 36 in the water collection chamber 16, the hygroscopic solution is concentrated and preferably, the process is conducted until the hygroscopic solution is concentrated to its original concentration (i.e. to hygroscopic solution 20). When the volume sensor 46 determines that the desired concentration has been achieved, the controller 44 preferably turns off the cooling fan 52 and the heater 48. The controller 44 then turns on return pump 66 and operates return valve 40 to allow the hygroscopic solution 20 to return to the desiccant reservoir 14. When concentration sensor 42, which preferably also contains a sensor for measuring volume, and/or volume sensor 46 indicate that all the hygroscopic solution 20 has been returned to the desiccant reservoir 14, the controller operates valve 24 and pump 22 to deliver hygroscopic solution 20 to the water adsorption chamber 12 while fan 30 may be turned on such that the process is repeated.
It will be appreciated that a plurality of water collection chambers 16 may be used, such as in counter current flow (as is discussed with respect to FIG. 2). Further, a plurality of water collection chambers 16 may be employed either in parallel or in series. In one embodiment, the process may be conducted on a continuous or a partially continuous basis wherein a portion of the hygroscopic solution is treated to remove water while another portion is being contacted with the air to absorb water. Further, the reconcentrated hygroscopic solution may be cooled prior to the process being recommenced.
Referring to FIG. 2, an alternate reactor 72, which demonstrates a continuous process, is shown. In the alternate reactor 72, the water adsorption chamber 12 comprises two chambers which operate in counter flow, namely a first water adsorption chamber 74 and a second water adsorption chamber 76. In this embodiment, the hygroscopic solution is atomized to increase the contact area with ambient air 32, although any contact method discussed with respect to FIG. 1 may be utilized.
A fan 30 controlled by a controller 44 is used to introduce ambient air 32 into the first water adsorption chamber 74. Once again, ambient air 32 preferably travels in a cyclonic flow pattern through the first water adsorption chamber 74. Ambient air 32 may exit from the top of the first water adsorption chamber 74 as discussed with respect to FIG. 1. Alternately, as shown in FIG. 2, ambient air may be fed directly into the second water adsorption chamber 76 where it preferably also flows in a cyclonic pattern. The ambient air 32 exits the water adsorption chamber 12 through the top of the second water adsorption chamber 76 as water lean air stream 38, water having been adsorbed by droplets 28 of hygroscopic solution 20 in the water adsorption chambers 74 and 76.
Hygroscopic solution 20 is delivered under pressure to water adsorption chamber 12 through supply pipe 78 by supply pump 80. The hygroscopic solution 20 is atomized by nozzle 26 in the second water adsorption chamber to create droplets 28 which contact the ambient air 32. The droplets 28 collect at the bottom of the second water adsorption chamber 76, having adsorbed some water to become an intermediate hygroscopic solution 82. Recirculation pump 84 pumps the intermediate hygroscopic solution 82 to nozzle 26 in the first water adsorption chamber 74. The intermediate hygroscopic solution 82 is atomized into droplets 28 which collect at the bottom of the first water adsorption chamber as a water rich hygroscopic solution 36.
Preferably, the counter-current contact of hygroscopic solution 20 results in a water rich hygroscopic solution 36 of, eg., 30%-40% lithium chloride. This can be achieved by atomizing the hygroscopic solution 20 into very fine droplets 28 which provide an extremely large surface area for contact of the hygroscopic solution 20 with ambient air 32. The cyclonic air-flow of ambient air 32 in the water adsorption chamber 12 serves to separate the droplets 28 from the ambient air 32 despite their small size.
Through the use of a water adsorption chamber 12 having two separate chambers, hygroscopic solution 20 contacts the ambient air 32 twice to allow a greater proportion of its drying capacity to be used. As in the embodiment of FIG. 1, the drying efficiency is of lesser importance and the flow rate of ambient air is again preferably maintained at a high rate so that the partial pressure of water in the ambient air 32 remains high in both stages of contact. The two stages of contact are operated counter-current as described so that the difference in partial pressures of water vapour between the ambient air 32 and the hygroscopic solution is maintained at a higher level Although the ambient air 32 loses some of its moisture in the first water adsorption chamber 74, and thus has a decreased partial pressure of water vapour in chamber 76, the partial pressure of water vapour in the hygroscopic solution 20 which enters the second water adsorption chamber 76 is also at its lowest level. In the first water adsorption chamber 74 the partial pressure of water vapour of the ambient air 32 is higher as is the partial pressure of water vapour in the intermediate hygroscopic solution. Hence there is a difference in partial pressures of water vapour between the ambient air 32 and the hygroscopic solution 20 or the intermediate hygroscopic solution 82 such that the adsorption of water in both stages is maximized.
In a further alternative, the fan 30 could be used to move air only through the first water adsorption chamber 74 and the air released to the atmosphere through the top of the first water adsorption chamber 74. A second fan could be used to introduce fresh ambient air to the second water adsorption chamber which would similarly exit through the top of the second water adsorption chamber 76 to the atmosphere. In this alternative, a higher difference in partial pressures of water vapour between the air and the hygroscopic solution is maintained in the second water adsorption chamber 76 through the addition of a second fan.
The embodiment shown in FIG. 2 is a continuous process whereby the hygroscopic solution continually recirculates between water adsorption chambers 74 and 76 and the water separation portion of the process. In the water separation portion of the process, the hygroscopic solution is preferably heated which increases the partial pressure of water vapour in the hygroscopic solution and encourages the removal of water from the diluted hygroscopic solution. The elevated temperature of the reconcentrated solution decreases the ability of the hygroscopic solution to adsorb water from the air. Accordingly, it is desirable to cool the hygroscopic solution which is to be contacted with air while heating the hygroscopic solution which is to be reconcentrated and preferably to transfer heat between these two streams of hygroscopic solution.
The water rich hygroscopic solution 36 is preferably heated so as to evolve water thereform and obtain water and a concentrated hygroscopic solution. The heat liberated by the concentration step is preferably transferred to the water rich hygroscopic solution 36 thus heating the water rich hygroscopic solution 36 and simultaneously cooling the concentrated solution. To this end, the water rich hygroscopic solution 36 may be fed via circulation pump 88 to indirect heat exchanger 98 to first be heated by the heat liberated by the condensation of water in vaporization chamber 94. Subsequently, the water rich hygroscopic solution 36 may be further heated by indirect contact with hygroscopic solution 20 in liquid exchanger 86. Subsequently, the water rich hygroscopic solution 36 may be further heated by cooling fan 30 where it flows in a jacket 90 around the fan 30 and adsorbs heat produced by the fan. The water rich hygroscopic solution 36 may then flows, still under the influence of circulation pump 88, to a pressure nozzle 92 located on a vaporization chamber 94. These heating steps may occur in a different order.
Through these heating steps, the water rich hygroscopic solution 36 reaches vaporization chamber 94 at a temperature sufficiently high so as to cause a portion of the water, and preferably all of the water which was absorbed in chambers 74 and 76, to be vaporized thus reconcentrating the hygroscopic solution to obtain solution 20. Due to heat transfer inefficiencies external heating means, as discussed above with respect to FIG. 1, may optionally be used to supplement the heat transfer at steady state conditions.
The water rich hygroscopic solution 36 reaches the pressure nozzle 92 heated and preferably under pressure so as to form water rich droplets 96 on passage through nozzle 96 as it is released into a vaporization chamber 94. Water vapour 50 spontaneously leaves the water rich droplets 96 (which is encouraged by the increased surface area of the droplets) and condenses on a cool surface. Preferably condensing heat exchanger 98, which preferably has the coolest surface within the vaporization chamber 94,is provided. The water rich hygroscopic solution 36 passes through the condensing heat exchanger 98 and adsorbs heat of condensation liberated by the condensation of the water vapour evolved from solution 36 in vaporization chamber 94.
The concentrated hygroscopic solution 20 collects in the bottom of vaporization chamber 94 and is driven by supply pump 80 through supply pipe 78 to chamber 12. On its passage to chamber 12, the hygroscopic solution 20 is preferably cooled by an indirect liquid heat exchanger 86 (which may be operated counter current). Heat removed from the hygroscopic solution 20 in the liquid exchanger 86 is transferred to the water rich hygroscopic solution 36 which is pushed by circulation pump 88 to the liquid heat exchanger 86. Further, the hygroscopic solution may be further cooled, such as by a heat exchanger 54 which is preferably cools the solution by blowing air over it from a cooling fan 52.
In this way, three sources of heat energy are reclaimed, namely heat produced by fan 30, sensible heat in the hygroscopic solution 20 (via heat exchanger 86), and heat of condensation of water vapour 50 are all recaptured and circulated within the alternate reactor 72.
Water vapour 50 condensing on the condensing heat exchanger 98 collects as water 62 in a temporary reservoir 100 in the vaporization chamber 94 from which it can be withdrawn for use (eg. purification for use as potable water).
As a further alternative to the alternate reactor 72, not illustrated, an additional heater may be used to heat the water rich hygroscopic solution 36 before it reaches the pressure nozzle 92. Preferably, a sensor is used to detect the temperature of the water rich hygroscopic solution 36 before it reaches the pressure nozzle 92 and the controller 44 activates the heater only as necessary to achieve adequate production of water vapour 50 such that the hygroscopic solution 20 is preferably maintained at a concentration of, for example, 40% of lithium chloride on an on-going basis.
As a further alternative embodiment, vaporization of heated water rich hygroscopic solution 36 as described in the alternate reactor 72 could be used in place of the water collection chamber 16 and associated processes in the reactor 10 of FIG. 1.
Referring to FIG. 3, a second alternate reactor 102 is shown. As in the reactor 10 of FIG. 1, there is a water adsorption chamber 12. A fan 30 causes ambient air 32 to enter the water adsorption chamber 12 where it moves, preferably, in a cyclonic air-flow pattern and exits through the top of the water adsorption chamber 12 as a water lean air stream 38. Simultaneously, hygroscopic solution 20 is sprayed into the water adsorption chamber 12 through a nozzle 26 which causes the hygroscopic solution 20 to be atomized into droplets 28. Droplets 28 adsorb water from the ambient air flowing in the water adsorption chamber 12 then fall to the bottom of the water adsorption chamber 12 as a water rich hygroscopic solution 36. As in the alternate reactor 72 of FIG. 2, this is a continuous process and a cooling fan 52 is preferably used to cool a heat exchanger 54 which cools the hygroscopic solution 20 before it enters a supply pipe 78 leading to the nozzle 26 of the water adsorption chamber 12. Once again, the alternate contact methods discussed above and/or the use of a plurality of contact stages, which may be operated counter current, may be used. Discussion of the present embodiment is primarily intended to illustrate an efficient alternate method for separating water from the water enriched desiccant.
Referring now to FIG. 3, a circulation pump 88 causes the water rich hygroscopic solution 36 to travel from the bottom of the water adsorption 12 to a flow-splitter 104. From the flow-splitter 104, the total flow of water rich hygroscopic solution 36 is divided into two separate flows, a heat collecting flow 106 and a heated flow 108. Preferably the heat collecting flow 106 is approximately 40% of the total flow entering the flow-splitter 104 and the heated flow 108 is further subdivided into 3 separate flows each having 20% of the total flow entering the flow-splitter 104.
All flows pass through an evaporation chamber 110 which includes a first evaporation area 112 at the bottom, three vacuum chambers 114 located sequentially above the first evaporation chamber 112. It will be appreciated that evaporation chamber 110 may have a plurality of chambers and may be of varying configurations. The vacuum chambers 114 are maintained at less than atmospheric pressure by vacuum pumps 116. On top of the upper most vacuum chamber 114 is top chamber 118. The overall structure of the evaporation chamber 110 is such that each of the first evaporation chamber 112, the vacuum chambers 114 and the top chamber 118 are stacked one on top of the other and separated by condensing dishes 120. The conditions inside each of the first evaporation chamber 112 and vacuum chambers 114 are such that water vapour 50 leaves water rich hygroscopic solution 36 which flows into the bottom of each of the first evaporation chamber 112 and the vacuum chambers 114. The water vapour 50 rises to the top of each of the first evaporation chamber 112 and the vacuum chambers 114 and condenses on the condensing surface such as dish 120 positioned adjacent the top of each of these chambers. Water droplets 58 form on the lower surface of the condensing dishes 120, collect at the centre of the condensing dishes 120 and fall to water collectors 60 where a pool of water 62 forms and flows to a storage tank 122. Each condensing dish 120 is warmed by the heat of condensation of the water vapour 50 condensing on it and thus warms the water rich hygroscopic solution 36 flowing in the respective chamber 114 or 118 positioned thereabove.
At steady state conditions, in each chamber 114, the latent heat in the hygroscopic solution, the heat from the vacuum chamber 114 or first evaporation chamber 112 below the chamber 114, in combination with the vacuum produced by the vacuum pumps 116 is sufficient to cause water in the water rich hygroscopic solution 36 to vaporize. Thus water rich hygroscopic solution 36 enters from the left side of each of the vacuum chambers 114 as illustrated and a more concentrated hygroscopic solution 20 exits from the right side of each of the vacuum chambers 114 as illustrated. The hygroscopic solution 20 in the heated flow 108 then flows through indirect liquid heat exchangers 86 to a flow collector 124.
The heat collecting flow 106 is similarly treated in the first evaporation chamber 112 where water vapour 50 leaves the water rich hygroscopic solution 36 entering on the left side of the first evaporation chamber 112 as illustrated and hygroscopic solution 20 leaves from the right side of the first evaporation chamber 112 as illustrated. There is no vacuum in the first evaporation chamber 112 but the heat collecting flow 106 is sufficiently heated by the time that it enters into the left side of the first evaporation chamber 112, as will be describe below, to cause water within it to vaporize. The hygroscopic solution 20 leaving from the right side of the first evaporation chamber also preferably flows through a liquid heat exchanger 86 to the flow collector 124.
Between the flow-splitter 104 and the flow-collector 124, the heat collecting flow 106 is warmed by heat liberated in other parts of the process. The heat collecting flow 106 flows through the top chamber 118 where it is warmed by the heat of condensation of the upper vacuum chamber 114. The heat collecting flow 106 then travels through the liquid heat exchangers 86 collecting heat preferably from all flows leaving the right side of the evaporation chamber 110 while those flows are simultaneously cooled. The heat collecting flow 106 then preferably travels through a jacket 90 on the fan 30 and is warmed by heat produced by the fan 30. In a further embodiment, not illustrated, heat could also be collected from the cooling fan 52. As mentioned above, by the time that the heat collecting flow 106 enters the left side of the first evaporation chamber 112, it is sufficiently heated to cause vaporization of the water within it. Due to heat transfer inefficiencies external heating means, as discussed above with respect to FIG. 1, may optionally be used to supplement the heat transfer at steady state conditions.
Hygroscopic solution 20 which is collected from all sources at the flow collector 124 preferably is concentrated to maintain the concentration of the hyproscopic solution substantially stable throughout the reactor, eg. it may maintain a concentration of 30-40% lithium chloride throughout the system. A return pump 126 pushes the hygroscopic solution 20 from the flow collector 124 to the heat exchanger 54 and the supply pipe 78 to complete the process.
Now referring to FIG. 3B, a further alternate embodiment of the second alternate reactor 102 is shown where modifications have been made to the flow pattern between the flow-splitter 104 and the flow collector 124. As in FIG. 3A, the flow of water rich hygroscopic solution 36 is split in the flow-splitter 104 into a heat collecting flow 106 and a heated flow 108. In FIG. 3B, the flow path of the heated flow 108 is unchanged but the circulation of the heat collecting flow 106 is modified.
As shown in FIG. 3B, the heat collecting flow 106 is warmed by the heat of condensation of the condensing dish 120 that is the bottom of the top chamber 118. As the heat collecting flow 106 leaves the right side of the top chamber 118 it flows through liquid heat exchangers 86 which have been warmed while simultaneously cooling the heated flows 108 leaving the right side of the evaporation chamber 110. In contrast to the embodiment shown in FIG. 3A, however, the heat collecting flow 106 leaving the right side of the evaporation chamber 110 does not flow through a heat exchanger 86. Accordingly, once the heat collecting flow 106 leaves the last heat exchanger 86 warmed by the heated flow 108 it then flows directly to the jacket 90 surrounding the fan 30 where it is warmed by the heat of the fan motor. The heat collecting flow 106 then enters the first evaporation chamber 112 at the left side having been sufficiently warmed to cause vaporization of water contained in the water rich hygroscopic solution 36. The heat collecting flow 106, now consisting of hygroscopic solution 20, leaves the right side of the first evaporation chamber 112 and flows through liquid heat exchangers 86 located in each of the vacuum chambers 114 wherein the heat collecting flow 106 is simultaneously cooled while warming the heated flows 108 in the vacuum chambers 114. The heat collecting flow 106 then returns to the flow collector 124. As a further alternative, the heat collecting flow might also be re-joined with the heated flow at a point between the pump 126 and the heat exchanger 54.
A further alternative embodiment, not illustrated, is to use a reverse osmosis process wherein the water rich hygroscopic solution is contacted, eg., under pressure against the feed side of a solute impermeable membrane. Water is then collected from a permeate side of the membrane while a retentate of re-concentrated hygroscopic solution is withdrawn from the feed side of the membrane. | A process of separating water from ambient air involves a liquid desiccant to first withdraw water from air and treatment of the liquid desiccant to produce water and regenerated desiccant. Water lean air is released to the atmosphere. Heat generated in the process is recycled. The drying capacity, or volume of water produced, of the system for a given energy input is favored over the production of dried air. | 1 |
BACKGROUND OF THE INVENTION
The present invention generally relates to toilet apparatus and, in a preferred embodiment thereof, more particularly relates to flushing systems for tank type toilets.
Conventional toilets for residential use typically include a bowl having a bottom outlet opening, a trapway communicating with the bottom outlet opening and forming therewith a flushing discharge passage from the bowl, and a water holding tank positioned behind and adjacent the bowl. In the "low tank one piece" version of the toilet, the tank is formed integrally with the bowl and has a top side positioned only a relatively short distance higher than the top side of the bowl. In the "high tank two piece" version of the toilet, the tank is formed separately from the bowl and has a top side considerably higher than its low tank counterpart.
In toilets of conventional low tank, one piece construction and operation, flushing of the toilet is typically initiated by rotating and then releasing a handle externally mounted on the tank to, in turn, upwardly rotate and then release a trip lever disposed within the tank and connected by a chain to a flapper member covering and sealing an open inlet seat portion of a flushing passageway routed from the interior of the tank to the interior of the bowl. Rotation and release of the trip lever momentarily raises the flapper member from the flushing passageway inlet seat, thereby permitting a quantity of tank water to flow through the passageway into a lower portion of the bowl to create a bowl flushing action therein.
At the same time that the tank water is flowing into the bowl via the flushing passageway, a float within the tank begins to drop as flushing water exits the tank. The downward movement of the float opens a ballcock valve within the tank which, via a diverter valve and a conduit structure connected thereto, permits pressurized water from an external source thereof to flow into the bowl to create therein a rim flushing action that supplements the bowl flushing action generated by tank water entering the bowl at the same time.
The entry of the bowl flushing and rim flushing water into the bowl rapidly raises the bowl and trapway water levels, thereby creating a trapway siphoning action that flushes water from the bowl. When the water level in the tank downwardly reaches a predetermined level, the diverter valve reroutes the pressurized water supplied thereto via the ballcock valve to refill the tank and the bowl. As the tank is filled, its internal float rises until it shuts off the ballcock valve, thereby readying the toilet for a subsequent flush.
Although residential toilets of this general type previously required about 3.5 gallons of water for each flush, recent federal regulations have reduced the permissible per flush water amount to 1.6 gallons. The need to meet this criteria led to substantial redesigns of tank type toilets and their flushing mechanisms. However, for a variety of reasons, none of these redesigned toilets and associated flushing mechanisms have proven to be entirely satisfactory.
For example, in conjunction with a low tank, one piece toilet, one proposed design for creating a suitably efficient flush using only 1.6 gallons of water has been to reduce the toilet bowl trapway diameter, and install a specially designed inner pressurized water holding flush tank within the larger main flush tank portion of the toilet. After the toilet is flushed, this internal tank is filled with inflowing supply water, via a pressure reduction valve, in a manner such that when the internal tank is filled the water therein is pressurized by a quantity of pressurized air trapped in the internal tank. When the toilet is flushed, 1.6 gallons of pressurized water is forcefully injected into the bowl, the air pressurized water cooperating with the reduced diameter trapway to effect flushing with the mandated reduced volume of water. The use of this pressurized flushing tank concept, despite its effectiveness at reducing flushing water usage, has the decided disadvantages of being noisy and relatively expensive to incorporate into a toilet.
Another approach used to modify a low tank, one piece toilet is to place an electric motor-driven impeller mechanism into the trapway and cause the impeller to forcefully drive the 1.6 gallons of water rapidly through the trapway, in response to the initiation of a flushing cycle, thereby improving the flushing efficiency of the sharply reduced quantity of water discharged from the bowl. This technique has the disadvantages of being complex, requiring an electrical system to be associated with the toilet, and adding considerable cost to the overall cost of the toilet.
A somewhat different approach has been proposed for use in conjunction with a high tank, two piece toilet. In this type of toilet, as in the case of its low tank one piece counterpart, the cross-sectional area of the trapway is substantially reduced. Additionally, the larger tank water head available in the high tank toilet is used to create a gravity-created flushing jet originating on the front interior side of the bowl and directed at the trapway entrance opening.
This approach also has several disadvantages. For example, the need to have the main flushing discharge opening at the front side of the bowl increases casting complexity and cost. Additionally, because gravity-created flushing jet is not as powerful as the flushing jet emanating from the previously described internally pressurized tank, the wash-down performance of this flushing technique tends to be marginal, and the smaller trapway is more prone to clogging.
From the foregoing it can readily be seen that a need exists for a tank type toilet having improved flushing apparatus and methods that operate with a per flush water quantity of 1.6 gallons and eliminate, or at least substantially reduce, the above-mentioned problems, limitations and disadvantages commonly associated with tank type toilets having conventional lowered water quantity flushing systems. It is accordingly an object of the present invention to provide such an improved tank type toilet.
SUMMARY OF THE INVENTION
In carrying out principles of the present invention, in accordance with a preferred embodiment thereof, a tank type toilet is provided with an improved, vacuum-assisted flushing system that permits the toilet to be flushed using only 1.6 gallons of water. Representatively, the toilet is of a low tank, one piece configuration, but the flushing system could also be advantageously be incorporated in other types of toilets, including high tank two piece toilets, as well.
The toilet includes a bowl having an outlet opening, a water holding tank disposed adjacent the bowl, and a trapway communicating with the outlet opening and forming therewith a flushing discharge passage from the bowl. Specially designed flushing means are provided and are selectively operative to flush the toilet. The flushing means include valve means, disposed within the tank and operative to receive pressurized water from a source thereof and responsively creating a jet from the received water, utilize the jet to create a vacuum area within the valve means, and then discharge the received water.
First passage means are provided and are operative to flow the discharged water into the bowl, and second passage means are provided and are operative to communicate the vacuum area with the interior of the trapway in a manner facilitating the flushing of the toilet and reducing its flushing water volume requirement. In a preferred embodiment thereof, the flushing means are further operative to cause the water jet to entrain tank water therein and deliver the entrained tank water therewith to the bowl through the first passage means.
Representatively, the valve means are incorporated in a specially designed diverter valve that is used in conjunction with generally conventional flapper valve and ballcock valve assemblies also disposed in the water holding tank portion of the toilet. In a preferred embodiment of the toilet, the diverter valve vacuum area is communicated with an uppermost portion of the trapway, above its weir portion, and the jet and entrained tank water are delivered to the toilet bowl interior via its rim flushing passage. When the tank water level falls to a predetermined level caused by the flushing operation, a float associated with the diverter valve causes a poppet valve within the diverter valve body to shift away from its spring biased pre-flush position, terminate the formation of the water jet, and divert the incoming pressurized water away from the jet-forming portion of the valve and discharge it for use in refilling the tank and the bowl.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially sectioned side elevational view of a tank type toilet, representatively a low tank one piece toilet, incorporating therein a specially designed water-saving, vacuum-assisted flushing system embodying principles of the present invention;
FIG. 2 is an enlarged scale, partially sectioned side elevational view of flapper valve portion of the flushing system;
FIG. 3 is an enlarged scale perspective view of a ballcock and diverter valve portion of the flushing system;
FIG. 4 is a cross-sectional view through a portion of the toilet tank taken generally along line 4--4 of FIG. 1 and illustrating, at an enlarged scale and in partially cutaway side elevation, the ballcock and diverter valve portion of the flushing system; and
FIG. 5 is a partially schematic side elevational view of the ballcock and diverter valve portion of the flushing system taken generally along line 5--5 of FIG. 4.
DETAILED DESCRIPTION
Referring initially to FIG. 1, the present invention provides a tank type toilet 10, representatively a low tank, one piece toilet, having a floor supportable bowl 12 with an open top around which a rim 14 extends. A water holding tank 16, having a removable lid 16a, is cast integrally with the balance of the toilet, and is disposed behind and projects upwardly beyond the top side of the bowl 12. To facilitate the efficient flushing of the toilet 10 using only 1.6 gallons per flush, the present invention provides a specially designed vacuum-assisted flushing system 18 that is primarily disposed within the tank 16 and which will be illustrated and described in detail subsequently herein.
Toilet 10 is shown in FIG. 1 in a pre-flush mode thereof in which the tank and bowl water levels 20,22 are as indicated. Formed in the front tank wall 24 is an opening 26 that communicates with a chamber 30 disposed in a casting portion 34 positioned between the bowl 12 and the tank 16. A trapway 36 is disposed generally beneath the casting portion 34 and forms a flushing discharge passageway from the bowl 12. Trapway 36 has an inlet opening 38 at a bottom rear portion of the bowl 12, beneath its pre-flushing water line 22; an inlet leg 40 sloping upwardly and rearwardly away from the inlet opening 38; an uppermost interior portion 42 positioned above a weir section 44 of the trapway; an intermediate leg portion 46 sloping downwardly and rearwardly away from the weir 44; and a generally horizontal outlet leg portion 48 extending forwardly from the lower end of the leg portion 46 and having a downwardly facing discharge opening 50 positioned at its forward end and connectable to a sanitary sewer line.
Still referring to FIG. 1, an open outlet end portion of a rim flushing supply conduit 52 extends from the interior of the tank 16 outwardly through the tank wall opening 26 and is sealingly received in the opening 26. The upper chamber 30 communicates with a generally annular interior casting passage 54 that horizontally extends around the rim 14 and has a bottom wall 56 with a circumferentially spaced series of rim flushing openings (not shown) therein. A bottom interior portion of the tank 16 is communicated with the interior of the bowl 12 by means of a bowl passageway 58 connected to the bottom side wall 59 of the tank 16 and having an outlet opening 60 opening outwardly into a lower interior side portion of the bowl 12, adjacent the inlet 38 of the trapway 36, and horizontally facing generally transversely to the length of the trapway 36. For purposes later described, an air suction conduit 62 extends outwardly from the interior of the tank 16 and has an open inlet end 62a downwardly and sealingly received in an opening 64 formed in the top wall 66 of the uppermost interior trapway area 42 generally above the weir 44.
Structure of the Vacuum-Assisted Flushing System 18
Turning now to FIGS. 2-5, the water saving, vacuum-assisted flushing system 18 of the present invention includes, within the interior of the tank 16, a specially designed diverter valve 70 operatively associated with a generally conventional flapper valve assembly 72 (see FIG. 2) and a generally conventional ballcock valve assembly 74 (see FIGS. 3-5).
As illustrated in FIG. 2, the flapper valve assembly 72 has a tubular body portion 76 that vertically extends through the bottom tank wall 59 and connects into the upper end of the bowl passageway 58. Secured to the body 76, and communicating with its interior, is a standpipe structure 78 to which a flapper valve 80 is pivotally secured. One end of a trip lever 82 is operatively secured to a flush handle 84 externally mounted on the tank 16, and the other end of the trip lever 82 is connected via a depending chain 86 to an upper side of the flapper valve 80. With the toilet 10 in its pre-flush mode, the trip lever 82 is in its FIG. 2 orientation, and the flapper valve 80 seats on the upper seat end 88 of the valve body 76, thereby preventing tank water from downwardly entering the open upper end of the bowl passageway.
Referring now to FIGS. 3-5, the ballcock valve assembly 74 has a vertically oriented tubular body portion 90 having a lower end portion that sealingly extends downwardly through the bottom tank wall 59 and is connected to a pressurized water supply pipe 92 (see FIG. 1). An annular float member 94 coaxially circumscribes the valve body 90 for vertical movement relative thereto and is anchored to a vertically oriented actuating rod 96. Actuating rod 96 is secured at its upper end to a valve operating lever 98 mounted on the upper end 100 of the valve 74 for driven pivotal movement relative thereto to open and close the valve. Ballcock valve 74 has an outlet 102 to which a downwardly bent water discharge tube 104 is connected.
Still referring to FIGS. 3-5, the interior of diverter valve 70, the conduit 52, the chamber 30 (see FIG. 1), and the rim passage 54 collectively define a second flushing passageway extending through the interior of the tank 16 and having an inlet for receiving pressurized water from a source thereof and an outlet communicated with the interior of the bowl 12 by way of rim jet holes (not shown) formed in the bottom side wall 56 of the rim flushing passage 54.
Diverting valve 70 has a horizontally elongated configuration and generally includes an inlet end portion 106 conveniently secured to the ballcock valve body 90 by means of a mounting collar structure 107, and a tubular outlet end portion 108 having an open, rightwardly facing discharge end 110. The inlet end portion 106 has an inlet opening 112 that sealingly receives the open lower end of the ballcock valve assembly water discharge tube 104.
As cross-sectionally illustrated in FIG. 4, inlet opening 112 leftwardly communicates, via an interior wall port 114, with an internal chamber 116 that in turn is upwardly communicated with the interior of the tank 16 through an exterior valve body wall port 118 that is cross-sectionally larger than the interior port 114. Inlet opening 112 also downwardly communicates with a chamber 120. To the left of chamber 120 is a chamber 122 that is separated from the chamber 120 by an internal wall structure 124 and upwardly communicates with the chamber 116 via an interior wall opening 126. A right side portion of the chamber 122 is appropriately vented to the interior of the tank 16. The chamber 120 communicates with the interior of a tubular outlet portion 126 of the valve 70 via an opening 128 in the internal wall structure 124.
A poppet valve 130 has a cylindrical left head portion 132 slidingly and sealingly received in the chamber 122, a horizontal stem portion 134 slidingly received in an opening in the internal wall structure 124, and a cylindrical right head portion 136 disposed in the chamber 120 and having a diameter smaller than that of head portion 132. A horizontally oriented internal nozzle member 138 has a tubular inlet end 140 positioned in the chamber 120 and facing the poppet valve head portion 136, and a reduced diameter outlet end 142 disposed in a vacuum chamber 144 positioned in a left end of the outlet end portion 108 of the diverter valve 70. A cylindrical return spring element 146 seated as shown between the poppet head 136 and the nozzle 138 leftwardly biases the poppet valve 130 to its FIG. 4 pre-flush orientation in which the poppet head 136 leftwardly engages the wall structure 124 and seals off its opening 128.
To the right of the nozzle 138 within the diverter valve outlet end portion 108 is a tubular reducer fitting 148 which has an inlet end 149 disposed in the vacuum chamber 144 just to the right of the nozzle 138, and an externally tapered outlet end 150 positioned at a circumferentially spaced plurality of side wall tank water inlet openings 152 formed in the outlet end portion 108 of the diverter valve 70. Referring now to FIGS. 3-5, the inlet end of the rim flushing supply conduit 52 is connected to the open discharge end 110 of the valve portion 108, and the tubular outlet portion 126 of the diverter valve 70 is coupled to a plugged left end portion of a conduit 154 which, in turn is coupled to a conduit 156 by two aligned legs of a tee fitting 158 having a reducer fitting 160 received in the leg portion thereof connected to the conduit 156. As best illustrated in FIG. 3, the outer end 156a of the conduit 156 is open and disposed within the tank 16. The third leg of the tee 158 is connected to one end of a conduit 162, the other end of which is routed into the open top end of the stand pipe 78 as illustrated in FIG. 2.
As best illustrated in FIG. 5, the diverter valve 70 has an inlet fitting 164 that communicates with the vacuum chamber 144. One end of the suction conduit 62 is connected to the inlet fitting 164, while the opposite end of the suction conduit 62 is communicated with the top side of the uppermost interior trapway portion 42 as previously described (see FIG. 1). Operatively interposed in the suction conduit 62 (see FIG. 5) is a vertically oriented floating ball type check valve 166 having a hollow cylindrical body 168 with reduced diameter inlet and outlet ends 170 and 172, and an interior floating ball member 174.
A float member 176 is anchored to one end of a lever member 178. The opposite end of lever member 178 is pivotally connected, as at 180, to the top side of the inlet end portion 106 of the diverter valve 70. With the toilet 10 in its pre-flush mode, the float 176 pivots the lever 178 in a counterclockwise direction away from its FIG. 4 orientation in which a transverse stop projection 182 on the lever uncovers the exterior port 118. When the toilet 10 is flushed, and the level of the tank water drops, the lever 178 pivots downwardly in a clockwise direction (as indicated by the arrow 184 in FIG. 4) until the projection 182 stops against the valve inlet portion 106 and blocks the upper end of the port 118 as later described herein.
Operation of the Vacuum-Assisted Flushing System 18
The flushing of the toilet 10 is initiated by turning the handle 84 (see FIGS. 1 and 2) which upwardly pivots the trip lever 82, as indicated by the arrow 186 in FIG. 2, thereby lifting the flapper valve 80 off the seat 88 and allowing tank water to flow downwardly through the passageway 58 (see FIG. 1) and enter the bowl 12 at the outlet 60 of the passageway. As tank water enters the bowl 12, the water level 22 in the bowl rises, thereby causing water to begin flowing rearwardly through the trapway 36 over its internal weir 44.
Referring now to FIGS. 3-5, this discharge of water from the tank 16 causes the ballcock float 94 to descend, thereby forcing the actuating rod 96 downwardly to pivot the lever 98 in a manner opening the ballcock valve 74. Opening of the ballcock valve 74 causes pressurized water to be discharged therefrom and into the diverter valve inlet opening 112 via tube 104. During this initial inflow of pressurized water into the diverter valve 70, the diverter valve float 176 is upwardly pivoted in a counterclockwise direction from its FIG. 4 orientation so that the lever stop projection 182 uncovers the exterior valve port 118.
A small portion of the pressurized water entering the diverter valve 70 is forced leftwardly into the chamber 116 through the interior port 114. However, the water entering chamber 116 does not appreciably pressurize such chamber. Since the port 118 is considerably larger than the port 114, the pressurized water flowing into chamber 116 simply flows outwardly therefrom into the tank interior via the port 118. Additionally, since the pressure in chamber 116 is not appreciably increased, the pressure in the portion of chamber 122 to the left of the poppet head 132 is not appreciably increased. Accordingly, the poppet valve 130 remains in its leftwardly spring-biased position shown in FIG. 4 in which the right poppet head 136 covers the interior wall opening 128 and uncovers the inlet end of the nozzle 138.
The balance of the pressurized water initially entering the diverter valve 70 via the discharge tube 104 enters the valve body chamber 120 and is forced rightly through the nozzle 138 to thereby create a water jet 188 (see FIG. 4) that rightwardly exits the nozzle 138, passes through the reducer fitting 148, and rightwardly enters the balance of the diverter valve outlet end portion 108 to the right of its side wall inlet openings 152.
According to a key aspect of the present invention, the water jet 188 functions to draw a vacuum in the vacuum chamber 144, thereby also creating a vacuum in the uppermost interior portion 42 of the trapway 36 (see FIG. 1), during flushing of the toilet 10, by drawing air from the trapway portion 42 into the diverter valve vacuum chamber 144 through the conduit 62. The floating ball 174 in check valve 166 (see FIG. 5) permits air to be vertically passed through the valve body 168, but prevents upward passage of water through the valve body. The vacuum assist created in the trapway portion 42 by the water jet 188 substantially facilitates the flushing of the toilet 10 with 1.6 total gallons of water. During this vacuum-assisted flushing operation, water flowing downwardly through trapway portion 46 and into trapway portion 48 creates a momentary seal across the trapway interior from approximately first point 190 to second point 192 (see FIG. 1) to further facilitate the vacuum-assisted flushing of the toilet 10.
As the water jet 188 exits the reducer fitting 148 (see FIG. 4) it creates a venturi action inwardly adjacent the tank water inlet openings 152, thereby drawing tank water 194 into the openings 152 and entraining the incoming tank water in the jet 188. The jet water and entrained tank water are then flowed outwardly through the rim flushing conduit 52 and into the annular rim flushing passage 54 (see FIG. 1). Water forced into the passage 54 is discharged therefrom as rim flushing water 196 that, by a wash-down action, augments the main flushing action forcing water outwardly through the trapway 36.
These discharges of tank water cause the floats 94 and 176 to drop within the tank 16. When the diverter valve float 176 drops to the location shown in FIG. 4, the stop projection 182 blocks the outlet port 118 and terminates water outflow therethrough from the chamber 116. This blockage of port 118 permits pressurized ballcock valve supply water being flowed into the chamber 116 via internal port 114 to pressurize the chamber 116 while the water jet 188 is still rightwardly flowing through the diverter valve 70 and the bowl flushing is in progress.
The build-up of pressure in the chamber 116 in turn increases the pressure in the portion of the chamber 122 to the left of the larger poppet head 132 until the poppet valve 130 is pressure driven rightwardly, against the resilient resistance of the biasing spring 146, to cause the smaller poppet head 136 to unblock wall structure opening 128 and then engage and seal off the inlet to the nozzle 138, thereby terminating the water jet 188 and thus the trapway vacuum and the delivery of rim flushing water to the bowl 12.
The poppet valve sealing of the nozzle inlet diverts pressurized water still entering the diverter valve 70 from the ballcock valve 74 leftwardly around the rightwardly shifted poppet head 136 and downwardly through the tubular outlet portion 126 and into the plugged left end portion of the conduit 154 (see FIG. 4). Pressurized water entering the conduit 156 is flowed outwardly through conduit 162 into the upper end of the stand pipe 78 (see FIG. 2), and outwardly through the open end 156a of conduit 156 (see FIG. 3), to respectively refill the bowl 12 and the tank 16.
As the tank is refilled in this manner, the ballcock float 94 and the diverter valve float 176 are upwardly driven until the tank water reaches its pre-flush level 20 at which point the float 94, via the actuating rod 96, closes the ballcock valve 74 to terminate pressurized water flow to the diverter valve 70 and return the toilet 10 to its original pre-flush mode. The termination of pressurized water flow to the diverter valve 70 permits the spring 146 to drive the poppet valve 130 to its original FIG. 4 position.
The vacuum-assisted flushing action achieved using the water jet 188, coupled with the use of the jet to entrain tank water and use the entrained water to augment the rim-washing action of the jet water, uniquely enables the representative tank type toilet 10 to be adequately flushed using only 1.6 gallons of water per flush. Importantly, this low water flushing capability is achieved relatively inexpensively by using the mechanically simple diverter valve 70 which operates in a quiet, reliable fashion. Moreover, it is not necessary in the flushing system 18 of the present invention to reposition the flushing passage outlet opening 60 to the front interior side of the bowl 12.
As will be readily appreciated by those of ordinary skill in this particular art, while the flushing system of the present invention has been representatively illustrated and described in conjunction with a low tank, one piece toilet, the invention could also be advantageously utilized in other types of tank type toilets such as a high tank, two piece toilet. Accordingly, as used herein, phrases such as "tank type toilet" are not limited to the illustrated low tank, one piece toilet.
The foregoing detailed description is to be clearly understood as being given by way of illustration and example only, the spirit and scope of the present invention being limited solely by the appended claims. | A tank type toilet has a water saving, vacuum-assisted flushing system that incorporates a diverter valve disposed in the tank portion of the toilet. During the flushing of the toilet, pressurized water is discharged from a ballcock valve assembly in the tank and delivered to the diverter valve which creates from the received water a water jet that is used to create a vacuum area within the diverter valve. The vacuum area is communicated with an uppermost interior portion of the bowl trapway to facilitate a main flushing action in the bowl that requires less flushing water. At the same time, the water jet entrains tank water therein, through water inlet openings in the diverter valve body, and delivers the jet and entrained water to the rim flushing passage of the bowl to augment the vacuum-assisted main flushing action. When the tank water level falls to a predetermined level, a float assembly on the diverter valve acts through a poppet valve therein to terminate the jet and divert water flow through the diverter valve to refill the tank and bowl, thereby readying the toilet for another flush cycle. | 4 |
BACKGROUND OF THE INVENTION
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is an application under 35 USC 111(a) and claims priority under 35 USC 119 from Provisional Application Ser. No. 60/002,725, filed Aug. 24, 1995 under 35 USC 111(b), the disclosure of which is incorporated herein by reference. This application is a continuation of commonly assigned application Ser. No. 08/701,285, filed Aug. 22, 1996, abandoned, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to circuit protection devices comprising conductive polymers, particularly circuit protection devices for use in protecting batteries.
INTRODUCTION TO THE INVENTION
Circuit protection devices for use in protecting batteries from overcurrent and overtemperature conditions are well-known. See, for example, U.S. Pat. Nos. 4,255,698 (Simon) and 4,973,936 ((Dimpault-Darcy et al), and Japanese Utility Model Application No. 4-75287 (filed Oct. 29, 1992), the disclosures of which are incorporated herein by reference. In these applications, a device which exhibits a positive temperature coefficient of resistance (PTC behavior) is connected in series with a battery terminal. During normal operation the PTC device is in a low resistance, low temperature condition. When a very high current occurs, for example, due to a short circuit, or a very high temperature occurs, for example, during excessive charging, the device "switches" into a high resistance, high temperature condition, thus decreasing the current through the battery to a low level and protecting any components in contact with the battery. The temperature at which this transition from low resistance to high resistance occurs is the switching temperature, T s . T s is defined as the temperature at the intersection point of extensions of the substantially straight portions of a plot of the log of the resistance of the PTC element as a function of temperature which lie on either side of the portion of the curve showing a sharp change in slope.
Battery packs, in which a plurality of batteries, i.e. cells, are present, are commonly used with electrical equipment such as cameras, video recorders, tools, portable computers, and cellular phones. It is desirable to make the battery packs as small and lightweight as possible, but still provide adequate protection in the event of a short circuit, a runaway charge fault, charging at the wrong voltage, and/or reverse charging. One technique to maximize the use of space in the battery pack is to place the PTC device directly onto the button terminal of the battery, inside the battery pack. If the device is in the form of a disk with a central hole, the hole can be sized to allow it to be placed over the button terminal. Electrical connection is then made from an electrode on one surface of the disk to the button terminal and from an electrode on the opposite surface of the disk to a second battery. Alternatively, the PTC device can be in the form of a chip with attached straps. One strap is electrically connected to the button terminal of one battery and the other strap is attached to the second battery. Such an arrangement is useful in applying the device outside the battery pack.
Battery packs for cellular phones have special requirements. Due to the digital nature of such phones, battery packs are discharged in short bursts of high current. Because the circuit protection device is in series with the cells of the pack, there may be an unacceptable high voltage drop across the protection device if the device resistance in the unswitched state is too high. This attenuates the pulse and results in audio static as well as reduced battery capacity. In addition to requiring a very low resistance, i.e. less than 30 milliohms, it is also desirable that the device have a low switching temperature, i.e. less than 100° C., so that batteries with relatively long discharge times, e.g. nickel-metal hydride batteries and lithium-ion batteries, which are sensitive to over-temperature conditions switch at a temperature low enough to prevent damage to the battery itself or the case surrounding it. Thus an appropriate circuit protection device will provide recharging protection by protecting in the event of overtemperature conditions, and will provide discharging protection by protecting in the event of overcurrent conditions. In addition, the device should be as small as possible in order to conserve space within the battery pack. This is particularly important as electrical equipment continues to decrease in size.
SUMMARY OF THE INVENTION
We have now found that a circuit protection device that meets the requirements of battery pack protection under both overtemperature and overcurrent conditions can be made small enough and with sufficiently low switching temperature and resistance if a particular composition, dimensions, and process are used. Such devices allow protection against charger runaway voltages for portable electronic equipment. Thus this invention provides a circuit protection device for protecting batteries which comprises
(A) a resistive element which is composed of a PTC conductive polymer composition which comprises
(1) a polymeric component having (a) a crystallinity of less than 40% and (b) a melting point T m of less than 110° C., and
(2) dispersed in the polymeric component, a particulate conductive filler; and
(B) two electrodes which (1) are attached to the resistive element, (2) comprise metal foils, and (3) can be connected to a source of electrical power,
said device having the following characteristics:
(i) a resistive element thickness of 0.025 to 0.20 mm;
(ii) a crosslinking level equivalent to 1 to 20 Mrads;
(iii) a surface area of at most 120 mm 2 ;
(iv) a resistance at 20° C., R 20 , of at most 0.030 ohm; and
(v) a resistivity at 20° C., ρ 20 , of at most 2.0 ohm-cm.
In a second aspect, the invention provides an assembly which comprises
(I) a battery; and
(II) a circuit protection device of the first aspect of the invention which is in electrical contact with the battery.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by the drawings in which FIG. 1 is a plan view of a device of the invention;
FIG. 2 is a cross-sectional view of the device of FIG. 1 along line 2--2;
FIG. 3 is a plan view of another device of the invention; and
FIG. 4 is a schematic view of an assembly of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The circuit protection device of the invention comprises a resistive element composed of a PTC conductive polymer composition. Such compositions comprise a polymeric component, and dispersed therein, a particulate conductive filler such as carbon black or metal. Conductive polymer compositions are described in U.S. Pat. Nos. 4,237,441 (van Konynenburg et al), 4,388,607 (Toy et al), 4,534,889 (van Konynenburg et al), 4,545,926 (Fouts et al), 4,560,498 (Horsma et al), 4,591,700 (Sopory), 4,724,417 (Au et al), 4,774,024 (Deep et al), 4,935,156 (van Konynenburg et al), 5,049,850 (Evans et al), 5,250,228 (Baigrie et al), 5,378,407 (Chandler et al), and 5,451,919 (Chu et al), and in pending U.S. Application Ser. Nos. 08/255,497 (Chu et al, filed Jun. 8, 1994) now U.S. Pat. No. 5,582,771, 08/408,768 (Toth et al, filed Mar. 22, 1995) now abandoned in favor of continuation application Ser. No. 08/798,887, filed Feb. 10, 1997, and 08/408,769 (Wartenberg et al, filed Mar. 22, 1995) now abandoned in favor of continuation application Ser. No. 08/789,962, filed Jan. 30, 1997. The disclosure of each of these patents and applications is incorporated herein by reference.
The composition exhibits positive temperature coefficient (PTC) behavior, i.e. it shows a sharp increase in resistivity with temperature over a relatively small temperature range. The term "PTC" is used to mean a composition or device that has an R 14 value of at least 2.5 and/or an R100 value of at least 10, and it is preferred that the composition or device should have an R 30 value of at least 6, where R 14 is the ratio of the resistivities at the end and the beginning of a 14° C. range, R 100 is the ratio of the resistivities at the end and the beginning of a 100° C. range, and R 30 is the ratio of the resistivities at the end and the beginning of a 30° C. range. It is preferred that compositions of the invention show a PTC anomaly at at least one temperature over the range from 20° C. to (T m +5° C.) of at least 10 4 , preferably at least 10 4 .5, particularly at least 10 5 , especially at least 10 5 .5, i.e. the log resistance at (T m +5° C.)/resistance at 20° C.! is at least 4.0, preferably at least 4.5, particularly at least 5.0, especially at least 5.5. If the maximum resistance is achieved at a temperature T x that is below (T m +5° C.), the PTC anomaly is determined by the log(resistance at T x /resistance at 20° C.). In order to ensure that effects of processing and thermal history are neutralized, at least one thermal cycle from 20° C. to (T m +5° C.) and back to 20° C. should be conducted before the PTC anomaly is measured.
The polymeric component of the composition comprises one or more crystalline polymers and has a crystallinity of at most 40%, preferably at most 35%, particularly at most 30%, as measured by a differential scanning calorimeter. For some applications it may be desirable to blend the crystalline polymer(s) with one or more additional polymers, e.g. an elastomer or an amorphous thermoplastic polymer, in order to achieve specific physical or thermal properties, e.g. flexibility or maximum exposure temperature. It is preferred that the polymeric component comprise a low density polymer, i.e. a polymer having a density of less than about 0.935 g/cm 3 . Examples of such low density polymers are low density polyethylene and ethylene copolymers, in particular an ethylene copolymer that comprises units derived from a first monomer which is ethylene and a second monomer which is an alkyl acrylate having the formula CH 2 ═CHCOOC m H 2 m+1, where m is at least 4. Particularly preferred are ethylene/butyl acrylate copolymer (also referred to as ethylene/n-butyl acrylate) and ethylene/isobutyl acrylate copolymer, for which m equals 4. The polymeric component has a melting temperature, as measured by the peak of the endotherm of a differential scanning calorimeter, of T m . When there is more than one peak, T m is defined as the temperature of the highest temperature peak. For compositions suitable for battery protection T m is at least 70° C., but is less than 110° C., preferably less than 100° C.
Dispersed in the polymeric component is a particulate conductive filler that comprises carbon black. For some applications, other particulate conductive materials such as graphite, metal, metal oxide, conductive coated glass or ceramic beads, particulate conductive polymer, or a combination of these, may also be present. Such particulate conductive fillers may be in the form of powder, beads, flakes, or fibers. It is preferred, however, that the particulate filler consist essentially of carbon black that has a DBP number of 60 to 120 cm 3 /100g, preferably 60 to 100 cm 3 /100g, particularly 60 to 90 cm 3 /100g, especially 65 to 85 cm 3 /100g. The DBP number is an indication of the amount of structure of the carbon black and is determined by the volume of n-dibutyl phthalate (DBP) absorbed by a unit mass of carbon black. This test is described in ASTM D2414-93, the disclosure of which is incorporated herein by reference.
The conductive polymer composition may comprise additional components, such as antioxidants, inert fillers, nonconductive fillers, radiation crosslinking agents (often referred to as prorads or crosslinking enhancers), stabilizers, dispersing agents, coupling agents, acid scavengers (e.g. CaCO 3 ), or other components.
The desired resistivity of the composition determines the amount of polymeric component, conductive filler, and option additional components. It is preferred that the device prepared from the composition have a resistivity at 20° C., ρ20, of at most 2.0 ohm-cm, preferably at most 1.5 ohm-cm, particularly at most 1.0 ohm-cm, especially at most 0.9 ohm-cm, most especially at most 0.8 ohm-cm. For compositions meeting these criteria, the polymeric component generally comprises at most 64% by volume, preferably at most 62% by volume, particularly at most 60% by volume, especially at most 58% by volume of the total volume of the composition. The quantity of conductive filler needed is based on the resistivity of the conductive filler itself, as well as on the required resistivity of the composition. For compositions of the invention, the conductive filler generally comprises at least 36% by volume, preferably at least 38% by volume, particularly at least 40% by volume of the total volume of the composition. The additional components generally comprise at most 20% by volume of the total composition.
While dispersion of the conductive filler and other components in the polymeric component may be achieved by any suitable means of mixing, including solvent-mixing, it is preferred that the composition be melt-processed using melt-processing equipment including mixers made by such manufacturers as Brabender, Moriyama, and Banbury, and continuous compounding equipment, such as co- and counter-rotating twin screw extruders. Prior to mixing, the components of the composition can be blended in a blender such as a Henschel™ blender to improve the uniformity of the mixture loaded into the mixing equipment. The composition can be prepared by using a single melt-mixing step, but it is often advantageous to prepare it by a method in which there are two or more mixing steps, as described in copending U.S. application No. 08/408,769 (Wartenberg et al, filed Mar. 22, 1995) now abandoned in favor of continuation application Ser. No. 08/789,962, filed Jan. 30, 1997 the disclosure of which is incorporated herein by reference.
After mixing, the composition can be melt-shaped by any suitable method, e.g. melt-extrusion, injection-molding, compression-molding, and sintering, in order to produce a resistive element. The element may be of any shape, e.g. rectangular, square, circular, or annular. For many applications, it is desirable that the composition be extruded into sheet from which the resistive element may be cut, diced, or otherwise removed.
For the circuit protection devices of the invention the resistive element is in physical and electrical contact with at least one electrode that is suitable for connecting the element to a source of electrical power. The type of electrode is dependent on the shape of the element, and may be, for example, solid or stranded wires, metal foils, metal meshes, or metallic ink layers. Particularly useful devices comprise two laminar electrodes, preferably metal foil electrodes, with the conductive polymer resistive element sandwiched between them. Particularly suitable foil electrodes have at least one surface that is electrodeposited, preferably electrodeposited nickel or copper. Appropriate electrodes are disclosed in U.S. Pat. Nos. 4,689,475 (Matthiesen), 4,800,253 (Kleiner et al), and copending U.S. application Ser. No. 08/672,496 (Chandler et al, Jun. 28, 1996, which is a continuation of application Ser. No. 08/255,584, filed Jun. 8, 1994, now abandoned) now abandoned in favor of continuation application Ser. No. 08/816,471, filed Mar. 13, 1997, the disclosure of each of which is incorporated herein by reference. The electrodes may be attached to the resistive element by compression-molding, nip-lamination, or any other appropriate technique. Additional metal leads, e.g. in the form of wires or straps, can be attached to the foil electrodes to allow electrical connection to a circuit. The leads may extend in opposite directions from the surface of the resistive element to form an "axial" device, or they may extend in the same direction from the resistive element to form a "radial" device. In addition, elements to control the thermal output of the device, e.g. one or more conductive terminals, can be used. These terminals can be in the form of metal plates, e.g. steel, copper, or brass, or fins, that are attached either directly or by means of an intermediate layer such as solder or a conductive adhesive, to the electrodes. See, for example, U.S. Pat. Nos. 5,089,801 (Chan et al) and 5,436,609 (Chan et al).
In order to improve the electrical stability of the device, it is generally necessary to subject the resistive element to various processing techniques, e.g. crosslinking and/or heat-treatment, following shaping, before and/or after attachment of the electrodes. Crosslinking can be accomplished by chemical means or by irradiation, e.g. using an electron beam or a Co 60 γ irradiation source. Devices of the invention are generally crosslinked to the equivalent of 1 to 20 Mrads, preferably 1 to 15 Mrads, particularly 2 to 15 Mrads, especially 5 to 12 Mrads.
Devices of the invention are preferably exposed to a thermal treatment after the device is cut from a laminate comprising the conductive polymer composition positioned between two metal foils, and before crosslinking of the conductive polymer composition is done. A preferred procedure is described in U.S. patent application Ser. No. 08/408,768 (Toth et al, filed Mar. 22, 1995) now abandoned in favor of continuation application Ser. No. 08/798,887, filed Feb. 10, 1997, the disclosure of which is incorporated herein by reference. The device is first cut from the laminate in a cutting step. In this application, the term "cutting" is used to include any method of isolating or separating the resistive element of the device from the laminate, e.g. dicing, punching, shearing, cutting, etching and/or breaking as described in pending U.S. application Ser. No. 08/257,586 (Zhang et al, filed Jun. 9, 1994) now abandoned in favor of continuation application Ser. No. 08/808,135, filed Feb. 28, 1997, the disclosure of which is incorporated herein by reference, or any other suitable means.
The thermal treatment requires that the device be subjected to a temperature Tt that is greater than T., preferably at least (T m +20° C.), particularly at least (T m +50° C.), especially at least (T m +70° C.). The duration of the thermal exposure may be very short, but is sufficient so that the entire conductive polymer in the resistive element reaches a temperature of at least (T m +5° C.). The thermal exposure at T t is at least 0.5 seconds, preferably at least 1.0 second, particularly at least 1.5 seconds, especially at least 2.0 seconds. A suitable thermal treatment for devices of the invention made from ethylene/butyl acrylate copolymer is dipping the device into a solder bath heated to a temperature of about 240 to 245° C., i.e. at least 100° C. above T m , for a period of 1.5 to 2.5 seconds. Alternatively, good results have been achieved by passing the devices through an oven on a belt and exposing them to a temperature at least 100° C. above T m for 3 seconds. During either one of these processes, electrical leads can be attached to the electrodes by means of solder.
After exposure to the thermal treatment, the device is cooled to a temperature below T m , i.e. to a temperature of at most (T m -30° C.), preferably at most (T m -50° C.), especially at most (T m -70° C.). It is particularly preferred that the device be cooled to a temperature at which the conductive polymer composition has achieved 90% of it maximum crystallization. Cooling to room temperature, particularly to 20° C., is particularly preferred. The cooled device is then crosslinked, preferably by irradiation.
Devices of the invention are particularly useful because they have smaller mass and lower resistance than conventional devices, thus decreasing the weight for a given application. The thickness of the resistive element is 0.025 to 0.20 mm (0.001 to 0.008 inch), preferably 0.051 to 0.18 mm (0.002 to 0.007 inch), e.g. 0.13 mm (0.005 inch). The surface area of the device (i.e. the footprint of the resistive element, not including any additional metal leads) is at most 120 mm 2 , preferably at most 100 mm 2 , particularly at most 90 mm 2 , especially at most 85 mm 2 . Larger devices tend to dissipate more heat than is desirable for most battery applications, and are more difficult to install in the available space of a battery pack.
Devices of the invention have a resistance at 20° C., R 20 , of at most 0.050 ohm, preferably at most 0.040 ohm, particularly at most 0.030 ohm, especially at most 0.025 ohm.
Devices of the invention are particularly suitable for use in a battery assembly which may comprise one or more batteries. A typical assembly comprises first and second batteries. The device is in electrical contact with at least one of the batteries, often by contacting the button terminal of the battery (i.e. the positive terminal), and may be in contact with a second battery, generally at the end opposite the button terminal end (i.e. the negative terminal). The battery for which the small devices of the invention are particularly useful is a secondary rechargeable battery of the size equivalent to type AAA, AA, or 5 mm prismatic cells. Such a battery may be a nickel-cadmium, nickel-metal hydride, or lithium-ion battery.
The invention is illustrated by the drawing in which FIG. 1 is a plan view of circuit protection device 1 and FIG. 2 is a cross-sectional view along line 2--2 of FIG. 1. The device consists of PTC element 3 to which are attached first and second metal leads 11,13 in a configuration to give a radial device. PTC element 3 comprises resistive element 5 which is sandwiched between two metal electrodes 7,9. FIG. 3 shows an alternative configuration for the first and second leads 11,13 to give an axial device particularly suitable for attachment to the terminals of a battery.
FIG. 4 is a schematic plan view of assembly 15 of the invention in which first battery 17 and second battery 19 are in physical and electrical contact with device 1. First lead 11 contacts button terminal 21 of first battery 17, while second lead 13 contacts second battery 19.
The invention is illustrated by the following example.
EXAMPLE
Fifty-eight percent by volume of ethylene/n-butyl acrylate copolymer (Enathene™ EA 705-009, containing 5% n-butyl acrylate, having a melt index of 3.0 g/10 min and a melting temperature of 105° C., available from Quantum Chemical Corporation) was preblended with 42% by volume carbon black (Raven™ 430 Ultra, having a particle size of about 82 nm, a structure (DBP number) of 80 cm 3 /100 g, and a surface area of 34 m 2 /g, available from Columbian Chemicals), and the blend was then in a co-rotating twin screw extruder. The mixture was pelletized and extruded into a sheet having a thickness of 0.127 mm (0.005 inch). The sheet was nip-laminated with two layers of electrodeposited nickel-copper foil (Type 31, having a thickness of 0.043 ram (0.0013 inch), available from Fukuda) to produce a laminate. Pieces of the laminate were solder-coated. PTC elements with dimensions of 5×12×0.127 mm (0.2×0.47×0.005 inch) were cut from the laminate. The PTC elements were then heat-treated in an oven with settings such that the temperature of the elements reached 165° C. for 30 seconds, 5 to 10 seconds of which were at a peak temperature of 185° C. The PTC elements were then irradiated to a total of 10 Mrads using a Co 60 γ irradiation source. Nickel metal leads with dimensions of 4×17×0.13 mm (0.16×0.67×0.005 inch) were attached to opposite sides of the PTC element by reflowing the solder. The metal leads were each positioned so that a tab 5 mm (0.20 inch) extended from the edge of the PTC element. Each device was temperature cycled six cycles from -40° C. to 85° C. with a dwell time at -40° C. and 85° C. of 30 minutes.
After temperature cycling, devices were tested for voltage withstand, resistance, and switching temperature. Voltage withstand was measured by inserting a device into a circuit in series with a switch and a DC power source. Starting at 10 VDC, power was applied in increments for 5 seconds, then turned off for 60 seconds. The device was deemed to have failed when a lead or an electrode came off or when the device arced and burned. Devices of the example had excellent voltage withstand at 24 volts, suitable for use in most rechargeable battery applications which require 16 to 24 volt withstand.
The devices had a resistance at 20° C. of 0.025 ohm, substantially lower than a conventional device prepared from a mixture of ethylene/n-butyl acrylate copolymer and high density polyethylene as described in U.S. patent application Ser. No. 08/255,497 (Chu et al, filed Jun. 8, 1994), now U.S. Pat. No. 5,582,770, the disclosure of which is incorporated herein by reference. The conventional device had a resistive element with dimensions of 5×12×0.25 mm (0.2×0.47×0.010 inch), and had been processed by irradiating the laminate to a total of 10 Mrads prior to cutting PTC elements from the laminate. The resistance at 20° C. of the conventional device after temperature-cycling was 0.055 to 0.060 ohm, too high for many battery applications. A conventional device of ethylene/n-butyl acrylate copolymer and high density polyethylene, made with the same surface area and processing as the conventional device described above, but with a resistive element thickness of 0.13 mm (0.005 inch), would have a resistance at 20° C. of about 0.027 ohm. However, the voltage withstand of such a device would be less than 16 volts and thus not suitable for battery applications.
The resistance versus temperature properties of the device of the invention were determined by positioning the device in an oven and measuring the resistance at intervals over the temperature range 20 to 160 to 20° C. The switching temperature T s , as defined above, was 93° C. | A circuit protection device for protecting batteries is formed from a resistive element composed of a PTC conductive polymer composition and two electrodes. The device has a resistive element thickness of 0.025 to 0.20 mm; a crosslinking level equivalent to 1 to 20 Mrads; a surface area of at most 120 mm 2 ; a resistance at 20° C., R 20 , of at most 0.030 ohm; and a resistivity at 20° C., ρ 20 , of at most 2.0 ohm-cm. Devices of the invention are sufficiently small to be easily inserted into an assembly comprising a battery, particularly a rechargeable battery, and the device. Such assemblies are used for powering portable electronic equipment such as cellular telephones. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/385,170, now U.S. Pat. No. 8,556,933, which is a continuation of U.S. patent application Ser. No. 11/821,323, now U.S. Pat. No. 8,114,124, which is a continuation-in-part of, and claims priority benefit from, U.S. patent application Ser. No. 10/358,735 filed Feb. 4, 2003, now U.S. Pat. No. 7,235,090, entitled “Method and Apparatus for Solid Organ Tissue Approximation”, the entire contents of all of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The field of this invention relates to devices and methods for trauma and general surgery, combat medicine, and emergency medical services.
BACKGROUND OF THE INVENTION
[0003] As recently as the early 1990s, surgical operations for trauma were directed at the anatomic repair of all injuries at time of the initial operation. It was observed during these exercises that many patients became hypothermic, acidotic, and coagulopathic. Patients showing these three signs often died. Death often occurred in the operating room due to exsanguination, or postoperatively, due to the complications of prolonged shock and massive transfusion to replace blood lost as a result of the trauma.
[0004] One of the most notable developments in the recent evolution of surgery has been the reintroduction of the concept of staged laparotomy to overcome the deficiencies of the repair all-at-once approach. This new strategy of staged laparotomy employing new tactics that have been termed damage control is now used in 10% to 20% of all trauma laparotomies.
[0005] This strategy opens the way for a variety of new devices and methods for control of hemorrhage from solid organs or viscera. Although there are procedures for controlling these injuries, none of these procedures utilize optimal devices or tactics in their execution. Each area offers technological opportunities to improve the devices and procedures for applying those devices.
[0006] Sources of hemorrhage within the abdomen that are most difficult to manage include major stellate fractures in the thick, solid, parenchymal organs, especially the liver. Such injuries may involve more than one hepatic lobe, involve massive hemorrhage, and may be caused by severe blunt or penetrating trauma. While the control of most liver hemorrhage is simple, these very severe anatomic wounds are difficult to manage and have a high mortality, sometimes exceeding 80%. Standard approaches to control of these wounds involve packing with gauze or omentum, if available, and deep liver sutures. Each of these techniques has serious limitations and often fails. A major technical problem has to do with the depth to which the sutures can be placed within the liver. The limitation of liver sutures to coapt tissue edges or tamponade deep parenchymal wounds is clear for several reasons. Sutures may be attached to or come pre-mounted to needles of limited size and curvature making deep placement difficult or impossible. The sutures tend to tear through the friable parenchyma. Another problem with sutures is that since they need to be tied off to themselves or other sutures, they form a circular configuration around certain tissues and may strangulate the tissues within that circle. This strangulation causes reduced blood flow and potentially damaging ischemia for those tissues. In addition, the suture does not distribute its force adequately to compress tissues outside of a very narrow plane described by the circle of the suture path. Another key problem with the current treatment is the time taken to achieve suture hemostasis. Massive bleeding must be stopped quickly or the patient will exsanguinate and die. Placement of sutures is a time consuming process given the tools available today, the friable nature of parenchymal tissue, and the undesirability of intra-hepatic gauze packing.
[0007] The size and curvature of currently marketed needles is pre-set by the manufacturer. Current needles are not long or big enough to transfix major liver lacerations. Even if the needle was large, the suture method of repair causes inadequate force distribution to create hemostasis and resist progressive wound tearing.
[0008] New devices, procedures and methods are needed to support the strategy of damage control in patients who have experienced massive visceral injury. Such devices and procedures are particularly important in the emergency, military, and trauma care setting. These new devices, specifically parenchymal bolts, rely on the principles of broad force distribution on the tissue, pressure tamponade, ease of placement, ease of locking in place with the pressure pads, the ability to adjust tension to optimize tissue compression, and the lack of progressive tearing of the friable wound due to the high shear caused by the suture.
SUMMARY OF THE INVENTIONS
[0009] This invention relates to an improved haemostatic tissue apposition device for use in trauma care. The present invention is a transfixing trans-parenchymal bolt. Key features of the bolt include column strength, adjustable depth of penetration, flexibility, tissue non-reactivity, quick and simple application, and adjustment of the pressure plates. The trans-parenchymal bolt uses pressure plates that are affixed to the ends of the bolt to distribute the pressure over a wide area of tissue and compress the tissue. Key features of the pressure plates include one-way ratcheting with quick release or a friction lock, ability to quickly and cleanly remove the pressure plate, and the ability to adjust the pressure plate to ensure optimum tissue apposition and compression. The trans-parenchymal bolt generates pressure tamponade to provide for wound hemostasis. The pressure plates are atraumatic structures such as tabs, leafs, solids, meshes, or other structures that distribute force over a wide area of tissue. By contrast, traumatic structures include pointed projections or small thin wires or whiskers that could rip through parenchymal, or other, tissue. The trans-parenchymal bolt may be placed through an open surgical access site or through a laparoscopic access and manipulation system. The trans-parenchymal bolt, or bolt, can act as, perform the function of, or be equivalent to a soft-tissue rivet. The bolt can also be placed blindly into tissue wherein the distal end of the bolt expands to form a pressure plate thus eliminating the need to access the distal end of the bolt to apply the pressure plate. In this embodiment, the distal pressure plate is activated or expanded by control energy or force applied at the proximal end of the bolt, said control energy being transmitted along the length of the bolt by a linkage, coupling, electronic cabling, or the like. The control energy, or force, then expands the distal pressure plate. Release, or re-collapse, of the distal pressure plate can also be accomplished using the same mechanism at the proximal end of the bolt. The distal and proximal pressure plates are not sharp but are blunted and atraumatic and apply distributed pressure to the tissue.
[0010] Once the bolt has been placed, it remains in place either temporarily or permanently. Temporary placement necessitates removal of the bolt. The bolt may be made from materials that permit long-term implantation or it may be fabricated from resorbable materials that obviate the need to remove the bolt in a subsequent surgical procedure. Both the bolt and the pressure plates are fabricated from materials with smooth outer surfaces that do not encourage tissue or clot ingrowth. The bolts and pressure plates are radiopaque and can be visualized on fluoroscopy or X-ray. Thus, the bolts and pressure plates may be removed with minimal re-bleeding.
[0011] The current medical practice of utilizing sutures is not an optimized solution to open visceral wound repair. Sutures were not designed for use in parenchymal tissue. The present invention distinguishes over the current medical practice because the present invention is tailored to the needs of open visceral wound repair. The parenchymal bolts are stiff enough to serve as their own needles, trocars, or stylets. They may be flexed or permanently deformed to achieve the desired tissue compression. They are suited for either open surgical implantation and removal, or they are suited for laparoscopic placement and removal using specialized access, grasping and delivery instruments. When the trans-parenchymal bolts of the present invention are removed from the patient, re-bleeding does not occur because there is minimal penetration of the wound tissues or clot into the interstices of the bolt and pressure plate.
[0012] For purposes of summarizing the invention, certain aspects, advantages and novel features of the invention are described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
[0013] These and other objects and advantages of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A general architecture that implements the various features of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements.
[0015] FIG. 1A illustrates a longitudinal cross-sectional view of the parenchymal bolt, according to an embodiment of the invention;
[0016] FIG. 1B illustrates a lateral cross-sectional view of the parenchymal bolt near one of the ends, according to an embodiment of the invention;
[0017] FIG. 1C illustrates a lateral cross-sectional view of the parenchymal bolt near the center, according to an embodiment of the invention;
[0018] FIG. 2A illustrates a side view of the pressure plate and locking nut in cross-section, according to an embodiment of the invention;
[0019] FIG. 2B illustrates an end view of the pressure plate and locking nut also showing the lock release, according to an embodiment of the invention;
[0020] FIG. 3 illustrates a longitudinal cross-sectional view of the parenchymal bolt, two pressure plates and two locking nuts, according to an embodiment of the invention;
[0021] FIG. 4 illustrates a longitudinal cross-sectional view of the parenchymal bolt, two pressure plates and two locking nuts wherein the parenchymal bolt has been malleably deformed into a right angle bend, according to an embodiment of the invention;
[0022] FIG. 5A illustrates a typical wound to the liver, according to an embodiment of the invention;
[0023] FIG. 5B illustrates preparations for open access liver wound hemostasis using three parenchymal bolts, six pressure plates and six ratcheting locks, according to an embodiment of the invention;
[0024] FIG. 5C illustrates the wound to the liver following temporary repair with three parenchymal bolts, six pressure plates, and six ratcheting locks, according to an embodiment of the invention;
[0025] FIG. 6A illustrates a wound to the liver being repaired through laparoscopic access by application of a parenchymal bolt, according to an embodiment of the invention;
[0026] FIG. 6B illustrates application and tightening of a pressure plate and ratcheting lock via laparoscopic instrumentation, according to an embodiment of the invention;
[0027] FIG. 6C illustrates the wound to the liver following laparoscopic placement of three parenchymal bolts, six pressure plates, and six ratcheting locks, according to an embodiment of the invention;
[0028] FIG. 7A illustrates a side cross-sectional view of a parenchymal tissue injury with a parenchymal bolt, two pressure plates, and two ratcheting locks prior to tightening, according to an embodiment of the invention;
[0029] FIG. 7B illustrates a side cross-sectional view of the parenchymal tissue injury during tightening of the ratcheting locks, according to an embodiment of the invention;
[0030] FIG. 8 illustrates a longitudinal cross-sectional view of a parenchymal bolt comprising pressure plates and friction locks, according to an embodiment of the invention;
[0031] FIG. 9A illustrates a side cross-sectional view of a parenchymal bolt comprising a distal pressure plate that is integral to the bolt and opens to apply pressure to tissue once the bolt has been placed through tissue or released, according to an embodiment of the invention;
[0032] FIG. 9B illustrates a side cross-sectional view of a parenchymal bolt comprising a distal pressure plate that is integral to the bolt and has opened following partial withdrawal of the sharp trocar, according to an embodiment of the invention; and
[0033] FIG. 10 illustrates a side view of a delivery system for a soft tissue bolt, shown in partial breakaway view, according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
[0035] FIG. 1A illustrates a longitudinal cross-sectional view of a parenchymal bolt 10 of the present invention. The parenchymal bolt 10 comprises an inner core 12 , an outer coating 14 , a central region 16 , a plurality of ends 18 , and a plurality of serrations 20 on one or both ends 18 . The parenchymal bolt 10 further comprises an optional pointed tip or trocar 22 .
[0036] Referring to FIG. 1A , inner core 12 of the parenchymal bolt 10 is coaxially affixed to interior of the outer coating 14 . The central connecting region 16 is disposed between the ends 18 . One or more of the ends 18 of the parenchymal bolt 10 comprise a plurality of serrations 20 disposed longitudinally, along at least one side of one or more ends 18 . The optional pointed tip or trocar 22 is removably affixed coaxially to one or more of the ends 18 .
[0037] Referring to FIG. 1A , the inner core 12 of the parenchymal bolt 10 provides column strength and the ability to be malleable or elastomeric, depending on the patient requirements. The preferred configuration of the inner core 12 is that it is malleable and located in the central region 16 only. The ends 18 are, preferably, elastomeric and do not have the malleable inner core 12 disposed therethrough. Another important advantage of having only polymeric material comprise the ends 18 is that the ends can be cut off or trimmed to size once the parenchymal bolt 10 is fully installed or placed in the patient. Column strength is important so that tension may be transmitted through the parenchymal bolt 10 , even when the parenchymal bolt 10 has been bent into an arc. Column strength also permits the parenchymal bolt 10 to be forced through tissue much the same as a suture needle would be forced through tissue. Malleability is important so that the parenchymal bolt 10 can be bent into the correct curvature needed for optimum coaptation of the tissue being repaired.
[0038] The inner core 12 is fabricated from materials such as stainless steel, cobalt-nickel alloys, nitinol, tantalum, titanium, polylactic acid, polyglycolic acid, platinum, and the like. The inner core 12 is preferably radiopaque and visible under fluoroscopy or X-Ray. It is important that the parenchymal bolt 10 be radiopaque.
[0039] The outer coating 14 is fabricated from the same materials as are used to fabricate the inner core 12 . The outer coating 14 may be the same physical structure as the inner core 12 . Preferably, the outer coating 14 is smooth and does not allow tissue ingrowth. The outer coating 14 may be fabricated from polymers such as, but not limited to, polypropylene, polyethylene, polyester, polyurethane, polylactic acid, polyglycolic acid, polyimide or copolymers of these materials. In a preferred embodiment, the bolt 10 comprises radiopaque markers. The markers are fabricated from tantalum, gold, platinum, stainless steel, titanium, nitinol, cobalt nickel alloys and the like. The markers show the extents of the outer coating 14 . The addition of barium, barium compounds, or the like in concentrations of up to about 40% in the polymer provides for radiopacity.
[0040] One or more of the ends 18 comprise an optional sharpened or tapered tip 22 to pierce tissue with minimal resistance. The optional pointed tip or trocar 22 facilitates passage of the parenchymal bolt 10 through tissue. The pointed tip or trocar 22 may be removed to minimize further tissue damage while the parenchymal bolt 10 is in place. In a preferred embodiment, the pointed tip or trocar 22 is removably attached to the ends 18 by a male threaded stub that is mated into a female threaded adapter on the end 18 . A bayonet mount is another suitable method of attaching the pointed tip or trocar 22 to the end 18 . In another embodiment, the pointed tip or trocar 22 may also be longitudinally disposed through the entire core of the parenchymal bolt 10 and is removed by simply withdrawing the trocar 22 from the parenchymal bolt 10 . The removable sharp tip 22 , in a further embodiment, is retractable within the end 18 of the parenchymal bolt 10 . Retraction of the sharp tip 22 is either automatic or manually activated.
[0041] One or more of the ends 18 comprise the plurality of serrations 20 that permit locking with devices that are attached to the parenchymal bolt 10 in a later process. The serrations 20 are, preferably, triangular in shape and project outward from the longitudinal axis of ends 18 . In the preferred embodiment, the serrations 20 comprise triangular projections. One side of the triangular projection is perpendicular to the longitudinal axis of the end 18 . The perpendicular side of the triangle may also be undercut. Another side is tapered away from the end 18 and forms a ramp moving inward from the end 18 toward the center 16 of the parenchymal bolt 10 .
[0042] FIG. 1B illustrates a cross-section of the parenchymal bolt 10 taken near one of the ends 18 . The cross-sectional view of the end 18 further comprises one or more optional tracking grooves 24 and one or more optional longitudinal ratchet slots 25 .
[0043] Referring to FIG. 1B , the tracking groove 24 is a slot and is disposed longitudinally along the length of ends 18 . The longitudinal ratchet slot 25 is disposed longitudinally along the length of ends 18 .
[0044] Referring to FIGS. 1A and 1B , the serrations 20 are disposed within the ratchet slot 25 . The ratchet slot 25 holds and hides the serrations from the tissue as the parenchymal bolt 10 is advanced through the tissue to minimize trauma. The tracking groove 24 is used to provide alignment for parts that will be mated to the parenchymal bolt 10 . By having two sets of tracking grooves 24 , bilateral symmetry is achieved and parts can be mated in two orientations, rather than just one, thus facilitating the mating process. One ratchet slot 25 is required for each set of serrations and two ratchet slots 25 permit orientation of mating parts in more than one orientation. When more than one ratchet slot 25 and tracking groove 24 are used on each end, the second slot 25 or groove 24 is disposed 180 degrees around the end 18 circumference from the first slot 25 or groove 24 .
[0045] FIG. 1C illustrates a cross-section of the central region 16 of the parenchymal bolt 10 . The central region 16 comprises the core 12 and the outer coating 14 . The outer coating 14 is disposed coaxially around the core 12 . The optional tracking grooves 25 are not shown in this cross-section.
[0046] FIG. 2A illustrates a cross-sectional view of a pressure plate 26 and a ratcheting lock 28 . The pressure plate 26 further comprises one or more pass through holes 30 . The ratcheting lock 28 further comprises a plurality of locking tabs 32 , a tracking protrusion 34 , and a central hole 36 .
[0047] The ratcheting lock 28 is disposed coaxially with the pass through hole 30 on the pressure plate 26 . The ratcheting lock 28 is either affixed to the pressure plate 26 , is integral to said pressure plate 26 , or is mounted separately outside the pass through hole 30 of said pressure plate 26 . The locking tabs 32 are flexibly affixed to the ratcheting lock 28 and project inward with a vertical edge toward the pressure plate 26 and a ramped edge sloping away from the pressure plate 26 . The tracking protrusion 34 is one or more small projections into the central hole 36 of the ratcheting lock 28 .
[0048] The pressure plate 26 may have a single pass through hole 30 or it may have the plurality of pass through holes 30 . With the plurality of pass through holes 30 , one pressure plate 26 can be used with multiple parenchymal bolts 10 .
[0049] Referring to FIGS. 1A , 1 B, and 2 A, the end 18 is configured to mate with the ratcheting lock 28 and the pressure plate 26 . When the ratcheting lock 28 is advanced over one of the ends 18 , through the central hole 36 , the flexible locking tab 32 on the ratcheting lock 28 is bent aside by the ramp formed on the outside of serrations 20 and allows advancement of the ratcheting lock 28 to continue. Pulling backward on the ratcheting lock 28 or pressure plate 26 causes the vertical edge of the locking tab 32 to dig into the perpendicular sides described by the inner edges of the serrations 20 on the ends 18 so the ratcheting lock 28 will not slip backwards. The tracking protrusion 34 slideably mates with the alignment groove 24 on the end 18 to prevent the locking tabs 32 from becoming misaligned with the serrations 20 and inadvertently disengaging.
[0050] FIG. 2B illustrates an end view of the pressure plate 26 and the ratcheting lock 28 . As seen in this view, the ratcheting lock 28 further comprises a lock release 38 .
[0051] Referring to FIGS. 2A and 2B , the locking tabs 32 project inward toward the center of the central hole 36 in the ratcheting lock 28 . The lock release 38 is activated by manual pressure or by a laparoscopic instrument to bend back and release the locking tab 32 from the serrations 20 so that the ratcheting lock 28 and pressure plate 26 may be removed from the end 18 . The lock release 38 allows for quick release of the ratcheting lock 28 and pressure plate 26 . In another embodiment, the lock release 38 retracts the tracking protrusions 34 so that the ratcheting lock 28 can be rotated to disengage the locking tabs 32 from the serrations 20 and enable removal of the ratcheting lock 28 and the pressure plate 26 from the parenchymal bolt 10 .
[0052] The pressure plate 26 , the ratcheting lock 28 and the lock release 38 are fabricated from the same materials as are used in fabrication of the parenchymal bolt 10 . All parts are designed with smooth outer surfaces to minimize the opportunity for tissue or thrombus ingrowth. The pressure plate 26 is stiff enough to distribute pressure to gently hold the tissue together while it heals. In a preferred embodiment, the pressure plate 26 and the ratcheting lock 28 are radiopaque. Materials such as barium, barium compounds, or radiopaque metals or the like, comprise at least part of the pressure plate 26 or lock 28 .
[0053] Referring to FIGS. 1A , 1 B, 1 C, 2 A and 2 B, the length of the parenchymal bolt 10 ranges from 0.5 cm to 500 cm depending on the tissue being compressed. More preferably, the length of the parenchymal bolt 10 ranges from 2 cm to 50 cm. The diameter of the parenchymal bolt 10 varies and is in proportion to the length of the bolt 10 . Diameter ranges of between 0.5 mm and 10 mm are appropriate for the parenchymal bolt 10 . The pressure plate 26 is sized to the organ being compressed. The pressure plate 26 has roughly rectangular dimensions ranging from a minimum of 0.5 cm to a maximum of 100 cm. The preferred range of sizes for the pressure plate 26 is 1 cm to 20 cm. The pressure plate 26 thickness ranges from 0.5 mm to 30 mm.
[0054] FIG. 3 illustrates a longitudinal cross-sectional view of the parenchymal bolt 10 with two pressure plates 26 and two ratcheting locks 28 . The pointed tip or trocar 22 has been removed in this view. The pressure plates 26 and ratcheting locks 28 have been pushed over the ends 18 of the parenchymal bolt so that the locking tabs 32 have engaged the serrations 20 .
[0055] FIG. 4 illustrates a longitudinal cross-sectional view of the parenchymal bolt 10 with two pressure plates 26 and two ratcheting locks 28 . The parenchymal bolt 10 has been malleably deformed in its central region 16 and maintains that shape because the core 12 has sufficient strength to overcome the elastic forces generated by the outer covering 14 .
[0056] FIG. 5A illustrates a wound 42 in a liver tissue 40 . The liver is a prime example of parenchymal tissue that often receives damage during abdominal trauma. Note that the parenchymal tissue of the liver 40 is friable and unable to sustain high stresses without fracturing or tearing.
[0057] FIG. 5B illustrates open surgical preparation for repair of the liver wound 42 according to the methods of the present invention. In this case, three parenchymal bolts 10 , six pressure plates 26 and six ratcheting locks 28 are prepared for the procedure while the liver 40 apposition is accomplished with manual pressure.
[0058] FIG. 5C illustrates completion of the repair of the wound 42 to the liver 40 using the parenchymal bolts 10 , pressure plates 26 and ratcheting locks 28 . The ratcheting locks 28 are tightened sufficiently to hold the pressure plates 26 firmly against the tissue causing complete wound 42 closure and hemostasis.
[0059] FIG. 6A illustrates the wound 42 to the liver 40 with the parenchymal bolt 10 being applied by a laparoscopic instrument 44 . In this embodiment, the laparoscopic instrument 44 is a grasper or set of jaws, placed through an axially elongate hollow structure 48 , that may be manipulated by the surgeon from the outside of the patient.
[0060] FIG. 6B illustrates the wound 42 to the liver 40 following placement of the first parenchymal bolt 10 , two pressure plates 26 and two ratcheting locks 28 using the first laparoscopic instrument 44 and a second laparoscopic instrument 46 . Again, the laparoscopic instruments 44 and 46 are placed through an axially elongate hollow structure 48 that provides access to the internal organs of the patient. The laparoscopic grasping device 46 is placed around the ratcheting lock 28 and is used to advance the ratcheting lock 28 and pressure plate 26 inward against the liver tissue 40 . The laparoscopic grasping device 44 applies tension to the parenchymal bolt 10 so that the pressure plate 26 and the ratcheting lock 28 move relative to the parenchymal bolt 10 . The laparoscopic grasping instruments 44 and 46 , which may be similar to very long nosed pliers, may be replaced by a single instrument that performs both functions of stabilizing the parenchymal bolt 10 and advancing the ratcheting lock 28 . This type of procedure is generally performed under direct vision through a lens and illuminator placed laparoscopically within the surgical field.
[0061] FIG. 6C illustrates the wound 42 to the liver 40 following laparoscopic repair with three parenchymal bolts 10 , six pressure plates 26 and six ratcheting locks 28 .
[0062] FIG. 7A illustrates a side cross-sectional view of the wound 42 to parenchymal tissue 40 , in this case the liver 40 , following initial repair with the parenchymal bolt 10 of the present invention. The repair of the wound 42 comprises placement of the parenchymal bolt 10 followed by placement of two pressure plates 26 and two ratcheting locks 28 .
[0063] Referring to FIG. 7A , FIG. 1A and FIG. 2A , the pointed tip or trocar 22 has been removed or retracted following full tissue 40 penetration by the parenchymal bolt 10 . Two pressure plates 26 have been applied to the ends 18 of the parenchymal bolt 10 to transfix the tissue 40 . Two ratcheting locks 28 are in the process of being tightened over the pressure plates 26 and the wound 42 is still open.
[0064] FIG. 7B illustrates the wound 42 in the parenchymal tissue 40 at a point where the ratcheting locks are nearly tightened against the tissue 40 . The wound 42 has achieved nearly complete closure. Additional inward tightening of the ratcheting locks 28 will compress the pressure plates 26 and achieve full wound 42 closure and hemostasis. The parenchymal bolt 10 flexes to accommodate the change in wound geometry as the ratcheting locks 28 are tightened.
[0065] FIG. 8 illustrates another embodiment of the parenchymal bolt 10 , shown in longitudinal cross-section. The parenchymal bolt 10 further comprises an axially elongate shaft 14 , a malleable central component 12 , a sharpened tip 22 , one or more pressure plates 26 , and one or more friction locks 50 . The friction lock 50 further comprises a friction generator 52 and a housing 54 , which further comprises a grasping bump 56 .
[0066] The key enhancement to this embodiment of the parenchymal bolt 10 is the friction lock 50 . The friction lock 50 may be separate or integral to the pressure plate 26 . The friction lock 50 is fabricated from biocompatible polymeric materials such as, but not limited to polyethylene, polypropylene, ABS, PVC, stainless steel, PTFE, titanium, polylactic acid (PLA), polyglycolic acid (PGA), and the like. The PLA or PGA fall under a class of materials that are bioresorbable. These bioresorbable, or resorbable, materials will absorb when implanted in body tissue, over a period of time extending from 1 day to 6 months, preferably in the range of 1 week to 3 months. The formulation of the bioresorbable materials can be modified to adjust the resorption time. Other bioresorbable materials include those fabricated with sugars, collagen, protein, or the like. In the preferred embodiment, the friction lock 50 comprises a friction generator 52 , which is a disc with a hole in the center. The hole is smaller in diameter than the outside diameter of the axially elongate shaft 14 of the parenchymal bolt 10 . The friction generator 52 comprises elastomeric materials that exert an inward pressure and generate friction against the outside diameter of the axially elongate shaft 14 . Such elastomeric materials include, but are not limited to, polyurethane, silicone elastomer, latex rubber, and the like. The friction exerted by the friction lock 50 against the axially elongate shaft 14 is sufficient to resist the force of the tissue resilience once engaged in contact but insufficient to prevent manual movement generated by the surgeon either applying or removing the friction lock 50 from the axially elongate shaft 14 . The housing 54 further comprises a grasping surface 56 , which is a bump or other feature that allows for easy grasping by the surgeon in a wet or slick environment so that the friction lock 50 may be removed retrograde from the shaft 14 of the parenchymal bolt 10 . Other embodiments of the friction lock 50 include those that comprise a jam cleat, an over-center cam, a spring-loaded friction member, and the like. The friction lock 50 preferably does not comprise a release mechanism but in certain configurations, a button or latch to release the friction is required.
[0067] FIG. 9A illustrates another embodiment of a parenchymal bolt 100 with a distal pressure plate 90 that is pre-affixed to the bolt 100 prior to use in a patient. The bolt 100 comprises a shaft 14 , a trocar 80 further comprising a sharp tip 82 and a trocar handle 84 , at least one distal pressure plate 90 , a connection region 86 , a proximal pressure plate 26 , a lock 50 , and an actuation lever 100 .
[0068] The distal pressure plate 90 is configured to fold against the shaft 14 of the bolt 100 when the bolt 100 is being inserted distally through tissue. When the bolt 100 distal end, which carries the distal pressure plate 90 , has been advanced through the tissue and is released, the distal pressure plate 90 opens, at least partially due to spring force applied, and can exert pressure on the tissue when pulled proximally. The distal pressure plate 90 is affixed to the shaft 14 by the connection region 86 , which can be bendable, can comprise a spring, can comprise an actuator, can comprise releasable locks, or can comprise a hinge. The shaft 14 can be malleable, elastomeric, rigid, pre-bent, shape-memory such that it takes a curved configuration upon exposure to body temperature or a temperature above body temperature generated by Ohmic heating, or the like.
[0069] The distal pressure plate 90 , in this embodiment, comprises narrow plates or arms that are separated from the shaft 14 by slots or gaps that allow for expansion of all but the distal region of the pressure plate 90 where it is affixed to the shaft 14 at the connection region 86 . In an embodiment, the distal pressure plate 90 can be integral to the shaft 14 and be created by slits or slots in the shaft 14 to form the distal pressure plate 90 elements. The distal pressure plate 90 expandable elements can be held against the side of the shaft 14 by releasable locks, such as those that release or are activated when the tip 82 is withdrawn proximally. The proximal pressure plate 26 and lock 50 are applied in the same way as that of other embodiments of the parenchymal bolt 10 . In the preferred embodiment, the proximal pressure plate 26 and lock 50 , which can be a friction lock, are pre-positioned on the shaft 14 of the parenchymal bolt 100 or applier and is advanced by the bolt applier, laparoscopic instrument, or manually by the surgeon. In an embodiment the parenchymal bolt 100 can be applied by an instrument such as a bolt applier, laparoscopic instrument, or the like ( FIG. 10 ). This embodiment can be useful when the distal side of the tissue is not easily accessed by the surgical approach and placement of the distal pressure plate 90 would be difficult or impossible. In an embodiment, the sharp pointed tip 82 is retractable or is withdrawn proximally by the user by pulling on the trocar handle 84 affixed to shaft 80 and further affixed to tip 82 once the tissue has been penetrated. The length of the bolt 100 can be adjusted by trimming with the bolt applier or other instrument such as a cutter or pair of scissors. In another embodiment, the length of bolt 100 can also be adjusted using a telescoping, locking configuration in the shaft 14 . The telescoping shaft 14 eliminates the need for length trimming. This type of bolt 100 can be used to affix prosthetic devices to soft tissue. The actuator lever 100 is affixed near the proximal end of the shaft 14 and can be moved, either by hand or by an instrument, to force the distal pressure plates 90 outward to engage the tissue.
[0070] FIG. 9B illustrates a cross-section of the bolt 100 of FIG. 9A with the distal pressure plate 90 expanded or released. The bolt 100 comprises the shaft 14 , the trocar 80 , the sharp tip 82 , the proximal pressure plate 26 , the lock 50 , the distal pressure plates 90 , the connection region 86 , the actuation lever 150 , an actuation linkage 102 , a linkage lumen 104 , one or more lever arms 106 , a lever arm hinge 108 , an optional distal pressure plate hinge 110 , and one or more shaft windows 112 .
[0071] Referring to FIG. 9B , the distal pressure plate 90 , in this embodiment, will appear as a series of radial projections or fingers. Integral or separate leaf springs 86 bias the expandable elements of the distal pressure plate 90 to expand outward. The pointed distal tip 82 and its shaft 80 are slidably movable within the shaft 14 . In a preferred embodiment, one or more detents in the shaft 14 mate with protrusions in the shaft 14 to provide a positive positioning index that may be overcome by manual force. In one embodiment, when the distal pressure plate 90 passes beyond tissue, the spring biased pressure plate elements open. In another embodiment, the pressure plate 90 is released when the pointed distal tip 82 and its shaft 80 , which are affixed to each other, are withdrawn proximally. The connection region 86 can comprise a spring, an actuator, releasable locks to keep the pressure plates 90 open, or a hinge.
[0072] In another embodiment, when the control, or actuation, lever 150 is advanced forward, it forces the actuation linkage 102 to slide distally within the linkage lumen 104 and advance the proximal end of the actuation levers 150 . Distal motion of the actuation levers 150 forces the distal pressure plates 90 to open outward around the distal pressure plate hinge 110 . Friction in the system or a lever lock 86 , which can be releasable and controllable from the proximal end of the bolt 10 , or non-releasable, keeps the distal pressure plates 90 open such that they project laterally away from the shaft 14 . Backup reinforcements, such as the lever arms 106 prevent the leafs of the distal pressure plate 90 from rotating substantially beyond a plane perpendicular to the axis of the bolt 100 .
[0073] The distal pressure plates 90 can be configured as wings as shown, or they can be bendable or hinged in the middle such that they open radially or laterally when force is applied at the proximal end of the distal pressure plates 90 . In this embodiment, the proximal end of the pressure plate 90 , which is constrained not to expand radially is moved distally causing the center of the distal pressure plates 90 to bend, bow, or hinge. This arrangement, similar in configuration to a Moly-bolt, for example, can provide for distal fixation and a pressure-plate effect. Transmission of power from the actuation lumen 104 to the lever arms 106 or distal pressure plates 90 , which do not use the lever arm 106 , can occur through a window 112 cut in the side of the shaft 14 . In yet another embodiment, the distal pressure plates 90 comprise shape memory nitinol that is shape-set during heat-treating to expand radially at body temperature. The nitinol-actuated pressure plates 90 can also be configured to expand radially with the application of electrical energy to the pressure plates 90 causing Ohmic or resistive heating of the nitinol elements above body temperature past a transition temperature, such as the austenite start temperature or austenite finish temperature. The nitinol-actuated pressure plates 90 can be heated using adjunctive heaters such as a nickel chromium wire routed around or near the nitinol actuator. Hysteresis effects can keep the nitinol open even when the bolt 100 or pressure plates 90 are exposed to body temperatures or slightly below. The pressure plates 90 in this embodiment can take the shape of ribbons or wings that are longitudinally disposed along the shaft 14 but bend outward radially or laterally to cause the pressure plate effect. The pressure plates 90 can also take the form of a coil of wire that expands to form a ball or other three-dimensional mesh which can serve the function of a pressure plate.
[0074] In an embodiment, the proximal pressure plate 26 can be configured as the mirror image of the distal pressure plate 90 . In this embodiment, the proximal pressure plate 26 is actuable, rather than being pre-attached to the shaft 14 with the lock 50 . The proximal pressure plate 26 of this embodiment can be a Moly-bolt, a balloon, an expanding wire structure or other configuration similar to that described for the distal pressure plate 90 using the same or similar actuation mechanisms or means. In another embodiment, the bolt 100 can be configured to bend in response to shape memory actuators affixed thereto. The actuation of the shape memory actuators can be performed using electrical energy delivered through a delivery system such as that shown in FIG. 10 .
[0075] Another aspect of the inventions includes the method of use of the bolt 10 . In an embodiment, the bolt 100 is inserted into a patient through the tissue using the fingers or with the aid of an instrument which is axially elongated to provide additional reach into small, narrow spaces unreachable except through undesirable open surgery. The bolt 100 is advanced with its sharp tip 82 exposed through tissue until it has achieved the desired penetration. The sharp tip 82 is then retracted and optionally completely withdrawn from the bolt 100 . The distal pressure plates 90 are expanded by actuation from the proximal end, by automatic means such as shape memory expansion, or by proximal pullback or removal of the core, sharp trocar 80 . Proximal end pressure plates 26 are either applied, actuated, or expanded using the same or similar means as the distal pressure plates 90 . The plates can be adjusted for tightness by causing the proximal pressure plate 26 to slide axially along the shaft 14 and then lock in place with the lock 50 . The instrument or hand is then decoupled from the bolt 100 and removed. The bolt 100 is either left permanently, removed by surgery, or left to resorb into the tissue. The bolt 100 can be used to repair damaged parenchymal tissue, or it can be used to repair damaged muscle such as smooth muscle or striated muscle. The use of soft tissue rivets, such as the bolt 100 , can be used to speed closure of wounds that result from trauma or surgery. The application of a rapid-fire bolt 100 by means of an installation tool (not shown) can result in placement of multiple bolts 100 in a very short period of time. For example, it is possible to place 5 to 20 bolts 100 in one minute or up to one rivet or bolt 10 every 5 seconds using this type of system.
[0076] FIG. 10 illustrates a delivery system 1000 for a soft tissue bolt 100 comprising a main shaft 1002 , a pushrod 1004 , a distal engagement tab 1006 , a grabber control handle 1008 , a pushrod control handle 1010 , an actuator control lever 1012 , a main handle 1014 , one or more grasper tabs 1018 , a grasper hinge 1020 , one or more grasper linkages 1022 , one or more grasper linkage connectors 1024 , one or more electrical input jack 1026 , and one or more grasper electrode 1028 .
[0077] Referring to FIG. 10 , the main handle 1014 is affixed to the main shaft 1002 near the proximal end of the main shaft 1002 . The pushrod 1004 is affixed, at or near its proximal end to the pushrod control handle 1010 and at or near its distal end, to the distal engagement tab 1006 . The pushrod 1004 is slidably disposed within or near the main shaft 1002 , with respect to which it is oriented generally parallel. The grasper tabs 1018 are rotatably affixed about the grasper hinge 1020 , which is affixed near the distal end of either the main shaft 1002 or the pushrod 1004 . The grasper linkages 1022 are affixed to the grasper tabs 1018 at linkage connectors 1024 . Electrical input jack 1026 is affixed to the main handle 1014 , the pushrod control handle 1010 , or near the proximal end of the main shaft 1002 . The grasper electrodes 1028 are affixed to either the grasper tabs 1018 or the distal engagement tab 1006 and are operably connected to the electrical input jacks 1026 by an electrical bus, which can be, in the illustrated embodiment the grasper linkages 1022 .
[0078] The delivery system 1000 can be used in conjunction with a laparoscopic or thoracoscopic trocar, for example, or through an open surgical port to deliver the soft tissue bolt 100 to a surgical target site. Referring to FIGS. 9A and 9B , the operator grasps the delivery system 1000 by the main handle 1014 with the distal engagement tab 1006 releasably engaging the distal pressure plate 90 expansion control lever 150 on the bolt 100 . In another embodiment, the distal graspers can be used to releasably engage the distal pressure plate 90 control lever 150 on the bolt 100 . In this embodiment, the distal engagement tab 1006 can be used to withdraw the obturator, shaft 80 , or sharpened point of the bolt either partially or fully proximal and out of the bolt 100 . In this embodiment, the grasper electrodes 1028 can be used to deliver electrical energy to either bend the bolt 100 or to radially expand the distal pressure plates 90 by shape memory effects using nitinol, or the like in one or both applications. The distal engagement tab 1006 or the grasper tabs 1018 can be configured, in one or more embodiments, to provide cutting action to cut off excess length of the soft tissue rivet, or bolt, 100 during or after the implantation and securing process has been completed. Alternatively, an additional cutter 1030 can be affixed near the distal end of the delivery system 1000 to cut the bolt 100 to length. This is facilitated by removal of any metallic core materials leaving primarily polymeric bolt 100 shaft materials, which can more easily be severed. Control over the cutting action is applied at or near the proximal end of the delivery system 1000 and the control is transmitted to the cutting mechanism by linkages such as the grasper linkages 1022 or the pushrod 1004 .
[0079] The components of the delivery system 1000 can be fabricated from polymeric materials such as, but not limited to, polycarbonate, polypropylene, polyethylene, PEEK, polyvinyl chloride, acrilonitrile butadiene styrene, polysulfone, or the like. The components can also be fabricated in part, or in whole from metals such as, but not limited to, stainless steel, cobalt nickel alloy, titanium, nickel titanium, tantalum, or the like. The length of the main shaft can range from 2 cm to 50 cm and the diameter of the main shaft can range from 1 mm (3 French) to 25 mm (75 French). The delivery system 1000 can be releasably affixed to the bolt 100 in singles. In another embodiment, multiple bolts 100 can be loaded into the delivery system to permit rapid fire, multiple applications. The delivery system 1000 can control the expansion of the distal, or second, pressure plate. The delivery system 1000 can control retraction of the obturator. The delivery system 1000 can control bending of the bolt 100 .
[0080] Application of the parenchymal bolt system provides improved speed of solid organ trauma repair and minimizes the chance of tissue tearing or fracture, relative to the use of sutures for said repair. The parenchymal bolt system provides pressure tamponade to the injured tissue to provide for hemostasis and maximize the recovery process while minimizing complications common to suture-based approaches.
[0081] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. For example, the ratcheting locks could be replaced by simple threaded nuts that engage threads on the parenchymal bolt. The distal pressure plate can comprise one or more radially expandable wings such as are found in a hollow wall anchor, or the distal pressure plate can comprise a fluid-filled balloon such as a non-elastomeric balloon or an elastomeric, Foley-type balloon, or they can be of a radially different shape such as a three-dimensional wire mesh or a solid such as when a hydrogel, constrained within a water permeable membrane, expands due to fluid uptake to swell into a flexible volume. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Surgical bolts are useful for solid visceral wound hemostasis. The devices utilize flexible, variable depth transfixing bolts that penetrate the viscera. These bolts bring the tissue into apposition and hold said tissue in apposition while the wound heals. These bolts, or soft tissue rivets, overcome the limitations of sutures that are currently used for the same purposes. The devices are flexible, bendable, and conformable in their wet or dry state. The bolts include pressure plates that are capable of exerting compressive pressure over broad areas of visceral wounds without causing tearing of the friable parenchyma. The bolts are placed and removed by open surgery or laparoscopic access. The bolts can be placed into tissue where both sides of the bolt are exposed, or they can be placed blindly into tissue where the bolt does not protrude out of the tissue at its distal end. | 0 |
[0001] This invention claims the benefit of Japanese patent application No. 2004-094774, filed on Mar. 29, 2004, and Japanese patent application No. 2004-094720, filed on Mar. 29, 2004, which are both hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a light emitting diode (LED), and more particularly to an LED that emits light of so-called electric bulb color such as white, off-white, light blue, light yellow, etc.
[0004] 2. Description of the Related Art
[0005] In recent years, there is an increasingly strong demand for power-saving and long-lasting lighting equipment from the viewpoint of preventing global warming, effectively using resources, and so on. In response thereto, LEDs are rapidly becoming shorter in wavelength and higher in brightness. Particular hope is placed on white LED's that use blue LED's for finding application in lighting.
[0006] White LEDs that have a shell-shaped or surface-mount configuration are conventionally known. The conventional white LED is designed to externally emit white light by converting light from a blue LED chip to yellow light with a phosphor layer, and mixing the yellow light with blue light from the blue LED chip to create the white light.
[0007] A conventional shell-shaped white LED is configured, for example, as shown in FIG. 4 . That is, in FIG. 4 , a white LED 1 includes a pair of lead frames 2 and 3 , and a blue LED chip 4 mounted on top of a chip mounting portion 2 a formed on the upper end surface of the lead frame 2 . A phosphor layer 5 is formed surrounding the blue LED chip 4 on top of the chip mounting portion 2 a of the lead frame 2 and includes phosphor 5 a mixed therein. A lens portion 6 is formed with mold resin so as to surround the upper ends of the lead frames 2 and 3 , the blue LED chip 4 , and the phosphor layer 5 .
[0008] The lead frames 2 and 3 are formed with a conductive material such as aluminum and are provided with the chip mounting portion 2 a and bonding portions 2 b and 3 a at respective ends thereof. The other ends of the lead frames extend downward to make up terminal portions 2 c and 3 b.
[0009] The blue LED chip 4 is joined on top of the chip mounting portion 2 a of the lead frame 2 , with two electrodes provided on the upper surface thereof electrically connected to the bonding portions 2 b and 3 a at the ends of the lead frames 2 and 3 by bonding wires 4 a and 4 b . Here, the blue LED chip 4 is configured, for example, as a GaN chip and designed, when applied with a drive voltage via the lead frames 2 and 3 , to emit light having a peak wavelength of about 450 to 470 nm.
[0010] The phosphor layer 5 is made, for example, of clear epoxy resin into which the phosphor 5 a in fine particulate form is mixed. The phosphor layer 5 is formed and hardened on top of the chip mounting portion 2 a of the lead frame 2 .
[0011] As blue light from the blue LED chip 4 falls on the phosphor layer 5 , the phosphor 5 a is excited, producing yellow light from the phosphor 5 a and externally emitting white light as a result of mixing of the two lights. Here, the phosphor 5 a includes a phosphor that emits a wide range of lights centering around yellow light such as YAG phosphor doped with cerium, TAG phosphor doped with cerium or orthosilicate phosphor (BaSrCa) SiO 4 , and is designed to produce a fluorescence, for example, with a peak wavelength of about 530 to 590 nm.
[0012] The lens portion 6 is made, for example, of clear epoxy resin, and is formed such that it surrounds the whole area near the upper ends of the lead frames 2 and 3 centering around the blue LED chip 4 and the phosphor layer 5 .
[0013] Based on the white LED 1 thus configured, the blue LED chip 4 emits light when a drive voltage is applied via the pair of lead frames 2 and 3 . The light falls on the phosphor 5 a mixed into the phosphor layer 5 , exciting the phosphor 5 a and producing yellow light. Then, this yellow light is mixed with blue light from the blue LED chip 4 , thus causing the mixture to be externally emitted as white light. In this case, white light has a spectrum distribution, for example, as shown in FIG. 5 .
[0014] On the other hand, a surface-mount white LED 7 can be configured, for example, as shown in FIG. 6 . In FIG. 6 , the white LED 7 includes a chip substrate 8 , a blue LED chip 4 mounted on top of the chip substrate, a frame-shaped member 9 formed on top of the chip substrate 8 so as to surround the blue LED chip 4 , and a phosphor layer 5 charged into a depressed portion 9 a of the frame-shaped member 9 .
[0015] The chip substrate 8 is made of a heat-resistant resin as a flat copper clad wired board, and is provided with a chip mounting land 8 a and an electrode land 8 b on the surface. Surface-mount terminal portions 8 c and 8 d extend around from these lands onto the lower surface via both end edges. The blue LED chip 4 is joined on top of the chip mounting land 8 a of the chip substrate 8 , with the blue LED chip 4 electrically connected to the chip mounting land 8 a and the electrode land 8 b through wire-bonding.
[0016] The frame-shaped member 9 , similarly formed on top of the chip substrate 8 with a heat-resistant resin, is provided with a recessed portion 9 a - a portion in the form of an inverted truncated cone—so as to surround the blue LED chip 4 . It is to be noted that the inner surface of the recessed portion 9 a is configured as a reflecting surface.
[0017] Based on the white LED 7 thus configured, the blue LED chip 4 emits light when a drive voltage is applied via the surface-mount terminal portions 8 c and 8 d , causing light to fall on the phosphor 5 a mixed into the phosphor layer 5 , exciting the phosphor 5 a and producing yellow light. Then, this yellow light is mixed with blue light from the blue LED chip 4 , thus causing the mixture to be externally emitted as white light.
[0018] However, there are problems with the white LEDs 1 and 7 configured as described above. For example, blue light emitted from the blue LED chip 4 is converted in wavelength by the phosphor 5 a to produce yellow light, with blue and yellow lights mixed together to emit white light. This white light has a color temperature, for example, of 5000 to 6000K. In contrast, an incandescent lamp (a lamp conventionally used over the last 100 plus years), has a color temperature, for example, of 2800 to 3000K.
[0019] Incidentally, when a conventional white LED lamp is used in place of an incandescent lamp in lighting equipment, the white LED produced light appears as a bluish white light unlike the so-called electric bulb light color for an incandescent lamp (which appears as a warm-looking color tinged with red). This is true because the conventional white LED light has insufficient light intensity in the red region, as shown in FIG. 5 , due to relatively high color temperature as described above, thus giving a cold impression.
[0020] On the other hand, while a red phosphor that produces red light by excitation with blue light—a recent development—may be used, red phosphors are generally made of alkaline earth metal and therefore vulnerable to humidity, making it difficult to configure a highly reliable LED and difficult to obtain a sufficient intensity of red light.
SUMMARY OF THE INVENTION
[0021] In light of the above, and in accordance with an aspect of the invention, a white LED light can be provided that emits warm-looking white light and which has a simple configuration.
[0022] According to a second aspect of the invention there is provided an LED that can include a pair of electrode members, an LED chip joined on top of a chip mounting portion disposed at an end of one of the pair of electrode members, the LED chip being electrically connected to both of the pair of electrode members, and a clear resin portion formed such that it surrounds the LED chip. The clear resin portion can include a wavelength converting material mixed therein, wherein the LED chip emits ultraviolet, blue and/or yellow light, and wherein the wavelength converting material mixed in the clear resin portion converts at least part of the light from the LED chip to green and/or red light that is longer in wavelength.
[0023] In the above-described LED, the pair of electrode members can include two lead frames extending parallel with each other. The LED can further include a lens portion made of a clear resin that surrounds both the LED chip and the clear resin portion. The pair of electrode members can also be configured with a conductive pattern formed on a chip substrate and which extends around onto the rear surface of the chip substrate to define surface-mount terminals. The clear resin portion can be charged into a recessed portion that is upwardly spread in such a manner as to expose a chip mounting portion formed on top of the chip substrate.
[0024] The wavelength converting material can be configured to produce green light having a peak wavelength of about 535 to 560 nm and red light having a peak wavelength of about 620 to 640 nm as converted from the light originally emitted from the LED chip. The wavelength converting material can also contain thiogallate phosphor as a first phosphor and rare-earth-activated aluminate or rare-earth-activated orthosilicate as a second phosphor. The wavelength converting material can be dispersed in an alicyclic epoxy resin that does not containing phenyl radical or olefin-based resin.
[0025] Based on the above configuration, a drive voltage can be applied to an LED chip via a pair of electrode members, thus allowing the LED chip to emit light. Then, ultraviolet, blue or yellow light emitted from the LED chip can be externally emitted via a clear resin portion. At this time, part of the light emitted from the LED chip can be directed to fall on a wavelength converting material within a clear resin portion, thus exciting the wavelength converting material and emitting green light having a peak wavelength of about 535 to 560 nm and red light having a peak wavelength of about 620 to 640 nm. Thus, ultraviolet, blue or yellow light and green and red light from the wavelength converting material can be mixed together, making it possible to obtain warm-looking white light having light characteristics in the red region. The white light has excellent color reproducibility, as compared with a conventional white LED that emits bluish white light by mixing blue light and yellow fluorescence.
[0026] It is possible to obtain a shell-shaped LED by configuring the pair of electrode members as two lead frames extending parallel or substantially parallel with each other and further providing a lens portion made of a clear resin that surrounds both the LED chip and the clear resin portion.
[0027] It is also possible to obtain a surface-mount LED by configuring the pair of electrode members as a conductive pattern formed on a chip substrate and including surface-mount terminals by extending the pattern around onto the rear surface of the chip substrate. The clear resin portion can be charged into an upwardly spread recessed portion so as to expose a chip mounting portion of a frame-shaped member formed on top of the chip substrate.
[0028] A highly reliable LED can be obtained when the wavelength converting material contains thiogallate phosphor as a first phosphor and rare-earth-activated aluminate or rare-earth-activated orthosilicate as a second phosphor. The high resistance of these materials to humidity results in high reliability and other benefits.
[0029] A highly reliable LED can also be created when the wavelength converting material is dispersed in alicyclic epoxy resin not containing phenyl radical or olefin resin. The wavelength converting material can remain similarly unaffected by humidity thanks to secure sealing.
[0030] Thus, by radiating ultraviolet, blue or yellow light from the LED chip and converting the light from the LED chip to green and red light with the wavelength converting material, and radiating the resultant light, it is possible through mixing of these lights to obtain a white LED with excellent color reproducibility and reliability. Therefore, warm-looking white light containing light in the red range can be radiated, making the white LED applicable for use in various lighting equipment such as lighting sources for a variety of lighting instruments and LCD backlights (in place of conventional incandescent and other lamps). This makes it possible to obtain the same lighting effect as when a conventional incandescent or other conventional lamp is used, and at the same time obtaining a long-lasting light source with low power consumption and heat generation, among other benefits.
[0031] According to a third aspect of the invention there is provided an LED that can include a pair of electrode members, two LED chips joined on top of a chip mounting portion disposed at an end of one of the pair of electrode members, each of the LED chips being electrically connected to both of the pair of electrode members, and a clear resin portion formed such that it surrounds the LED chips. The clear resin portion can include a wavelength converting material mixed therein, wherein one of the LED chips emits blue light, and another of the LED chips emits red light, wherein the wavelength converting material mixed in the clear resin portion converts at least part of the light from the one LED chip to green light that is longer in wavelength.
[0032] In the above-described LED, the one of the LED chips that emits blue light can have a peak wavelength of about 440 to 480 nm, and the other of the LED chips that emits red light can have a peak wavelength of about 620 to 660 nm. The wavelength converting material can be configured to convert blue light from the one LED chip into green light that can have a peak wavelength of about 535 to 560 nm.
[0033] Based on the above configuration, a drive voltage can be applied to two LED chips via a pair of electrode members, thus allowing the LED chips to emit blue light and red light. So, one of the LED chips emits blue light that can have a peak wavelength of about 420 to 480 nm, and another of the LED chips emits red light that can have a peak wavelength of about 620 to 660 nm. Then, blue and red light emitted from the LED chips can be externally emitted via a clear resin portion. At this time, part of the blue light emitted from the one of the LED chips can be directed to fall on a wavelength converting material within a clear resin portion, thus exciting the wavelength converting material and emitting green light that can have a peak wavelength of about 535 to 560 nm. Thus, blue light, red light, and green light can be mixed together, making it possible to obtain warm-looking white light having light characteristics in the red region. The white light can have excellent color reproducibility, as compared with a conventional white LED that emits bluish white light by mixing blue light and yellow fluorescence.
[0034] Thus, by radiating blue and red light from the LED chips and converting the blue light from one of the LED chips into green light with the wavelength converting material, and radiating the resultant so-called primaries light, it is possible through mixing of these lights to obtain a white LED with excellent color reproducibility and reliability. Therefore, warm-looking white light containing light in the red range can be radiated, making the white LED applicable for use in various lighting equipment such as lighting sources for a variety of lighting instruments and LCD backlights (in place of conventional incandescent and other lamps). This makes it possible to obtain the same lighting effect as when a conventional incandescent or other conventional lamp is used, and at the same time obtaining a long-lasting light source with low power consumption and heat generation, among other benefits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The above and other aspects, features and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0036] FIG. 1 is a schematic sectional view showing a configuration of a first embodiment of an LED made in accordance with the principles of the invention;
[0037] FIG. 2 is a graph showing a spectrum distribution of white light produced by the LED of FIG. 1 ;
[0038] FIG. 3 is a schematic sectional view showing a configuration of a second embodiment of an LED made in accordance with the principles of the invention;
[0039] FIG. 4 is a schematic sectional view showing a configuration of a third embodiment of an LED made in accordance with the principles of the invention;
[0040] FIG. 5 is a graph showing a spectrum distribution of white light produced by the LED of FIG. 4 ; and
[0041] FIG. 6 is a schematic sectional view showing a configuration of a fourth embodiment of an LED made in accordance with the principles of the invention;
[0042] FIG. 7 is a schematic sectional view showing a configuration of an example of a conventional shell-shaped white LED;
[0043] FIG. 8 is a graph showing a spectrum distribution of white light produced by the LED of FIG. 7 ; and
[0044] FIG. 9 is a schematic sectional view showing a configuration of an example of a conventional surface-mount white LED.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0045] A detailed description will be given below of embodiments of the invention with reference to FIGS. 1 to 6 . It is to be noted that while the embodiments described below are specific examples and thereby include various technical features, the scope of the invention is not limited to these embodiments.
[0046] FIG. 1 shows a configuration of a first embodiment of an LED made in accordance with the principles of the invention. In FIG. 1 , an LED 10 can be configured as a so-called shell-shaped LED and can include a pair of lead frames 11 and 12 , a blue LED chip 13 mounted on top of a chip mounting portion 11 a formed on the upper end surface of the lead frame 11 , and a clear resin portion 14 formed soas to be adjacent to and/or surround the blue LED chip 13 on top of the chip mounting portion 11 a of the lead frame 11 . A phosphor 14 a can be mixed into the clear resin portion 14 and a lens portion 15 can be formed with a mold resin so as to be adjacent to and/or surround the upper ends of the lead frames 11 and 12 , the blue LED chip 13 and the clear resin portion 14 .
[0047] The lead frames 11 and 12 can be formed out of a conductive material such as aluminum and can be provided with the chip mounting portion 11 a and bonding portions 11 b and 12 a at the respective upper ends thereof. Whereas the other ends of the lead frames can be formed to extend downward to make up terminal portions 11 c and 12 b.
[0048] The blue LED chip 13 can be joined on top of the chip mounting portion 1 a of the lead frame 11 , with two electrodes provided on the upper surface thereof electrically connected to the bonding portions 11 b and 12 a at the ends of the lead frames 11 and 12 through wire-bonding 17 .
[0049] Here, the blue LED chip 13 can be configured, for example, as a GaN chip and can be designed such that when a drive voltage is applied via the lead frames 11 and 12 , light is emitted having a peak wavelength of about 450 to 470 nm.
[0050] The clear resin portion 14 can be configured by combining, for example, epoxy resins hardened with acid anhydride or cation or olefin-based resins—resins into which the first phosphor 14 a and a second phosphor 14 b in fine particulate form can be mixed—and can be formed and hardened on top of the chip mounting portion 11 a of the lead frame 11 .
[0051] When blue light from the blue LED chip 13 falls on the clear resin portion 14 , the first phosphor 14 a is excited, producing green light from the phosphor 14 a . At the same time, the second phosphor 14 b is excited, producing red light from the phosphor 14 b . Here, the first phosphor 14 a can include, for example, thiogallate phosphor and can be designed to produce green fluorescence having a peak wavelength of about 535 to 560 nm.
[0052] On the other hand, the second phosphor 14 b can include YAG phosphor doped with cerium, TAG phosphor doped with cerium or orthosilicate phosphor, and can be designed to produce red fluorescence having a peak wavelength of about 620 to 640 nm.
[0053] The lens portion 15 can be made, for example, of clear epoxy resin, and can be formed such that it is adjacent to and/or surrounds the whole area near the upper ends of the lead frames 11 and 12 centering around the blue LED chip 13 and the clear resin portion 14 . The LED 10 can be configured as described above, and the blue LED chip 13 can produce blue light emission when a drive voltage is applied via the pair of lead frames 11 and 12 . Then, part of the light emitted from the LED chip 13 can fall on the phosphors 14 a and 14 b that are mixed into the clear resin portion 14 , thus exciting the phosphors 14 a and 14 b and producing green and red light. The green and red light can be mixed with blue light from the LED chip 13 , turning the subsequently emitted light into white light that can fall on the lens portion 15 through the clear resin portion 14 and be further emitted externally from the lens portion 15 .
[0054] Thus, based on the surface-mount white LED 10 , blue light from the LED chip 13 can be mixed with green and red light produced by the phosphor layers 14 a and 14 b , thus making it possible to obtain white light including light in the red range and light that is excellent in color reproducibility and, in particular, can approximate the light color produced by a typical electric bulb. A spectrum distribution of the white light is shown in the graph of FIG. 2 .
[0055] The phosphors 14 a and 14 b can also be securely sealed by the clear resin, thus making it possible to obtain a highly reliable LED 10 that is relatively resistant to humidity.
[0056] FIG. 3 shows a configuration of a second embodiment of an LED. In FIG. 3 , an LED 20 is configured as a so-called surface-mount LED and can include a chip substrate 21 , a blue LED chip 22 mounted on top of the chip substrate 21 , a frame-shaped member 23 formed on top of the chip substrate 21 such that it is adjacent to and/or surrounds the blue LED chip 22 . A clear resin portion 24 can be charged into a recessed portion 23 a of the frame-shaped member 23 to cover the blue LED chip 22 .
[0057] It is to be noted that the blue LED chip 22 and the clear resin portion 24 can have the same configuration as in the LED chip 13 , and that the clear resin portion 14 of the LED 10 shown in FIG. 1 can be omitted.
[0058] The chip substrate 21 can be made of a heat-resistant resin and include a flat copper clad wired board. A chip mounting land 21 a , and an electrode land 21 b can be provided on a surface of the chip substrate 21 . Surface-mount terminal portions 21 c and 21 d can be configured such that they extend around from these lands onto the lower surface via both end edges of the chip substrate 21 .
[0059] The blue LED chip 22 can be joined on top of the chip mounting land 21 a of the chip substrate 21 , with the surface of the blue LED chip 22 electrically connected to the chip mounting land 21 a and the adjacent electrode land 21 b through wire-bonding 25 . The frame-shaped member 23 , can also be formed on top of the chip substrate 21 with a heat-resistant resin, and can be provided with a recessed portion 23 a (for example, a portion in the form of an inverted truncated cone) so as to be adjacent to and/or surround the blue LED chip 22 . It is to be noted that the inner surface of the recessed portion 23 a can be configured as a reflecting surface.
[0060] Based on the white LED 20 thus configured, the blue LED chip 22 can emit blue light when a drive voltage is applied via the surface-mount terminals 21 c and 21 d . Then, part of blue light emitted from the LED chip 22 can be directed to fall on phosphors 24 a and 24 b that are mixed into the clear resin portion 24 , thus exciting the phosphors 24 a and 24 b and producing green and red light. The green and red light can then mix with blue light from the LED chip 22 , turning the light into white light. The white light can then be directed to pass through the clear resin portion 24 . Part of the white light can be directly omitted while another part is reflected by the inner surface of the recessed portion 23 a of the frame-shaped member 23 , thus being externally emitted.
[0061] The above-described LED 20 can function similar to the LED 10 shown in FIG. 1 , mixing blue light emitted from the LED chip 22 with green and red light produced by the phosphor layers 24 a and 24 b to produce white light. The white light can include light in the red range that is excellent in color reproducibility and, in particular, can have a color similar to the color of light for a conventional electric bulb.
[0062] The phosphors 24 a and 24 b can be securely sealed by the clear resin, thus making it possible for the LED 20 to be highly reliable and relatively resistant to humidity.
[0063] In the above-described embodiments, the LED chip can have a peak wavelength of about 450 to 470 nm. However, the invention is not limited thereto, and the range can be broadened such that the LED chip has a peak wavelength, for example, of about 440 to 480 nm. The LED chip is also not limited to a blue LED chip and may be an ultraviolet or green LED chip.
[0064] On the other hand, while in the above-described embodiments, epoxy resins hardened with acid anhydride or cation or olefin-based resins can be combined for use as the clear resin to make up the clear resin portions 14 and 24 , the invention is not limited thereto. The phosphors 14 a , 14 b , 24 a and 24 b can be dispersed and securely sealed, and alicyclic epoxy resin not containing phenyl radical or olefin resin, for example, may also be used. Thus, it is possible to provide, through a simple configuration, an LED capable of emitting warm-looking white light.
[0065] FIG. 4 shows a configuration of a third embodiment of an LED made in accordance with the principles of the invention. In FIG. 4 , an LED 30 can be configured as a so-called shell-shaped LED and can include a pair of lead frames 31 and 32 , a blue LED chip 33 , and a red LED chip 34 mounted adjacent each other on top of a chip mounting portion 31 a formed on the upper end surface of the lead frame 31 , and a clear resin portion 35 formed so as to be adjacent to and/or surround the blue LED chip 33 and the red LED chip 34 on top of the chip mounting portion 31 a of the lead frame 31 . A phosphor 35 a can be mixed into the clear resin portion 35 and a lens portion 36 can be formed with a mold resin so as to be adjacent to and/or surround the upper ends of the lead frames 31 and 32 , the blue LED chip 33 , the red LED chip 34 and the clear resin portion 35 .
[0066] The lead frames 31 and 32 can be formed out of a conductive material such as aluminum and can be provided with the chip mounting portion 31 a and bonding portions 31 b and 32 a at the respective upper ends thereof. Whereas the other ends of the lead frames can be formed to extend downward to make up terminal portions 31 c and 32 b.
[0067] The blue LED chip 33 can be joined on top of the chip mounting portion 31 a of the lead frame 31 , with two electrodes provided on the upper surface thereof electrically connected to the bonding portions 31 b and 32 a at the ends of the lead frames 31 and 32 through wire bonding 37 .
[0068] Here, the blue LED chip 33 can be configured, for example, as a GaN chip and can be designed such that when a drive voltage is applied via the lead frames 31 and 32 , light is emitted having a peak wavelength of about 450 to 470 nm. Here the blue LED chip 33 also can be configured as an InGaN chip.
[0069] The red LED chip 34 can be die-bonded on top of the chip mounting portion 31 a of the lead frame 31 , with an electrode provided on the upper surface thereof electrically connected to the bonding portion 32 a at the ends of the lead frame 32 through wire-bonding 37 .
[0070] Here, the red LED chip 34 can be configured, for example, as an AlInGaP chip and can be designed such that when a drive voltage is applied via the lead frames 31 and 32 , light is emitted having a peak wavelength of about 620 to 660 nm. Here, the red LED chip 34 also can be configured as an AlGaAs chip.
[0071] The clear resin portion 35 can be configured by combining, for example, epoxy resins hardened with acid anhydride or cation or olefin-based resins—resins into which the phosphor 35 a in fine particulate form can be mixed—and can be formed and hardened on top of the chip mounting portion 31 a of the lead frame 31 .
[0072] When blue light from the blue LED chip 33 falls on the clear resin portion 35 , the phosphor 35 a can be excited producing green light from the phosphor 35 a . Here the phosphor 35 a can include, for example, thiogallate phosphor and can be designed to produce green fluorescence having a peak wavelength of about 535 to 560 nm.
[0073] The lens potion 36 can be made, for example, of clear epoxy resin and can be formed such that it is adjacent to and/or surrounds the whole area near the upper ends of the lead frames 31 and 32 centering around the blue LED chip 33 , the red LED chip 34 and the clear resin portion 35 .
[0074] The LED 30 can be configured as described above, and the blue LED chip 33 and the red LED chip 34 can produce blue and red light emission when a drive voltage is applied via the pair of lead frames 31 and 32 . Then, part of the blue light emitted from the blue LED chip 33 can fall on the phosphor 34 a that is mixed into the clear resin portion 35 , thus exciting the phosphor 35 a and producing green light. The green light can be mixed with blue and red lights from the LED chips 33 and 34 , turning the subsequently emitted light into white light that can fall on the lens portion 36 through the clear resin portion 35 and be further emitted externally from the lens portion 36 .
[0075] Thus, based on the surface-mount white LED 30 , blue and red light from the LED chips 33 and 34 can be mixed with green light produced by the phosphor layer 35 a , thus making it possible to obtain white light including light in the red range and light that is excellent in color reproducibility and, in particular, can approximate the light color produced by a typical electric bulb. A spectrum distribution of the white light is shown in the graph of FIG. 5 .
[0076] The phosphor 35 a can also be securely sealed by the clear resin, thus making it possible to obtain a highly reliable LED 30 that is relatively resistant to humidity.
[0077] FIG. 6 shows a configuration of a fourth embodiment of an LED. In FIG. 6 , an LED 40 can be configured as a so-called surface mount LED and can include a chip substrate 41 , a blue LED chip 42 , and a red LED chip 43 mounted on top of the chip substrate 41 , a frame-shaped member 44 formed on top of the chip substrate 41 such that it is adjacent to and/or surrounds the blue LED chip 42 and the red LED chip 43 . A clear resin portion 45 can be charged into a recessed portion 44 a of the frame-shaped member 44 to cover the blue LED chip 42 and the red LED chip 43 .
[0078] It is to be noted that the blue LED chip 42 , the red LED chip 43 and the clear resin portion 45 can have the same configuration as in the LED chip 33 and 34 , and that the clear resin portion 35 of the LED 30 shown in FIG. 4 can be omitted.
[0079] The chip substrate 41 can be made of a heat-resistant resin and include a flat copper clad wired board. A chip mounting land 41 a , and an electrode land 41 b can be provided on a surface of the chip substrate 41 . Surface-mount terminal portions 41 c and 41 d can be configured such that they extend around from these lands onto the lower surface via both end edges of the chip substrate 41 .
[0080] The blue LED chip 42 and the red LED chip 43 can be joined on top of the chip mounting land 41 a of the chip substrate 41 , with the surface of the blue LED chip 42 electrically connected to the chip mounting land 41 a and the adjacent electrode land 41 b through wire-bonding 46 . The surface of the red LED chip 43 can be electrically connected to the electrode 41 b through wire-bonding 46 .
[0081] The frame-shaped member 44 , can also be formed on top of the chip substrate 41 with a heat-resistant resin, and can be provided with a recessed portion 44 a (for example, a portion in the form of an inverted truncated cone) so as to be adjacent to and/or surround the blue LED chip 42 and the red LED chip 43 . It is to be noted that the inner surface of the recessed portion 44 a can be configured as a reflecting surface.
[0082] Based on the white LED 40 thus configured, the blue LED chip 42 and the red LED chip 43 can emit blue and red light when a drive voltage is applied via the surface-mount terminals 41 c and 41 d . Then, part of the blue light emitted from the blue LED chip 42 can be directed to fall on phosphor 45 a that is mixed into the clear resin portion 45 , thus exciting the phosphor 45 a and producing green light. The green light can then mix with blue and red light from the LED chip 42 and 43 , turning the light into white light. The white light can then be directed to pass through the clear resin portion 45 . Part of the white light can be directly omitted while another part is reflected by the inner surface of the recessed portion 44 a of the frame-shaped member 44 , thus being externally emitted.
[0083] The above-described LED 40 can function similar to the LED 30 shown in FIG. 4 , mixing blue and red light emitted from the LED chips 42 and 43 with green light produced by the phosphor layer 45 a to produce white light. The white light can include light in the red range that is excellent in color reproducibility and, in particular, can have a color similar to the color of light for a conventional electric bulb.
[0084] In the above-described embodiments, the LED chip can have a peak wavelength of about 450 to 470 nm. However, the invention is not limited thereto, and the range can be broadened such that the LED chip has a peak wavelength, for example, of about 440 to 480 nm. The LED chip is also not limited to a blue LED chip and may be an ultraviolet or green LED chip.
[0085] On the other hand, while in the above-described embodiments, epoxy resins hardened with acid anhydride or cation or olefin-based resins can be combined for use as the clear resin to make up the clear resin portions 14 and 24 , the invention is not limited thereto. The phosphors 14 a , 14 b , 24 a and 24 b can be dispersed and securely sealed, and alicyclic epoxy resin not containing phenyl radical or olefin resin, for example, may also be used. Thus, it is possible to provide through a simple configuration, an LED capable of emitting warm-looking white light.
[0086] The means for converting light as described above includes a first phosphor and a second phosphor. The first and second phosphors can include thiogallate phosphor as the first phosphor and at least one of rare-earth-activated aluminate and rare-earth-activated orthosilicate as the second phosphor. However, it should be understood that it is within the spirit and scope of the invention for the first and second phosphors to include, comprise, or consist of other materials that are well known to convert light into green and/or red wavelength light. In addition, the wavelength converting material is described above as being dispersed in alicyclic epoxy resin not containing phenyl radical or olefin-based resin. However, other epoxy resins, plastics, crystalline structures and materials can be used to carry the wavelength converting material. Furthermore, while a shell type LED and a surface mount LED are described above, there are other types of LED configurations in which the principles of the invention can be applied.
[0087] While illustrative embodiments of the invention have 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. | An LED can include a pair of electrode members, an LED chip joined on top of a chip mounting portion disposed at an end of one of the pair of electrode members. The LED chip can be electrically connected to both of the pair of electrode members, and a clear resin portion can be formed to surround the LED chip. The clear resin portion can include a wavelength converting material mixed therein, wherein the LED chip emits ultraviolet, blue and/or yellow light, and wherein the wavelength converting material mixed in the clear resin portion converts light from the LED chip to green and red light that is longer in wavelength than the originally emitted light from the LED chip. | 7 |
DESCRIPTION
The present invention is related to a system (method and apparatus) for detecting radiation which may be in the form of light that is both visible and invisible to the human eye. Particularly, the invention provides a portable, sensitive detector of light energy. The method and apparatus provided by the invention is capable of detecting with wide dynamic range, invisible light energy such as IR (Infra-Red) as may be found on “low observable” aircraft collision avoidance lighting. The system provided by the invention detects light from such sources while discriminating against other light sources which may be present and provide light of much greater intensity which illuminate a single, common detector. Such sources include the sun and taxi ramp lighting.
Generally the invention relates to the detection or measurement of radiation and particularly light energy that may not be normally visible to the human eye in order to easily and quickly ascertain the proper operation of sources (emitters) of such light energy, even if invisible to the unaided human eye. It is a feature of the invention to provide a detection system which is simple, low cost, portable, sensitive and reliable. It is a further feature of the invention to provide a system which detects light from such emitters in the presence of illumination which may be of greater intensity than that provided by the emitter, such as the sun or other lighting and it is capable of distinguishing between the emitter of interest and such other emitters, thus enabling identification of emitters of particular interest.
Historically, the detection or measurement of light has involved the measurement of a voltage or resistance change produced by a material or substance that is sensitive to light energy. Most commonly, semiconductors such a silicon, germanium or other materials such as Cadmium Sulfide. A difficulty arises when attempting to measure a relatively low level of light in the presence of a large level of light. For example, trying to detect a small light emitter while being outdoors in the bright sunlight. Various techniques have been used to increase the sensitivity of the detector in the presence of such bright light. Most common are; shielding or shrouding of the detector, direct placement of the detector over the emitter source, the use of optical filters selected to respond only to the wavelength of the emitter, and the use of multiple sensors that measure the light from various points combined with cancellation circuitry. All of these techniques of detection or measurement are based only upon quantifying the intensity of light received and not the frequency or amplitude modulation characteristics of the light received.
As an example, in verifying the proper operation of IR aircraft collision avoidance lighting, pre-flight inspection of the aircraft can take place on a flight ramp in broad daylight. The IR lighting on the aircraft is many orders of magnitude less intense than the ambient light, thus “swamping-out” the very light we are trying to measure. Also, since some of the lighting is not physically accessible, using a detector that requires direct placement over the source is not feasible. In the case of optical filtering, the detector will still allow light within the filter's bandwidth to reach the detector. In this particular case, the sun's ambient light has a major portion of its energy within the very bandwidth we wish to measure.
An objective of the invention is to provide a low cost, light detector system that is sensitive to the modulation characteristics of a light source, the invention is especially suitable to detect the emission of IR light from aircraft collision avoidance lighting. Present and future warfare technology capitalizes on night operation. The darkness rendering the forces less visible to ordinary participants. Night vision goggles as used by aircraft pilots are responsive to IR light. Team aircraft are equipped with suitable IR collision avoidance lighting to allow formation flying with other aircraft whose pilots are equipped with night vision goggles. Thus the aircraft lighting is visible to night vision users, but invisible to normal unaided human vision. Preflight inspection of aircraft before flight requires check out of this lighting, often under battle conditions or other such difficult environments. A simple portable hand-held detection device that is easily used by non-technical personnel is needed.
Among the available electrical power on aircraft is 400 Hz AC. If this power source is used to power the lighting, a valuable benefit results in that the light will be modulated with this frequency. Ambient lighting from the sun or taxi ramp is not of this frequency, thus allowing easy discrimination of the light. It is the purpose of this invention to produce a detector system that responds specifically to such modulated light.
Use of this frequency discrimination technique is not limited to aircraft. Various equipment could be equipped with suitable light sources of different frequencies, thus enabling the night vision equipped user to determine what source he is viewing. For example, friendly military tanks could be assigned frequency A, while jeeps frequency B. Thus a night vision equipped pilot or commander could immediately identify such equipment in the darkness of night.
The foregoing and other objects, features and advantages of the invention as well as a presently preferred embodiment thereof will become more apparent from a reading of the following description in connection with the accompanying drawings in which:
FIGS. 1, 2 and 3 are simplified schematic diagrams illustrating prior art circuits for detection of illumination in the presence of background illumination of intensity which is of the order of magnitude of, or exceeds the intensity of, the illumination of interest;
FIGS. 4 and 5 illustrate the modulation of illumination from an emitter of interest;
FIG. 6 is a simplified block diagram of a system embodying the invention;
FIG. 7 is a block diagram illustrating a system in accordance with a presently preferred embodiment of the invention;
FIGS. 8A, B and C are a schematic diagram of the system illustrated in FIG. 7; and
FIG. 9 is a perspective view of a portable device of approximately the same size as a flashlight in which the system of FIGS. 8A, B and C may be incorporated.
FIGS. 1-3 are examples of prior art utilizing different types of detectors married with a comparator threshold detector to illuminate an LED, light emitting diode, indicator. Each circuit requires setting of the threshold adjustment to the edge of triggering when in the presence of ambient light. When the detector then senses additional light from the source it is designed to detect, the comparator switches and illuminates the indicator LED. Note that the threshold adjustment must be readjusted whenever the ambient light changes and that the detector is designed to respond only to the amount of light impacting upon the detector. It should be noted that any of the detectors also detects any amplitude modulation that may be on the light source, but this modulation, if any, is not employed.
FIGS. 4 and 5 outline various methods of powering light emitters as could be found on aircraft. It can be seen that FIGS. 4 and 5 will both cause the light output from the emitter to be modulated at a 400 Hz rate due to the AC excitation signal.
FIG. 6 shows an implementation of the invention in its most basic form. The light detector, A, can be of the form of any of the detectors as shown in FIGS. 1-3. The 400 Hz bandpass filter is designed to allow only the detected amplitude modulated signal from the detector to pass. The Level detector, 3 , is designed to illuminate the indicator LED whenever a 400 Hz signal emerges from the 400 Hz bandpass filter.
FIG. 7 shows the preferred embodiment of the invention. The light detector, A, is contained within a feedback control loop that automatically compensates for ambient light by detecting the static level of light and rebiasing the detector to place it in its most optimum area of operation, avoiding any threshold adjustments. The 400 Hz modulation signal (which may be called a first signal) is coupled off and presented to a 300 Hz high pass filter before being applied to a 400 Hz bandpass filter. The 400 Hz bandpass filter allows the 400 Hz modulation signal to pass through (thereby providing what may be called a second signal) while rejecting other signals. The 400 Hz signal is then detected by a phase-locked-loop frequency detector (a type of synchronous detector) which will illuminate the indicator LED when the proper 400 Hz signal is present. PLL detector is used and designed to have fast lock-up time and long “hang” time after detection. This allows LED to stay lit for a second or so even if PLL detects only a few cycles of 400 Hz, as discussed in greater detail hereinafter. Detecting such modulation according to the invention can also be used to selectively detect different light sources which are modulated by different frequencies. To do so, it is only necessary to retune the associated filters and PLL to the desired frequency to match the emitter.
The present embodiment of the invention provides several improvements and advantages over prior art light detectors. These improvements include more sensitivity, freedom from user adjustments for ambient light, response to only particularly modulated light, and ease of operation.
FIG. 8A shows a light sensor feedback control loop when the photodetector transistor, Q 1 , produces a current that is proportional to the light it receives, typical variations in ambient light are on the order of 5 or 6 magnitudes (100,000-1,000,000:1). It is desirable to operate the detector in its most linear region for best sensitivity, but over such a large range it is difficult. Prior art sensors used various operator adjustments to balance out or compensate for these extremes. A feedback control loop, FCL, is used to automatically center the detector to operate in its most efficient region. Feedback loops are not uncommon, however this FCL loop is designed to keep the detector in the optimum region for detection of 400 Hz source modulated light. Typically, ambient light is either DC, the sun, or of a low frequency such as 60 Hz electrical mains lighting, in these cases the feedback loop effectually cancels their effect.
The combination of Q 1 and Q 2 form a voltage divider whose voltage at point A is monitored by operational amplifier, A 1 , which is configured as a voltage follower. If the ambient light level is high, sensor transistor Q 1 produces more current causing the voltage at point A to rise. The output of A 1 is amplified by opamp A 2 which then controls current sink transistor Q 2 to sink more of sensor transistor Q 1 's current to ground, dynamically adjusting the light sensing portion of the circuit to be in the optimum region for detecting a modulated light source. Loop filter components R 10 , 11 C 5 , 6 characterize the loop for the desired dynamics of canceling out static or low frequency components from the sensor. The signal from the feedback control loop (FCL), which has been called the first signal, goes to the 300 Hz high pass filter.
FIGS. 8A and B show the 300 Hz high pass filter and 400 Hz bandpass filter (UI). Opamps A 3 and A 4 comprise a high pass filter that limits the amount of undesired low frequency signal that the 400 Hz bandpass filter receives. The 400 Hz bandpass filter utilizes a switched capacitor filter which provides high Q and small size. Many different filter topologies could be used here, although the use of a high Q band pass filter is required. A high Q filter is required not only for its bandpass characteristics, but also for its ringing characteristics as will become apparent. If the light sensor is used to detect a strobe light as may be found on an aircraft, the light pulse will cause the filter to ring, producing a plurality of cycles (long burst) of 400 Hz energy (the second signal) that the following PLL detector will respond to, thus allowing the light sensor to respond to such strobe lighting. In the present embodiment, a switched capacitor bandpass filter is used since such a filter is small, easily and precisely tuned using a stable digitally derived clock.
FIG. 8B also shows the 400 Hz phase-locked-loop PLL detector. The PLL detector detects the 400 Hz energy from the output of the bandpass filter and provides an output to illuminate an indicator light emitting diode LED. The PLL dynamics are chosen so that the loop will lock rapidly upon the 400 Hz signal and remain on for a short period of time after signal decay, this period of time being long enough to allow an operator to see the LED illuminated. In this way a short burst of 400 Hz energy (as from a strobe light) will be observable by the operator. Although many different forms of annunciators could be used, the present embodiment uses a two color LED that glows red normally and turns green upon detection of 400 Hz energy, thus making the light sensor easy to operate and interpret.
FIG. 8C shows a generally conventional power supply for providing operating voltage to the circuits of FIGS. 8A and B.
The values of the components are in ohms for resistors (R) and microfarads for capacitors (C). U 1 & 2 & VR-1 are suitably of the type indicated in the drawing. The values and types indicated are given by way of illustration and not limitation. Other component types and values may be used to implement the system of the invention.
FIG. 9 shows a housing similar to a standard hand held flashlight. The sensor is placed at the focal point of a reflector, using lens and reflector optics to concentrate and provide a measure of directionality to the assembly. This arrangement has a reflector able to be easily moved or adjusted axially so as to change the focal length of the optics to optimize detection distance.
The previous description of the preferred embodiment is provided to enable any person skilled in the art to make or use the present invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of inventive faculty. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest possible scope consistent with the principles and novel features disclosed herein. | A system for sensitively discriminating against background radiation which tends to swamp and prevent detection of radiation from a source of interest such as IR (Infra-Red) light radiation as may be found on “low observable” aircraft collision avoidance lighting, utilizes the modulation of such radiation as a mechanism for tracking the radiation and discriminating against the background radiation, for example, from other light energy sources. The radiation is detected and tracked even though the source of interest produces the radiation in bursts or pulses by controlling the sensitivity of the detector inversely with the amplitude of the radiation to which the detector is exposed, translating the electrical signals into a plurality of cycles at the modulation frequency with the aid of a high Q bandpass filter tuned to the modulation frequency and detecting the output of the filter in a phase-locked-loop detector circuit thereby providing an indication of the intensity of the radiation from the source of interest of an acceptable level. An instrument for detecting the radiation of interest may be portable and of the size approximating that of a conventional flashlight. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to the field of the treatment of metal components by putting layers subjacent the surface of the components in compression. The invention relates in particular to the field of aeronautical turbomachines, where such a technique is used in order to improve the lifetime of the components subjected to high stresses, both mechanical and thermal. Thus, in particular the blades, rotor disks or blisks (one-piece bladed disks) are treated.
DESCRIPTION OF THE PRIOR ART
Several techniques for putting internal layers of metal components in compression are known. According to a first conventional technique, said layers are put in compression by spherical shot peening, the purpose of which is to create residual stresses on the surface and in the sublayers of the metal parts. The purpose of this compressive stress is to delay the appearance of cracks or to close up existing crack initiators. As a result, their mechanical behavior is improved. The shot used is made of a hard material, such as glass, ceramic or steel, and these are blasted at high velocity onto the surface of the components to be treated. The blasting is carried out in a turbine machine or by entrainment in a gas (air) stream, for example by means of a nozzle. The gas is subjected to an expansion and the shot is introduced into the stream created by the expansion.
Under the peening action of the shot, the surface, having exceeded the yield point is plastically deformed, creating a subjacent metal layer in compression. These compressive stresses thus improve the fatigue strength, the corrosion resistance and the friction coefficient. The impact of the shot creates compressive stresses in the metal down to a certain depth.
Using this technique, the depths in compression are up to 150 μm, with compressive stresses of around 400 to 500 MPa on the surface and 500 to 600 MPa at depths of around 50 μm.
Another prestressing shot peening technique uses ultrasound (hereafter called US shot peening) and this is described in patent applications EP 1 208 942 and EP 1 207 013 in the name of the Applicant, this technique consisting in making the shot move in the form of a spray of shot created, in a sealed chamber containing the component to be treated, by the active surface of a sonotrode excited by ultrasonic oscillation production means. In this technique, the depths under compression are down to 300-400 μm with residual compressive stresses of around 500 to 600 MPa on the surface and 700 to 900 MPa at depths of 50 to 100 μm. In general, ultrasonic shot peening generates compressive stresses that are substantially more intense and at larger depths than gas jet shot peening.
In the present application, the term “shot peening” is understood to mean shot peening by mechanical shock, the term covering peening using shot moved either by being blasted by a jet of gas or by ultrasonic vibration, or else roller burnishing.
In another technique, different than shot peening, the compression is induced by laser shock peening in which greater depths may be treated with higher levels of compression. The depths under compression are from around 0.5 to 1.5 mm, but may reach several millimeters, with residual compressive stresses of around 350 to 1000 MPa. In general, laser shock treatment generates residual compressive stresses at depths two to three times greater than for example US shot peening, for comparable stress levels. However, this laser shock peening process is relatively tedious to implement. Application of the laser requires the surfaces undergoing treatment to be covered with an ablative coating, either a paint or an adhesive tape, the ablation of which paint or tape by sputtering under the effect of the laser beam produces the shockwave that causes the treated material to be put in compression. This wave is confined by a material that covers the ablative coating and is transparent to the laser beam. In general, this is a curtain of flowing water. The laser must be capable of delivering a power density of the order of 10 GW/cm 2 with pulse durations of around ten to thirty nanoseconds (10 ns to 30 ns) and a firing frequency between less than one hertz and a few hertz.
The laser shock impact spots have a round, square, elliptical or possibly other shape, covering an area of the order of ten square millimeters (especially 10 to 20 mm 2 ). The impacts are repeated three or four times at each spot, in order for the entire range of depths to be treated and for the highest stress levels expected to be achieved gradually. However, at each impact of the laser, the coating is sputtered onto the surface of the laser spot (or even slightly beyond it), and it is therefore necessary to renew the ablative coating at each firing.
Furthermore, it is not possible to scan the entire surface to be treated with laser spots in a single sequence, even less so as the coating is destroyed by the laser impact beyond the area of the spot. Thus, according to the prior art, the treatment of a given surface requires a series of three or four scans. The treatment of a given surface is carried out by partial overlap of the impact spots in order not to leave any untreated areas between impacts. The surface is treated by making a scan by rows of spaced-apart spots and by repeating the scan several times with a slight shift in the rows of spots in order to reach all points on the surface.
This also entails renewing the coating each time. As a result, in order to treat a given surface, the coating has to be renewed up to twelve times (see for example the process described in EP 0 794 264). The implementation of this technique is lengthy and complex and, as a consequence, costly. It is therefore preferred to limit the extent of the zones to be treated.
In the case of a blade, the above treatment is applied in zones located in the zones lying on the periphery of the blade, such as the leading edge or the trailing edge. These edges are the most exposed to damage caused by the impact of highly erosive particles or of foreign bodies that may cause local deformation, tearing or cracks. However, other parts of the blade are not free of damage. For example, it has been found that there are scratched zones on the pressure face.
For the abovementioned reasons, it would not be economically advantageous to treat an extensive area of the blade by laser shock peening.
The objective of the invention is therefore to provide a component, in particular a blade, in which all the surface parts liable to be damaged to a greater or lesser extent, especially damaged by foreign bodies and erosive agents, are treated by putting surface sublayers in compression, but the cost of which remains acceptable.
Moreover, it has been found that zones treated by peening as intense as laser shock peening result in local tensile stresses on their periphery, which balance out all the stresses. It would therefore be desirable to reduce the effects of these tensile stresses by preventing large tensile gradients and by ensuring that the zones in tension are away from the sensitive zones.
SUMMARY OF THE INVENTION
These objectives are achieved in accordance with the invention with a metal component comprising at least a first zone treated by putting subjacent layers in compression, wherein said zone comprises at least a first layer put in compression by shot peening and a second layer, subjacent the first layer, which is put in compression by laser shock peening.
Putting the second layer in compression may also have the effect of increasing the residual compressive stresses in the first layer—if these stresses are obtained by conventional shot peening, and are around 300 to 500 MPa. In the case of prior ultrasonic shot peening, these stresses are around 700 to 800 MPa, but the laser shock peening causes little or no increase.
In the case of a turbomachine blade, said zone advantageously extends along the leading edge, the trailing edge and/or the tip of the blade. The blades concerned are in particular solid compressor blades such as the fan blades in fan jet engines. The invention however is not limited to turbomachine blades—it applies also to rotors, especially to rotor disks and more particularly to blisks.
The solution of the invention results from the observation that the compression treatment by shot peening, particularly ultrasonic shot peening, can provide residual stress levels comparable to those obtained by laser shock peening, although they are created only over a shallower depth. By combining the less expensive shot peening compression treatment with laser shock peening compression treatment, a product that is generally more economic from the standpoint of its manufacture is obtained.
Preferably, the component has a second zone, different than said first zone, which is put in compression by only shot peening. More particularly the shot peening is ultrasonic shot peening.
The invention also relates to a method of treating a metal component, comprising a first treatment step in which said first zone is treated by shot peening, followed by a second treatment step in which this same zone is treated by laser shock peening.
In particular, in a first step, said first zone and a second zone different than the first are treated by shot peening, and then, in a second step, only the first zone is treated by laser shock peening.
Preferably, the two zones are adjacent, thus creating a progressive residual stress gradient. Unlike in components comprising zones treated by laser shock peening bordered by adjacent zones not in compression, no adjacent portions are created which are subjected to a sudden jump in stress in which cracks may appear. Moreover, any deformation in components such as thin blades generated by these sudden changes in stress is avoided.
The reduction in overlap of the laser impacts also has an advantage as regards the deformation generated by the laser shock treatment. This is because it has been found that the level of distortion in for example a compressor blade is higher the larger the amount of overlap of the impact. This has for example been reported in patent U.S. Pat. No. 5,531,570. The reduction in the amount of overlap favored by the invention is therefore also beneficial from this standpoint.
The present application also relates to a turbomachine rotor disk, in particular a blisk, comprising blades according to the invention. It also relates to a turbomachine comprising blades according to the invention in particular to a turbojet provided with compressor blades according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages are mentioned in the following description of a nonlimiting embodiment of the invention, together with the appended drawings consisting of the following figures:
FIG. 1 is a schematic representation of a turbomachine blade;
FIG. 2 is a sectional view on the direction A-A of the blade of FIG. 1 , showing the surface treated by shot peening;
FIG. 3 is a view of a blade showing zones treated by shot peening and by laser shock peening according to the invention;
FIG. 4 is a sectional view along the direction BB of the blade of FIG. 3 , showing the layers subjacent the surface put in compression by shot peening and laser shock peening according to the invention;
FIG. 5 is an illustration of the laser shock compression treatment; and
FIG. 6 shows a scanning sequence of laser beam impacts during the treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As may be seen in FIG. 1 , a blade 1 comprises a root 3 , a platform 5 and an airfoil 7 . The blade is mounted via the root 3 on the periphery of a rotor disk in a suitable housing. The platform provides the continuity of the annular duct in which the gas stream is guided.
The airfoil 7 of aerodynamic shape is swept by the gas stream. It is this part of the blade that is exposed to the external stresses, which have an effect on the lifetime. The leading edge LE and trailing edge TE are possibly exposed to violent shocks, such as from foreign bodies ingested by the motor and striking the fan blades. These impacts may have a depthwise effect in the peripheral zones of the airfoil. Other impacts, such as those of erosive particles, are more superficial, but are found in more extended zones of the airfoil in the form of scratches and abrasions. The residual stresses generated by the peening help to limit damage and crack propagation and to increase the fatigue resistance—their purpose is to maintain the lifetime of the component.
According to the invention, the component is firstly treated by shot peening, over an extended surface corresponding at least partly, but preferably, to all of the zones liable to be damaged. This treatment is advantageously an ultrasonic shot peening treatment. The zone treated by this technique is shown schematically at 71 . It extends over the pressure face of the airfoil between the leading edge LE and the trailing edge TE. This zone extends partially over the suction face of the airfoil downstream of the leading edge LE. The thickness of the layer in compression below the surface is about 0.3 mm, and more generally around 0.2 mm. The residual stress level reached at this depth is around 400 to 500 MPa.
In order to achieve this result, an example of US shot peening treatment on a TA6V titanium alloy is described below. 100C6 steel shot 1.5 mm in diameter was made to undergo a movement with an amplitude of 85 microns by a sonotrode vibrating at ultrasonic frequency. The intended degree of overlap was 40% and the treatment time was 52 s. The compressive stresses obtained reached up to 700 MPa and extended over a depth of 250 to 300 microns.
The laser shock treatment was then carried out in the zones that are most highly stressed, namely in particular the LE and TE, but also possibly the tip. Here, this zone 73 was limited to the region of the leading edge LE over a specified distance downstream.
The principle of this technique will be recalled below in relation to FIG. 5 .
The component 100 to be treated is coated with what is called an ablative layer 102 , and the pulsed laser beam 106 is applied to the component through a confinement layer 104 .
The various steps of the method are the following:
1) preparation of the ablative layer 102 , by application of a paint or of an adhesive tape; optionally, the ablation may take place directly on the metal surface; 2) positioning of the confinement layer 104 , which is for example a curtain of flowing water or a glass plate; 3) laser firings 106 , the impact spots of which are in the form of a disk, which has a round, elliptical or other shape, with an area of the order of 10 mm 2 . The impact spots are close to one another, but without any overlap so as always to correspond to a virgin zone of the ablative layer. The component and the laser focusing head undergo a relative displacement; 4) removal of those parts of the ablative layer that are not vaporized; cleaning of the surface; and 5) application of a fresh ablative layer; and 6) repetition of the cycle from point 2).
The ablative layer is vaporized ( 108 ) by the laser beam and confined by the confinement layer. This results in the formation of a shockwave 110 , which propagates into the metallic material, thus putting it in compression.
These operations form a sequence which has to be repeated 10 to 12 times in the laser shock peening method of the prior art in order to cover the surface in question with the desired number of impact overlaps.
According to the invention, the number of operations is reduced by laser shock peening a zone treated beforehand by shot peening especially US shot peening. This prior shot peening is carried out in such a way that the residual compressive stresses are around 500 to 700 MPa at a depth of 0.2-0.3 mm below the surface of the component.
FIG. 6 shows an example of the distribution of the impact spots on the component. The first impact spots I 1 are touching disks. The second row of impact spots I 2 also consists of touching disks, but offset by one radius both transversely and longitudinally with respect to the run direction RD.
The treatment of the invention requires fewer laser impacts, since the treated zones already include a layer having residual compressive stresses of the same level as those produced by the laser shock peening. Since the compressive stress level between two neighboring impact spots is not zero, it is unnecessary for there to be perfect overlap thereof. This results in a fewer number of passes and also a fewer number of times that the coating has to be renewed. The treatment time may be reduced by 40 to 50%.
Where appropriate, the compression treatment is followed by a polishing operation, by tribofinishing or by abrasion, especially by means of an abrasive tape or an abrasive paste. It should be noted in this case that it is unnecessary to apply a coating, the ablation being carried out directly on the metal surface.
The treatment applies to new components, but it is also suitable for blades repaired by material surfacing. | The invention relates to a metal component comprising at least a first zone treated by putting layers beneath the surface thereof in compression. It is characterized in that it comprises at least a first layer put in compression by shot peening and a deeper subjacent second layer put in compression by laser shock peening.
The component may be a turbomachine blade. According to the method, said zone is firstly treated by prestress shot peening followed by compression treatment by laser shock peening. | 5 |
BACKGROUND OF THE INVENTION
The invention concerns a single tracked two-wheeled vehicle in particular a bicycle, an electrical bicycle, an electrical scooter or a motorized scooter consisting essentially of a front portion and a rear portion connected to each other for pivoting by means of a pivot mechanism disposed approximately in the middle position between the front and the rear wheels, wherein the front portion comprises a front wheel suspension with the front wheel, a handle bars displaced relative to the pivot mechanism in the forward direction and a connection element for the handle bars, and the rear portion comprises a rear wheel suspension with the rear wheel and a saddle support bearing the saddle, and a drive unit is provided for belonging to either the front portion or the rear portion. A two-wheeled vehicle of this kind is disclosed in the publication DE 98366 C1.
The majority of conventional single track two-wheeled vehicles, whether they are bicycles, motorcycles or motor scooters, have a steering geometry with trailing action of the front wheel. The extension of the pivot axis joining the rear frame portion with the front fork and the handle bars has a point of intersection with the path of the vehicle which is situated several centimeters in front of the seating position of the front wheel. This trailing action effects a more stable straight travel for the two-wheeled vehicle. Every steering system for a single track two-wheeled vehicle has two contact surfaces with the travel path at the seating surfaces of the front and the rear wheels. Conventional two-wheeled vehicles effect steering of the vehicle through operation of the handle bars which are connected to and rotate together with the fork and the front wheel. Another measure influencing the stability of the vehicle is a displacement between the pivot axis and the front wheel axis. This displacement effects a slight lifting of the head of the fork during steering causing a restoring force leading to a more stable straight line dependence for the two-wheeled vehicle. When driving around curves, the operator must displace his weight and a tilting of the two-wheeled vehicle is required in order to effect a new equilibrium state compared to the initial situation. The equilibrium position thereby depends on the degree of steering of the front wheel relative to the rear wheel, the speed, and the weight of the operator. The non-centered disposition of the common pivot axis of the front and the rear frame units facilitates easy steering of a single track two-wheeled vehicle but has however associated problems.
The asymmetric configuration of the pivot axis in a single track two-wheeled vehicle of conventional construction causes the front and rear wheels to have a differing tilt with respect to the path traveled when going around a curve. This has, among other things, the consequence that unnecessary frictional forces occur during steering resulting e.g. in uneven wear on the tread surfaces of the front and rear wheels. A further aspect affecting the safety of the vehicle concerns the position of the wheels in curves. In curves, neither the front nor the rear wheel assume a perfect position for traveling through the curve. An optimum wheel position would be tangent to the curve with an equal tilt for both wheels. Traveling through curves in conventional two-wheeled vehicles therefore entails a danger of falling, in particular on slippery surfaces. In the event of insufficient friction between the wheels and the underlying surface, the steering acting on the front wheel alone leads to skidding of the front wheel and to crashing. Acceleration and braking in a curve can lead to skidding of the rear wheel and thereby also cause a crash. An additional disadvantage of conventional bicycles is evident during uphill travel. The increased pedal forces necessary thereby lead to compensation reactions on the steering wheel as result a of which the front wheel is deflected back and forth. This leads to a path which is not straight as well as to increased friction between the front wheel and the underlying surface. The uneven weight distribution on the front and rear wheels caused by the asymmetric configuration of the frame of conventional two-wheeled vehicles leads to additional loads on the frame which e.g. must be accepted by structures which are stiff when subjected to torques.
A single track two-wheeled vehicle categorizing the invention is disclosed in German patent DE 98366 C.
This patent describes a single track two-wheeled vehicle having a pivot axis disposed between a front and a rear wheel which is tilted in a forward direction and displaced from the middle towards the front. With this two-wheeled vehicle, the connecting element bearing the handlebars is borne for rotation in the front part of the frame. The steering motion of the handlebars is transferred to the rear frame portion via two circular segment shaped toothed racks. This configuration does not allow balanced deflection of the front and rear frame portions. The rotating bearing of the handlebars in the front frame member prevents direct transfer of steering motion from the front to the rear frame portion.
A bicycle has become known in the art by means of French patent 982,683 which can be transformed into a cart in a simple manner. In correspondence with this purpose, this bicycle has two vertical axes which are disposed on the left and the right of a central frame portion and which allow the front and the rear portions of the frame to pivot through 90° so that a single axis two-track cart is created. This configuration does not allow the pivot axis to be in a central position. The steering does not act equally on both wheels.
The so-called FLEVO-bike represents a current development as described in the magazine “Radfahren EXTRA” [Bike-riding EXTRA] 4.92. This bicycle also has a pivot in an approximately middle position between the front and the rear wheel. This pivot mechanism is however tilted to such a strong extent in the backward direction that the pivot axis intersects the vehicle path in front of the seating position of the front wheel. The stability of this bicycle is therefore realized through trailing action. In addition, the pedals form a non-rotating unit together with the front frame portion so that the steering capability of such a reclining operator bicycle is extremely limited.
SUMMARY OF THE INVENTION
Departing from the prior art mentioned, it is the underlying purpose of the invention to further improve a single track two-wheeled vehicle of this kind in such a fashion that the steering acts evenly on both wheels. This purpose is achieved in that the front wheel suspension and the connecting element bearing the handle bars form an intrinsically non-rotating first unit, and the rear wheel suspension and the saddle support form an intrinsically non-rotating second unit, wherein the saddle is displaced in a backward direction relative to the pivot mechanism and the drive unit acts either on the front wheel or on the rear wheel. The two-wheeled vehicle in accordance with the invention requires cooperation among three steering lever arms for influencing the motion of the pivot mechanism wherein the expression “steering lever arm” comprises the following steering elements;
a first upper steering lever arm joined without relative rotation to the front wheel suspension and acting from a forward position on the pivot mechanism,
a second upper steering lever arm joined without relative rotation to the rear wheel suspension and acting on the pivot mechanism from the rear,
and a lower steering lever arm likewise joined without relative rotation to the rear wheel suspension and acting either from the front or from the rear on the pivot mechanism.
The front upper steering lever arm is formed by the forwardly displaced position of the handle bars relative to the pivot mechanism. The rear upper steering lever arm is formed from the backward displacement of the saddle support relative to the pivot mechanism. The lower steering lever arm is formed by the displacement of the pedals or of the rigid foot rests relative to the pivot mechanism. The point of application of the lower steering lever arm is always between the handle bars and the saddle support.
In accordance with the invention, the points of force application for the steering lever arms form a triangle standing on its tip, with the pedals being disposed in the lower corner and the upper corners of which being defined by the handle bars and the saddle. The pivot axis of the pivot mechanism intersects this triangle between the upper corners.
By means of the mutually interacting steering lever arms, a secure steering and extremely sharp curving is facilitated for a single track two-wheeled vehicle having a centralized pivot mechanism. The folding-tilt-steering system proposed herein leads to a fundamental new handling capability for all two-wheeled vehicles categorizing the invention which is distinguished with respect to prior art of two-wheeled vehicles through a series of advantages which will be further described below. In addition, the structure and mechanical construction of single track two-wheeled vehicles can be substantially simplified compared to prior art. The weight can be reduced and the manufacture of fold-together bicycles can be substantially simplified. Bicycles having the front and the rear wheel units connected in either a vertically or horizontally displaced manner to a pivot mechanism have the particular advantage that both parts can be pivoted about the pivot mechanism with respect to each other in such a fashion that the bicycle can be folded together to half of its length with the parts seating in close proximity to each other. Further advantages are given through the integration of a multiple gear system, back pedal brakes, and/or an electrical or combustion engine drive within a frame having a middle pivot mechanism.
Further advantageous configurations of the invention are described in the dependent claims.
Performance
The intermediate location of the pivot mechanism between the front and the rear wheel transmits the weight of the operator along the shortest path to the wheel axes. In addition, the support elements can be more compact compared to the conventional frame construction which simplifies constructional difficulty and expense and reduces weight. The frame of a single track two-wheeled vehicle in accordance with the invention consists essentially of e.g. two triangles having a common side with the pivot axis. In some embodiments, the two triangles for suspension of the front and the rear wheel are identical which leads to additional simplification in manufacture of the frame. Distribution of static and dynamic loads via a system having two triangles provides structural optimization and facilitates a light construction.
In the simplest embodiment, the two-wheeled vehicle frame consists essentially of two straight or curved structures for the wheel suspensions which are connected to each other for pivoting via the pivot mechanism. The steering lever arm is joined without relative rotation to form a unit with the front wheel suspension, whereas the rear wheel suspension with the saddle support and a lower steering lever arm form an additional intrinsically non-rotating unit. The position of the pivot mechanism facilitates a centralized compact two-wheeled vehicle in accordance with the invention which can be folded together and allows construction of a foldable tubular frame. Frame constructions, subjected to flexural as well as tensile or compression loads, for the front and rear units can be borne in a pivotable manner with respect to each other using only one pivot mechanism to additionally reduce constructional difficulty and expense. Towards this end, the pivot mechanism comprises a guide pipe connected in a non-rotating fashion to one of the two units and connected to the second unit via an upper and a lower rolling bearing. The configuration of an upper and a lower pivot point in the pivot mechanism reduces the forces acting on the pivot mechanism and facilitates a lighter construction. In particular with vehicles with which the pivot mechanism is disposed at the height of or beneath the wheel axes, the torques acting on the pivot point can be accepted by a plate-shaped widened pivot. In a motor scooter having such a pivot in the floor of the vehicle, the lower steering lever arm is extended into a running board. Finally, the rear unit can accept a partially or completely transparent casing to protect the operator from wind and rain.
Performance
When one displaces the pivot mechanism of single track two-wheeled vehicles into a position intermediate between the tread surfaces of the front and the rear wheels, one fundamentally changes the performance of the vehicle. Operation of the steering lever arm leads not only to motion of the front wheel, rather both the front and the rear wheels are moved out of their base positions at which the longitudinal central axes of the front and the rear wheels lie along a straight line. In this manner, the separation between the seating surfaces of the front and the rear wheels is shortened and the frame folds along the pivot axis. Equilibrium in a curve is then only possible by tilting the pivot axis in the radial direction relative to the curve in dependence on the speed of travel.
When going around curves, both wheels are tangential to the arc of the curve being traveled through. In this fashion, frictional losses are minimized and both wheel surfaces are loaded evenly. The weight of the operator is equally distributed on the seating surfaces of the wheels. A further important advantage of the folding-tilt steering system is that only one half as large a steering deflection is required compared to a front steering system when going around a curve since the deflection angle is evenly distributed between both wheels. Steering is effected by pulling or pushing the front steering lever arm on the side facing the intended direction. A shifting of weight overcomes the restoring forces associated with straight travel, the two-wheeled vehicle folds together, the pivot axis tilts, and a new equilibrium situation is established. This unstable equilibrium position is stabilized during operation through the force action of the operator at five force introduction points: namely the right and left handles of the handle bars, the saddle, and the left and right pedals. The simultaneous introduction of force at all of these points leads to stabilization of the single track two-wheeled vehicle for any operating condition. The five point supported folding-tilt-steering system is a safe and easily operable steering mechanism for single track two-wheeled vehicles having a central pivot axis. The effectiveness of the lower steering lever arm is substantially improved using a gear mechanism since the force on the pedals can thereby be regulated. A steady and precise straight line travel is achieved by the operator by an intuitive balancing of the steering forces on the front steering lever arm imparted via the pedals. When starting up, the torques acting on the pedals in the pivot axis are compensated for by an opposing force on the steering lever arm. In this regard, the smaller the deflection, the smaller the amount of force necessary for steering. It is also possible to stand up from the saddle and to pedal while standing. When going uphill, the increased pedal forces on the lower steering lever arm effect precise and steady straight line travel. For downhill travel where high speeds can be obtained it is advisable to transfer a force into the pivot axis through light operation of back pedal brakes so that the front and the rear steering lever arms remain under tension to completely avoid the danger of alternating load reactions in the pivot axis which could be undesirable at high speeds. The same is true for a motorcycle or a motor scooter where the operator can influence the steering using his hands and feet. If the seat is shell-shaped good sideward containment is guaranteed to facilitate a completely safe travel operation even at extreme speeds. For straight travel, the pivoting mechanism is disposed at a bottom dead center. Each steering motion shortens the distance between the wheels and the pivot mechanism is lifted. When going around a curve, the pivot mechanism is therefore located at a higher position. The restoring forces necessary for a stable straight travel cause the system to always attempt to return to its initial state. Additional influencing of the operating properties within the context of this coupled folding-tilt-mechanism can be effected through a tilting of the pivot axis in the longitudinal direction or when the front and rear wheel suspension engage the wheel axes at a displacement therefrom. The steering motion in the pivot axis can be influenced by a steering damper e.g. in the form of a gas pressure spring connecting the rear and the front portions. The resistance of this damping element must be overcome for all steering motion. An additional possibility for influencing the steering properties is the use of resilient elements which engage the pivot mechanism and whose restoring forces must be overcome for all steering motions deviating from a straight line. Finally, the pivot mechanism can be further improved in such a fashion that the front and rear wheel suspensions move away from each other via guiding surfaces having oppositely directed pitches along the pivot axes to generate an additional restoring force.
The drive mechanism can act either on the front wheel or on the rear wheel or on both wheels. Important within the framework of the invention is the position the drive mechanism assumes relative to the pivot axes. In accordance with the invention, new and advantageous possibilities are given for the configuration of combustion engines, electrical motors and battery storage elements which will be more closely described in association with the figures.
In summary, a single track two-wheeled vehicle having a steering device evenly influencing the two wheels is superior to conventional systems due to the ideal interaction with the road. The safe and proper steering of a two-wheeled vehicle of the above mentioned kind under all operating conditions had been, up to this point of time, an unsolved problem. The configuration and cooperation of the steering lever arms proposed in accordance with the present invention and their embodiments leads to the resolution of this problem in the simplest of manners.
The invention is described more closely in the embodiments represented in the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a bicycle in accordance with the invention having a rear wheel drive and a vertical pivot mechanism in isometric view.
FIG. 2 a shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in a side view.
FIG. 2 b shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism configuration in plan view.
FIG. 2 c shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism, folded together in plan view.
FIG. 3 shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism configuration in a side view.
FIG. 4 shows a side view of a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism.
FIG. 5 a shows a side view of an electric scooter in accordance with the invention having front wheel drive and a vertical pivot axes.
FIG. 5 b shows a plan view of the electrical scooter in accordance with the invention having front wheel drive and a vertical pivot axes.
FIG. 6 shows a side view of a motor driven scooter in accordance with the invention having rear wheel drive and a vertical pivot mechanism.
FIG. 7 shows a motorized scooter in accordance with the invention in an isometric view having front wheel drive and vertical pivot mechanism.
FIG. 8 shows a bicycle in accordance with the invention in side view having rear wheel drive and a vertical pivot mechanism.
FIG. 9 shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in a side view.
FIG. 10 shows a side view of a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism.
FIG. 11 shows a side view of a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism.
FIG. 12 shows a bicycle in accordance with the invention having rear wheel drive and a pivot mechanism tilted in a backward direction in side view.
FIG. 13 shows a bicycle in accordance with the invention having rear wheel drive and a pivot mechanism tilted in the forward direction in side view.
FIG. 14 shows a bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 15 shows a bicycle in accordance with the invention having rear wheel drive and a pivot mechanism tilted in the backward direction in side view.
FIG. 16 shows an electrical bicycle in accordance with the invention having front and rear wheel drive and a vertical pivot mechanism in side view.
FIG. 17 shows a folding bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in isometric representation.
FIG. 18 shows a folding bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 19 a shows a tubular frame for a folding bicycle in accordance with the invention in the unfolded state.
FIG. 19 b shows a tubular frame for a folding bicycle in accordance with the invention in the folded together state.
FIG. 20 a shows a folding bicycle in accordance with the invention in side view in a position ready for operation.
FIG. 20 b shows a folding bicycle in accordance with the invention in a folded together state.
FIG. 21 shows an electrical bicycle in accordance with the invention having front wheel drive and a vertical pivot mechanism in side view.
FIG. 22 shows an electrical scooter in accordance with the invention having front wheel drive and a vertical pivot mechanism in side view.
FIG. 23 shows a motorized bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 24 shows an electrical scooter in accordance with the invention having a closed compartment and support wheels in side view.
FIG. 24 a shows the electrical scooter of FIG. 24 without compartment and in isometric view.
FIG. 25 shows a folding bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 25 a shows the folding bicycle of FIG. 25 in a perspective representation.
FIG. 26 shows a folding bicycle in accordance with the invention having rear wheel drive and vertical pivot mechanism in a side view.
FIG. 26 a shows the folding bicycle of FIG. 26 in perspective representation.
FIG. 27 shows a folding bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 27 a shows the folding bicycle of FIG. 27 in perspective representation.
FIG. 28 shows a lady's bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in side view.
FIG. 28 a shows the lady's bicycle of FIG. 28 in perspective representation.
FIG. 29 shows a lady's bicycle in accordance with the invention having rear wheel drive and a vertical pivot mechanism in isometric representation.
FIG. 30 shows an electrical bicycle in accordance with the invention having front wheel drive and a pivot mechanism tilted in a backward direction in isometric representation.
FIG. 31 shows an electrical bicycle in accordance with the invention having front and rear wheel drive and a vertical pivot mechanism in isometric representation.
FIG. 32 shows an electrical bicycle in accordance with the invention having front wheel drive and vertical pivot mechanism in isometric representation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The figures show a single track two-wheeled vehicle, in particular a bicycle, electric bicycle, an electric scooter or a motorized scooter consisting essentially of a front member and a rear member connected for pivoting to each other by means of a pivot mechanism located approximately in a central position between the front and the rear wheel, wherein the front member comprises a front wheel suspension with the front wheel, a handle bars displaced in the forward direction relative to the pivot mechanism and a connection element for the handle bars, and the rear member comprises a rear wheel suspension with the rear wheel and a saddle support bearing the saddle. A drive unit is provided for in either the rear or the front member. Towards this end, one can recognize in each figure that the front wheel suspension ( 31 , 33 , 35 , 37 ) and the connecting element ( 21 ′) bearing the handle bars ( 21 ) form an intrinsically non-rotating first unit and the rear wheel suspension ( 30 , 32 , 34 , 36 ) and the saddle support ( 26 ′) form an intrinsically non-rotating second unit, wherein the saddle ( 26 ) is displaced in a backward direction relative to the pivot mechanism ( 1 - 4 ), and the drive unit ( 40 - 53 ) acts either on the front wheel ( 11 ) or on the rear wheel ( 10 ).
FIG. 1 shows an isometric overview of a bicycle in accordance with the invention. In this example, the front unit comprises the handle bars ( 21 ), the connecting element ( 21 ′) and the fork ( 31 ), whereas the rear unit is fashioned from the saddle ( 26 ), the saddle support ( 26 ′), the fork ( 30 ) and a collar member for accepting the pedal bearing ( 42 ). Both intrinsically non-rotating units are borne for rotation relative to each other at the pivot mechanism. The pivot mechanism is formed by an upper pivot ( 1 , 2 ) disposed above the wheel axes of the front wheel ( 11 ) and the rear wheel ( 10 ). The pedals ( 20 ) lie below the wheel axes and act on the pivot axis ( 0 ) in the form of a lower steering lever arm (c). The drive is a conventional pedal crank ( 40 ). A particular advantage is that the front and rear units are configured identically. The handle bars ( 21 ) and the saddle ( 26 ) are borne in a height adjustable fashion in the front wheel suspension ( 31 ) and in the rear wheel suspension ( 30 ), respectively.
In the bicycle in accordance with FIG. 2 a , the front wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) engage the front wheel ( 11 ) and the rear wheel ( 10 ) below the wheel axes. They are formed by fork-shaped tubular frames. A rounded hollow section is located in the extension of the perpendicular pivot mechanism which is curved toward the rear wheel ( 10 ). The pedal crank ( 40 ) is located at the end thereof. Additional braces ( 38 ) are disposed between the rear wheel axis and the pedal crank ( 40 ) to accept the pedal forces on the lower steering lever arm (c). The bicycle also has the pivot mechanism ( 1 , 2 ) disposed above the wheel axes.
FIG. 2 b shows the bicycle in accordance with the invention in a partially folded position in plan view representing a operable deflection angle.
FIG. 2 c shows the bicycle in accordance with the invention in a transport position in which the front and rear units are folded up together about the pivot axis ( 0 ).
FIG. 3 shows a bicycle in accordance with the invention with which the fork-shaped front wheel suspension ( 31 ) and the fork-shaped rear wheel suspension ( 30 ), the saddle support ( 26 ′), the handle bars ( 21 ) as well as the pedal crank ( 40 ) are connected to a common guiding tube defining the pivot axis ( 0 ). The pedal bearing for the pedal crank ( 40 ) is located on the lower end of the pivot mechanism and is connected to the rear unit ( 30 ) via a straight pipe section. The position of the pedals ( 20 ) along with the pedal bearing in the pivot mechanism stabilizes straight travel of the bicycle. The forked wheel suspensions ( 30 , 31 ) are configured as load bearing shell structures and are connected with the axes of the front wheel and the rear wheel below the wheel axes and via a joining plate.
FIG. 4 shows a bicycle in accordance with the invention as shown in FIG. 3, wherein the front wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) engage above the wheel axes on the front and rear wheels.
FIG. 5 a shows an electrical scooter in accordance with the invention having front wheel drive effected by a wheel hub motor ( 47 ). The scooter consists essentially of two units which can be rotated about a common pivot axis ( 0 ), wherein the pivot ( 3 , 4 ) is located below the wheel axes. The front wheel suspension ( 33 ) is configured as a shell construction, wherein the rear wheel suspension ( 30 ) is formed from tubular frames. Steering is effected by pulling or pushing on the upper steering lever arm ( 21 ) while simultaneously supporting the feet on the foot rests ( 22 ) acting as the lower lever arm.
FIG. 5 b shows an electrical scooter in accordance with the invention in plan view at an operable deflection angle.
FIG. 6 shows an electrical scooter in accordance with the invention corresponding to the construction of the scooter shown in FIG. 5, wherein both wheel suspensions ( 32 , 33 ) have shell construction.
FIG. 7 shows a motorized scooter in accordance with the invention in isometric representation. The front wheel suspension ( 33 ) consists essentially of a self-supporting shell construction and the rear wheel suspension ( 30 ) is fork-shaped. The front and rear units are connected to each other by means of a disc-shaped pivot ( 3 , 4 ) for rotation below the wheel axis. During steering, the steering lever arm (a) acts from a forward position, the steering lever arm (b) acts from the rear, and the lower steering lever arm (c) also acts from the front on the pivot axis ( 0 ). The disposition of the force introduction points for steering facilitates an easy and safe handling of the folding-tilt-steering system. The disposition of the pivot mechanism ( 3 , 4 ) at the height of or directly below the wheel axes together with front wheel drive facilitates advantageous operation. The width of the scooter in the region of the pivot mechanism likewise facilitates, if desired, the installation of vibrational dampers acting on the pivot ( 3 , 4 ). The front unit ( 33 ) is substantially simplified, compared to the conventional construction, since the pivot ( 3 , 4 ) is located in the middle and the internal combustion engine ( 45 ) with all mechanisms needed for operation can be integrated within the aerodynamic casing of the shell structure. Towards this end, the rear unit ( 30 ) can be utilized as a resilient seat ( 26 ) for one to two people and the platform widened lower steering lever arm ( 22 ) can be used to transport objects.
FIG. 8 shows a bicycle in accordance with the invention having a vertical pivot mechanism and rear wheel drive. In this case, the upper pivot ( 1 , 2 ) is disposed above the wheel axes, and the lower pivot ( 3 , 4 ) is located below the wheel axes. A pedal crank ( 40 ) is introduced between the pivots ( 1 - 4 ) which, in turn, are connected by a hollow structure ( 6 ). Each of the front and the rear wheel suspensions ( 30 , 31 ) are configured as a curved tubular frame. The lower frame member is lower than the lower bottom dead center of the pedal crank ( 40 ) so that the pedal crank ( 40 ) does not come in contact with the tubular frame even under extreme steering deflection. The low center of gravity of this system leads to a stable straight line operation, since the supporting members of the frame join onto the wheel axes from the lower and from the upper direction. In this case as well, the pedal crank ( 40 ) directly engages at the pivot axis ( 0 ) and is disposed as a lower steering lever arm (c) between the saddle ( 26 ) and the handle bars ( 21 ), the connecting elements of which ( 26 ′ and 21 ′ respectively) form the upper steering lever arm (a, b).
FIG. 9 shows a bicycle with which the front and the rear wheel suspensions ( 30 , 31 ) are each configured as triangular-shaped tubular frames connected together via an upper pivot ( 1 , 2 ) and a lower pivot ( 3 , 4 ).
FIG. 10 shows a bicycle with which the front and the rear wheel suspensions ( 30 , 31 ) form a triangle wherein the upper pivot ( 1 , 2 ) is located in the upper corner of the triangle with the wheel axes of the front wheel ( 11 ) and the rear wheel ( 10 ) defining the two lower corners of the triangle and the lower pivot ( 3 , 4 ) divides the side of the triangle facing the road in half. Both pivots ( 1 - 4 ) are connected to each other by means of a hollow structure ( 6 ). The bicycle has 18 inch wheels ( 10 , 11 ). The saddle-support ( 26 ′) and the connecting element ( 21 ′) for the handle bars ( 21 ) are attached to the wheel suspensions ( 30 , 31 ) such that their heights can be adjusted.
FIG. 11 shows a bicycle in accordance with the invention having a fork-shaped curved wheel suspension ( 30 , 31 ) connected to the front wheel ( 11 ) and the rear wheel ( 10 ) within the wheel separation defined by the wheel axes. Two additional braces connect the pedal bearing ( 42 ) with the rear wheel axis and pass the pedal and steering forces into the rear unit.
The bicycle shown in FIG. 12 has a pivot mechanism titled in a rear direction. In this case as well, the braces stabilize the pedal bearing ( 42 ). The forward larger unit is stabilized by an additional brace. In this case, the saddle support ( 26 ′) is coaxial with the pivot mechanism and is connected to a guide pipe ( 6 ) at which the rear wheel suspension ( 30 ) and the front unit are connected to each other for pivoting.
FIG. 13 shows a bicycle in accordance with the invention having a pivot mechanism tilted in a forward direction. The wheel suspensions ( 32 , 33 ) are configured as self-supporting shell constructions made from sheet metal or plastic. The saddle ( 26 ) and the handle bars ( 21 ) extend outwardly from the pivot mechanism. The elastic deformation of the connecting elements ( 21 ′, 26 ′) is utilized for resilient suspension of the saddle ( 26 ) and the handle bars ( 21 ).
The bicycle shown in FIG. 14 has two identical wheel suspensions ( 30 , 31 ) formed as fork-shaped hollow box cross sections. The saddle support ( 26 ′) and the steering lever arm ( 21 ′) have adjustable heights and are mounted to the wheel suspensions ( 30 , 31 ). The pedal bearing ( 42 ) is displaced slightly in a backward direction relative to the pivot mechanism, lies below the wheel axes, and is borne by a fork-shaped structure engaging the lower pivot ( 3 , 4 ).
The bicycle shown in FIG. 15 has wheel suspensions ( 36 , 37 ) configured as resilient elements. There is no structural connection between the upper pivot ( 1 , 2 ) and the lower pivot ( 3 , 4 ). In this manner, the front unit and the rear unit constitute an interacting resilient element. In this embodiment the separation between the wheels increases under abrupt load. A reinforced portion of the rear wheel suspension ( 36 ) accepts the pedal bearing ( 42 ).
FIG. 16 shows an electrical bicycle in accordance with the invention having a construction corresponding to that of the bicycle in FIG. 15, wherein drive is effected by two wheel hub motors ( 47 , 48 ) in the front wheel ( 11 ) and the rear wheel ( 10 ). A removable container ( 414 ) is inserted between the upper pivot ( 1 , 2 ) and the lower pivot ( 3 , 4 ) and serves to accept storage cells ( 404 ). The storage cells ( 404 ) can be easily removed from the vehicle and charged. For downhill stretches, the wheel hub motors ( 47 , 48 ) can be utilized to produce current. The foot rests ( 22 ) are disposed below the wheel axes.
FIG. 17 shows a bicycle in accordance with the invention with which the wheel suspensions ( 34 , 35 ) are formed as one-sided arms. The symmetrical construction facilitates folding together into a minimum volume.
FIG. 18 shows a folding bicycle. The attachment locations ( 70 - 73 ) of the front and the rear wheel suspension ( 30 , 31 ) are configured herein as pivot mechanisms ( 70 , 71 ). The bicycle can be folded together into a compact bundle through release of a hinge locking mechanism on the pivot mechanism.
FIGS. 19 a and 19 b show the tubular frame of the bicycle in FIG. 18 in the unfolded and folded states.
FIG. 20 a shows a folding bicycle ready for operation, whereas FIG. 20 b shows the folded together bicycle. A locking mechanism ( 74 ) is disposed on the lower end of the pivot mechanism to which the pedal bearing ( 42 ) and the lower braces for the front and the rear wheel suspensions ( 30 , 31 ) are connected. Release of the locking mechanism ( 72 , 73 ) allows the bicycle to be folded together into a compact bundle. The separation between the pedal bearing ( 42 ) and the axis of the rear wheel ( 10 ) remains constant during the folding procedure, so that the drive belt or chain does not become disengaged. The saddle support ( 26 ′) and the handle bars ( 21 ) are configured as slanted modules whose heights can be adjusted at the front and rear wheel suspensions ( 30 , 31 ). This folding bicycle is extremely light and can be transported all over when folded together.
The electrical bicycle of FIG. 21 has a front wheel drive given by a wheel hub motor ( 47 ) with an additional rear wheel drive effected by means of a pedal crank ( 40 ) located at the pivot mechanism.
The electrical scooter of FIG. 22 has a container ( 414 ) for electrical storage cells ( 404 ) disposed at the pivot mechanism. A plug ( 406 ) for connection to a charging unit is disposed on the upper end of the pivot mechanism. Drive is effected by means of an electrical motor ( 44 ) located on the lower end of the pivot mechanism. The wheel axes are driven by means of a cardan shaft ( 50 ). The foot rests ( 22 ) act as the lower steering lever arm (c).
FIG. 23 shows a motorcycle in accordance with the invention. The combustion engine ( 36 ) is hereby located between the upper pivot ( 1 , 2 ) and the lower pivot axes ( 3 , 4 ). The tank ( 407 ) is integrated into the rear unit. The rear wheel is driven via a cardan shaft ( 50 ). In this case as well, the foot rests ( 22 ) serve as the lower steering lever arm (c) to support steering. Together with the upper steering lever arm (a, b) the operator can influence the equilibrium in the pivot axis ( 0 ) at three force introduction points.
FIG. 24 shows an electrical drive enclosed scooter in accordance with the invention in which the rear wheel suspension ( 32 ) consists essentially of a self-supporting shell construction expanded into an operator compartment ( 70 ) having a cover made from acrylic glass. The pivot ( 3 , 4 ) is located at the bottom of this compartment ( 70 ) to which the front wheel suspension ( 33 ) is borne for rotation. The front wheel suspension ( 33 ) is also mounted for rotation to the circular arc forward portion of the rear wheel suspension ( 32 ). When standing, this electrical scooter has two support wheels ( 96 ), for purposes of stabilization, which can be pivoted-in. Drive is effected by means of a wheel hub motor ( 47 ) at the front wheel ( 11 ).
FIG. 25 shows a folding bicycle in accordance with the invention with which the front wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) are configured as tubular frames. They are disposed in displaced relationship relative to each other on an upper pivot ( 1 , 2 ) so that the bicycle can be folded together to assume half its length.
FIG. 25 a shows a perspective view of this folding bicycle.
FIG. 26 shows folding bicycle in accordance with the invention with which the front wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) consist essentially of rectangular hollow sections under flexural load. They are displaced with respect to each together at an upper pivot ( 1 , 2 ) so that the bicycle can be folded together to half of its length.
FIG. 26 a shows this folding bicycle in a perspective representation.
FIG. 27 shows a folding bicycle in accordance with the invention with which the front wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) consist of flexural loaded rectangular hollow sections. They are displaced relative to each other at an upper pivot ( 1 , 2 ) so that the bicycle can be folded together to assume half its length.
FIG. 27 a shows this folding bicycle in a perspective representation.
FIG. 28 shows a folding lady's bicycle in accordance with the invention with which a V-shaped mounting opening is provided for between the saddle support ( 26 ′) and the handle bars ( 21 ) via the connecting element ( 21 ′) to the pivot mechanism. The forward wheel suspension ( 31 ) and the rear wheel suspension ( 30 ) are connected to each other for rotation at a lower pivot ( 3 , 4 ) disposed below the wheel axes.
FIG. 28 a shows this lady's bicycle in a perspective representation.
A lady's bicycle in accordance with the invention is shown in FIG. 29 with which the forward wheel suspension ( 33 ) and the rear wheel suspension ( 32 ) are formed as a self-supporting shell structures. The forward and rear units are connected via a lower pivot ( 3 , 4 ) disposed below the wheel axes. The pedal bearing ( 42 ) is displaced in a backward direction with respect to the pivot mechanism and is likewise disposed below the wheel axes. The drive unit and the wheel surfaces facing the U-shaped mounting opening are surrounded up to the pedal crank ( 40 ) by a non-supporting protective cover ( 15 , 14 ). This embodiment has the particular advantage of the low mounting opening between the front and the rear wheel as well as the shielding of the wheel surfaces by means of the front and rear protective covers ( 15 , 14 ). This bicycle also has two upper steering lever arms (a, b) and a lower steering lever arm (c) which engage at the pivot axis ( 0 ).
FIG. 30 shows an electrical bicycle in accordance with the invention in isometric representation. The pivot mechanism is tilted in the backward direction by 7°. A removable container ( 414 ) for the acceptance of electrical storage cells ( 404 ) is inserted between the upper pivot ( 1 , 2 ) and the lower pivot ( 3 , 4 ). The upper pivot ( 1 , 2 ) and the lower pivot ( 3 , 4 ) are ring-shaped. A plug ( 406 ) which can be closed by a lid is located on the upper pivot ( 1 , 2 ) for connection to a charging apparatus. The front and the rear units are elastically connected to the upper and the lower pivots ( 1 - 4 ). The front and the rear wheel suspension ( 36 , 37 ) are configured as resilient elements. Drive is effected by means of a wheel hub motor ( 47 ) in the axis of the front wheel ( 11 ). The saddle support ( 26 ′) and the steering lever arm ( 21 ′) are connected as resilient arms to the rear and front wheel suspensions respectively ( 36 , 37 ). The foot rests ( 22 ) are located substantially below the wheel axes to be optimally effective as the lower steering lever arm.
FIG. 31 shows an electrical bicycle in accordance with the invention having the front wheel ( 11 ) and the rear wheel ( 10 ) in the form of disks ( 12 , 13 ). Circular electrical storage cells ( 403 , 404 ) are inserted into the disks. Drive is effected by means of wheel hub motors ( 47 , 48 ) in the front wheel ( 11 ) and the rear wheel ( 10 ). A resilient element ( 61 ) is integrated into the pivot mechanism.
FIG. 32 shows an electrical bicycle in accordance with the invention having extremely large front and rear wheels ( 11 , 10 ) formed from carbon fiber reinforced disks ( 12 , 13 ) and are equipped with photo voltaic cells. In order to increase the collector surface, the wheel surface can be correlated or folded. Assuming a bicycle wheel diameter of 1.25 m, a collector surface of at least 4.9 sm results. Assuming a power of approximately 0.5 PS per square meter of collector surface, a drive power of approximately 2.5 PS results for the front wheel hub motor ( 47 ). The folding-tilt-steering system is particularly advantageous for this relatively long single track two-wheeled vehicle.
Reference Symbols
front
rear
axes, lever arm
pivot
1-4
pivot axis 0
mechanism
upper pivot 1
upper pivot
2
1. upper steering
a
lever arm
lower pivot 3
lower pivot
4
2. upper steering
b
lever arm
lower steering
c
lever arm
guide tube
6
front wheel
11
rear wheel
10
wheel disc
13
wheel disc
12
protecting
15
protecting
14
cover for the
cover for the
wheels
wheels
pedals
20
foot rests
22
handle bars
21
saddle
26
handlebar
21′
saddle support
26′
connection
element
30-37
wheel sus-
31
fork
31
pension fork
self-support-
33
self-support-
32
ing shell
ing shell
structure
structure
one sided
35
one sided
34
leg
leg
frame as re-
37
frame as re-
36
silient ele-
silient element
ment
additional
38
braces
drive 40-53
pedal crank
40
pedal bearing
42
electrical
43
electrical motor
44
motor
combustion
45
combustion
46
engine
engine
wheel hub
47
wheel hub
48
motor
motor
additional car-
50
dan shaft
resilient ele-
resilient ele-
60
ment
ment
driver compart-
700
ment
attachement
71, 73
attachement
70, 72
locations
locations
locking mech-
74
anism
support wheels
96
tank
400
photo voltaic
401
photo voltaic
402
cells
cells
electrical
403
electrical stor-
404
storage cells
age cells
hollow struc-
413
hollow struc-
414
ture
ture
plug
406 | The invention relates to a single-track two-wheeled vehicle, in particular a bicycle, electric bicycle, electric scooter or motor scooter. The vehicle comprises a front section and a rear section which are both pivotably connected to each other by a pivot mechanism ( 1-4 ) arranged substantially centrally between the front and the rear wheel. The front section comprises a front wheel suspension with the front wheel ( 11 ), a handlebar ( 21 ) offset towards the front in relation to the pivot mechanism ( 1-4 ), and a connection member ( 21 ′) of the handlebar ( 21 ). The rear section comprises a rear wheel suspension with the rear wheel ( 10 ) and a saddle support ( 26 ′) on which the saddle ( 26 ) is mounted. A drive unit ( 40-53 ) is provided which is either part of the front section or the rear section, the front wheel suspension and the connection member ( 21 ′) on which the handlebar ( 21 ) is mounted forming a first unit which cannot be rotated. The rear wheel suspension and the saddle support ( 26 ′) form a second unit which cannot be rotated, the saddle ( 26 ) being offset to the rear in relation to the pivot mechanism ( 1-4 ), and the drive unit ( 40-53 ) acting either on the front wheel ( 11 ) or the rear wheel ( 10 ). | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to compositions and interventions, which aim to improve wound healing by reducing fibroblast formation and extra-cellular matrix deposition and hence scarring.
BACKGROUND OF THE INVENTION
[0002] Scar formation during wound healing is a cosmetically undesired process, especially if the scars are formed on the face and other conspicuous or identity-determining parts of the body. Scar formation can also have health implications. As a prominent example, myocardial scar formation occurring after myocardial infarction impairs cardiac function by inducing cardiac remodeling, reducing cardiac compliance and compromising normal electrical conduction across the heart.
[0003] When we are injured, the body launches a complex rescue operation. Specialized cells called fibroblasts present just beneath the surface of the skin come into action, enter the provisional wound matrix (the clot) and start secreting collagen to close the wound as fast as possible. This matrix is initially soft and loaded with growth factors. The fibroblasts “crawl” around the matrix, pulling and reorganizing the fibers. The matrix grows stiffer, and at a certain point, the fibroblasts stop migrating and change into powerful contractile cells, anchoring themselves to the matrix and pulling the edges of the wound together.
[0004] Although this process will heal a wound quickly, it can also lead to a build-up of fibrous tissue. Following trauma to vital organs such as the heart, lung, liver and kidney, overzealous fibroblasts can continue to build fibrous strands, leading to scar tissue formation that can impair the organ's function. This condition, called “fibrosis”, can be fatal. Fibroblasts are also the culprits in problems caused by implants; if the implant is too smooth, it never becomes properly incorporated into the connective tissue. However, if it is too rough, scar tissue develops around it and the tissue will not function properly. Occasionally, following plastic surgery, unsightly excessive scar tissue can develop in the skin as well. The process can also cause problems in mesenchymal stem cell cultures; if the culture's substrate is stiff, considerable efforts have to be made to prevent the stem cells from turning prematurely into fibroblasts instead of the desired cell type. Controlling the rigidity of the cell culture is therefore critical.
[0005] A fibroblast is a type of cell that synthesizes and maintains the extracellular matrix of many animal tissues. Fibroblasts provide a structural framework (stroma) for many tissues, and play a critical role in wound healing. They are the most common cells of connective tissue in animals.
[0006] The main function of fibroblasts is to maintain the structural integrity of connective tissues by continuously secreting precursors of the extracellular matrix. Fibroblasts secrete the precursors of all the components of the extracellular matrix, primarily the ground substance and a variety of fibers. The composition of the extracellular matrix determines the physical properties of connective tissues.
[0007] Fibroblasts are morphologically heterogeneous with diverse appearances depending on their location and activity. Though morphologically inconspicuous, ectopically transplanted fibroblasts can often retain positional memory of the location and tissue context where they had previously resided, at least over a few generations.
[0008] Unlike the epithelial cells lining the body structures, fibroblasts do not form flat monolayers and are not restricted by a polarizing attachment to a basal lamina on one side, although they may contribute to basal lamina components in some situations (e.g. subepithelial myofibroblasts in intestine may secrete the a-2 chain carrying component of the laminin, which is absent only in regions of follicle associated epithelia which lack the myofibroblast lining). Fibroblasts can also migrate slowly over substratum as individual cells, again in contrast to epithelial cells. While epithelial cells form the lining of body structures, it is fibroblasts and related connective tissues which sculpt the “bulk” of an organism.
[0009] Nakao and colleagues studied the effects of annexin A5 on normal human keratinocytes (NHK) in vitro and in a surgical wound assays for reepithelialization (Nakao et al.: A new function of calphobindin I (annexin A5): Promotion of both migration and urokinase-type plasminogen activator activity of normal human keratinocytes; Eur. J. Biochem. (1994) 223: 901-908). These in vitro studies showed promotion by Calphobindin of both uPA synthesis of epithelial keratinocytes and their migration (but not proliferation). Topical application of Calphobindin to cutaneous wounds in rat skin appeared to promote reepithelialization in these experiments.
[0010] Watanabe and colleagues have reported that Annexin A5 promotes corneal epithelial wound healing both in vitro and in vivo and that upregulation of uPA release from corneal epithelial cells may contribute to this effect of annexin A5 (Watanabe et al.; Promotion of Corneal Epithelial Wound Healing In Vitro and In Vivo by Annexin A5; Invest. Ophthalmol. Ms. Sci. 2006 47: 1862-1868).
[0011] However, these authors do not suggest to use annexins pharmaceutically in the context of scar formation.
SUMMARY OF THE INVENTION
[0012] It was found according to the invention, that scar formation occurring during wound healing of a mammalian subject can be prevented or reduced by administering a phosphatidylserine-binding compound to the mammalian subject.
[0013] The reduction of scar formation can be carried out as part of cosmetic treatment. Alternatively, it can be carried out as part of plastic surgery, or as part of a post-treatment of plastic surgery.
[0014] The reduction of scar formation can also be carried out as part of a treatment for prevention of heart failure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] In a first aspect, the invention concerns the use of a phosphatidylserine-binding compound for preventing, inhibiting or otherwise reducing scar formation in the skin of a mammalian subject. Pharmaceutically suitable formulations are especially formulations for topical or intravenous administration, such as ointments, creams, plasters and injectable solutions or suspensions.
[0016] The reduced scar formation is relevant in conditions where excessive fibrosis may occur. Such condition may be a form of pathological scarring of the skin (e.g. hypertrophic scarring or keloids) or an internal scar or fibrosis. Alternatively the condition may be a fibrotic disease or disorder also as mentioned above. Other conditions that may be treated include fibrotic disorders of the skin such as: Sclerodemia, Systemic sclerosis, Crest Syndrome, Tuberous sclerosis with skin patches, Familial cutaneous collagenoma, metabolic and immunologic disorders of the skin (porphyria cutanea tarda, chronic graft versus host disease), Eosinophilic facsitis, Discoid lupus erythematosus, Dermatomyositis, Mixed connective tissue disease, Drug-induced skin fibrosis, Peyronie's disease, Oral submucous fibrosis, Fibrosis-induced following dietary and environmental exposures, fibrotic disorders of other organs including: Pulmonary/cardiac fibrosis, Liver fibrosis/cirrhosis, Renal fibrosis, GI tract fibrosis, Drug induced fibrosis (e.g. post organ transplantation), Central and peripheral nervous system fibrosis, Vascular system (veins and arteries) fibrosis, Male and female genito-urinary tract fibrosis, and Gynaecological fibrosis (fallopian tube fibrosis, uterine fibromas).
[0017] In a preferred embodiment, the invention is concerned with preventing myocardial scar formation, thus reducing the chance of heart failure. Thus, the invention concerns a phosphatidylserine-binding compound as defined above for preventing, inhibiting or otherwise reducing fibrosis in the heart of a mammalian subject. Pharmaceutically suitable formulations are especially formulations for intravenous and intra-pericardial administration, such as injectable solutions or suspensions.
[0018] The reduction of fibrosis in the heart can be part of a program of treating mammalian subjects suffering from myocardial infarction or from the effects thereof. Such program comprises the administration of annexin A5 or a derivative thereof for example to a patient that has experienced myocardial infarction in a period of seven days prior to annexin A5 administration. The amount of annexin A5 or derivative thereof may range from 0.002 mg/kg to 10 mg/kg body weight, more particularly 0.02 to 2 mg/kg body weight.
[0019] Alternatively or in addition, phosphatidylserine-binding compound can be administered to a mammalian subject as part of a treatment to reduce the chance on development of heart failure.
[0020] The phosphatidylserine-binding compound is believed to inhibit or reduce the load of fibroblasts in the injured and surrounding tissue, and hence to reduce or smoothen the formation of connective tissue and reducing scar.
[0021] As described herein, a phosphatidylserine binding-compound is a compound, in particular a proteinaceous compound capable of binding to phosphatidylserine, especially with a dissociation constant for phosphatidyl serine Kd<10 −6 M, preferably a Kd<10 −8 M, and preferably not binding to phosphatidylcholine, especially having a dissociation constant for phosphatidylcholine Kd>10 −7 , preferably >10 −6 . Examples thereof are compounds of the so-called annexin family and derivatives of annexins, including the human annexin described in WO 2007/069895, such as Annexin A4, Annexin A5 and Annexin A8. In particular, the phosphatidylserine-binding compound is an Annexin A5 or a derivative thereof.
[0022] As a result of its capability of recognizing phosphatidylserine exposed on the cell surface of cells which are present at healing wounds, the phosphatidylserine binding-compound which is administered will concentrate at the site of the healing wound.
[0023] The annexin, such as annexin A5, may be the non-modified form, having the amino acid sequence (in case of A5) of FIG. 1 of WO 2007/069895, which is incorporated herein by reference. As such, the annexin may be a native annexin, or it may be a recombinant annexin produced by methods known in the art. The non-modified annexin may or may not comprise an N-terminal methionine residue or other leader sequence.
[0024] The annexin may also be in a modified form, wherein one or more amino acids are substituted. A suitable example of a modified annexin is an annexin having a single cysteine residue at the concave side of the annexin, such as a cysteine residue at one of the N-terminal positions 1-15 of the amino acid sequence of annexin A5. Such modifications are described e.g. in WO 2006/003488, which is incorporated herein by reference. Such modification of the annexin compounds allows the compound to be covalently bound to biologically active compounds capable of assisting in the reduction of extracellular matrix formation, or capable of performing another desired biological function. As an alternative, the annexin may be coupled to a nanoparticle, which can be used as a carrier for biologically active compounds and increase the payload of annexin-coupled biological compounds. Examples of such biologically active compounds include anti-infective compounds such as antibiotics (tetracyclin, minocyclin, erythromycin, clindamycin, metronidazol, sulfacetamide, amoxicillin, trimetroprim, quinones), anti-apoptotic compounds (caspase inhibitors, calpain inhibitors, cathepsin inhibitors), anti-inflammatory compounds such as steroids, anti-matrix metalloproteinases (TIMP-1, 2, 3 and 4), especially small (MW 150-750) anti-MMP molecules such as derivatives of methylpentanamide (marimastat), prinomastat (AG-3340), peptide-based inhibitors (batimastat, ilomastat (GM6001), FN-439), hydroxamic based inhibitors (RO113-2908), plasmin inhibitors (alpha2-plasmin inhibitor, amino acid based inhibitors from snake venom, peptide based inhibitors), anti-viral compounds. The nanoparticles can be e.g. of solid, semi-solid or liquid lipids nature, e.g. following conventional lipid nanoparticle technology, and emulsions of polymers. Examples of suitable nanoparticles include liposomes. The covalent binding can be performed using known methods, such as those described in WO 2006/003488 and WO 2007/069895, for example by coupling of the cysteine residue through a maleimide-activated linker to the biologically active compound or the nanoparticle carrying such active compound.
[0025] The phosphatidylserine binding-compound is administered to a mammalian, especially human, subject in an effective amount in a pharmaceutically suitable formulation. An effective amount is determined in accordance with the condition and general status, age, body weight, administration form, etc. of the patient. It can be e.g. between 0.15 mg-150 mg per patient per day, or in particular between 0.5 and 50 mg per patient per day or more in particular between 1 and 20 mg per patient per day. In case of topical administration, the dosage amount can in particular be e.g. between 0.15 and 50, more in particular between 0.25 and 20, most especially between 0.5 and 10 mg per patient per day. In case of systemic (e.g. intravenous) administration, the dosage amount can in particular be e.g. between 0.5 and 200 mg, more in particular between 1 and 100 mg, most especially between 5 and 50 mg per patient per day. It is preferred to express the dosage amount in mg per kg body weight per day. Thus, the dosage amount is e.g. 0.002 mg/kg-10 mg/kg per day, or in particular between 0.01 and 1 mg/kg per day or more in particular between 0.02 and 0.4 mg/kg per day. For systemic administration, the preferred dosage amount is 0.01-5, more preferably 0.02-2.5, most preferably 0.05-1 mg/kg.
[0026] The pharmaceutically suitable formulation can generally be a formulation suitable for systemic (i.e. non-topical) administration. Suitable administration forms comprise inhalation, intravenous injection, intra-pericardial injection, intradermal injection, and a transdermal drug patch.
[0027] Intra-pericardial administration can be performed using endoscopic (thoracoscopic or laparoscopic) techniques using minimal incisions and local visual control of an injection through the pericardium. Alternatively, intra-pericardial administration may be performed using injection without incision and external visual control. Intra-pericardial administration is described e.g. in WO 2000/44443.
[0028] Injection forms comprise aqueous solutions, dispersions and the like, for example lipid nanoparticles suspensions, containing phosphatidylserine binding compound at a concentration ranging from 0.1 mg/ml to 50 mg/ml. The carrier medium is advantageously an iso-osmolaric (or isotonic) solution containing physiologic salt and/or sugar levels.
[0029] Systemic, including intravenous, administration can be effected using a continuous administration (drip infusion) or by repeated or single (bolus) injections.
[0030] Another form of systemic injection is through a transdermal device patch, allowing passage of the drug through the skin into the blood circulation. Transdermal administration can be combined with topical application through appropriate patches.
[0031] The pharmaceutically suitable formulation can in general also be a formulation suitable for topical administration. Suitable administration forms comprise creams, ointments, gels and lotions. Creams and lotions are emulsions of oil in water and contain emulsifiers. Phosphatidylserine binding compounds can be formulated in creams and lotion at a concentration ranging from 0.1 mg/ml to 50 mg/ml, especially 1-20 mg/ml. The emulsions may contain pH-stabilizing agents, fragrances, preservatives, antioxidants, and color additives. Gels are based on hydrophilic polymers such as polysaccharides, acrylic polymers, oxyethylene, oxypropylene and the like polymers. Phosphatidylserine-binding compounds can be formulated in gels at a concentration ranging from 0.1 mg/ml to 50 mg/ml. The gels may contain pH stabilizing agents, fragrances, preservatives, antioxidants, and color additives.
[0032] The invention also relates to a pharmaceutical composition, in which the phosphatidyl-serine-binding compound is formulated with pharmaceutically acceptable excipients. Examples of such excipients include water, cations, anions, stabilizing proteins, stabilizing carbohydrates, and chelating agents etc.
[0033] The reduction of scar formation can be carried out as part of a cosmetic treatment, especially where the scar is present at exposed areas, such as the face. Alternatively, it can be carried out as part of plastic surgery, or as part of a post-treatment of plastic surgery, where the plastic surgery results in, or has the risk of resulting in, scar formation. The administration forms and dosages can be the same for cosmetic treatment or plastic surgery as for the therapeutic treatment as described above, although topical administration will often be preferred.
EXAMPLE
[0034] This experiment was designed to study the effect of annexin A5 on infiltration of fibroblasts and the deposition of connective tissue in the skin that was injured by incision with a scalpel. This design is a general model for wound healing and represents fundamental processes of wound healing as they can occur in the heart following for example myocardial infarction.
[0035] Mice were anaesthesized using standard techniques. An incision of the dorsal skin was made with a scalpel. A mini osmotic pump was implanted dorsally and subcutaneously. The mini osmotic pumps were filled either with a solution of annexin A5 or a saline solution. The administration dose was 2.8 mg/kg per day. The incision of the skin was stitched and the mice were allowed to move around freely and drink and eat ad libitum.
[0036] Two weeks later the mice were sacrificed and samples of the skin were taken for histochemical analysis. The samples were fixed with paraformaldehyde and further processed according to standard techniques.
[0037] Paraffin embedded samples were sectioned and the sections were further processed according to standard techniques. The sections were stained with hematoxylin & eosin (H&E), and standard connective tissue staining techniques. Fibroblasts were detected in the H&E stained sections.
[0038] Histochemical analysis revealed that annexin A5 reduced both the infiltration and connective tissue deposition in the area of the incised and subsequently stitched skin compared to mice that were treated with the blanc. The analyses also showed that scar formation was remarkably reduced. Reduced scar formation likely results from decreased infiltration of fibroblasts and diminished connective tissue deposition.
[0039] In this example annexin A5 was applied through a mini osmotic pump that releases annexin A5 into the subcutaneous interstitium. Annexin A5 can also be applied topically using carrier systems such a creams, lotions and gels, locally through subcutaneous injection and systemically through intravenous injection.
REFERENCES
[0040] Nakao et al. U.S. Pat. No. 5,360,789 (Nov. 1, 1994)
[0041] Hiroshi Nakao, Masanao Watanabe and Masahiro MA: A new function of calphobindin I (annexin V) Promotion of both migration and urokinase-type plasminogen activator activity of normal human keratinocytes ; Eur. J. Biochem. (1994) vol. 223, pp 901-908.
[0042] Masanao Watanabe, Shoichi Kondo, Ken Mizuno, Wataru Yano, Hiroshi Nakao, Yukio
[0043] Hattori, Kazuhiro Kimura, and Teruo Nishida; Promotion of Corneal Epithelial Wound Healing In Vitro and In Vivo by Annexin AS Invest. Ophthalmol Vis Sci. 2006; 47:1862-1868. | The invention pertains to a method of reducing scar formation during wound healing by administering a phosphatidylserine-binding compound, in particular an annexin, to a subject in need thereof. The healing wound may be a skin damage, but it may also be a myocardium e.g. which is at risk of suffering or is recovering from a heart failure. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates generally to electric utility meters. More specifically, the present invention relates to data transmission protocols for electric utility meters.
BACKGROUND ART
[0002] Electric utilities use meters to measure and record electricity, usage by their customers. The utilities must read their meters for billing purposes. The readings may be conducted manually by utility personnel or automatically with radio signals, telephone connections, etc. Electric Utilities also have the need to collect other measurements at the electric meter that are not used for billing, such as voltage or other system status readings. For example, a voltage measurement is important because it indicates the quality of the power that is delivered to the customer.
[0003] Often when the utility needs this additional information, they must make a special effort to collect it. Further, these measurements often require special equipment and labor to gather. It also can only be collected from that point in time. No historical data is typically available. Consequently, it would be advantageous to collect the additional information such as a voltage reading at the meter, along with the billing information.
SUMMARY OF THE INVENTION
[0004] In some aspects, the invention relates to a method of transmitting electric utility data, comprising: collecting electric usage data at a utility meter; collecting a voltage level at the utility meter; and transmitting the voltage level to a utility receiving station synchronous to the transmission of the electric usage data to a utility receiving station.
[0005] Other aspects and advantages of the will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0006] It should be noted that identical features in different drawings are shown with the same reference numeral.
[0007] FIG. 1 shows a block diagram of the arrangement of the system meter in accordance with one example of the present invention.
[0008] FIG. 2 shows a block diagram of a data transmission that includes consumption, status indicators, and voltage measurements in accordance with one example of the present invention.
[0009] FIG. 3 shows a block diagram of a data transmission that includes consumption and voltage measurements in accordance with one example of the present invention.
DETAILED DESCRIPTION
[0010] A compact data transmission protocol for electric utility meters has been developed. The present invention gathers consumption/usage data at the customer's meter that is used for billing purposes. Supplemental information is also gathered at the same time at the meter. Such information includes data not used for billing or by the meter readers such as voltage levels, tamper alarms, error indicators and any other status indicators that are well known to those of skill in the art. The information is collected by the utility along with the billing information, and passed through the same systems as the billing information. The supplemental information may be combined with the usage data into a single combined transmission message. In other embodiments, the supplemental information may be transmitted synchronously (i.e., close in time) to the usage data.
[0011] FIG. 1 shows an example an automated meter reading (AMR) unit 10 that is used in the present invention. The unit 10 uses a metrology board 12 to collect the usage data (in kWh), voltage levels, and any other status readings or indicators desired. This data is then transferred to the AMR radio board 14 and transmitted to the utility via radio signals 16 . While this example shows a radio for data transmission, other embodiments could use other methods such as a transmission over a telephone line, interrogation by a fixed or mobile receiver, or a manual reading by utility personnel. In some embodiments of the present invention, one piece of equipment may be used to collect all of the desired data from the meter.
[0012] The collection of the supplemental data in addition to the usage data has the advantage of providing the utility with a historical record of the supplemental data. Historical data is particularly valuable because voltage information is often only available after the fact (e.g. After the voltage level has gone outside of the normal ranges because of a customer complaint). In some embodiments, the invention collects real time voltage level root mean squared and peak readings at the meter. Additionally, the present invention reduces the need for a special request from the utility to measure such data as voltage which reduces cost and effort to the utility.
[0013] FIG. 2 shows one example block diagram of a data transmission 20 that includes consumption, status indicators, and voltage measurements. The transmission 20 begins with a preamble 22 that identifies and initializes the communicating stations. Next, the consumption on reading 24 provides the usage data of the customer for billing purposes. Status Indicators 26 that indicate any system errors and/or tampering follow. Finally, the voltage measurement 28 is included that indicates the power quality at the meter.
[0014] FIG. 3 shows another example of block diagram of a data transmission 30 that includes only consumption and voltage measurements. The transmission 30 begins with a preamble 32 as described previously for FIG. 2 . It is followed by a consumption reading 34 and a voltage measurement 36 . The last segment is an optional end of transmission indicator 38 that tells the receiving station that the transmission message is complete. It is important to understand that a comparison of the examples shown in FIGS. 2 and 3 indicate the flexibility of the present invention. In addition to voltage measurements, the utility has the option of including a wide variety of supplemental information from the meter.
[0015] In some examples, the voltage level is a real-time measurement that measures the voltage at the meter from a range of 0-552 Volts. This will cover the standard typical voltage range that may be present for residential customers. Any measurement that falls outside this range, may be represent as a “High” or “Low” reading. This range may be adjusted for non-residential customers who have different needs. For measurements in this range, the voltage is typically represented to the nearest volt. In some embodiments, the voltage measurement data shown in FIGS. 2 and 3 contain a byte of data that contains 8 bits. This provides for 256 possible voltage levels for the measurement.
[0016] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed here. Accordingly, the scope of the invention should be limited only by the attached claims. | A communication protocol for compacting data transmissions from electric utility meters has been developed. The present invention is a method of transmitting the utility meter data using the protocol. The protocol includes collecting electric usage data and a voltage level at the utility meter. The usage data and the voltage level are then transmitting in synchronous order the utility receiving station. | 8 |
BACKGROUND
[0001] 1. Technical Field
[0002] The present invention is related to a composition for enhancing intestine metabolism, especially by using chitosan.
[0003] 2. Description of Related Art
[0004] The intestine is where digestion takes place and also a temporary storage place for digested food residues. Although an intestine is physically inside human body, it is considered as a physiologically outside part of human body in view of human physiology, which means the intestine directly contacts with outer environment and is a critical place that needs well-functional immune system.
[0005] Recently, the metabolism of intestine has drawn more and more attention. Researches reveal that the metabolism of intestine is highly related to body health and allergy condition of some individuals. As mentioned above, the intestine is a temporary storage place for digested food residues before being defecated. It is believed that if the digested food residues are retained inside the intestine for too long, the food residues would be further digested by intestinal flora and results in the increase of intestinal flora communities, especially of so called “bad” intestinal flora. Consequently, the amount of bad intestinal flora is increased, the balance inside the intestinal environment is broken, and the activities of the intestinal immune system is consumed so that the intestine metabolism and functionality may be effected, which eventually leads to influence health of the individual concerned. Therefore, although constipation or having excreta reserved in bowel is not a disease, they may be an abnormal or adverse condition that have serious impact on the health of an individual.
[0006] In light of the foregoing, it has been acknowledged that the health of an individual is reflected by the well condition in intestine thereof. The intestine metabolism is considered as a key factor that keeps in health. Therefore, there is constantly a need of a composition that is favorable for enhancing intestine metabolism.
SUMMARY
[0007] One object of the present invention is to provide a novel composition has good efficiency in enhancing intestinal metabolism.
[0008] In order to achieve the above objects, the present invention provides a composition for enhancing intestinal metabolism, comprising: 0.1 to 80 wt % of an aqueous soluble-chitosan; and 1 to 50 wt % of a pharmaceutically acceptable carrier.
[0009] The present invention also provides a method for enhancing intestinal metabolism, comprising: applying a subject in need an effective amount of an aqueous soluble-chitosan.
[0010] Preferably, said aqueous soluble-chitosan has a molecular weight of 0.3 to 1500 kDa; more preferably, said aqueous soluble-chitosan has a molecular weight of 0.5 to 300 kDa.
[0011] Preferably, said aqueous soluble-chitosan is a chitosan modified by alkyl sultone. More preferably, said alkyl sultone is 1,3-propanesultone, 1,4-propylenesultone, 1,4-butanesultone, 2,4-butanesultone, or a mixture thereof
[0012] Preferably, said aqueous soluble-chitosan is a sulfonic acid-modified chitosan.
[0013] Preferably, said effective amount is 1 to 500 mg/kgBW.
[0014] To sum up, the present invention surprisely found that the aqueous soluble-chitosan has superior effect on increasing the defecation rate of experimental rats. The experimental data supports that the aqueous soluble-chitosan may be a potential candidate for enhancing intestinal metabolism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows the comparison of the intestinal tracts of rats in the embodiment 3 of the present invention; (A) ND, (B) HFD, (C) CH, low dosage, (D) CH, high dosage, (E) AS-CH, low dosage, (F) AS-CH, high dosage.
DETAILED DESCRIPTION
[0016] The term of “intestine metabolism” is referred as the efficiency of an intestine tract to digest food and discharge waste. The term of “enhancing intestine metabolism” means to enhance defecation and prevent from constipation or having excreta reserved in bowel.
[0017] As known in the field, a high fat diet will cause bad effects on the intestine metabolism of an object. The high correlation between having high fat diet and bad intestine metabolism condition such as constipation or having excreta reserved in bowel has been proved. In this research, the experimental rats were fed with high fat diet to induce the bad intestine metabolism condition and to see if the aqueous soluble-chitosan of the present invention may recover it.
Embodiment 1
Preparation of Aqueous Soluble-Chitosan
[0018] The aqueous soluble-chitosan of the present invention is chitosan that is modified by alkyl sultone. Examples of alkyl sultone include but not limited to 1,3-propanesultone, 1,4-propylenesultone, 1,4-butanesultone, 2,4-butanesultone, or a mixture thereof. More specifically, the aqueous soluble-chitosan of the present invention is a sulfonic acid-modified chitosan. For example, the aqueous soluble-chitosan is alkyl sulfonic acid-modified chitosan. The alkyl sulfonic acid-modified chitosan may be fabricated by the following procedures:
[0019] 161 gram of chitosan (with molecular weight of 140,000) was put into a flask, and 700 ml of methanol was added in to obtain a mixture. The mixture was heated at 65 to 67° C., and 122 gram of 1,3-propanesultone was slowly dropped in while stirring. The mixture was kept refluxing for 4 hours after all 1,3-oxathiolane was added in. Then the flask was cooled down to room temperature, and product (alkyl sulfonic acid-modified chitosan) was collected by filtering. The product was washed by methanol from several times and dried overnight in a vacuum oven. The dried product was weighted 282 gram. The yield rate of the alkyl sulfonic acid-modified chitosan was 99.7%.
Embodiment 2
Experiment Design of Animal Model
[0020] The experiment was conducted by using 4-weeks old weaned Sprague-Dawley rats (purchased from BioLASCO Taiwan Co., Ltd). 64 rats were randomly separated into 8 groups. Each group had 8 rats. The experimental rats were maintained in plastic cages with free access to food and water. The temperature of those cages were kept at 25±1° C., and the day-night cycle was 12 hours per day. For experiments, rats were fed with normal diet (AIN-93G, ICN Biomedicals, Costa Mesa, Calif., USA) or high calorie diet to induce obesity (Modify AIN-93G high fat diet, 20% lipid) for 4 weeks before the administration of aqueous soluble-chitosan. Beginning from the fifth week, the experimental rats were fed with various dosages (10 or 25 mg/kg body weight) of unmodified chitosan and aqueous soluble-chitosan at every Monday, Wednesday, Friday and Saturday. Chitosan used was resolved in sterile water for feeding. One group of normal diet and one group of high calorie diet were instead fed with water as control. The experimental period was 8 to 12 weeks (the experiments were stopped depending on when the body weight of control group and test group show significant difference). The body weight and feeding amount (food intake) of the animals under experiments were measured and recorded every week.
[0021] The experimental animals were to be sacrificed by applying carbon dioxide after 12 weeks. Before sacrificing, those animals were starved for 12 hours. Rats' blood and intestinal tract were collected for further analysis.
Embodiment 3
Experimental Results
[Blood Sugar Analysis]
[0022] After starvation for 12 hours, the experimental animals were anesthetized by ether. Then the blood was collected from abdominal aorta for analyzing the blood sugar level by enzymatic method and colorimetry method. The results are showed in the following Table 1 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)).
[0000]
TABLE 1
Effects of AS-CH on the blood sugar in HFD rats
Blood sugar
mg/dL
ND
163 ± 27.7
HFD
185 ± 19.6
AS-CH or CH
CH (L)
172 ± 15.4
CH (H)
173 ± 23.0
AS-CH (L)
191 ± 28.7
AS-CH (H)
168 ± 37.9
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8).
[Hepatic & Kidney Function Analysis]
[0023] The AST, ALT, creatinine, uric acid were detected by enzymatic method and colorimetry method for determining the hepatic function. The results are showed in the following Table 2 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)).
[0000]
TABLE 2
Effects of AS-CH on the function
of hepatic and kidney in HFD rats
AST
ALT
Creatinine
Uric acid
U//L
mg/dLc
ND
162 ± 27.7
47.5 ± 8.01
0.53 ± 0.07
3.44 ± 0.98
HFD
145 ± 35.3
49.0 ± 7.78
0.51 ± 0.08
4.56 ± 0.69
AS-CH or
CH
CH (L)
176 ± 41.6
49.6 ± 9.24
0.54 ± 0.05
4.90 ± 0.88
CH (H)
159 ± 32.2
44.1 ± 7.71
0.50 ± 0.08
4.27 ± 0.91
AS-CH (L)
172 ± 34.9
66.6 ± 18.99
0.54 ± 0.05
4.77 ± 0.38
AS-CH (H)
161 ± 38.1
58.1 ± 25.68
0.47 ± 0.05
4.45 ± 0.71
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8).
[Ketone Bodies and Electrolyte Balance Analysis]
[0024] After starvation for 12 hours, the experimental animals were anesthetized by ether. Then the blood was collected from abdominal aorta for analyzing the concentration of ketone bodies, Na + ion and K + ion in the blood by enzymatic method and colorimetry method. The results are showed in the following Table 3 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)).
[0000]
TABLE 3
Effects of AS-CH on the electrolyte
balance and ketone bodies in HFD rats
Na +
K +
Ketone bodies
mEq/L*
nmole
ND
150 ± 3.06 ab
7.73 ± 1.4 ab
0.96 ± 0.34
HFD
151 ± 1.33 a
6.92 ± 0.5 ab
1.04 ± 0.35
AS-CH or CH
CH (L)
150 ± 0.92 ab
7.23 ± 1.0 ab
1.25 ± 0.43
CH (H)
149 ± 1.25 ab
8.16 ± 0.7 a
1.02 ± 0.28
AS-CH (L)
148 ± 1.63 b
8.39 ± 0.3 a
1.08 ± 0.51
AS-CH (H)
150 ± 1.33 ab
7.30 ± 1.2 ab
0.99 ± 0.13
*mEq/L: molar concentration of ion per liter
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8). Significance of difference in activities of different compounds was evaluated by Tukey's test statistical analysis. Different superscript letters a,b,c electrolyte balance are statistically different from each other (p < 0.05).
[0025] By summarizing the analysis of the aforesaid Table 1, Table 2 and Table 3, it was noted that the administration of the aqueous soluble-chitosan of the present invention had no effects on blood sugar, the ketone bodies and electrolyte balance in the blood. Also, it was showed that the administration of the aqueous soluble-chitosan of the present invention had no harm on the liver and kidney function of the experimental animals.
[0000] [Analysis for Food Intake, Body Weight, and Feed availability]
[0026] As mentioned in the aforementioned paragraphs, the body weight and food intake of the experimental animals were recorded regularly. Based on the recorded body weight, the change in body weight was calculated. Moreover, the feed efficiency was also calculated according to the formula: Feed Efficiency=(Weight Gain/Food Intake)×100%. Also, the organ weight was examined.
[0027] The results are showed in the following Table 4, Table 5, Table 6, and Table 7 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)).
[0000]
TABLE 4
Effects of AS-CH on the food intake and body weight in HFD rats
Food intake *
Body weight
(g/day)
(g)
8 wks
16 wks
0 wks
8 wks
16 wks
ND
30.8
29.4
111 ± 8
352 ± 18 c
459 ± 36 c
HFD
21.5
22.6
116 ± 5.5
520 ± 31 a
753 ± 24. a
AS-CH or CH
CH (L)
19.9
16.9
107 ± 10.8
421 ± 31 b
585 ± 57 b
CH (H)
21.4
16.3
113 ± 6.1
424 ± 31 b
602 ± 51 b
AS-CH (L)
21.8
16.9
115 ± 7.3
440 ± 14 b
602 ± 61 b
AS-CH (H)
20.1
13.5
110 ± 15.0
432 ± 21 b
598 ± 62 b
* Data was averaged of groups
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8). Significance of difference in activities of different compounds was evaluated by Tukey's test statistical analysis. Different superscript letters a,b,c body weight are statistically different from each other (p < 0.05)
[0000]
TABLE 5
Effects of AS-CH on the body weight gain percent in HFD rats
Body weight gain (%)
Change percentage (%)
8 wks
16 wks
16 − 8 wks
ND
0
0
0
HFD
48
64
16
AS-CH or CH
CH (L)
20
27
8
CH (H)
20
31
11
AS-CH (L)
25
31
6
AS-CH (H)
23
30
8
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8).
[0000]
TABLE 6
Effects of AS-CH on the feed bioavailability in HFD rats
Feed bioavailability
%
ND
363.9
HFD
1029.8
AS-CH or CH
CH (L)
967.5
CH (H)
1091.2
AS-CH (L)
965.2
AS-CH (H)
1232.4
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8).
[0000]
TABLE 7
Effects of AS-CH on the organ weight in HFD rats
Heart
Liver
Spleen
Kidney
% of body weight
ND
0.29 ± 0.02
2.88 ± 0.09 b
0.14 ± 0.02
0.69 ± 0.01
HFD
0.25 ± 0.03
3.45 ± 0.23 a
0.10 ± 0.01
0.62 ± 0.04
AS-CH or
CH
CH (L)
0.29 ± 0.02
2.90 ± 0.06 b
0.12 ± 0.02
0.62 ± 0.09
CH (H)
0.27 ± 0.02
3.18 ± 0.19 ab
0.14 ± 0.02
0.62 ± 0.04
AS-CH (L)
0.28 ± 0.02
2.97 ± 0.09 b
0.13 ± 0.02
0.60 ± 0.02
AS-CH (H)
0.29 ± 0.03
2.94 ± 0.20 b
0.12 ± 0.02
0.64 ± 0.07
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8). Significance of difference in activities of different compounds was evaluated by Tukey's test statistical analysis. Different superscript letters a,b,c organs weight are statistically different from each other (p < 0.05).
[0028] The above results indicated that the administration of the aqueous soluble-chitosan of the present invention did not cause significant change in food intake, body weight gain, feed bioavailability and organ weight.
[Analysis for Intestinal Length and Diarrhea Score]
[0029] After scarified, the intestinal tracks of rats were cut for measuring the length. Also, the diarrhea score was examined according to Melgar et al., (2005) by using the following standard table (Table 8).
[0000]
TABLE 8
Standard table for diarrhea score examination
Score
Diarrhea Degree
0
Solid and well-formed stools
1
Slightly soft stools
2
Soft stools
3
Watery stools
[0030] The results are showed in the following Table 9 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)).
[0000]
TABLE 9
Effects of AS-CH on the intestinal physiology in HFD rats
Intestinal length (cm)
Diarrhea score (%)
ND
18.19 ± 1.12 a
0.00 ± 0.00
HFD
16.29 ± 0.98 ab
0.00 ± 0.00
AS-CH or CH
CH (L)
15.20 ± 1.3 b
0.00 ± 0.00
CH (H)
16.46 ± 1.87 ab
0.00 ± 0.00
AS-CH (L)
16.76 ± 1.96 ab
0.00 ± 0.00
AS-CH (H)
17.36 ± 1.81 ab
0.00 ± 0.00
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8). Significance of difference in activities of different compounds was evaluated by Tukey's test statistical analysis. Different superscript letters a,b,c intestinal physiology are statistically different from each other (p < 0.05).
[0031] The result showed that the aqueous soluble-chitosan of the present invention has no effects on the intestinal length and did not cause any diarrhea.
[Analysis for Stool Volume and Defecation Rate]
[0032] The stool defecated by rats were weighted and recorded, and the defecation rate was calculated by formula: (Stool Volume/Food Intake)×100%. The results are showed in the following Table 10 (ND: normal diet; HFD: high fat diet; CH: chitosan (unmodified); AS-CH: aqueous soluble-chitosan (the present invention); L: low dosage (10 mg/kg BW); H: high dosage (25 mg/kg BW)). Also the intestinal tracks cut were pictured as showed in FIG. 1 .
[0000]
TABLE 10
Effects of AS-CH on the stool volume
and defecation rate in HFD rats
Stool volume
Defecation rate
(g/day/animal)
(% of HFD group)
ND
6.5
81
HFD
6.1
100
AS-CH or CH
CH (L)
4.2
91
CH (H)
4.2
96
AS-CH (L)
4.9
108
AS-CH (H)
4.5
122
*Defecation rate = (stool volume/food intake) × 100. Data was shown by taking HFD group as 100%.
SD rat was orally administered with various dosages AS-CH (10 or 25 mg/kg BW) for 8 wks. Data is expressed as means ± SD (n = 8). Significance of difference in activities of different compounds was evaluated by Tukey's test statistical analysis. Different superscript letters a,b,c intestinal physiology are statistically different from each other (p < 0.05).
[0033] According to FIG. 1 , more stools were observed to be retrained in the intestinal tract of rats under high fat diet; whereas the intestinal tracks of rats fed with the aqueous soluble-chitosan of the present invention were cleaner or had fewer stools retrained. This observation was consistent with the defecation rate showed in Table 10; wherein the defecation rate was significantly increased in rats fed with the aqueous soluble-chitosan of the present invention.
[0034] Those having ordinary skill in the art can understand various modifications according to the disclosed embodiments without departing from the spirit of the present invention. Therefore, the above-recited embodiments shall not be used to limit the present invention but shall intend to cover all modifications under the spirit and scope of the present invention along with the attached claims. | The present invention related to a composition comprising an aqueous soluble-chitosan and a pharmaceutically acceptable carrier. Said composition can be used to increase the defecation rate of an individual. Together with the well known biocompatibility of chitosan, the present invention proves that the aqueous soluble-chitosan may be a potential candidate for enhancing intestinal metabolism. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an IC card including a circuit board on which parts are mounted and to a method of manufacturing the IC card.
2. Description of the Related Art
FIG. 10 is an exploded view which illustrates a method of assembling a conventional IC card. A main frame 1 comprises a U-shaped frame portion 1a for forming a frame of the card together with a connector 4 to be described later and board supporting portions 1b and 1d, each of which is integrally formed with the frame portion 1a. The board supporting portion 1b has a projecting portion 1c formed at the central portion thereof. A circuit board 2 has circuit patterns (omitted from illustration) or both sides thereof. An IC package 3, which is a function part, is mounted on the circuit board 2 so that an electrical connection is established between them. A connector 4 is connected to either side of the circuit board 2, while a board fixing hole 2a is formed in the central portion of the circuit board to receive the projecting portion 1c of the board supporting portion 1b. The connector 4 constitutes a portion of the frame of the card, the connector 4 being electrically connected to external equipment (omitted from illustration) to which the IC package 3 and the IC card are connected. A surface panel 8a and a reverse panel 8b are protection panels made of metal plates or the like. A sub-frame 6 is disposed between the surface panel 8a and the circuit board 2 as a spacer. Since FIG. 10 is a schematic view which illustrates the IC card, some portions are omitted or schematically illustrated.
The structure of a conventional IC card is illustrated further in detail in FIGS. 11A and 11B. FIG. 11A is a plan view which illustrates the structure of the main frame 1. FIG. 11B is a cross sectional view taken along line XIB--XIB of FIG. 11A. Referring to FIGS. 11A and 11B, reference numeral 1d represents a board supporting portion formed at a position opposing the connector 4 of the frame portion 1a, the board supporting portion 1d being formed integrally with the frame portion 1a similarly to the board supporting portion 1b. Reference numerals 7a and 7b represent connector leads for establishing electrical and mechanical connection between the connector 4 and the circuit board 2.
A conventional method of assembling the IC card will now be described. First, the IC packages 3 are connected to both of the surfaces of the circuit board 2 by soldering so that the IC packages 3 are mounted. Then, the connector 4 is electrically and mechanically connected to the circuit board 2 by soldering the connector leads 7a and 7b to both surfaces of either side of the circuit board 2 (see FIG. 11B). A structure constituted by combining the circuit board 2 and the connector 4 is called a "module". Then, the module is so fastened to the main frame 1 that the connector 4 constitutes one of the sides of the frame of the card. At this time, the projecting portion 1c formed on the board supporting portion 1b is inserted into the board fixing hole 2a formed in the central portion of the circuit board 2, followed by deforming of the leading portion of the projecting portion 1c.
Then, the sub-frame 6 is secured to the upper surface of the circuit board 2 by an adhesive agent (omitted from illustration). The sub-frame 6 is secured at the position at which the board supporting portion 1d of the circuit board 2 is located so that the circuit board 2 is interposed between the sub-frame 6 and the board supporting portion 1d. The height of the sub-frame 6 is the same as the distance from the circuit board 2 to the surface panel 8a. Finally, the surface panel 8a and the reverse panel 8b are bonded to the frame portion 1a of the main frame 1, the connector 4 and the sub-frame 6 from their two sides with a sheet adhesive agent (omitted from illustration). As a result, the module composed of the circuit board 2 and the connector 4 is secured to the main frame 1. Further, the surface panel 8a and the reverse panel 8b are supported by the frame portion 1a of the main frame 1, the connector 4 and the sub-frame 6. Therefore, desired mechanical strength can be satisfied.
The conventional IC card has suffered from the problem that the number of IC packages that can be mounted has been unsatisfactorily limited because only one circuit board can be mounted if the IC card is intended to have desired mechanical strength.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide an IC card having, at a predetermined interval, circuit boards vertically stacked to form two layers therein while maintaining a predetermined mechanical strength.
In order to achieve the foregoing object, according to one aspect of the present invention, there is provided an IC card having two sides of board supporting portions, which are secured to a frame portion of a main frame and extend into the frame portion, support circuit boards in two stacked layers, and sub-frames as spacers between each of the circuit boards and panels to hold the circuit boards from the board supporting portions. According to another aspect of the present invention, there is provided an IC card further including fixing means for locating and fixing the circuit boards and the sub-frames or the board supporting portion, the fixing means having in one of projecting portions are formed in either of the board supporting portions or both sides of the circuit boards or the sub-frames, receiving holes in the other and board fixing holes in the circuit boards so that the projecting portions are received by the receiving holes via the board fixing holes of the circuit board.
According to another aspect of the present invention, there is provided a method of manufacturing an IC card including two circuit board layers with that an elongated circuit board formed by connecting circuit boards having a length, with which two layers can be formed with a member that can be bent is folded back to maintain a desired distance between the two circuit board layers so that the board supporting portions secured to the frame portion of the main frame and having the desired thickness is held between the two layers so that the circuit board forms the two layers. Then, a connector is electrically and mechanically connected to the two end portions of the folded back elongated circuit board and sub-frames serving as spacers between each of the circuit boards, and the panels are so disposed on the two sides of the board supporting portions as to hold the circuit boards from the board supporting portions. Then, panels are bonded on the two sides to cover the circuit boards.
The present invention includes other aspects.
The IC card according to the present invention has board supporting portions extending in the main frame and the sub-frames so disposed on both sides of the board supporting portions as to hold the circuit boards at desired intervals between the two circuit boards and between each circuit board and the panels. Further, the mechanical strength of the card is maintained. According to the another aspect of the present invention, the projecting portions and receiving holes formed in the board supporting portions or both sides of the circuit boards and the sub-frames and the board fixing holes formed in the circuit boards enable the circuit boards and the sub-frames to be located with respect to the board supporting portions and secured firmly.
The method of manufacturing an IC card according to the present invention has an elongated circuit board formed by connecting circuit boards for two layers to each other with a member that can be bent folded back so that two layers of the circuit board are formed. Therefore, the circuit board for two layers can be formed from one circuit board and the circuit board can easily be located.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cross sectional view which illustrates an IC card according to an embodiment of the present invention;
FIG. 1B is a plan view which illustrates the structure of a main frame of the foregoing IC card;
FIG. 2A is a plan view which illustrates the main frame shown in FIGS. 1A and 1B;
FIG. 2B is a side elevational view which illustrates the foregoing main frame;
FIG. 3A is a plan view which illustrates the sub-frame shown in FIGS. 1A and 1B;
FIG. 3B is a side elevational view which illustrates the foregoing sub-frame;
FIG. 4 is an exploded view which illustrates an embodiment of a method of manufacturing an IC card according to the present invention;
FIG. 5 is a side elevational view which illustrates an IC card having a different structure from the IC card shown in FIGS. 1A and 1B;
FIG. 6 is a schematic cross sectional view which illustrates an IC card according to a second embodiment of the present invention;
FIG. 7 is a schematic cross sectional view which illustrates an IC card according to a third embodiment of the present invention;
FIG. 8 is a schematic cross sectional view which illustrates an IC card according to a fourth embodiment of the present invention;
FIG. 9A is a plan view which illustrates the sub-frame shown in FIG. 6;
FIG. 9B is a side elevational view which illustrates the foregoing sub-frame;
FIG. 10 is an exploded view which illustrate a conventional method of manufacturing an IC card;
FIG. 11A is a plan view which illustrates a conventional IC card; and
FIG. 11B is a cross sectional view taken along line XIB--XIB.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described with reference to the drawings.
FIGS. 1A and 1B illustrate an IC card according to an embodiment of the present invention. FIG. 1B is a plan view which illustrates the structure of a main frame. FIG. 1A is a cross sectional view taken along line IA--IA of FIG. 1B. The same reference numerals as those of the conventional structure represent the same or similar elements. Reference numeral 10 represents a main frame made of resin, 20 represents an elongated circuit board folded back to form two layers in the card and 60 represents a sub-frame. FIGS. 2A and 2B illustrate the main frame 10 shown in FIGS. 1A and 1B. FIG. 2A is a plan view and FIG. 2B is a side elevational view. The main frame 10 comprises a U-shaped frame 10a and three board supporting portions 10b, 10d and 10f within the frame portion 10a, the three board supporting portions 10b, 10d and 10f being respectively integral with the main frame 10 project in opposite directions from. The three board supporting portions 10b, 10d and 10f respectively are located at the central portion of the frame potion 10a in a direction of the height of the frame portion 10a. Further, projecting portions 10c and 10e respectively project in opposite directions from the board supporting portions 10b and 10d.
The elongated circuit board 20 is a unitary elongated circuit board of two circuit board portions 21 and 22 with a bending portion 23 which is made of flexible material that can be bent. Function parts, for example, IC packages 3 are mounted on opposite sides of each of the circuit board portions 21 and 22. Further, board fixing holes 2a, as shown in FIG. 1, in the circuit board 20 engage the board supporting portions 10b and 10d when the circuit board 20 is accommodated in the main frame 10. The board fixing holes 2a receive the projecting portions 10c and 10e of the board supporting portions 10b and 10d (see FIG. 4). It should be noted that the circuit board portions 21 and 22 may be electrically connected by means of a circuit pattern (omitted from illustration) in the bending portion 23. The electrical connection between the two sides of the circuit board is established by, for example, a through hole (omitted from illustration).
Sub-frames 60 serve as spacers between the circuit board portions 21 and 22 and the panels 8a and 8b. The sub-frames 60 are shown in FIGS. 3A and 3B which are a plan view and a side elevational view, respectively. Each of the sub-frames 60 has a receiving hole 60a. The receiving holes 60a are, as shown in FIG. 1A, holes for receiving the projecting portions 10c and 10e of the board supporting portions 10b and 10d that penetrate the board fixing holes 2a of the circuit board portions 21 and 22. A fixing means includes the foregoing projecting portions 10c and 10e, the receiving holes 60a, and the board fixing holes 2a.
FIG. 4 illustrates an embodiment of a method of manufacturing the IC card according to the present invention. The structure of the IC card will now be described in accordance with the sequential order of the manufacturing method. First, the elongated circuit board 20 in a flat state in which the IC packages 3 are mounted on the two sides of each of the circuit board portion 21 and 22 is inserted into a gap 9 formed between the frame portion 10a of the main frame 10 and the board supporting portion 10d until the bending portion 23 reaches the gap 9, followed by folding back the circuit board 20 at the bending portion 23 (a circuit-board bending process). Then, the upward and downward projections 10c and 10e of the board supporting portions 10b and 10d are respectively inserted into the board fixing holes 2a of the circuit board portions 21 and 22 of the bent elongated circuit board 20 so that the elongated circuit board 20 is positioned (a circuit board position process). The positioning process is performed in the following sequential order: the upper projecting portion 10c of the board supporting portion 10b, the upper projecting portion 10e of the board supporting portion 10d, the lower projecting portion 10c of the board supporting portion 10b and the lower projecting portion 10e of the board supporting portion 10d.
Then, the connector 4 is fastened to the main frame 10 (a connector fastening process), the connector 4 being fastened as designated by an arrow of FIG. 4 so that the connector leads 7a and 7b hold the circuit board portions 21, 22 and the board supporting portion 10f at their opposite sides. The connector leads 7a and 7b are, by soldering, secured to the end portions of the circuit board portions 21 and 22, as shown in FIG. 1A. As a result, the elongated circuit board 20, which is folded over, is brought into a state where it is secured to the main frame 10. Then, the sub-frames 60 are fastened to the two upward and two downward projecting portions 10c and 10e penetrating the board fixing holes 2a of the circuit board portions 21 and 22 so that the projecting portions 10c and 10e are received by the receiving holes 60a, the sub-frames 60 being bonded with an adhesive agent (omitted from illustration). Finally the surface panel 8a and the reverse panel 8 b are bonded to the frame portion 10a of the main frame 10, the connector 4 and the sub-frames 60 with, for example, a sheet adhesive (omitted from illustration). Thus, the IC card is manufactured (a panel fastening process).
By controlling the thickness of each of the board supporting portions 10b, 10d and 10f on the inside of the frame portion 10a of the main frame 10 and those of the sub-frames 60 disposed on the board supporting portions 10b, 10d and 10f to hold the circuit board to the desired thicknesses, the IC card manufactured as described above has a distance between the two circuit board portions 21 and 22 and that between the two circuit board portions 21, 22 and the panels 8a and 8b at a desired interval. Since the interval between the circuit board portions and between the circuit board portions and the panels can be determined arbitrarily by changing the height of the board supporting portions and that of the sub-frame, measures against heat radiation from the IC package and against radiation noise can easily be taken. Further, the board supporting portions 10b, 10d and 10f and the sub-frame 60 enable the card to have the required mechanical strength. If the manufacturing method is not considered, the IC card according to this embodiment may be composed of two independent circuit boards 24 and 25 as shown in FIG. 5 to obtain a similar effect.
When the IC card including a circuit substrate formed into a two-layer structure as described above is manufactured in the foregoing manner with the elongated circuit board having a sufficient length for two circuit boards bent to hold the board supporting portions, the number of parts can be decreased, the circuit board can easily be located with respect to the main frame and the IC can can easily be manufactured. Further, the foregoing manufacturing method causes the module composed of the connector 4 and the elongated circuit board 20 to be secured to the main frame 10 when the connector is fastened in the connector fastening processes. Therefore, the ensuing process can easily be performed.
Although the foregoing embodiment has the projecting portions 10c and 10e on the board supporting portions 10b and 10d, the projecting portions may be on the sub-frames 60. FIG. 6 is a schematic cross sectional view which illustrates an IC card according to a second embodiment of the present invention in which projecting portions 60b are on the sub-frame 60 and a receiving hole 10g penetrates the board supporting portion 10b. FIGS. 9A and 9B illustrate the sub-frame 60 shown in FIG. 6, where FIG. 9A is a plan view and FIG. 9B is a side elevational view. The foregoing structure, of course, enables a similar effect to be obtained.
FIG. 7 is a schematic cross sectional view which illustrates a third embodiment of the present invention in which board supporting portions are formed separately from the main frame. This embodiment has an arrangement that two board supporting portions 70 each having one-half the height of those according to each of the foregoing embodiments face in opposite directions so that projecting portions 70a of the two board supporting portions 70 penetrate board fixing holes in the two circuit board portions 21 and 22 of the circuit board 20. Further, sub-frames 60 are so bonded that the projecting portions 70a penetrating the circuit board 20 are received by receiving holes 60a. A method of manufacturing the IC card according to this embodiment will now be described. First, the projecting portions 70a of the two board supporting portions 70 are inserted into the corresponding board fixing holes of the circuit board 20 in a flat state (a state before the circuit board 20 is bent). Then, the sub-frames 60 are bonded on the opposite sides of the circuit board 20 with the projecting portions 70a in the receiving holes 60a. Then, the elongated circuit board 20 is so folded back that the two board supporting portions 70 are bonded to face in the opposite directions. Then, a connector 4 is fastened to the elongated circuit board 20 to which the board supporting portions 70 and the sub-frames 60 are fastened and which are folded back so that a module is formed. The foregoing module is secured to a frame portion 10a. At this time, the two end portions of the board supporting portions 70 and/or the sub-frames 60 are bonded to the frame portion 10a with an adhesive agent (omitted from illustration). Finally, the panels are fastened on two sides.
FIG. 8 is a schematic cross sectional view which illustrates an IC card according to another embodiment in which a board supporting portion is separate from the main frame. The IC card according to this embodiment employs a board supporting portion 70 and a sub-frame 60 from which the projections and receiving holes are omitted. Therefore, the circuit board 20 has no board fixing hole.
A similar effect can be obtained from arrangements according to the third and fourth embodiments in which the board supporting portions interposed between the two layers of the circuit board are separate from the frame portion of the main frame and are fixed to the frame portion during the assembly process.
Also in the case of the first and second embodiments in which the main frame has internal board supporting portions, a structure may be employed in which the projecting portions and the receiving holes are omitted from the board supporting portions and the sub-frames.
As described above, the an IC card according to the present invention has two sides of a board supporting portions secured to a frame portion of a main frame supporting the circuit board having two stacked layers. Further, sub-frames serving as spacers between each of the circuit boards and the panel on both sides of the board supporting portions hold the circuit board from the board supporting portions. Therefore, the distance between the two circuit boards and the distance between each circuit board and the panels can be maintained at desired intervals in accordance with the thicknesses of the board supporting portions and of the sub-frame so that the mechanical strength of the card can be ensured. Further, the projecting portions are formed on one of the board supporting portions or the sub-frames and the receiving holes are formed in the other of those elements. In addition, the board fixing holes in the circuit board are received by the receiving holes so that the circuit board and the sub-frame are located and secured to the board supporting portions.
A method of manufacturing an IC card according to the present invention has an elongated circuit board formed by connecting a circuit boards having a length so that two layers can be formed with a member that can be bent folded back to maintain a desired distance between the two circuit board layers so that the board supporting portions secured to the frame portion of the main frame and having the desired thickness are held between the two layers. Therefore, the number of parts can be decreased, the circuit board can easily be located with respect to the main frame and manufacturing can easily be performed. By interposing the board supporting portions between the two layers of the circuit board that are separate from the frame portion of the main frame and by securing the board supporting portions to the frame portion during the assembling process, the number of parts can be decreased in comparison to the arrangement in which two circuit boards are used. Further, a module composed of the circuit board forming the two layers, the connector, the board supporting portions and the sub-frame can easily be formed. Therefore, the IC card comprising the circuit board forming the two layers can easily be manufactured. | An IC card exhibiting improved electrical insulation, heat radiation capability, and radiation noise resistance includes circuit boards stacked in two layers and spaced apart from each other and surface panels of the IC card while maintaining satisfactory mechanical strength in the card. Board supporting portions extending in a frame portion of a main frame and sub-frames disposed on the board supporting portions hold the circuit boards, maintain a predetermined interval between the two circuit boards and between each circuit board and the surface panels, and provide the desired mechanical strength for the card. | 7 |
FIELD OF THE INVENTION
[0001] The present invention provides a biopulp and a biopulping method thereof, and more particularly to a biopulp for non-woody fiber plants and a biopulping method thereof.
BACKGROUND OF THE INVENTION
[0002] The paper-making industry is an universally traditional industry. The development of paper-making industry is the index of the economy and living standard for a country. The source of paper pulp mostly comes from cutting down the forest. (It needs four metric tons of woods to produce one metric ton of paper pulp. It equals to cut down twenty-three trees.) Because of that, the forest area on the earth is rapidly decreased. The ecological balance problem becomes more and more serious. Furthermore, it needs a great quantity of water and chemicals to wash pulp. However, the waste liquid is discharged from factory in the traditional chemical paper-making process. It also results in environmental pollution. The rivers and oceans are polluted. Nowadays, people in the whole world pay much attention to environmental protection. The corporations in paper-making industry are obliged to spend much money to improve the environmental quality. The production costs are thus raised. Those problems really strike against the paper-making industry.
[0003] The annual yield of rice straws is about 2300 thousand metric tons in Taiwan. The organic components of rice straws are almost more than 95%. The organic components include 41.3% carbon, 0.81% hydrogen, 20.6% semicellulose, 24.7% cellulose and 7.7% lignin. Conventionally, the handling methods for rice straws include manufacturing them into straw ropes, straw bags, straw mats and cardboards, serving them as covering material for a plot of land, utilizing them as fuel, and mixing them with other material to produce a compost. Also, the rice straw could be directly buried in soil or burned for recyclably using the nutrition. Nowadays, the rice straws are rarely used to be the fuel, feed, straw bags or straw mats because of the expensive costs and the advanced science and technology. Most of the rice straws are locally burned or directly buried in soil, which often result in environmental pollution. On the other hand, since the rice straws are in abundant fiber, it will be very helpful to mitigate the environmental pressure of logging the trees for papermaking if the non-woody fiber plants could be well developed and used. In the past, the fiber production methods by using non-woody fiber plants as original material are generally chemical or semi-chemical methods. However, there exist three difficult problems in the paper-making industry resulting from the chemical production method for pulp. They are described as follows. (1) Large amount of silicates and black liquid with high viscosity produced in the process often result in the serious problems of recycle systems. (2) The deposition of calcium carbonate will be affected by the silicates and thus will lead to the dirt appearance attached on the vapor apparatus. In addition, the piping of evaporator will get undesirable black viscous liquid attached on. Therefore, it needs to stop working for cleaning the apparatus. (3) The unstable status of the steamer and boiling machines will waste the fuel and thus will raise the production costs.
[0004] The biotechnology is the key for reorganizing the traditional industry structure. It is a very important direction moved towards the use of the biotechnology for papermaking in the industry. Recently, the advantages of using biotechnology for papermaking are the reduction of production cost, the improvement of pulp quality and the safety maintenance of the working environment, etc. There are many methods and products produced, for example, the removal of the gum or printing ink by using enzymes, paper bleaching by using xylanase or lignin oxidizing enzyme, and the improvement of pulp viscosity by using enzymes (non-woody fiber pulp especially). However, these methods also have the drawbacks of environmental pollution caused by waste liquid and energy consumption and so on. Therefore, it is imperative to seek the assistance of biotechnology for solving and overcoming the drawbacks of papermaking by using chemical methods.
[0005] Researchers in many countries of Europe and American attempt to use white-rot fungi, such as Phanerochaete chrysosporiumand and Cereporiopsis subvermispora , grown on wood slices for removing the lignin of woods and saving the cost and energy of paper making. Although there are some results came from those researches, it takes too much time for the industry to grow the white-rot fungi on woods outdoors.
[0006] The main purpose of the present invention is to apply the decomposition ability of the microorganisms for decomposing the organic matters in the papermaking processes of waste straws so as to establish a model of biopulping processes for non-woody fiber plants. The non-woody fiber plants will become an important source of the raw materials of paper pulp. This approach can decrease the consumption of forest reservations and the production of chemical wastes. And then the problems of papermaking are solved.
[0007] From the above description, it is known that how to develop a new pulping method with the advantages of low production costs, low or non pollution has become a major problem waited to be solved. In order to overcome the drawbacks in the prior art, a biopulp for non-woody fiber plants and a biopulping method thereof is provided. The particular design in the present invention not only solves the problem described above, but also uses the waste rice straws and a biopulping method to produce paper pulp for paper-making. It does not need to use the chemical or semi-chemical method, and therefore no pollution problems exist. Thus, the invention has the utility for the industry.
[0008] Therefore, the present invention provides a biopulp for non-woody fiber plants and a biopulping method thereof which overcomes the disadvantages described above.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to apply the decomposition ability of the microorganisms for decomposing the organic matters in the papermaking processes of waste straws so as to establish a model of biopulping processes of a non-woody fiber plant. The non-woody fiber plants will become an important source of the raw materials of paper pulp. This approach can decrease the consumption of forest reserves and no chemical pollution is produced. And then the problems of papermaking are solved.
[0010] It is another object of the present invention to provide a biopulping method for recycling the waste straws and decreasing the cost of papermaking.
[0011] In accordance with an aspect of the present invention, a production method for a paper pulp includes steps of providing a culture solution, adding a fiber plant into the culture solution, adding a suspension of a microorganism into the culture solution, fermentatively culturing the culture solution for preparing a pulp solution, boiling the pulp solution, pulping the pulp solution, and screening the pulp solution for isolating a paper pulp from the pulp solution.
[0012] Preferably, the fiber plant is a non-woody fiber plant.
[0013] Preferably, the fiber plant is pretreated by one selected from a group consisting of a relatively high pressure treatment under a relatively high temperature, a steaming treatment under a relatively high temperature, a boiling treatment under a relatively high temperature, a fumigated treatment and a soaking treatment under a room temperature.
[0014] Preferably, the fiber plant is added into the culture solution by a ratio of 4˜15%.
[0015] Preferably, the microorganism is isolated from one of a non-woody fiber plant and a livestock excrement compost.
[0016] Preferably, the microorganism is inoculated at a concentration ranged from 0 to 10 8 cfu/ml.
[0017] Preferably, the microorganism is a Gram positive bacterium.
[0018] Preferably, the microorganism is one selected from a group consisting of a Bacillus licheniformis (PMBP-m5), a Bacillus subtilis (PMBP-m6) and a Bacillus amyloliquefaciens (PMBP-m7).
[0019] Preferably, the fermentatively culturing process is proceeded at a temperature ranged from 20 to 50° C.
[0020] Preferably, the fermentatively culturing process is one of a static culture and a shaking culture.
[0021] Preferably, the fermentatively culturing process is proceeded over 0˜10 days.
[0022] Preferably, the step (e) further includes a step of adding 0˜4% (w/v) CaO into the pulp solution and boiling the pulp solution for 25˜40 minutes under 120˜150° C.
[0023] Preferably, the pulp solution is screened by 18˜300 meshes.
[0024] In accordance with another aspect of the present invention, a biopulping method for a non-woody fiber plant includes steps of providing a culture solution, adding a non-woody fiber plant into the culture solution, adding a suspension of a microorganism into the culture solution, fermentatively culturing the culture solution for preparing a pulp solution, boiling the pulp solution, pulping the pulp solution, and screening the pulp solution for isolating a paper pulp from the pulp solution.
[0025] Preferably, the fiber plant is pretreated by one selected from a group consisting of a relatively high pressure treatment under a relatively high temperature, a steaming treatment under a relatively high temperature, a boiling treatment under a relatively high temperature, a fumigated treatment and a soaking treatment under a room temperature.
[0026] Preferably, the inoculation concentration of a microorganism is at a range from 0 to 10 8 cfu/ml.
[0027] Preferably, the microorganism is one selected from a group consisting of a Bacillus licheniformis (PMBP-m5), a Bacillus subtilis (PMBP-m6) and a Bacillus amyloliquefaciens (PMBP-m7).
[0028] Preferably, the step (e) further includes a step of adding 0˜4% (w/v) CaO into the pulp solution and boiling the pulp solution for 25˜40 minutes under 120˜150° C.
[0029] Preferably, the pulp solution is screened by 18˜300 meshes.
[0030] In accordance with another aspect of the present invention, a biopulp of a non-woody fiber plant, includes the components of a non-woody fiber plant and a suspension of a microorganism. The non-woody fiber plant and the suspension of the microorganism suspension are mixed and fermentatively cultured for preparing the biopulp.
[0031] Preferably, the microorganism is a Gram positive bacterium.
[0032] Preferably, the microorganism is one selected from a group consisting of a Bacillus licheniformis (PMBP-m5), a Bacillus subtilis (PMBP-m6) and a Bacillus amyloliquefaciens (PMBP-m7).
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] [0033]FIG. 1 shows the effects of different treatments on the decomposition percentages of rice straw;
[0034] [0034]FIG. 2 shows the ability of various strains to decompose the rice straw of Japonica rice;
[0035] [0035]FIG. 3 shows the effects of different inoculation concentrations of PMBIII strain group on the recovery percentages of the rice straw pulp fibers;
[0036] [0036]FIG. 4 shows the effects of different fermentation culturing periods on the recovery percentages of various straw pulp fibers;
[0037] [0037]FIG. 5 shows the effects of microorganism fermentation treatment and chemical treatment on the recovery percentages of various straw pulp fibers; and
[0038] [0038]FIG. 6 shows the flow chart of biopulping method for waste rice straw according to a preferred embodiment of the present invention.
[0039] The foregoing and other features and advantages of the present invention will be more clearly understood through the following descriptions with reference to the drawings, wherein:
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] (A) The Effects of Various Rice Straw Treatments on the Decomposition of Rice Straws:
[0041] The waste rice straws of Japonica rice ( Oryza sativa L. subsp. japonica ) and Indica rice ( Oryza sativa L. subsp. indica ) are provided. The rice straws are sun-dried, cut into small segments at the length of 2-3 cm and pretreated in different ways. For example, the rice straws are pretreated by an autoclave treatment (121° C., 15 lb/in 2 for 15 minutes), a steaming treatment under relatively high temperature (100° C. for 30 minutes), a boiling treatment under a relatively high temperature (100° C. for 30 minutes), a fumigated treatment (Propylene oxide treatment for one day), or a soaking treatment under a room temperature (25˜30° C. for 30 minutes). The various treatments of rice straws can further affect the pulp recovery efficiency. The detail steps are described as follow. The rice straws are treated by an autoclave treatment (121° C., 15 lb/in 2 for 15 minutes), a soaking treatment under a room temperature (25˜30° C. for 30 minutes), a fumigated treatment (Propylene oxide treatment for one day), a steaming treatment under relatively high temperature (100° C. for 30 minutes) respectively. The pretreated rice straws are added into the flasks containing 100 ml sterile water at the amount of 5% (w/v) and then respectively incubated at 50° C., 200 rpm shaking culture and static culture for a week. Each treatment has duplicate samples. The changes of the rice straws are observed. The decomposition percentage of rice straws is investigated and recorded.
[0042] Please refer to FIG. 1, which shows the effects of different treatments on the decomposition percentages of rice straw, which includes an autoclave treatment (121° C., 15 lb/in 2 for 15 minutes), a soaking treatment under a room temperature (25˜30° C. for 30 minutes), a fumigated treatment (Propylene oxide treatment for one day), a steaming treatment under relatively high temperature (100° C. for 30 minutes). The decomposition percentage of rice straws is calculated by the following formula.
Decomposition % = (Total dry weight of fermentative rice straws -
Dry weight of intact rice straws) (Total dry weight of fermentative rice straws) × 100
[0043] The results reveal that the shaking culture is helpful to increase the decomposition of rice straws. After shaking culture, the decomposition percentage of rice straws of Indica rice is obviously higher than that of Japonica rice. The decomposition percentage of the fumigated (Propylene oxide) treatment is quite low in both shaking culture and static culture. It indicates that the microorganisms on the surface of the rice straws are disinfected by the Propylene oxide. Therefore, very few microorganisms are left in the sample treated with propylene oxide. Comparing the effect of soaking treatment under a room temperature with the effect of fumigated treatment, it is proved that the microorganisms are helpful to the decomposition of rice straws. With regard to the steaming treatment under relatively high temperature, the boiling treatment under a relatively high temperature and the soaking treatment under a room temperature, they are all helpful to the decomposition of rice straws. By shaking culture, the aerobic fermentation speeds up the decomposition of the rice straws by the microorganisms.
[0044] (B) The Selection of Bacterial Strains having Decomposition Ability:
[0045] The microorganism strains are obtained by the following method according to a preferred embodiment. First, 10 g of the rice straws and 10 g of livestock excrements are prepared and added into 90 ml of sterile water containing agar (0.1%, w/v). The materials are well mixed and a serious dilution is made. Then, 0.1 ml of 10 3 × and 10 4 × diluted solution are uniformly spread on Nutrient Agar plate, pH 8 (NA, purchased Nutrient Agar from Difco company) and Potato Dextrose Agar plate, pH 8 (PDA, purchased Potato Dextrose Agar from Difco company) respectively. Next, the plates are placed in the incubators under 30° C. and 50° C. for 24 hours and 48 hours respectively. Single colonies grown on plates are picked and isolated for obtaining the microorganism strains. The number of microorganisms isolated from the rice straws and the livestock excrements having the decomposition ability is more than 200 strains. Finally, the microorganisms are identified by the Gram stain. It is found that most of the microorganisms are Gram-positive bacteria.
[0046] The isolated microorganisms are further selected by the following steps for selecting the microorganism strains having the decomposition ability for rice straws. (1) 19 strains of the isolated strains, named PMBP-m1, PMBP-m2, PMBP-m3, PMBP-m4, PMBP-m5, PMBP-m6, PMBP-m7, PMBP-O1, PMBP-O2, PMBP-O3, PMBP-O4, PMBP-e1, PMBP-e2, PMBP-e3, PMBP-e4, PMBP-H1, PMBP-H2, PMBP-H3 and PMBP-H4 (as shown in Table 1), are divided into 9 strains groups, including PMBP-I, PMBP-II, PMBP-III, PMBP-IV, PMBP-V, PMBP-VI, PMBP-O, PMBP-E and PMBP-H. Please refer to Table 1, which shows the bacterial strains of different strain groups and the characteristics thereof. (2) The strains groups are cultured with NA plates respectively and then a suspension of microorganism is prepared at the concentration of 10 8 cfu/ml. (3) 100 ml of solution containing rice straws of Japonica rice (5%, w/v) is prepared. (4) 1 ml of the microorganism suspension is added into the sterile solution prepared in step (3) and then cultured under 50° C. and 200 rpm shaking for a week. Each strain is set up in duplicate. (5) The decomposition percentage of rice straws is calculated.
TABLE 1 Characteristics Temp. Gram stain Isolate 50° C. pH8 (+/−) PMBP-m1 ++ + + PMBP-m2 ++ + + PMBP-m3 ++ + + PMBP-m4 ++ + + PMBP-m5 ++ + + PMBP-m6 ++ + + PMBP-m7 ++ + + PMBP-O1 ++ + + PMBP-O2 ++ + + PMBP-O3 ++ + + PMBP-O4 ++ + + PMBP-e1 ++ + + PMBP-e2 ++ + + PMBP-e3 ++ + + PMBP-e4 ++ + + PMBP-H1 ++ + + PMBP-H2 ++ + + PMBP-H3 ++ + + PMBP-H4 ++ + +
[0047] Please refer to FIG. 2, which shows the ability of various strains to decompose the rice straw of Japonica Rice. The Japonica rice straws treated with shaking culturing for a week are classified, dried and weighted. The decomposition percentage of rice straws treated with different microorganisms is calculated by the following formula.
Decomposition % = (Total dry weight of fermentative rice straws -
Dry weight of intact rice straws) (Total dry weight of fermentative rice straws) × 100
[0048] As shown in FIG. 2, the PMBIII strain group has the best decomposition ability than the others. The decomposition percentage of rice straws is about 10.38%. The PMBIII consists of Bacillus licheniformis (PMBP-m5), B. subtilis (PMBP-m6) and B. amyloloquefaciens (PMBP-m7).
[0049] (C) The Production of Biopulp by Utilizing Bacteria with Different Inoculation Concentrations:
[0050] The waste rice straws are the material for producing the biopulp. Different inoculation concentrations of bacteria are added to decompose the rice straws and those of decomposition effects on rice straws are compared. The steps are as follows.
[0051] (1) Preparation of culture solution: A LBY culture solution containing 0.25% lactose, 0.2% beef extract and 0.05% Yeast extract is prepared.
[0052] (2) Preparation of waste rice straws for testing: The waste rice straws are collected. The cultivated variety of rice is Taichung Sheng No. 10 (Indica rice). The rice straws are sun-dried and cut into small segments at the length of 2-3 cm.
[0053] (3) Fermentatively shaking culture: The PMBIII strain group consisting of Bacillus licheniformis (PMBP-m5), B. subtilis (PMBP-m6) and B. amyloloquefaciens (PMBP-m7) is picked and the suspension of PMBIII strain group is prepared. 1000 ml of concave-bottom flasks containing 500 ml LBY culture solutions is prepared. The bacteria suspensions of the PMBIII strain group are added into the culture solution at the concentrations of 1.5×10 4 cfu/ml (LBY-4 treatment), 1.5×10 6 cfu/ml (LBY-6 treatment) and 1.5×10 8 cfu/ml (LBY-8 treatment) respectively. The culture solution without adding any bacteria suspension is the control (LBY-1 treatment). The rice straw segments are added into the culture solutions at the amount of 0.5% (w/v). And then the culture solutions are fermented in shaking culture under 50° C., 200 rpm for a week. Each concentration of bacteria is set up in four repetitions to prepare a pulp solution.
[0054] (4) Boiling of the pulp solution: 1% (w/v) CaO is added into the pulp solution, which is then heated up to 140° C. for 30 minutes.
[0055] (5) Generation of the pulp solution: The pulp solution is generated by further pulping for 15 minutes.
[0056] (6) Filtration of the pulp solution: The pulp solutions are sieved by sieves with 18, 200 and 270 meshes respectively for isolating the incompletely decomposed rice straw pulp from the pulp solutions. The recovery percentages of the rice straw pulp fibers sieved through sieves with different meshes are calculated. The recovered rice straw pulp fibers sieved through 200 meshes are made into the handmade papers. The physical properties of the handmade papers are tested.
[0057] The results are shown in FIG. 3 and Table 2. FIG. 3 shows the effects of different inoculation concentrations of PMBIII strain group on the recovery percentages of the rice straw pulp fibers. The recovery percentages of rice straw pulp fibers are slightly decreasing with increasing inoculation concentrations of PMBIII strain group. High inoculation concentration of PBMIII strain group has no significant effect on the decomposition of rice straws. Please refer to Table 2, which shows the comparisons of physical properties of handmade papers made from the pulp treated with different inoculation concentrations of bacteria. The permeability to gases and the general strength of handmade papers of the LBY-6 treatment (The inoculation concentration is 1.5×10 6 cfu/ml) is better than the others. The characteristic differences among the papers treated with other inoculation concentration of bacteria are not significant. However, the general strengths of the papers treated with the inoculation of bacteria are all higher than that of the control (LBY-1) which is treated without the inoculation of bacteria.
TABLE 2 Treatment LBY-1 LBY-4 LBY-6 LBY-8 Test item C.S.F.:143 ml C.S.F.:162 ml C.S.F.:137 ml C.S.F.:212 ml Basic weight 72.4 71.0 71.7 71.4 (g/m 2 ) Thickness 0.134 0.126 0.124 0.125 (mm) Bulk 1.85 1.77 1.73 1.75 (ml/g) Breaking length 5.74 5.69 6.24 5.99 (Km) Tear Index 3.74 4.14 3.50 3.90 (mN · m 2 /g) Burst Index 2.56 2.90 3.20 3.20 (Kpa · m 2 /g) Cohesion Force 2.11 2.34 2.31 2.15 (kg-cm) Permeability to 550.8 556.5 930.2 524.0 Gases (sec/100 ml) Surface Strength 12 13 13 13 (A) Stiffness 1.52 1.36 1.36 1.42 (g-cm) Opacity 97.3 95.6 97.0 96.5 (%) Whiteness 22.3 22.2 21.7 23.1 (%) Ash Content (%) 11.6 11.6 11.3 11.3 *General Strength 16.26 17.41 17.56 17.39
[0058] (D) The Effects of Different Fermentation Culturing Periods on the Production of Rice Straw Pulp Fiber:
[0059] The length of fermentation culturing time can be various according to a preferred embodiment. First, a LBY liquid medium and the rice straw segments of Indica rice are prepared (The rice straws are sun-dried and cut into small segments at the length of 2-3 cm.). The LBY liquid medium is aliquoted into sterile 1000 ml concaved-bottom flask, 500 ml per flask. The PMBPIII strain group is added into the LBY liquid media at the concentration of 1.5×10 6 cfu/ml. Then, the rice straw segments are added into the LBY liquid media containing PMBIII strain group at the concentration of 5% (w/v). And then the mixed solution is cultured in shaking culture at 200 rpm under 50° C. for 0, 1, 4, 7 and 10 days respectively. Each treatment is set up in four repetitions. Next, CaO is added into the fermentative culture solution at the concentration of 1% (w/v) and then the fermentative culture solution is boiled up to 140° C. for 30 minutes for preparing the pulp solution. The pulp solution is further pulped for 15 minutes. The pulp solutions are sieved by sieves with 18, 200 and 270 meshes respectively for isolating the incompletely decomposed rice straw pulp fibers from the pulp solutions. The recovery percentages of the rice straw pulp fibers sieved through sieves with different meshes are calculated. The recovered rice straw pulp fibers sieved through 200 meshes are made into the handmade papers. The physical properties of the handmade papers are tested.
[0060] Please refer to FIG. 4 and Table 3. FIG. 4 shows the effects of different fermentation culturing periods on the recovery percentages of various straw pulp fibers. The recovery percentage is decreased as the fermentation culturing period is increased. The pulp fibers recovered from the fibers sieved through 200 meshes, which are fermented for different fermentative periods, are compared. The recovery percentage of 1-day fermentative culture is higher than that of the other periods. Table 3 shows the effects of different fermentation culturing periods on the physical properties of handmade papers made from rice straw pulp fibers. The 4-day fermentative culture has the best gases permeability. And 10-day fermentative culture has the lowest gases permeability. Also, the 4-day fermentative culture has the best general strength.
TABLE 3 Treatment LBY-d0 LBY-d1 LBY-d4 LBY-d7 LBY-d10 Item C.S.F.: 209 ml C.S.F.: 227 ml C.S.F.: 179 ml C.S.F.: 138 ml C.S.F.: 198 ml Basic weight 72.5 71.7 70.6 72.7 73.8 (g/m 2 ) Thickness 0.135 0.126 0.120 0.126 0.143 (mm) Bulk 1.86 1.76 1.70 1.73 1.94 (ml/g) Breaking length 3.73 4.61 5.17 4.41 3.38 (Km) Tear index 2.49 4.05 4.00 3.56 3.89 (mN · m 2 /g) Burst Index 1.61 2.45 2.57 2.01 1.82 (Kpa · m 2 /g) Cohesion Force 1.76 1.75 2.04 1.69 1.69 (kg-cm) Permeability to 245.2 174.5 368.8 200.9 57.0 Gases (sec/100 ml) Surface Strength 7 9 8 10 7 (A) Stiffness 1.27 1.28 1.23 1.57 1.62 (g-cm) Opacity 98.7 98.4 98.2 99.1 99.3 (%) Whiteness 18.1 22.0 22.0 24.1 22.3 (%) Ash Content 17.5 15.2 14.4 18.2 19.4 (%) *General Strength 11.35 14.61 15.82 13.36 12.47
[0061] (E) The Comparison Between the Biopulping Method and the Chemical Pulping Method:
[0062] The followings are to compare the differences between biopulping method and chemical pulping method. First, a LBY liquid medium and the rice straw segments of Indica rice are prepared (The rice straws are sun-dried and cut into small segments at the length of 2-3 cm.). The LBY liquid medium is aliquoted into sterile 1000 concaved-bottom flasks, 500 ml per flask. The PMBPIII strain group is added into the LBY liquid media at the concentration of 1.5×10 6 cfu/ml. Then, the rice straw segments are added into the LBY liquid media containing PMBIII strain group at the concentration of 5% (w/v). And then the mixed solution is cultured in shaking culture at 200 rpm under 50° C. for 4 days. Each treatment is set up in four repetitions. Next, two treatments are respectively proceeded. First treatment (LBYIII-CaO treatment) is to add CaO into the fermentative culture solution at the concentration of 1% (w/v) and then boil the fermentative culture solution up to 140° C. for 30 minutes for preparing a pulp solution. Second treatment (LBYIII) is to directly boil the fermentative culture solution up to 140° C. for 30 minutes for preparing a pulp solution. In addition, the controls are prepared respectively that the rice straw segments are directly mixed with 1% (w/v) sodium hydroxide solution (NaOH treatment) or 1% (w/v) CaO solution (CaO treatment). Each treatment is set up in four repetitions. The pulp solutions of all treatments are further pulped for 15 minutes. The pulp solutions are sieved by sieves with 18, 200 and 270 meshes respectively for isolating the incompletely decomposed rice straw pulp fibers from the pulp solutions. The recovery percentages of the rice straw pulp fibers sieved through sieves with different meshes are calculated. The recovered rice straw pulp fibers sieved through 200 meshes are made into the handmade papers. The physical properties of the handmade papers are tested.
[0063] Please refer to FIG. 5, which shows the effects of microorganism fermentation treatment and chemical treatment on the recovery percentages of various rice straw pulp fibers. The total recovery percentage of CaO treatment is the highest. The recovery percentage is 77.79%. The effect of LBYIII treatment came second, in which the recovery percentage is 47.31%. The LBYIII-CaO treatment has a recovery percentage of 43.07%. The recovery percentage of NaOH treatment is 41.45%, the lowest. When comparing the recovery percentage between the pulp fibers obtained by biopulping method and chemical method, which are recovered from the fibers sieved through 200 meshes, the results of NaOH treatment and the CaO treatment are higher than the other treatments. The result of treatment by microorganism plus CaO (LBYIII-CaO treatment) came second and the result of microorganism treatment (LBYIII treatment) is the lowest. The recovery percentages of the pulp fiber recovered from the fibers sieved through 200 meshes and treated with NaOH, CaO, LBYIII-CaO and LBYIII are 41.21%, 41.0%, 27.53% and 11.45% respectively.
[0064] Please refer to Table 4, which shows the physical properties of handmade papers produced from rice straw pulp fibers which are treated by microorganisms and chemicals. The recovered rice straw pulp fiber sieved through from 200 meshes is made into the handmade papers. The physical properties of the handmade papers are tested. The obtained pulp fibers treated by CaO has the best ionization degree (325 ml), while the obtained pulp fibers treated with LBYIII-CaO has the ionization degree of 267 ml. The handmade paper of LBYIII treatment has the highest gases permeability (302.3 sec/100 ml). The CaO treatment is the lowest (110.3 sec/100 ml). The handmade papers of both NaOH treatment and LBYIII-CaO treatment have the best surface strengths of all treatments (10A and 9A respectively). The handmade paper of the NaOH treatment has the best general strength of all (21.8). The second is the LBYIII-CaO treatment (15.13). The lowest is the LBYIII treatment.
TABLE 4 Treatment NaOH LBYIII CaO LBYIII-CaO Test item C.S.F.:252 ml C.S.F.:257 ml C.S.F.:325 ml C.S.F.:267 ml Basic weight 72.8 72.9 73.3 73.4 (g/m 2 ) Thickness 0.136 0.153 0.144 0.147 (mm) Bulk 1.87 2.10 1.96 2.00 (ml/g) Breaking length 7.21 2.87 3.36 4.89 (Km) Tear Index 5.99 1.28 2.61 4.21 (mN · m 2 /g) Burst Index 4.34 0.89 1.58 2.47 (Kpa · m 2 /g) Cohesion Force 2.13 0.93 1.26 1.78 (kg-cm) Permeability to Gases 157.7 302.3 110.3 157.3 (sec/100 ml) Surface Strength 10 4 7 9 (A) Stiffness 2.20 1.57 1.38 1.55 (g-cm) Opacity 94.8 99.5 99.5 99.3 (%) Whiteness 43.5 22.7 20.4 24.9 (%) Ash Content 4.59 13.60 20.80 16.50 (%) *General Strength 21.80 6.90 10.07 15.13
[0065] Please refer to FIG. 6, which is the flow chart of biopulping method illustrating the full process of the biopulping method for waste rice straws according to a preferred embodiment of the present invention. First, the rice straw is cut into segments at the length of 2-3 cm. The segments are added into the LBY medium containing 10 6 (cfu/ml) PMBPIII strain group. The mixed solution is cultured in the shaking culture under 50° C. and 200 rpm for four days. The culture solutions are boiled up to 140° C. for 30 minutes to prepare pulp solutions. The pulp solutions are further pulped and sieved through sieves for preparing rice straw pulp fibers. And then the papermaking procedure is proceeded.
[0066] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | The present invention relates to a biopulping method, and more particularly to a biopulping method for non-woody fiber plants. A biopulping method for a non-woody fiber plant is provided. It includes steps of providing a culture solution, adding a non-woody fiber plant to the culture solution, adding a microorganism suspension to the culture solution, fermentatively culturing the culture solution for preparing a pulp solution, boiling the pulp solution, pulping the pulp solution, and screening the pulp solution for isolating the paper pulp from the pulp solution. | 3 |
FIELD OF THE INVENTION
The present invention relates to polymer resins for use in meltblown processing. Specifically, the present invention relates to a process for the production of polymer resins with very low melt viscosity by post-reactor molecular weight alteration of high melt viscosity resins using prodegradants, where the final resins are suitable for meltblown processing without further preparation and contain low concentrations of or no residual prodegradants.
BACKGROUND OF THE INVENTION
It is well known in the art that it is a desirable processing property for polymer resins in meltblown processing to have a low viscosity when molten. For many commercial end-users, the melt-flow characteristics of standard, commercial polymer resins are not suitable because of their relatively high molecular weight, which results in a high melt viscosity. As low melt viscosity is desired, prior art references have sought to achieve low melt viscosity of polymer through controlled scission of the polymer chain. This controlled scission, in effect, reduces the post-reactor average molecular weight of the polymer chains. As the average molecular weight is reduced, the melt viscosity is lowered. Furthermore, the molecular weight distribution (MWD) is significantly altered.
It is well-known that polymer resins suitable for meltblown processing may be produced by preparing polymer with a relatively high melt viscosity and then subjecting it to a post-reactor molecular weight alteration using a chemical prodegradant, typically a free radical initiator, such as a peroxide. This degradation treatment occurs under such conditions that the melt viscosity of the polymer decreases to a specific value. However, when producing a pelletized polymer for future processing, this process has presented problems. U.S. Pat. Nos. 4,451,589; 4,897,452 and 5,594,074 all report that when peroxide treatment is used to produce a low melt viscosity polymer in a extrusion process, the resulting polymer is not easily pelletized. Specifically, the degraded polymer on exiting the extruder becomes so fluid and soft that it is difficult or impossible to cut into pellet form.
To avoid this problem, several processing techniques have used a degradation process involving a primary degradation wherein the average molecular weight of the polymer is reduced to a value above that desired for meltblown processing. The degradation is performed in an extruder wherein an additional amount of prodegradant remains impregnated in the pelletized polymer for further degradation. The additional prodegradant acts to further reduce the average molecular weight to the desired value during meltblown processing. U.S. Pat. No. 5,594,074 to Hwo, et al, U.S. Pat. No. 4,451,589 to Morman, et al and U.S. Pat. No. 4,897,452 to Berrier, et al all describe processes for making polymer pellets containing an unreacted free radical initiator. Using the impregnated free radical initiator, the polymers can be further degraded upon thermal treatment to form an ultra low melt viscosity polyolefin. U.S. Pat. No. 4,897,452 describes a process for the manufacture of propylene homopolymer or copolymer pellets in the presence of a primary and secondary free radical initiator, wherein the half-life of the second free radical initiator is at least twenty times longer than that of the first free radical initiator. In that invention at least 80% by weight of the second free radical initiator, and not more than 20% by weight of first free radical initiator remain intact in the pellets and available for subsequent decomposition during the conversion of the pellets into finished articles.
Another method consists of higher melt viscosity reactor granules that are coated with peroxide so that they crack to lower melt viscosity during meltblown processing. In all cases, the un-reacted peroxide cracks the polymer to low melt viscosity during meltblown processing.
However, materials having prodegradants either impregnated into or coated onto pelletized polymer have some disadvantages. In particular, there is a danger that the residual prodegradant within the polymer will react early, either before it gets to the end-user or before the end-user processes it. As a result, various lots of the polymer material may behave with a degree of inconsistency.
It is also known to produce polymer having a low melt viscosity directly from an in-reactor process. In this case no post-reactor molecular weight alteration is required, as the desired melt viscosity property is produced directly by the in-reactor polymerization of the monomer. A draw back of resins produced by in-reactor processes is that they are supplied in a flake rather than pellet form, resulting in the presence of a significant amount of powdery fines, which create difficulties in handling and transporting the material. Finally, in-reactor processing is not a viable option for a number of meltblown fabric processors that lack the particular conveying systems necessary to transport materials supplied in flake form.
Therefore, it would be desirable to provide a process for producing a polymer resin that has low melt viscosity and good melt flow in meltblown processing. A polymer resin produced by such a process would have a low melt viscosity, as measured by melt flow index, in combination with a low residual content of prodegradant. Such material would be provided fully or nearly fully reacted prior to melt blown processing. Such material would also be provided in a pellet form for easy handling and transport.
SUMMARY OF THE INVENTION
The present invention provides a process for producing a homopolymer or copolymer resin having a melt flow index of greater than 1000 dg/min. and containing less than 300 ppm of residual prodegradant. The polymer resin produced according to the process of the present invention can be used to produce a fiber that can be incorporated into a non-woven fabric and can be processed on a meltblown line to form a fabric (“web”) using standard commercial processing conditions and rates. The polymer resin of the current invention provides improved melt viscosity homogeneity during meltblown processing relative to granules or pellets coated or impregnated with prodegradants, such as free radical initiators.
The process of the current invention further provides improved lot-to-lot consistency relative to products that contain substantial amounts of un-reacted peroxides or other prodegradants, which can react during shipping and storage, initiating degradation that results in unpredictable melt viscosity.
The process according to the current invention is applicable to a variety of polyolefin homopolymers and copolymers. In a preferred embodiment, the high melt flow index polymer resin produced is a polypropylene homopolymer, or random or block copolymer.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a process for producing polymer resins with low melt viscosity, suitable for melt blown processing. The process provides polymer resins having a melt flow index of greater than 1000 dg/min. Preferably, the melt flow index of the resin is from 1000 dg/min. to 2500 dg/min. Additionally, the polymer resins produced according to the invention contain less than 300 ppm of residual prodegradant, preferably, less than 50 ppm.
Further, polymer resins produced according to the invention have relatively narrow molecular weight distributions (MWDs), as defined by the function:
MWD=Mw/Mn
where: Mw=weight average molecular weight
Mn=simple average molecular weight
In general, polymer resins produced according to the invention typically have molecular weight distributions of less than 3.0.
According to the process of the present invention a high melt flow index polymer resin is produced by extruding a low melt flow index polymer powder with a prodegradant to initiate controlled degradation that results in a reduction of the average molecular weight of the polymer, providing a final product that has a melt flow index of greater than 1000 dg/min. and containing minimal residual prodegradant. According to one embodiment of the invention, polymer reactor granules are combined with additives. The polymer powder/additive blend is then fed into an extruder. The prodegradant is combined with the powder/additive during extrusion by injecting it directly into the extruder, either at the feed throat or through an opening in the barrel, preferably as a solution. According to an alternate embodiment, a prodegradant may be dry-blended with the polymer powder/additive blend before extrusion. Further, the additives may be added as a solution with the prodegradant, by injection into the molten resin during extrusion. Regardless of how the prodegradant or additional additives are added, at the elevated extrusion temperatures the prodegradant initiates controlled degradation that decreases the average molecular weight of the polymer. Vacuum devolitazation can be applied to the extruder barrel to remove any un-reacted prodegradant along with residual solvents. The resin leaves the extruder through a die and is then quenched by a water bath and chopped into pellets. The molecular weight reduction obtained results in a very low melt viscosity, as measured by melt flow index.
According to an alternative embodiment of the invention, a low melt viscosity polymer resin may be produced through a two stage process, which begins by performing a first stage extrusion process as described above, resulting in polymer pellets with a final melt flow index of approximately 300 to 700 dg/min. The resulting polymer pellets then enter the second stage of the process which is identical to the first stage except that the starting material is the polymer pellet produced from the first stage processing. Specifically, the first stage polymer pellets of approximately 300 to 700 dg/min melt flow index are fed into the extruder where they are extruded with a prodegradant and vacuum devolatized to remove residual prodegradant. The resin then proceeds to a water bath followed by drying with an air knife and then proceeds to a strand pelletizer. This second stage extrusion process results in polymer pellets with a final melt flow index of approximately 1000 dg/min. or greater and less than 300 ppm of residual prodegradant. As with the one stage process, the polymer may be dry mixed with the prodegradant prior to extrusion.
Polymer resins that can be used as raw materials in the process of the current invention typically have melt flow indices of 60 or greater, but they may be as low as 0.7. Preferably, the prodegradant is added to the raw polymer resin in concentrations from 0.1 to 2.0 percent by weight, based on the weight of polymer. It will be apparent to those skilled in the art that the process of the present invention is not limited to a particular prodegradant or class of prodegradant. A number of prodegradants, including free radical initiators, such as organic peroxides, are useful with the present invention. The class of organic peroxides includes, but is not limited to: TRIGONOX 101® (2,5-dimethyl-2,5-di-[tert-butylperoxyl]hexane) and TRIGONOX 301® (3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxonane), both available from AKZO and (di-tert-amyl peroxide), available from CK Witco as DTAP® and from AKZO as Trigonox 201®. Additionally, a number of additives may be used with the current invention, including, but not limited to: anti-oxidants, processing stabilizers, and acid scavengers. Examples of additives that are useful in the current invention are: IRGAFOS 168® (tris-[2,4-di-tert-butylphenyl]phosphite) and IRGANOX 1076® (octadecyl-3,5-di-tert-butyl-4-hydroxyhydrocinnamate), both available from CIBA, and zinc oxide and calcium stearate.
High melt flow index polymer resins produced according to the current invention contrast with commercial meltblown resins, which contain an un-reacted peroxide that initiates resin degradation during meltblown processing. The fully reacted resins produced by the process of the current invention are expected to exhibit improved melt viscosity consistency over current commercial products.
EXAMPLES 1-5
One Step Process
Five samples of low melt viscosity polypropylene resin were produced using the single extrusion process. The initial melt flow indices (MFIs) of the resins put into the process were from 0.7 to 60. Table 1 shows the properties of the resins that were input into these five trials.
TABLE 1
Molecular Weight Distributions of Starting Materials
starting
Mn
Mw
material
MFI
(Kg/mole)
(Kg/mole)
Mw/Mn
granules
0.7
82
473
5.9
granules
18
44
205
4.7
granules
60
37
155
4.15
Examples were run using 30 mm, 43 mm and 240 mm extruders. The quantity of peroxide fed to the extruder varied from 0.31 to 1.2 weight percent. The polypropylene powder was dry-blended with a peroxide and fed to the hopper of the extruder. For the trials on the 43 mm extruder, the barrel temperature at the hopper was set to 350° F. and increased along the barrel to 450° F. at the vacuum port, which was located just upstream of the die. The die temperature was set to 375° F. After extrusion, the samples were quenched and pelletized. Table 2 details the properties of the low melt viscosity polymers produced in each trial.
TABLE 2
Processing Conditions and Properties
Example
1
2
3
4
5
Extruder
30 mm
30 mm
240 mm
43 mm
43 mm
starting MFI
0.7
60
18
18
18
final MFI
1600
1500
1000
1400
2210
residual peroxide
<50 ppm
<50 ppm
<50 ppm
15 ppm
25 ppm
Mn
30
24
34
24
22.5
Mw
57
58
91
57
51
Extruder barrel temperature settings are critical to forming a product that contains minimal un-reacted prodegradant. The prodegradant decomposition rate (i.e. the rate at which the prodegradant initiates controlled degradation of the polymer) is specified by its half-life, which decreases exponentially as temperature increases. The process temperature must be high enough to provide a half-life that is substantially shorter than the residence time of the extruder. In general, the residence time of the material in the extruder should be at least five times the half-life of the prodegradant. The residence time is determined by the extruder size, screw design, and throughput. The throughput rate and devolatilization vacuum pressure were varied to measure the effects of those parameters on product molecular weight and residual prodegradant. The data in Table 3 indicate that for the above examples the best residual peroxide levels were obtained using the 43 mm extruder.
TABLE 3
Extrusion Conditions for Producing Resins with
the Desired Melt Flow Viscosity
screw speed
throughput
vacuum
residence
Die T
half-life
(rpm)
(kg/hr)
(in Hg)
time (s)
(F)
(sec)
150
27
5
41
390
6
EXAMPLES 6 AND 7
Two Step Process
Two samples of low melt viscosity resin were produced from polypropylene pellets produced by extruding polypropylene homopolymer reactor granules in the presence of a peroxide to induce controlled reduction of the average molecular weight. One had a melt flow of 300 dg/min and the other had a melt flow of 600 dg/min. The molecular weight distributions of low melt viscosity pellets produced from pellet starting materials are provided in Table 4.
TABLE 4
Molecular Weight Distributions of Starting Materials
starting
Mn
Mw
material
MFI
(Kg/mole)
(Kg/mole)
Mw/Mn
pellets
300
36
111
3.1
pellets
600
34
96
2.9
The processing conditions and properties for the low melt viscosity polypropylene resins produced in these trials is shown in Table 5.
TABLE 5
Processing Conditions and Properties
Extruder
43 mm
43 mm
starting MFI
340 (pellet)
643 (pellet)
final MFI
1503
1470
residual peroxide
160 ppm
75 ppm
Mn
24.8
23.7
Mw
60
59
Mw/Mn
2.4
2.5
The foregoing examples using polypropylene homopolymers have been provided for illustrative purposes only and should not be construed as limiting the scope of the invention. Those skilled in the art will recognize that the process of the current invention can be applied to a variety of block and random copolymers of polypropylene and other polymers. The process according to the current invention has been practiced successfully with polymers of both standard and high isotacticity. Additionally, the prodegradants and additive packages used in the examples are only for illustrative purposes. The process of the current invention can be used successfully with various prodegradants and additive packages. The full scope of the invention will be clear to those skilled in the art from the claims appended hereto. | A process is provided for the production of a very low melt viscosity (high melt flow index) polymer resin, suitable for use in meltblown processing. According to the process of the current invention, a high melt viscosity (low melt flow index) resin is subjected to post-reactor molecular weight alteration by extrusion with a chemical prodegradant. The process produces a very low melt viscosity resin that can be used in meltblown processing without further treatment to reduce the average molecular weight of the resin. Further, the very low melt viscosity resins produced according to the process of the current invention contain very little or no residual prodegradant. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. provisional patent application serial No. 60/401,714 filed Aug. 7, 2002.
BACKGROUND OF THE INVENTION
The present invention relates generally to an apparatus and a method for separating sanitary effluent from storm water and/or infiltrated water in a municipal sewer system.
Municipal sewer systems include a web of pipes that convey wastewater from homes, businesses and industries and storm water from drains to treatment plants. The smallest pipes, typically twelve inches in diameter or less, are know as “collectors” that are connected to service lines running to the sanitary plumbing of buildings. The collectors are connected to “mink lines”, typically larger than twelve inches in diameter, and carrying one to ten million gallons per day. The trunk lines connect to “interceptors” that carry the wastewater to a treatment plant. The interceptors are of large diameter, often as much as ten feet.
The wastewater plumbing system in a typical house, office building or manufacturing facility combines toilet effluent with other wastewater, such as from sink and bath drains, to be carried by a single service line to the collector line at the street. Hereinafter, such combined wastewater will be termed “sanitary effluent”. The municipal sewer systems combine and carry in the same pipes the sanitary effluent from buildings, storm water from outside drains and any ground water leaking into the system (infiltrated water). When the treatment plant and the associated web of pipes are built, the system is sized to process a predetermined number of gallons per unit of time, the maximum flow capacity, including a certain rainfall amount. As additional buildings are connected to the system, less of the predetermined flow capacity is available for storm water. Thus, the system becomes susceptible to rainfall amounts less than the planned certain rainfall amount causing numerous overflows into streams and lakes and backups into buildings through the service lines. Overflows also can occur in systems where the storm water is carried in a separate set of pipes. Such overflows and backups cause serious environmental and health problems.
Also, some sewer systems were designed with less capacity than is required to carry typical rainfall amounts thereby always overflowing during normal rainfalls. Typically, such systems were installed before there was much concern for the effect of the overflow on the environment.
However, no matter what the configuration of an existing sewer system, it either now has or will in the near future have flow capacity problems causing overflows, backups and leaks. Consequently, the local governments responsible for maintaining these sewer systems face enormous expenses to repair or replace the existing pipes and/or add capacity.
SUMMARY OF THE INVENTION
The present invention concerns an apparatus and method for improving the operation of sewer systems while reducing the cost of increasing system capacity. The apparatus according to the present invention includes a first set of sewer lines connected to at least one storm water drain, and/or source of infiltrated water, and/or source of sanitary effluent, and a second set of sewer lines of smaller diameter than said sewer lines of said first set connected to sources of sanitary effluent, the first and second sets of lines being separately connected to a sewerage treatment plant. The second set of sewer lines has at least a portion thereof that extends inside the first set of sewer lines and the first set of sewer lines can be an existing sanitary sewer system. The apparatus can include at least one sanitary effluent process device connected to the second set of sewer lines such as a pumping station, a grinder pump or a vacuum system to assist the flow of the sanitary effluent through the second set of sewer lines. The apparatus can provide the same flow volume in a smaller diameter pipe that is under pressure.
The method according to the present invention includes the steps of: a. providing a first set of sewer lines connected between at least one source of storm water, and/or source of infiltrated water, and/or source of sanitary effluent, and at least one sewerage treatment plant; b. providing a second set of sewer lines connected between a source of sanitary effluent and the sewerage treatment plant; and c. installing at least a portion of said second set of sewer lines in said first set of sewer lines. Step b. can include installing a sanitary effluent collector line spaced from a collector line of the first set of sewer lines and connecting a service line from the source of sanitary effluent to the sanitary effluent collector line. Step c. can include running the sanitary effluent collector line to a manhole associated with the collector line of the first set of sewer lines and connecting the sanitary effluent collector line to a portion of the second set of sewer lines installed in the first set of sewer lines. Step c. can be performed by in situ forming of pipe included in the second set of sewer lines.
A sewer system according to the present invention reduces the size of the pipe required to carry sanitary effluent and/or increases the capacity of the sewerage treatment plant to treat sanitary effluent. Since the storm water and infiltrated water are separated from the sanitary effluent, they may require little or no treatment freeing plant capacity to treat the sanitary effluent. In some cases, treatment plant expansion can be delayed or eliminated.
DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:
FIG. 1 is a schematic block diagram of a typical prior art sewer system;
FIG. 2 is a schematic block diagram of a sewer system in accordance with a first embodiment of the present invention;
FIG. 3 is a cross-sectional view through one of the collector lines of the system shown in FIG. 2 with a nested sanitary collector line;
FIG. 4 is a schematic block diagram of a portion of the system shown in FIG. 2 with process devices added; and
FIG. 5 is a schematic block diagram of a sewer system in accordance with a second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIG. 1 a typical sanitary sewer system 10 of known construction. Each one of a plurality of building sewer systems 11 a through 11 c collects wastewater discharged from sources in the associated building and combines that wastewater as a discharge to a sanitary sewer system. Each one of the building sewer systems 11 a through 11 c is connected by an associated one of a plurality of service lines 12 a through 12 c respectively to a collector line 13 a . Thus, sanitary effluent from such sources as toilets, and other wastewater such as from sink drains, tub and shower drains, clothes washer drains and floor drains are combined to flow into the collector line 13 a . Also, one or more storm drains, such as a storm drain 14 , can be connected to the collector line 13 a . The collector line 13 a and collector lines 13 b through 13 c feeding from other areas are connected to a trunk line 15 a . In a similar manner, other service lines, storm drains and collector lines are connected to trunk lines 15 b and 15 c . The trunk lines 15 a through 15 c are connected to an interceptor line 16 a leading to a sewerage treatment plant 17 that is connected to other interceptor lines 16 b and 16 c . Thus, wastewater, including sanitary effluent and storm water combined, flows through the collector lines, the trunk lines and the interceptor lines in a typical sanitary sewer system 10 .
While the prior art sewer system 10 is adequate for most conditions, a heavy rain entering the storm drain 14 can cause a problem by exceeding the capacity of the system to carry all of the entering water to the treatment plant 17 . Overflow relief devices 18 are provided to release the wastewater from the system into drainage ditches, ponds, rivers and lakes. Although the overflow devices 18 are shown at the junction of the collector lines with the trunk line and the junction of the trunk lines with the interceptor line, the overflow devices can be connected at any suitable points in the sewerage system. A sewerage system operating near capacity may have frequent overflow problems causing contamination of swimming and boating areas with fecal matter and other wastes. Also, exceeding the system capacity causes backup through the service lines 12 a through 12 c typically flooding buildings with the combined sanitary effluent and storm water. The present invention seeks to solve the overflow and backup problem and increase the water treatment capacity of the sewer system by separating the sanitary effluent from the storm water as both flow through the system.
There is shown in FIG. 2 a first embodiment sanitary sewer system 20 according to the present invention wherein the sanitary effluent is completely separated from the remainder of the building wastewater. As also shown in FIG. 1, each of the building sewer systems 11 a through tic is connected by an associated one of-the plurality of service lines 12 a through 12 c respectively to the collector line 13 a . Thus, wastewater from such sources as sink drains, tub and shower drains, clothes washer drains and floor drains is combined to flow into the collector line 13 a . However, the sanitary effluent from the toilets is connected to each of a plurality of sanitary effluent service lines 22 a through 22 c to carry the sanitary effluent to a sanitary effluent collector line 23 a separate from the original collector line 13 a . While new construction can be built with the required separated plumbing, existing building would require conversion. As an alternative, the new service lines 22 a through 22 c could be connected to and the old service lines 12 a through 12 c disconnected from the existing plumbing. Sanitary effluent collector lines 23 a through 23 c are connected to a sanitary effluent trunk line 25 a that is connected to a sanitary effluent interceptor line 26 a with other sanitary effluent trunk lines 25 b and 25 c . The sanitary effluent lines 23 a through 23 c , 25 a through 25 c , and 26 a are interconnected at connectors 28 that do not require overflow protection. Thus, the sanitary effluent is separated from the other wastewater and will not overflow or back up into the buildings when storm water overloads the system 20 .
Although the sanitary effluent lines 22 a through 22 c , 23 a through 23 c , 25 a through 25 c and 26 a could be run parallel to the other lines 12 a through 12 c , 13 a through 13 c , 15 a through 15 c and 16 a , it is preferred that sanitary effluent lines run inside the other lines where possible to avoid digging separate trenches. Since existing sewer lines typically run through developed land, the installation of parallel lines can be extremely costly and very disruptive to homes and businesses. Thus, the existing sewer system 10 can be retrofitted with the new sanitary effluent lines. The sanitary effluent pipes will be of a smaller diameter than the corresponding pipes of the existing system 10 since the volume of sanitary effluent wastewater to be carried is less and the addition of pressure increases the flow rate. FIG. 3 shows the smaller diameter sanitary effluent connector line 23 a extending inside the larger diameter collector line 13 a that now only conveys storm water. Although the line 23 a is shown spaced above a bottom of the line 13 a , such representation is only for the purpose of clearly illustrating two separate lines and the sanitary effluent connector line 23 a typically would rest on the bottom of the connector line 13 a . Similarly, the sanitary effluent trunk line 25 a would run inside the trunk line 15 a and the sanitary effluent interceptor line 26 a would run inside the interceptor line 16 a.
In order to properly convey the sanitary effluent wastewater to the treatment plant 17 , one or more process devices may be required. For example, as shown in FIG. 4, a first process device 29 a is connected between the collector line 23 a and the trunk line 25 a . A second process device 29 b is connected between the trunk line 25 a and the interceptor line 26 a . The process devices 29 a and 29 b can be pumping stations, grinder pumps, vacuum systems, or any other type of device used to assist the flow through the lines of the sewer system 20 . The process devices can be inserted at any point in the sewer system 20 and different types can be used together as required.
Since the flow through the sanitary effluent lines 23 a , 25 a , and 26 a is assisted by pressure or vacuum, the flow rate is greater than in a prior art gravity system for the same diameter pipe. Thus, the cross-sectional area required to flow the same volume is reduced leaving more room in the other wastewater lines 13 a through 13 c , 15 a through 15 c and 16 a thereby increasing the capacity to carry storm water. When there is an overflow condition, the water escaping from the overflow devices 18 is not contaminated with effluent. Also, the wastewater flowing in the lines 12 a through 12 c , 13 a through 13 c , 15 a through 15 c and 16 a either does not have to be treated at the plant 17 or requires only a secondary treatment. Thus, another advantage of the present invention is the freeing of significant capacity of existing plants to treat additional wastewater from the sanitary effluent lines and a reduction in the size of new treatment plants.
In some situations, it is desirable not to provide the sanitary effluent service lines 22 a through 22 c shown in FIG. 2, such as when retrofitting an existing system. There is shown in FIG. 5, a second embodiment sanitary sewer system 30 wherein the service lines 12 a through 12 c are connected to the sanitary effluent connector line 22 a that runs parallel to the collector line 13 a . Both of the collector lines 13 a and 22 a run into a manhole 31 wherein the line 22 a can be inserted into the line 13 a . From the manhole 31 , the sanitary effluent lines run inside the corresponding existing sewer lines as in the system shown in FIG. 2 .
The sewer system according to the present invention can be installed as a complete new system or during the repair of an existing system wherein the existing collector, trunk and interceptor lines are used as a first set of sewer lines that are connected to a source of storm water. The sanitary effluent lines according to the present invention are a second set of smaller diameter sewer lines that can be made of any suitable material such as plastic or composition materials and these lines can be placed in sections that are connected together or formed in situ during installation. A sewer system according to the present invention will prevent, or at least reduce overflows, and will eliminate backups into buildings. A sewer system according to the present invention provides a relatively inexpensive way to solve pollution problems and to modernize and expand existing sewer systems.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | An apparatus and method for improving the operation of sewer systems includes a first set of sewer lines connected to a source of other water and a second set of sewer lines of smaller diameter than the sewer lines of said first set connected to sources of sanitary effluent, the first and second sets of lines being separately connected to a sewerage treatment plant. The second set of sewer lines has at least a portion thereof that extends inside the first set of sewer lines and the first set of sewer lines can be an existing sanitary sewer system. The apparatus can include at least one sanitary effluent process device connected to the second set of sewer lines such as a pumping station, a grinder pump or a vacuum system to assist the flow of the sanitary effluent through the second set of sewer lines. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to: (i) U.S. application Ser. No. 10/973,925, filed concurrently herewith, and entitled “MULTIPLE MEDIA TYPE SYNCHRONIZATION BETWEEN HOST COMPUTER AND MEDIA DEVICE,” which is hereby incorporated herein by reference; (ii) U.S. application Ser. No. 10/987,649, filed concurrently herewith, and entitled “WIRELESS SYNCHRONIZATION BETWEEN MEDIA PLAYER AND HOST DEVICE,” which is hereby incorporated herein by reference; (iii) U.S. application Ser. No. 10/277,418, filed Oct. 21, 2002, and entitled “INTELLIGENT INTERACTION BETWEEN MEDIA PLAYER AND HOST COMPUTER,” which is hereby incorporated herein by reference; and (iv) U.S. application Ser. No. 10/118,069, filed Apr. 5, 2002, and entitled “INTELLIGENT SYNCHRONIZATION OF MEDIA PLAYER WITH HOST COMPUTER,” which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to portable media devices and more particularly to data transfer with portable media devices.
2. Description of the Related Art
The hand-held consumer electronics market is exploding, and an increasing number of these products including for example PDAs, music players, cellular phones, cameras, and video games have increased their functionality to distance themselves from their competitors. By way of example, cellular phones have added PDA and camera functionality, PDAs have added cellular phone and music player functionality, music players have added PDA and video game functionality, etc. In the future, it is foreseeable that the functionality of all these devices will continue to merge into a single device. As these products evolve, it is believed that many design challenges will be encountered.
Many hand-held computing devices work hand in hand with a personal computer. The personal computer typically serves as a base to the portable hand-held computer device. For example, because they are hand-held, they are typically a portable extension of the personal computer. Like personal computers, these highly portable devices typically include a processor that operates to execute computer code and produce and use data in conjunction with an operating system. Unlike personal computers, however, these devices typically use less complex operating systems as well as smaller and less expensive processors that are slower than the processors used in personal computers. While this may be appropriate when the devices operate normally, difficulties arise when these hand-held computing devices are called upon to perform process intensive tasks. The difficulties include slow responsiveness and high power consumption. As a result, the user may be left with a negative user experience, i.e., users may not like a product that is slow and whose battery life is short.
Personal computers typically include software that helps manage the handheld computing devices. The personal computer may include for example a photo management program that helps transfer photos from the camera to the personal computer. The photo management program may also allow a user to sort, store and catalog their images as well as to provide touch- up capabilities such as red eye reduction, black and white conversion, image cropping and rotation. In some cases, the cameras modify the original image by embedding or storing thumbnail images inside the original image. The photo management program uses the embedded thumbnail images when importing the original image. For example, as each photo is being imported, the photo management program may show the thumbnail image thereby relaying to the user that the image is being imported.
In addition to photo management programs, the personal computer may also include music management programs that help transfer music from the personal computer to a music player such as an MP3 music player. Like the photo management program their music, the music management program may also allow a user to sort, modify, store and catalog their music. More particularly, the music program may give the user the ability to organize their music into playlists, edit file information, record music, download files to a music player, purchase music over the Internet (World Wide Web), run a visualizer to display the music in a visual form, and encode or transcode music into different audio formats such as MP3, AIFF, WAV, AAC, and ALE. Typically, music players only understand a single music format. Therefore, the music management program typically can to transcode the music stored in the personal computer from one music format to the desired music format of a music player.
In some cases, both the photo and music programs are linked so that the images and music stored therein can be played together. For example, the photo management program may allow a user to produce slide shows that show images to music. By way of example, the photo management program may correspond to iPhoto® and the music management program may correspond to iTunes®, both of which are manufactured by and available from Apple Computer Inc. of Cupertino, Calif.
Synchronization operations have been conventionally performed between portable devices, such as Personal Digital Assistants (PDAs) and host computers, to synchronize electronic files or other resources. For example, these files or other resources can pertain to text files, data files, calendar appointments, emails, to-do lists, electronic rolodexes, etc.
In the case of media players, such as MP3 players, files are typically moved between a host computer and a media player through use of a drag and drop operation, like is conventionally done with respect to copying of a data file from a Windows desktop to a floppy disk. Hence, the user of the media player can manually initiates synchronization for individual media items. As a consequence, synchronization tends to be tedious and time consuming for users. More recently, media players have been able to be synchronized with a host computer when a bus connection over a cable is made. Here, the synchronization can be automatically initiated when the cable is connected between the host computer and the media player. The iPod® offered by Apple Computer, Inc. of Cupertino, Calif. has the capability to provide such synchronization over a cable.
Thus, there is a continuing need for improved features for connecting and transferring data between media devices and their hosts.
SUMMARY OF THE INVENTION
The invention relates, in one embodiment, to a method of transferring image data between a host device and a portable media device capable of storing and presenting media items, namely, images. The method includes designating, at the host device, at least one image for downloading to the portable media device. The method also includes producing an image collection for each requested image at the host device. Each image collection contains new versions of the requested image. Each new version can have a different image profile based on the capabilities of the portable media device. The method further includes sending at least the image collection including each version of the requested image to the portable media device. In some cases, the requested image is also sent with the various versions thereof.
The invention relates, in another embodiment, to an operational method for a portable media device. The method includes storing image data. The image data includes a plurality of image collections. Each image collection contains a plurality of differently formatted images based on the same original image. The image collections are separately generated on a device other than the portable media device. In some cases, the original image is stored along with the differently formatted images. The method also includes receiving a display command. The display command designates one or more images of the image data to be displayed. The method further includes retrieving at least the designated images. The method additionally includes outputting one or more of the retrieved images.
The invention relates, in another embodiment, to a method of transferring image data between a host device and a portable media device capable of storing and playing media items. The method includes receiving an image download request. The image download request designates one or more images for downloading from the host device to the portable media device. The method also includes creating a database entry for each of the images to be downloaded. The method further includes copying the database entry on at least the portable media device. The method additionally includes creating an image collection for each requested image at the host. The image collection includes the original image and differently formatted images based on the original image. Moreover, the method includes copying the image collection to the portable media player and updating the database entry with information about each of the images in the image collection.
The invention relates, in another embodiment, to a portable media device capable of viewing images. The device includes a storage device containing downloaded image data. The downloaded image data includes a plurality of image collections. Each image collection includes a plurality of different versions of the original image. In some cases, the downloaded image data also includes the original image. The device also includes a processor configured to supply at least a portion of the image data to a display.
The invention relates, in another embodiment, to a computer readable medium including at least computer program code for managing images. The computer readable medium including capabilities for storing a plurality of image collections where each image collection includes a plurality of different versions of the original image and in some instances the original image as well. The computer readable medium also including capabilities for retrieving one or images from storage when a display command is generated and presenting one or more of the retrieved images.
The invention relates, in another embodiment, to a download embodied as a carrier wave in a media communication system that facilitates communications between a host device and a portable media device. The download includes image data including a plurality of image collections. Each image collection includes an a plurality of different versions of an original image, and in some cases the original image as well.
The invention relates, in another embodiment, to a media management method. The method includes loading one or more images to a personal computer and storing the one or more images on the personal computer. The method also includes connecting a hand held media device to the personal computer. The method further includes presenting images or image identifiers on personal computer and generating a download command designating one or more images to be downloaded from the personal computer to the hand held media device. The method additionally includes determining the image formats required by the hand held media device, creating new versions of the designated images and copying and storing at least the new versions of the designated images on the hand held media device. Moreover, the method includes disconnecting the hand held media device from the personal computer. Additionally, the method includes generating a display command on the hand held media device, retrieving one or more images from storage based on the display command, and presenting one or more of the retrieved images.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 is a method of transferring image data between a host device and a portable media device, in accordance with one embodiment of the present invention.
FIG. 2 is an operational method for a portable media device, in accordance with one embodiment of the present invention.
FIG. 3 is a method of transferring image data between a host device and a portable media device, in accordance with one embodiment of the present invention.
FIG. 4 is an exemplary diagram of a photo database file, in accordance with one embodiment of the present invention.
FIGS. 5A-5F are diagrams of image set files, in accordance with several embodiments of the present invention.
FIG. 6 is media method, in accordance with one embodiment of the present invention.
FIG. 7 is a block diagram of a media management system, in accordance with one embodiment of the present invention.
FIG. 8 is a block diagram of a media player, in accordance with one embodiment of the present invention.
FIG. 9 is perspective view of a handheld computing device, in accordance with one embodiment of the present invention.
FIG. 10 is a media device operational method, in accordance with one embodiment of the present invention.
FIGS. 11A-11E are diagrams of several exemplary screen shots of a media player with photo viewing capabilities, in accordance with several embodiments of the present invention.
FIG. 11F is a diagram of a pictorial of a TV screen image provided by a television coupled to the media player, in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to portable media devices with image functionality and also to image transfer between portable media devices and their hosts. Media devices with image functionality typically require several different image formats to support the various display modes of the media device. For example, media devices typically require a full screen image that fills the entire display screen of the media device as well as various thumbnail images, which may help a user browse through a group of images.
One method for creating these various images is to download the original image to the portable media device and then to transcode the original image into the required formats on the portable media device when they need to be displayed. This is sometimes referred to as processing data on-the-fly. While this may work, it is generally believed that this methodology has several drawbacks that make it less appealing to the user. For example, because formatting images is a process intensive task (especially on portable media devices that lack the horsepower of their larger hosts), portable media devices tend to operate slowly and consume more power. Hence, formatting images on portable media devices tend to result in an unsatisfactory user experience. For one, the user has to wait while the image is being formatted. For another, the battery of the portable media device tends to run out more regularly.
In order to overcome these drawbacks, the present invention provides a method where images are preformatted on the host before or during the download thereto. When an image is identified for download various preformatted images derived from the original image (and possibly the original images) are sent to the portable media device. The processing is performed on the host, which can handle these tasks more easily than the portable media player. The tasks may, for example, include scaling, cropping, rotation, color correction and the like. Once received by the portable media device, the preformatted images and possibly the original image are stored for later use. By storing these images, the media device is relieved from having to perform any of the labor intensive tasks associated with image formatting. That is, the preformatted images relieve the media device of much of the work required to display them. As a result, the device operates faster and without repeated needs for recharging. In one embodiment, at least some of the preformatted images are thumbnail images.
During media device use, a user may request that an image be displayed. Instead of processing the original image as in the method described above, the device simply obtains the appropriate preformatted image from storage and presents it to the user on a display. The preformatted images may include a full screen image and several different thumbnail sized images. The full screen image typically depends on the size of the display contained in the portable media device, i.e., the full screen image generally fills the entire screen. The different sized thumbnail images, which come in various sizes, may be used in a variety of ways including separately or together. For example, a plurality of smaller thumbnails may be grouped together so that a user can quickly browse through a large number of images. The preformatted images may also follow formats associated with standards or other devices to which the portable media device can be linked. For example, at least one the preformatted images may be based on television formats so that the portable media device can present images on televisions (TVs). The TV formats may, for example, include NTSC, PAL, HDTV, and the like. The formats may also be based on formats associated with printers, cameras or similar image using devices.
In some cases, the media device when connected to a host expresses or informs the host as to which image formats are desired when an image is downloaded to the media device. The media device may, for example, send various image profiles corresponding to the different formats to the host device. The image profile generally contains the attributes or keys for each image format. By way of example, the image profiles may describe size, orientation, pixel format, color depth, etc. for each image format. This particular methodology helps with compatibility issues that typically come up when different media devices having different versions of software and hardware are used, i.e., the version of the software/hardware is made irrelevant since the media device expresses what information it wants from the host device.
Embodiments of the invention are discussed below with reference to FIGS. 1-11F . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.
FIG. 1 is a method 100 of transferring image data between a host device and a portable media device, in accordance with one embodiment of the present invention. The method 100 may, for example, be performed by media management software. The method includes blocks 102 , 104 and 106 . In block 102 , an image download request is received at the host device. The image download request designates at least one image stored on the host device for downloading to the portable media device. In some cases, only a single image is requested and in other cases a plurality of images are requested. The request can be made at the host device or the media device through a user interface. For example, the user may select a group of images and then select a download button. Alternatively, the request can be made by the media device without user input.
In block 104 , an image collection for each requested image is produced at the host device. Each image collection contains the new versions or different formats of the original image. In some cases, the image collection may also contain the original image. For example, the new versions may include a full screen image, which corresponds to the screen size on the media player, various thumbnail images, each of which are typically smaller versions of the original image, as well as various other images including for example TV images. It should be noted that the file sizes of the new versions are typically much smaller than the file size of the original image. They therefore take up less space in storage than would the corresponding original image.
Each new version has a different image profile based on the display needs of the portable media device. The image profiles for particular media devices may be stored in the host device or the image profiles may be given to the host device by the media device. In the first case, the media device may provide the host device with an Identifier (ID), which can be used by the host to determine the image profiles for the requesting media device. For example, after obtaining the ID the host may refer to a previously stored table or list that includes all the capabilities of the identified media device. In the later case, the media device may automatically upload this information as part of synchronization or handshaking procedure with the host device.
The image profile generally includes a list of keys or attributes which define the qualities or characteristics of each image. The keys or attributes may include for example FormatID, RenderWidth, RenderHeight, DisplayWidth, DisplayHeight, PixelFormat, Sizing, BackColor, Rotation, ScanFormat, ColorAdjustment, GammaAdjustment, and the like.
FormatID refers to an identification number that defines the image profile. Changing any of the attributes within the image profile will change the identification number. The media management program uses this ID to identify thumbnail locations in both the host and media devices.
RenderWidth is the width of the image in pixels at render time. RenderHeight is the height of the image in pixels at render time. RenderWidth and RenderHeight generally refers to actual physical size.
DisplayWidth is the width of the image in pixels at display time. DisplayHeight is the height of the image in pixels at display time. It should be noted that DisplayHeight and DisplayWidth can differ from RenderHeight and RenderWidth in those cases like NTSC where the pixels are not square. DisplayWidth and DisplayHeight generally refer to the true size.
PixelFormat describes information encoded in each pixel (e.g., color components (RGB), transparency, etc.). Several formats can be used including, for example, the QuickDraw/QuickTime pixel format.
Sizing describes what happens if the original image is smaller than the desired thumbnail. By way of example, if 0, scale the image to the desired height/width. If 1, scale the image to the desired height/width only if the image is larger than RenderWidth or RenderHeight, i.e., don't scale small images. If 2, center-crop the image to the desired height/width rather than scaling it.
BackColor describes what color the background should be in cases where the images don't fill the entire viewing area. The background color may be in big-endian ARGB format as a hexadecimal string.
Rotation described if and how an image should be rotated. The image rotation is typically in degrees. For example, the rotation values may be 0, 90, 180 and 270.
ScanFormat designates what scan format the image is stored in. ImageFormat may include progressive format or interlace format.
ColorAdjustment describes whether or not a color adjustment is needed, and if needed what the color adjustment should be. By way of example, if 0, no color adjustment is applied. If 1, NTSC color adjustment is applied. If 2, PAL color adjustment is applied.
GammaAdjustment describes whether a gamma correction needs to be applied to the image (e.g., brightness). If not supplied, no correction is done.
In block 106 , the image collection for each requested image is sent to the portable media device as part of the downloading process. Once received by the portable media device, the image collection is stored in the portable media device for later use. The image collection may be stored in the memory of the portable media device. In order to efficiently store the images in memory, each of the different image sets may be stored in their own file. That is, images having the same image profile are grouped in the same file. For example, the original images may be stored in a first file, the full screen images may be stored in a second file, a first set of thumbnail images may be stored in a third file, a second set of thumbnail images may be stored in a fourth file, the TV images may be stored in a fifth file and so on.
It should be noted that in some cases, the original image may not be sent to or stored on the hand held media device. This may be done to save valuable storage space on the hand held media devices that typically have limited storage capacity. As should be appreciated, the file size of the original image is typically much larger than the thumbnail images and therefore they can take up more space in memory. The decision of whether to include the original image with the rest of the images may be made by the user. For example, the user may be presented with a choice as whether they desire or do not desire to download or store the original image. This decision may be based on how the user uses the media device. For some, the media device may be used to transfer images from one host to another. In cases such as these, the user typically wants to include the original image. The decision may be set for all downloads or it may be made at each down load request. Similarly, the same decision can be made for all the different formats if so desired (as some of these formats may not be needed).
Once downloaded and during operation of the media device, a display request may be made on the media device. Thereafter, one or more images are retrieved from memory based on the display request. The display request indicates the images to be shown on the media player and/or images that are to be sent to another device connected to the media device. Once retrieved, the images can be displayed. The manner in which the images are displayed are typically determined by the mode of the media device. The modes can include a browse mode, a slide show mode, a full screen mode, etc. In browse mode, a plurality of tiny thumbnail images are displayed in rows and columns. In a slide show mode, a medium thumbnail image may be displayed in the center and smaller thumbnail images may be displayed on either side of the medium thumbnail image. The small image to the left of the medium image may represent a previously shown image, the medium image may represent the current image being shown, and the small image to the left of the medium image may represent the next image in the slide show sequence. If a TV is connected to the media device, the media device may output the TV version of the current image being shown to the TV. In a full screen mode, the full screen image is displayed.
FIG. 2 is an operational method for a portable media device 200 , in accordance with one embodiment of the present invention. The method includes blocks 202 , 204 , 206 and 208 . In block 202 , image data is stored. The image data includes at least a plurality of image collections. The image collections contain a plurality of differently formatted images based on an original image and may also include the original image. The image collections are not formed on the portable media device. They are separately generated on a device other than the portable media device. The image collections may for example be generated on a host device that downloads them to the portable media device for storage. By way of example, the image collections may be provided by the method described in FIG. 1 . Alternatively or additionally, the image collections may be downloaded from another portable media device that has already downloaded them from a host.
In block 204 , a display command is received. The display command designates one or more images of the image data to be displayed. The display command may be generated via a user making a selection on the user interface of the media player.
In block 206 , at least the designated images are retrieved. In some cases, only the designated images are retrieved. In other case, more than the designated images are retrieved. For example, although the display command may only designate a single image, other images associated or linked to that image may be additionally retrieved.
In block 208 , the one or more retrieved images are outputted. The retrieved images may be outputted to a display. The display may be located on the portable media device or it may be located external to the portable media device. In either case, upon receiving the retrieved images, the retrieved images are displayed. In some cases, all of the images are displayed, and in other case only a portion of the images are displayed. The later case may be implemented when the size and number of images is greater than the screen size.
FIG. 3 is a method 300 of transferring image data between a host device and a portable media device, in accordance with one embodiment of the present invention. The method may for example be performed by a media management program operating on the host device. The method begins at block 302 where a down load request is received. The download request designates one or more images to be downloaded from the host device to the portable media device. The download request is typically implemented via a user selection, i.e., a user selects one or more images and initiates a downloading procedure.
Following block 302 , the method proceeds to block 304 where a database entry is created for each image to be downloaded. The database entry provides information about the images to be downloaded. The information may for example be metadata. Following block 304 , the method proceeds to block 306 where the database entry is written or copied on the media device. The database entry is typically copied to an image database on the media device. If an image database does not exist, one will typically be created. If one does exist, the database entry will be copied thereto.
Also following block 304 , the method proceeds to block 308 where an image collection is created on the host. This may include transcoding new versions of the selected image based on a plurality of image profiles, and grouping the new versions of the original image and in some cases the original image into an image collection. The image profiles define the features of the new images. By way of example, the image profiles may include keys for making thumbnails and other images such as those which can be used on TV, printers, and other media devices (e.g., camera). The image profiles may be supplied to the host device by the media device, and thereafter stored locally on the host device. This may be part of the synchronization procedure that occurs between the host device and media device when they are connected together.
Following block 308 , the method proceeds to block 310 where each image in the image collection is written or copied to the media device. That is, each new version of the original image and in some cases the original image are copied to the media device. In one embodiment, each particular type of image is stored in a separate file on the media device. For example, all of the originals are stored in an original image file, all of a first thumbnails are stored in a first thumbnail image file, and so on.
Following block 310 , the method proceeds to block 312 where the database entry is updated. That is, the database entry is filled with the appropriate image data. The step of updating typically includes grouping together all the images of a particular image collection (original, thumbnails, TV), and providing pointers to the location where the actual image is stored (e.g., image files).
It should be noted that in most cases the host device stores a copy of the database entry and image collections in parallel with the media device.
It should be noted that the all or some of the steps mentioned above can occur separately as distinct events or they can occur simultaneously. In the later case, at least some of the steps can be interleaved. In interleaving, while some images are being copied, other images are being created. Interleaving is generally preferred in order to reduce the amount of time needed for downloading.
The image data stored in the media device will now be described. As mentioned above the image data is spread among multiple files. The main image database file holds image metadata, photo album lists, and “pointers” to the original image as well as all available thumbnails. The images themselves are stored either as individual files (originals) or in image set files, which contain one or more thumbnails of the same type. This is typically done to save storage space. It should be noted, however, that this is not a limitation and that the images may be stored as an image collection rather than in separate files.
In one embodiment, the photo database file contains a header followed by several “sections.” The number of sections can be widely varied although it is expected that the photo database will contain three sections: image list section, album list section and the image record ID table. The image list section contains a list of all images stored on the media device. Each image entry contains all of the metadata for an image as well as a list of locations for all available images associated therewith including the original, thumbnails and TV. Each image has a unique persistent record ID which is used in both the album and record ID table sections. The album list section contains a list of the albums, each of which is simply an ordered list of image record IDs. The image record ID table is a table containing record IDs and file offsets for all images, sorted in ascending record ID order. This table allows the media device to quickly load only those image records for a given album, rather than requiring loading the whole image record list.
The images themselves are stored in image set files. Each image set file contains a file header, followed by one or more images, each with a header. This allows scavenging of the data should the need arise. The image records in the photo database are by file specification (path) and file offset, so it is not necessary to parse an image set file to get to a particular image. The number of images per file and/or the maximum image files size may be widely varied. By way of example, the maximum size may be 500 Megabytes.
The following is an exemplary layout for the photo database stored on the media device:
File header
Image List Section Header
Image List header
Image 1 metadata
Image 1 Original Image Location
Image 1 Thumbnail 1 Image location
<additional image locations>
Image 2 Metadata
Image 2 Original Image Location
Image 2 Thumbnail 1 Image location
<additional image locations>
<additional images>
Album List Section Header
Album 1 Metadata
Album 1 Image Record ID 1
Album 1 Image Record ID 2
<additional album images>
Album 1 Metadata
Album 1 Image Record ID 1
Album 1 Image Record ID 2
<additional album images>
<additional albums>
Record ID List Section Header
Record ID List Header
Record ID 1 Description
Record ID 2 Description
<additional record Ids>
The following is an exemplary layout for an image set file stored on the media device:
File Header
Image 1 Header
Image 1 Data
Image 2 Header
Image 2 Data
<additional images>
FIG. 4 is an exemplary diagram of a photo database file 350 , in accordance with one embodiment of the present invention. The photo database 350 includes a file header 352 , an image list section header 354 , an album list section header 356 and a record ID list section header 358 . Inside the images list section header 354 are image entries 360 , and pointers 362 , which provide image locations for the various images in the image entry including for example the original image O and a plurality of thumbnails T thereof. Inside the album list section header 356 are album entries 364 and record IDs 366 for each of the images in the album. Inside the record ID list section header 358 are Record ID list header 368 and record ID descriptions 370 .
FIGS. 5A-5E are diagrams of exemplary image set files 372 , in accordance with one embodiment of the present invention. FIG. 5A is a diagram of an original image set file 372 A, FIG. 5B is a diagram of a tiny thumbnail set file 372 B, FIG. 5C is a diagram of a small thumbnail set file 372 C, FIG. 5D is a diagram of a medium thumbnail set file 372 D, FIG. 5E is a diagram of a full screen image set file 372 E, and FIG. 5F is a diagram of a TV screen image set file 372 F. In each of these figures, the image set files 372 include a file header 374 , image headers 376 and the actual image data 378 .
FIG. 6 is media method 400 , in accordance with one embodiment of the present invention. The method may be performed on a media system including a host device such as a personal computer and a media device. The method begins at block 402 where one or more images are uploaded into a personal computer. The images may be uploaded from a camera, memory device, Internet or the like. After block 402 , the method proceeds to block 404 where the images are stored in the personal computer. Blocks 402 and 404 may be accomplished with a media management program. In Block 406 , a media player is connected to the personal computer. This may be accomplished through a wired or wireless connection. The connection may include a handshaking and/or synching procedure.
In some cases, the media management program is automatically opened when the two devices are connected. The particular media management program opened may depend on the type of media device. If the media device is a music player, the media management program may be a music program. If the media device is a photo player, the media management program may be an image program. If the media device is a combination music/photo player, the media management program may be music program or a photo program or a combination of the two. If the different programs are operated independently, the music program and the photo program may be linked so that information can be shared there between. For example, the music program may be able to access data from the photo program and vice versa.
In block 408 , images and/or image identifiers (e.g., text) are presented on the personal computer. This too may be accomplished with the media management program. In fact, the images and image identifiers may be included in a photo window associated with a graphical user interface. In block 410 , a download command is generated. The download command designates one or more images to be downloaded from the personal computer to the portable media device. The download command may be generated when a user selects one or more images and hits a download feature located in the photo window.
In block 412 , the image formats required by the portable media device are determined. The determination may be made before the download or it may be made as part of the downloading process. In some cases, the host device stores a list of required formats for a variety of media devices. In other cases, the portable media device supplies the personal computer with required formats and image profiles, which describe how to format each image. In block 414 , new versions of the original image are created. That is, using the image profiles, the personal computer transcodes the original image into differently formatted images based on the image profile. By way of example, the transcoding may be performed by a multimedia technology such as QuickTime of Apple Computers Inc. of Cupertino, Calif. QuickTime is a powerful, cross platform, multimedia technology for manipulating, enhancing, and storing video, sound, animation, graphics, text, music, and the like. In Block 416 , the new versions of the original image and in some cases the original image are copied and stored onto the media device.
In block 418 , the media device is disconnected from the personal computer thereby allowing the images to be transported via the portable media device. In block 420 , a display command is generated on the media device during transport. In block 422 , one or more images are retrieved based on the display command. In block 424 , at least one of the retrieved images is presented. The retrieved image can be any of the stored images including the original and/or the new images. The retrieved image can be presented on the portable media device as for example though an LCD and/or it can be presented on an external display such as a television.
FIG. 7 is a block diagram of a media management system 500 , in accordance with one embodiment of the present invention. The media management system 500 includes a host computer 502 and a media player 504 . The host computer 502 is typically a personal computer. The host computer, among other conventional components, includes a management module 506 , which is a software module. The management module 506 provides for centralized management of media items not only on the host computer 502 but also on the media player 504 . More particularly, the management module 506 manages those media items stored in a media store 508 associated with the host computer 502 . The management module 506 also interacts with a media database 510 to store media information associated with the media items stored in the media store 508 .
The media items may correspond to audio, images or video items. The media information, on the other hand, pertains to characteristics or attributes of the media items. For example, in the case of audio or audiovisual media, the media information can include one or more of: title, album, track, artist, composer and genre. These types of media information are specific to particular media items. In addition, the media information can pertain to quality characteristics of the media items. Examples of quality characteristics of media items can include one or more of: bit rate, sample rate, equalizer setting, volume adjustment, start/stop and total time, etc.
Still further, the host computer 502 includes a play module 512 . The play module 512 is a software module that can be utilized to play certain media items stored in the media store 508 . The play module 412 can also utilize media information from the media database 510 . Typically, the media information of interest corresponds to the media items to be played by the play module 512 .
The host computer 502 also includes a communication module 514 that couples to a corresponding communication module 416 within the media player 504 . A connection or link 518 removeably couples the communication modules 514 and 416 . In one embodiment, the connection or link 518 is a cable that provides a data bus, such as a FIREWIRE™ bus or USB bus, which is well known in the art. In another embodiment, the connection or link 518 is a wireless channel or connection through a wireless network. Hence, depending on implementation, the communication modules 514 and 516 may communicate in a wired or wireless manner.
The media player 504 also includes a media store 520 that stores media items within the media player 504 . The media items being stored to the media store 520 are typically received over the connection or link 518 from the host computer 502 . More particularly, the management module 506 sends all or certain of those media items residing on the media store 508 over the connection or link 518 to the media store 520 within the media player 504 . Additionally, the corresponding media information for the media items that is also delivered to the media player 504 from the host computer 502 can be stored in a media database 522 . In this regard, certain media information from the media database 510 within the host computer 502 can be sent to the media database 522 within the media player 504 over the connection or link 518 . Still further, lists identifying certain of the media items can also be sent by the management module 506 over the connection or link 518 to the media store 520 or the media database 522 within the media player 504 .
Furthermore, the media player 504 includes a play module 524 that couples to the media store 520 and the media database 522 . The play module 524 is a software module that can be utilized to play certain media items stored in the media store 520 . The play module 524 can also utilize media information from the media database 422 . Typically, the media information of interest corresponds to the media items to be played by the play module 524 .
Hence, in one embodiment, the media player 504 has limited or no capability to manage media items on the media player 504 . However, the management module 506 within the host computer 502 can indirectly manage the media items residing on the media player 504 . For example, to “add” a media item to the media player 504 , the management module 506 serves to identify the media item to be added to the media player 504 from the media store 508 and then causes the identified media item to be delivered to the media player 504 . As another example, to “delete” a media item from the media player 504 , the management module 506 serves to identify the media item to be deleted from the media store 508 and then causes the identified media item to be deleted from the media player 504 . As still another example, if changes (i.e., alterations) to characteristics of a media item were made at the host computer 502 using the management module 506 , then such characteristics can also be carried over to the corresponding media item on the media player 504 . In one implementation, the additions, deletions and/or changes occur in a batch-like process during synchronization of the media items on the media player 504 with the media items on the host computer 502 .
In another embodiment, the media player 504 has limited or no capability to manage playlists on the media player 504 . However, the management module 506 within the host computer 502 through management of the playlists residing on the host computer can indirectly manage the playlists residing on the media player 504 . In this regard, additions, deletions or changes to playlists can be performed on the host computer 502 and then by carried over to the media player 404 when delivered thereto.
As previously noted, synchronization is a form of media management. The ability to automatically initiate synchronization was also previously discussed. Still further, however, the synchronization between devices can be restricted so as to prevent automatic synchronization when the host computer and media player do not recognize one another.
According to one embodiment, when a media player is first connected to a host computer (or even more generally when matching identifiers are not present), the user of the media player is queried as to whether the user desires to affiliate, assign or lock the media player to the host computer. When the user of the media player elects to affiliate, assign or lock the media player with the host computer, then a pseudo-random identifier is obtained and stored in either the media database or a file within both the host computer and the media player. In one implementation, the identifier is an identifier associated with (e.g., known or generated by) the host computer or its management module and such identifier is sent to and stored in the media player. In another implementation, the identifier is associated with (e.g., known or generated by) the media player and is sent to and stored in a file or media database of the host computer.
FIG. 8 is a block diagram of a media player 600 , in accordance with one embodiment of the present invention. The media player 600 includes a processor 602 that pertains to a microprocessor or controller for controlling the overall operation of the media player 600 . The media player 600 stores media data pertaining to media items in a file system 604 and a cache 606 . The file system 604 is, typically, a storage disk or a plurality of disks. The file system 604 typically provides high capacity storage capability for the media player 600 . However, since the access time to the file system 604 is relatively slow, the media player 600 can also include a cache 606 . The cache 606 is, for example, Random-Access Memory (RAM) provided by semiconductor memory. The relative access time to the cache 606 is substantially shorter than for the file system 604 . However, the cache 506 does not have the large storage capacity of the file system 604 . Further, the file system 504 , when active, consumes more power than does the cache 606 . The power consumption is often a concern when the media player 600 is a portable media player that is powered by a battery (not shown). The media player 600 also includes a RAM 620 and a Read-Only Memory (ROM) 622 . The ROM 622 can store programs, utilities or processes to be executed in a non-volatile manner. The RAM 620 provides volatile data storage, such as for the cache 606 .
The media player 600 also includes a user input device 608 that allows a user of the media player 600 to interact with the media player 600 . For example, the user input device 608 can take a variety of forms, such as a button, keypad, dial, etc. Still further, the media player 600 includes a display 610 (screen display) that can be controlled by the processor 602 to display information to the user. A data bus 611 can facilitate data transfer between at least the file system 604 , the cache 606 , the processor 602 , and the CODECs 612 .
In one embodiment, the media player 600 serves to store a plurality of media items in the file system 604 . The media items may for example correspond to audio (e.g., songs, books), images (e.g., photos) or videos (e.g., movies). When a user desires to have the media player play a particular media item, a list of available media items is typically displayed on the display 610 . Then, using the user input device 608 , a user can select one of the available media items. The processor 602 , upon receiving a selection of a particular media item, supplies the media data (e.g., audio file, image file or video file) for the particular media item to the appropriate device. For audio items, the processor supplies the media item to a coder/decoder (CODEC) 612 . The CODEC 612 then produces analog output signals for a speaker 614 . The speaker 614 can be a speaker internal to the media player 600 or external to the media player 600 . For example, headphones or earphones that connect to the media player 600 would be considered an external speaker.
For visual items, the processor supplies the media item to the display 610 . The display may for example be a liquid crystal display (LCD) that is integral with the media player. Alternatively, the display may be an external display such as a CRT or LCD, or a television of any particular type. In some cases, the processor is configured to supply media data to both an integrated display and an external display. In cases such as this, the media data displayed on both displays may be the same of it may be different. In the later case, for example, the internal display may include a slide show interface showing the previous image, the next image and the image currently being displayed on the external display.
The media player 600 also includes a network/bus interface 616 that couples to a data link 618 . The data link 618 allows the media player 600 to couple to a host computer. The data link 618 can be provided over a wired connection or a wireless connection. In the case of a wireless connection, the network/bus interface 616 can include a wireless transceiver.
In another embodiment, a media player can be used with a docking station. The docking station can provide wireless communication capability (e.g., wireless transceiver) for the media player, such that the media player can communicate with a host device using the wireless communication capability when docked at the docking station. The docking station may or may not be itself portable.
The wireless network, connection or channel can be radio-frequency based, so as to not require line-of-sight arrangement between sending and receiving devices. Hence, synchronization can be achieved while a media player remains in a bag, vehicle or other container.
The host device can also be a media player. In such case, the synchronization of media items can between two media players.
The various aspects, embodiments, implementations or features of the invention can be used separately or in any combination.
The invention is preferably implemented by software, but can also be implemented in hardware or a combination of hardware and software. The invention can also be embodied as computer readable code on a computer readable medium. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, DVDs, magnetic tape, optical data storage devices, and carrier waves. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.
FIG. 9 is perspective view of a handheld computing device 700 , in accordance with one embodiment of the present invention. The computing device 700 is capable of processing data and more particularly media such as audio, video, images, etc. By way of example, the computing device 700 may generally correspond to a music player, game player, video player, camera, cell phone, personal digital assistant (PDA), and/or the like. With regards to being handheld, the computing device 700 can be operated solely by the user's hand(s), i.e., no reference surface such as a desktop is needed. In some cases, the handheld device is sized for placement into a pocket of the user. By being pocket sized, the user does not have to directly carry the device and therefore the device can be taken almost anywhere the user travels (e.g., the user is not limited by carrying a large, bulky and heavy device).
As shown, the computing device 700 includes a housing 712 that encloses and supports internally various electrical components (including integrated circuit chips and other circuitry) to provide computing operations for the device. The integrated circuit chips and other circuitry may include a microprocessor, memory, a battery, and various input/output (I/O) support circuitry. In most cases, the microprocessor executes instructions and carries out operations associated with the computing device. For example, using instructions retrieved for example from memory, the microprocessor may control the reception and manipulation of input and output data between components of the computing device 700 . In fact, the microprocessor may work with an operating system to execute computer code and produce and use data stored in memory. By way of example, the memory may include a hard drive, flash memory, Read-Only Memory (ROM), Random-Access Memory (RAM) and/or the like.
The computing device 700 also includes a display 714 . The display 714 , which is assembled within the housing 712 and which is visible through an opening in the housing 712 , is used to display a graphical user interface (GUI) as well as other information to the user (e.g., text, objects, graphics). The display 714 generally takes the form of a flat panel display such as a liquid crystal display (LCD).
The computing device 700 also includes one or more input devices 718 configured to transfer data from the outside world into the computing device 700 . The input devices 718 may for example be used to perform tracking/scrolling, to make selections or to issue commands in the computing device 700 . By way of example, the input devices 718 may correspond to keypads, joysticks, touch screens, touch pads, track balls, wheels, buttons, switches, and/or the like. In the illustrated embodiment, the computing device 700 includes a touch pad 718 A and a plurality of buttons 718 B, which are assembled within the housing 712 and which are accessible through openings in the housing 712 .
The computing device 700 may include one or more switches 720 including power switches, hold switches, and the like. Furthermore, the device 700 may include one or more connectors 722 including data ports and power terminals 722 A and B, as well as audio and/or video jacks 722 C.
In the illustrated embodiment, the computing device 700 is a pocket sized hand held music/photo player that allows a user to store a large collection of music and photos, and to listen to this music and view the photos on the go (e.g., while working, traveling, exercising, etc.). In such a case, the memory may contain media management software having both music playing and photo displaying capabilities. Furthermore, the GUI may visually provide music and photo menus, as well as music and photo controls to the user. Moreover, the touch pad may provide scrolling functions, which allow a user to traverse through menus or controls on the GUI as well as to browse through a list of songs or photos, and the buttons may provide button functions that open a menu, play a song, display a photo, fast forward through a song, seek through a playlist or album and/or the like. In addition, the music/photo player typically includes an audio jack for outputting audio, a video jack for outputting photos and videos and a data port for transmitting and receiving media data (and other data.) to and from a host device. In some cases, the audio and video jack are combined into a single jack. By way of example, the music photo player may correspond to the iPod® series music players manufactured by Apple Computer of Cupertino, Calif.
FIG. 10 is a media device operational method 800 , in accordance with one embodiment of the present invention. The operational method 800 may for example be performed on a portable media device, and more particularly a portable music/photo player. The method 800 generally begins at block 802 where a main menu is presented to a user on a display. See for example FIG. 11A , which shows the main menu 850 presented on the display. The main menu 850 generally includes several options 852 associated with operating the media device. By way of example, the main menu 850 may include options 852 such as music, photos, extras, settings, shuffle songs and backlight. In most cases, each of the options 852 includes its own sub menu of sub options, which are associated with the main option. Each of these sub options may open another sub menu of sub options or they may initiate an action. By way of example, the music submenu may include music library, playlist, and browse options and the photo sub menu may include photo library, album and slide show setting options
Following block 802 , the method proceeds to block 804 where a determination is made as to whether the photo option was selected. If not, the method waits or proceeds back to block 802 . If so (as shown by the slider bar in FIG. 11A ), the method proceeds to block 806 where the photo sub menu is presented to the user on the display. By way of example, see FIG. 11B which shows the photo sub menu 854 presented on the display. The photo sub menu 854 may include one or more photo options 856 , which may represent different modes of photo viewing, and which may give the user the ability to change settings associated with photo viewing. In the illustrated embodiment, the sub menu 854 includes a photo library option, one or more album options and a photo settings options.
Following block 806 , the method proceeds to block 808 where a determination is made as to whether or not the library option is selected. If the library option is selected, the method proceeds to block 810 where all the stored images are retrieved. Thereafter, in block 812 , the images are displayed based on predetermined settings. If the library is not selected, the method proceeds to block 814 where a determination is made as to whether or not the album option is selected. If the album option is selected, the method proceeds to block 816 where only the album images are retrieved. Thereafter, in block 818 , the images are displayed based on predetermined settings.
In either of blocks 812 and 818 , the entire group or some portion of the retrieved group can be displayed. The amount displayed generally depends on the number of images inside the library or album. If it is large, the screen may not be capable of displaying all of the images at once. In cases such as these, some of the images are kept out of the viewing area until the user decides to pull them up. The manner in which they are displayed generally depends on the desired display configuration established in the settings menu.
In browse mode, a large group of tiny thumbnails 858 are displayed in columns and rows as shown in FIG. 11C . The user can browse through the tiny thumbnails 858 via a scrolling action either image by image or row by row or column by column, etc. As the user scrolls through the images a new set of data (e.g., images or line of images) is brought into view in the viewing area. In most cases, once the viewing area is full, each new set of data appears at the edge of the viewing area and all other sets of data move over one position. That is, the new set of data appears for each set of data that moves out of the viewing area. In some cases, when a particular image is selected while browsing, the full screen version of that image is displayed as shown in FIG. 11E . Alternatively, the configuration shown in FIG. 11D may be displayed with the current image being the medium thumbnail of the image selected, and the previous and next images being the small thumbnails of the images located next to the image selected.
In slide show mode, only the previous, current, and next images are displayed. The previous and next images may be small thumbnails 860 while the current image may be a medium thumbnail 862 as shown in FIG. 11D . The user may traverse through the retrieved images by clicking a forward or back button, i.e., the forward button causes the current image to move to the previous image, the next image to move to the current image, and a new image to move into the next image. In some cases, when a the current image is selected while traversing through the slide show, the full screen version 864 of that image is displayed as shown in FIG. 11E .
In TV mode, the TV thumbnail(s) 866 is outputted to a TV for display as shown in FIG. 11F . The TV display may mimic what is being shown on the media player. For example, the TV display may display any of the previous screen shots ( FIGS. 11C , 11 D, 11 E) or variations thereof. During a slide show, for example, the TV screen image may be based on the same original image as the current image in the slide show window.
If the album option is not selected, the method proceeds to block 820 where a determination is made as to whether or not the setting option is selected. If the setting option is selected, the method proceeds to block 822 where a setting menu is presented to the user on the display. The setting menu may include control settings pertaining to one or more display events. In fact, the setting menu may serve as a control panel for reviewing and/or customizing the control settings, i.e., the user may quickly and conveniently review the control settings and make changes thereto. Once the user saves the changes, the modified control settings will be employed to handle future display events. By way of example, the settings may include features that allow a user to assign music tracks to albums, to turn the assigned music on/off, to turn TV out on/off, to choose between modes, etc. The settings may also allow a user to select slide shows and whether to display the images in full screen or slide show mode and whether to show the images in random or sequenced order as well as to end or repeat when finished.
While this invention has been described in terms of several preferred embodiments, there are alterations, permutations, and equivalents, which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. For example, although the invention is primarily directed at images, it should be noted that it may also be applied to music. In the case of music, different versions of the same song may be created, downloaded and stored. The different versions can be based on a variety of things including for example adjustments made to characteristics of the song (e.g., tempo, pitch), adding or removing elements of the song (e.g., voice or instrument), and/or the like. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention. | Methods and system for transferring images between devices is disclosed. For example, differently scaled images by a host device may automatically and/or selectively be transferred to a media player for display. In turn, appropriately scaled images may be transferred automatically and/or selectively to another display device for example a TV, camera or printer. The selectivity may occur either at the host level or at the player level. | 8 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] The invention relates to an inductive safety sensor for monitoring doors and gates and, more particularly, of elevators and/or lifts.
[0002] Two-channel inductive safety sensors are used for monitoring electrically and mechanically actuated revolving doors, sliding doors, rolling gates, flaps and hatches. Safety sensors ensure a secure monitoring of the open and closed position of doors and gates. Whereas commercially available inductive proximity switches can be actuated by means of virtually all metallic objects, the invention starts with the idea of further developing the proximity switch such that it emits a signal only by means of an especially constructed actuating element. It is an object of the invention to provide such an inductive proximity switch which has a constructively simple design.
[0003] The invention achieves this task by a safety sensor for monitoring the condition of doors and gates, particularly of elevators, that has a sensor device, which emits a signal only when sensing a target made of a defined material and switches from a first constant current to another constant current.
[0004] In contrast to the single-channel mechanical safety switches of the prior art, the safety sensors according to the invention, in particular, have the following advantages:
[0005] The sensor and the target operate in a contactless manner.
[0006] No mechanical wear occurs as a result of friction or burn-up at the contacts.
[0007] The sensor and the target can have a two-channel construction.
[0008] The sensor and the target can be mutually adapted. As a result of suitable measures, it can be ensured that a manipulation by foreign targets (non-ferrite) is excluded. A manipulation by magnets, jumpers and similar materials is, therefore, not possible. An internal signal evaluation takes place by way of interference-immune phase demodulation.
[0009] Protection Type IP67 can be implemented.
[0010] Several switch points can be securely monitored.
[0011] Changes of the distance between the sensor and the target by material fatigue are detected and are reported by the safety bus system to, for example, a control unit (preventive maintenance).
[0012] As a result of the linkage to a safety bus system, such as the applicant's (CAN OPEN SAFETY), the output signals are monitored in a redundant manner. The signal transmission to the bus node takes place by interference-immune current loops.
[0013] The fastening of the safety sensor can take place in a simple manner by thread bolts or internal threads.
[0014] According to a variant, a balancing of the operating data of the sensor (switching interval) can be implemented by an advantageously uncomplicated construction of the sensor coil.
[0015] According to an embodiment, the sensor reacts only to ferrite, for example, and, in the event of a detection, switches from one constant current to another constant current. This permits line monitoring because operating currents other than the defined currents indicate a cable interference.
[0016] For safety-related reasons, the sensor has a redundant construction; that is, each sensor housing contains two sensor systems which are mutually, completely separated, with the exception of the positive supply voltage. The two systems are identical, with the exception of the excitation frequency, which must differ slightly in order to prevent a mutual influencing. In the further course, only one system which therefore be discussed.
[0017] Other aspects of the present invention will become apparent from the following detailed description of the invention, when considered in conjunction with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram of an inductive sensor according to the invention.
[0019] [0019]FIG. 2 is a schematic diagram of an oscillator for an inductive sensor according to the invention.
[0020] [0020]FIGS. 3 a and 3 b are diagrams which reflect the behavior of the impedance when various targets are used in the resonant proximity.
[0021] [0021]FIGS. 4 a and 4 b are diagrams which reflect the behavior of the phase angle when various targets are used in the resonant proximity.
[0022] [0022]FIG. 5 is an exploded view of a coil for the sensor according to the invention.
[0023] [0023]FIG. 6 is a schematic diagram of a zero crossing detector for a sensor according to the invention.
[0024] [0024]FIG. 7 a is a schematic diagram of a phase comparator for a sensor according to the invention.
[0025] [0025]FIG. 7 b is a truth table for a phase comparator.
[0026] [0026]FIG. 7 c is a graph of various phase diagrams.
[0027] [0027]FIG. 8 is a schematic diagram of a threshold value switch for a sensor according to the invention.
[0028] [0028]FIG. 9 is a schematic diagram of a voltage regulator for a sensor according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] First, a block diagram of the sensor S with the target T according to FIG. 1 will be described. A sensor S is arranged, for example, in a part of a door (not shown here), and the target—if it is to be monitored whether the door is open or closed—is arranged in a second part of the door which is movable relative to the first part. The construction of this sensor S is as follows.
[0030] An oscillator 1 generates a crystal-precise rectangular oscillation which is supplied to two additional modules. By way of a resistor R 5 , the signal drives an oscillating circuit 2 consisting of capacitor C 1 and indicator L 1 , which reacts to field changes by external objects. The signal from the oscillator 1 is also supplied to a phase comparator 3 which compares the phase of this signal with the phase of the oscillating circuit 2 .
[0031] Since the phase comparator 3 processes only digital signals, the sinusoidal oscillation of the LC circuit 2 is first fed to a zero crossing detector (comparator) 4 , which converts the sinusoidal oscillation into a square wave signal. The phase comparator 3 is designed such that it reacts only to negative phase angles. On the output of the phase comparator 3 , a PWM signal is generated whose pulse to separation ratio is a measurement of the change of the LC circuit.
[0032] The PWM signal is transformed by an integrator 5 into a direct voltage following the pulse/separation ratio and is fed to a threshold switch 6 . The threshold switch 6 is dimensioned such that only the change of the oscillating circuit which is caused by a special material (ferrite, for example) at a precisely defined interval from the sensor results in a switching of this switch. As a result of this operation, another current is added to the operating current by a connected resistor. Because the entire circuit is maintained at a constant voltage by a controller 7 , the voltage change before the threshold value switch 6 has therefore become a current change by a voltage to current transformation.
[0033] Additional figures illustrate, among others, additional details of the above-explained components of the sensor according to the invention. The individual circuit components will be explained in detail with reference to the additional figures.
[0034] [0034]FIG. 2 shows the detailed construction of the oscillator 1 . A precision oscillator 1 includes the following components: inverters IC 3 and IC 4 , frequency divider IC 5 , crystal X 1 , capacitors C 10 and C 11 and resistor R 6 . The combination with the frequency divider IC 5 is based on cost because, as a result, very inexpensive quartzes in the megahertz range can be used. Also, it offers a maximum of flexibility with respect to the frequency selection. A last reason is the absolute symmetry (pulse to separation ratio=1) of the square wave signal. Because the inputs of the frequency divider IC 5 , for example, an HC4040, are edge-triggered, the signal of gate or inverter IC 4 is buffered by the gate or inverter IC 3 .
[0035] According to FIG. 1, the rectangular oscillation is supplied by the resistor R 5 to the oscillation circuit 2 with the capacitors C 1 and the coil L 1 . The size of the resistor R 5 is in the order of the active resistance of the LC circuit at resonance.
[0036] The rough position of the excitation frequency depends on the size of the ferrite coil or the quality maximum (parameter of the ferrite coil independently of the resonance of the LC circuit) of this coil in order to achieve maximal sensitivity.
[0037] The position of the excitation frequency with respect to the resonance frequency decisively determines the behavior of the sensor with respect to the different materials (targets). In principle, several different detection behaviors can be achieved. In order to differentiate ferrite from other materials according to the demands, an excitation frequency must be selected at which, for all proximity distances, phase angles occur for just this material which are achieved in no other damping situation. The precise position of this point can be determined in that, above the frequency, impedances |Z| and phase angles Phi are measured in the case of different damping materials (ferrite, iron, nonferrous heavy metals) at different distances (0<s<sn).
[0038] [0038]FIGS. 3 a and 3 b show graphs for undamped or no target, ferrite, steel and aluminum, within the resonance of the coil, at various frequencies for the impedance in resonance and the phase angle in resonance. The impedance is maximum at a zero phase angle for no target, ferrite or steel. The maximum for aluminum at zero phase angle is at a substantially lower frequency off the chart of FIGS. 3 a and 3 b.
[0039] [0039]FIGS. 3 a and 3 b show the materials at a distance SN, and FIGS. 4 a and 4 b show the impedance and phase angle over the same frequency range at a distance of zero. The distance for 3 a is 6 millimeters. In FIG. 4 a, the undamped impedance or no target is not shown since it is off the chart and is the same as in FIG. 3 a. With respect to the ferrite, it is barely visible, but it has a constant 90 degree phase angle.
[0040] The adjoining phase comparator 3 is designed such that it can react only to negative phase angles which are caused by materials of a high magnetic permeability. The resonance frequency of the LC circuit 2 is usefully designed such that the excitation frequency is situated on the trailing edge of the resonance curve. Here, the sensor exhibits its highest sensitivity. Because of the very narrow bandwidth of the LC circuit, these two frequency values differ only by several Hertz. Consequently, the oscillating circuit 2 has to be balanced because the precise position of the resonance cannot be achieved with the usual component tolerances.
[0041] Furthermore, this results in the demand to balance the LC circuit 2 as such. This led to the construction of coils which can be balanced according to FIG. 5.
[0042] Deviating from the conventional coils for proximity switches, in this construction, the wound body 100 was designed to be slightly flatter, and the coils can be adjusted in its position by an adjusting mechanism. Only one of a pair of coils is shown in FIG. 5. The wound bodies 100 are inserted into a housing 102 . They have terminal pins 103 , and their height can be adjusted by the spring 104 and the screw 105 . The pot core 101 , the printed circuit board 106 as well as the wound body 100 are fixed at the housing by a fixing pin 107 .
[0043] As a result, inductivity changes of 10% can be achieved which are sufficient for balancing the tolerances to be expected in the winding and in the core material. The balancing will then take place as follows: The sensor is damped by a desired target at the nominal switching interval. The winding body 100 position is adjusted by screw 105 until the output signal changes (switches). After the adjusting, the complete sensor is sealed by epoxy resin in order to ensure a durable stability and resistance with respect to environmental influences.
[0044] According to the definition, the sensor should react only to a certain counterpart or target. The target is naturally accommodated in a separate housing and electronically consists only of two pot cores of the same construction, as those used in the sensor. Under defined installation conditions, the pot core halves are situated opposite one another in pairs. The line-of-force path of the LC circuit is now drastically reduced, which results in an increase of inductivity and therefore in a lowering of the resonance frequency.
[0045] In the following, the zero crossing detector (comparator) 4 will be described by means of FIG. 6. The base of the LC circuit from C 1 and L 1 is on half the operating voltage. This point is also situated on the non-inverting input of the comparator 4 (IC 6 ). This voltage is generated by the resistors R 1 , R 8 connected in series between ground and Vcc.
[0046] With respect to the phase comparator 3 , it should be noted that normally EXCLUSIVE-OR gates are used for the phase detection. The basic circuit application also uses this possibility which in this application would, however, be difficult, because it cannot differentiate between phase angles with respect to the sign.
[0047] If, instead of the EXCLUSIVE-OR gate, a D Flip-Flop in a suitable arrangement is used, as shown in FIG. 7 a, it is possible to completely extract the reaction to the undesired positive phase angles. Under the condition that the clock inputs and data inputs of the delay element are constantly on a high potential, the truth table can be shown in a simplified manner as follows:
Set Reset Q L L H L H H H L L H H No Change
[0048] The pulse diagrams (FIG. 7 c ) will now illustrate that only negative phase angles cause a change of the pulse separation ratio. For negative phase angles of ferrite, the pulse width is greater than that of the set signal, or, for metal, the pulse width of the output Q is the same as that of the set signal from the oscillator 1 . If the reset signal from the oscillator 1 has a 1:1 ratio of pulse to separation from the desired target, the pulse to separation ratio of the sensor is greater than the pulse to separation ratio of the oscillator 1 , as shown in the top FIG. 7 c. For metal, the pulse to separation ratio of the oscillator 1 is equal to that of the pulse to separation ratio of the sensor.
[0049] The PWM signal from phase comparator 3 is integrated by resistor R 2 and capacitor C 4 of integrator 5 . A time constant of approximately 1 ms is far above the period of the oscillator, but is still fast enough in order to achieve the required switching frequency. A direct voltage, which can vary between 2.5 V (corresponds to 0°) and 5 V (corresponds to −90°), is outputted which is proportional to the phase angle.
[0050] The following is achieved by the threshold value switch 6 of FIG. 8. By means of the two comparators IC 1 A and IC 1 B of the IC 1 , in addition to the operating current, is almost constant, two more currents are produced and added to the operating current. One current is produced when the nominal or designed target switching interval is reached. A second current is produced when a slightly lower diagnostic switching interval (yellow or warning state) is reached. This second switching interval can be used for detecting a mechanical wear of the system. The threshold of the nominal switching interval results directly from the phase position or the frequency spacing which is necessary for detecting the target or ferrite. It is defined by resistors R 7 and R 9 /R 10 for each comparator. Switching hystereses are generated by resistors R 4 or R 12 , respectively. The outputs appear across resistors R 3 and R 11 .
[0051] The voltage controller or regulator V_REG of FIG. 9 provides a constant operating voltage of the entire sensor circuit. The entire sensor circuit operates completely with relative levels and would therefore be able to operate within wide ranges without such a precise voltage control. However, with the constant voltage, constant currents are generated which are independent of the input voltage. Thus, by means of this circuit arrangement, a controllable current source is implemented.
[0052] Landing Entrance Door and Cage Door Monitoring
[0053] The safety door switches are installed, for example, on an elevator landing entrance door and an elevator cage door for monitoring the locking and the closed position.
[0054] In the normal operation, it should not be possible to open a landing entrance door when the elevator cage is not situated behind this door or is situated within the unlocking zone. The safety door switches are used, for example, in the case of power-operated landing entrance doors driven jointly with the elevator cage door.
[0055] The mounting of the safety door switch on the landing entrance door takes place according to EN81 7.7.3.1. In the case of this application, the mechanical locking element is monitored by the safety door switch. The effective locking of the closed landing entrance door must precede the movement of the elevator cage. The elevator cage should not start before the locking device has engaged at least 7 mm. The safety door switch and target S-T monitors the position of the locking device in a two-channel manner. The required redundancy is ensured by the sensor node. The sensor node reports the position of the locking device to the bus master.
[0056] Closed Position
[0057] The safety door switches are used for monitoring the closed position according to EN 81 7.7.4.1, 7.7.6.2 and 8.9.2.
[0058] According to EN 81, the gap between the door blades or leaves should not be larger than 10 mm. If the distance between the door blades is larger than 10 mm, the elevator system should be brought into a secure condition. Should the gap, for example, be larger than 7 mm, this condition is detected by the safety door switch and by way of the safety bus additional information is supplied for adjusting the door.
[0059] By linking the elevator cage signals and the landing entrance door signals, it can, for example, be detected that, when the landing entrance door is opened (by an emergency unlocking), the elevator cage door or the elevator cage is not behind the landing entrance door. As a result of this analysis, the elevator system is brought into a secure condition.
[0060] When a mechanic opens the landing entrance door at the lowest stop in order to carry out maintenance work in the elevator shaft pit, he should actuate the emergency brake switch for safety purposes. Should the landing entrance door close before the emergency brake switch was actuated, the elevator system can start when an external call is present.
[0061] By analyzing the landing entrance door signals and the cage door signals, it is detected that a manipulation is present (landing entrance door was open; cage door closed). When this combination is present, a starting of the elevator system is prevented by the analysis of the signals in the control.
[0062] As a result of this combination, it is also ensured that a surfing on the cage roof as a result of the manipulation of the door switches is not possible.
[0063] In the case of mechanical door switches, such a logical linking of signals is not possible.
[0064] Although the present invention has been described and illustrated in detail, it is to be clearly understood that this is done by way of illustration and example only and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims. | Inductive safety sensor for monitoring the condition of doors and gates, particularly of elevators, having a sensor device for sensing a target which is designed such that it emits a signal only when sensing a target made of a defined material and switches from a first constant current to another constant current when the target is sensed. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of pending International patent application PCT/EP2008/001962 filed on Mar. 12, 2008 which designates the United States, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to suction of dust and vapours in a road planer or similar milling machines.
[0003] In particular the invention refers to a road planer improved with suction and disposal devices for dust and vapours, namely the invention refers to a self propelled road milling machine comprising a chassis mobile on crawler-tracks/wheels, a milling drum supported by said chassis and located inside a drum housing, at least a first and a second conveying device, supported by the machine chassis, receiving the material milled by the milling drum and transporting it to a discharge point, a suction-filtering device of the air polluted by dust and vapours produced by the milling process, upper and side sealing means on said conveying devices, suitable to create on said conveying devices a single channel sealing means on the discharge area of the first conveying device onto the second conveying device.
BACKGROUND OF THE INVENTION
[0004] A known road planer refers to a self propelled milling machine, generally used for removing a portion of asphalt road pavement in order to restore the road with re-deposition of renovated road-surface (repaving).
[0005] In the present invention the definitions “road planer” and “milling machine” are considered equivalent.
[0006] The road planer or milling machine consists of a self propelled chassis, supported by crawler tracks, or wheels, generally equipped with hydraulic actuators, powered by a diesel engine and having a milling drum to mill the asphalt road surface for repaving.
[0007] A milling drum is supported by the chassis transversally to the direction of travel, being directly operated by the diesel engine through a mechanical transmission, or by a hydraulic transmission.
[0008] Said crawler tracks or wheels are connected to telescopic columns, which consent the chassis to achieve the correct height and attitude to get the requested milling profile.
[0009] The material, milled by the drum, is removed by one or more conveyor belts, and finally discharged at the front section of the machine, or at its rear section. In the first case the milled material is discharged into a transport vehicle, which precedes the milling machine, whilst in the second case the vehicle follows the milling machine, running backward.
[0010] During the milling operation dusts arise, caused by the partial crushing of the aggregates included in the road pavement; if the road pavement consists of an asphalt mixture also bitumen vapours are produced due to the high temperature caused by the friction of the cutting tools.
[0011] In an open-air milling machine dust and vapours escape from the drum housing and from the conveyor belts, being emitted into the surrounding environment generating pollution and particularly close to the driving platform with potential health risk for the operator.
[0012] The main object of the present invention is to improve functionality of the road planer or milling machine in order to reduce pollution and other inconveniencies.
[0013] Patent EP 0 971 075 A1 foresees to fit a suction hood over the collecting conveyor and to connect said hood with a cyclone followed by a suction ventilator: said cyclone being located in the rear part of the milling machine.
[0014] This solution presents the following evident disadvantages:
the cyclone can knock down only the coarse dust particles, but it is not efficient at all in retaining the fine dust which is spread around in the atmosphere close to the operator's platform and sometimes close to the engine cooling air intake. The coarse dust is discharged onto the ground thus increasing the amount of material to be removed to clean the milled surface. the poor efficiency of the cyclone causes the ventilator to suck still dust-laden air which compromises the functionality of the unit in a short time.
[0017] Patent DE 102 23 819 A1 foresees the suction of the polluted air from the channel on the collecting conveyor and to convey it into the channel on the loading conveyor by means of the same suction-ventilator. This solution consents to exhaust the air, polluted by dust and vapours, into the atmosphere far away from the operator's platform. However the solution suffers the following disadvantages:
the ventilator sucks dust-laden air which compromises the functionality of the unit in a short time. no filtering system is foreseen able to agglomerate the dust and to limit its diffusion into the atmosphere.
[0020] DE 10 2005 035 480 discloses a milling machine comprising a dust box arranged in front of a ventilator and assigned to a suction channel having an outlet for passing clean waste air directly into the atmosphere.
[0021] U.S. Pat. No. 179,309 discloses a milling machine with a suction device for the polluted air, whereby the milled material is enclosed by a channel, the suction device is connected to a rear channel section of the channel in the direction of the material transport and sucks off the air polluted during milling blowing off the cleaned air into the environment.
[0022] Patents EP 1 507 925 B1 and U.S. Pat. No. 7,219,964 B2 foresee to suck the polluted air from both the channel on the collecting conveyor and from the channel over the loading conveyor, where:
the collecting conveyor is equipped with a sealing device, consisting of sets of flexible flaps, located close to its discharge head, which oppose to the entry of external air but do not oppose to the flow of the milled material; the channel on the collecting conveyor is connected to the corresponding channel on the loading conveyor by means of hoses with air intakes located upstream of the above mentioned sealing device; sealing devices, consisting of sets of flexible flaps are provided for the loading conveyor such as for the collecting conveyor. On the loading conveyor the sealing devices are located downstream of the connection points of the above hoses with the loading conveyor channel and downstream of the suction-filtering unit; the discharge area of the collecting conveyor onto the loading conveyor is not involved in the suction of the polluted area; the polluted air is forced to pass through a filtering unit before being exhausted by the suction-ventilator into the atmosphere.
[0029] The disadvantages of the solution are the following:
the bulk hoses connecting the channels of the two conveyors and the movements of said hoses caused by the slewing of the loading conveyor, compromise functionality; the discharge area of the collecting conveyor onto the loading conveyor is not interested by the suction process. In said area dust and vapours are emitted and spread into the atmosphere in the vicinity of the operator's platform.
SUMMARY OF THE INVENTION
[0032] The scope of the invention is to obviate the above disadvantages and to realize a more sure and simple milling machine, namely a road planer having improved performance to avoid pollution and damages on surroundings.
[0033] The object is achieved by provision of a self propelled road milling machine comprising a chassis mobile on crawler-tracks/wheels, a milling drum supported by said chassis and located inside a drum housing, at least a first and a second conveying device, supported by the machine chassis, receiving the material milled by the milling drum and transporting it to a discharge point, a suction-filtering device of the air polluted by dust and vapours produced by the milling process, upper and side sealing means on said conveying devices, suitable to create on said conveying devices a single channel sealing means on the discharge area of the first conveying device onto the second conveying device.
[0034] The sealing means realize one continuous chamber above the conveying devices and in the joint connections area among them. The joint between the first chamber and the secondary chamber/s being an articulated sealed joint, the continuous chamber extends continuously from the milling drum area up to the discharge head. The continuous chamber being free from external air-channellings between the first chamber and the second chamber/s, the continuous chamber being formed by: sidewalls of the milling drum housing, rear mouldboard, and side plates.
[0035] A first chamber enclosing the first conveying device, being this chamber formed by the side sealing means, the flexible means, top sealing mean above the conveyor belt, and the first chamber being closed and sealed on its lower part by the conveyor belt, being further provided with sealing junction flexible means on sliding contact with the upper part of the continuous belt of the conveying device, the junction being elastic.
[0036] One or more secondary chambers enclosing a secondary conveying device, being this chamber formed by the side sealing means, the flexible means, the top sealing means, and the first chamber being closed and sealed on its lower part by the conveyor belt, being further provided with sealing junction flexible means on sliding contact with the upper part of the continuous belt of the conveying device, the junction being elastic.
[0037] At least one sealing means and at least one sealing means enclosing an intermediate area being this area the discharge area of the first conveying device and the charge area of the second conveying device.
[0038] Two or more sets of sealing means on the top end of the continuous chamber fixed to the top sealing means. The sealing means being flexible flaps overlapping one with the other, the sets of flexible sealing means being free to slide on their side in correspondence to the sealing means and being free to slide on their bottom side in correspondence to the upper part of continuous belt and/or flow of the milled material carried by the mobile rubber belt itself. The sets of flexible sealing means being foldable upwards and externally to the secondary chamber by the flow of the milled material and being conceived in such a way that they are kept in contact one with the other and with the flow of the milled material itself by the depression induced by the suction device.
[0039] The suction-filtering device is located on the second chamber which is closer to the self propelled road milling machine body. The suction-filtering device comprises:
a suction device connected to the continuous chamber able to realize a maintained depression into the continuous chamber in respect of the outside, the suction device being conceived for sucking the polluted air from the continuous chamber and being connected to, the suction device being a radial centrifugal ventilator. a filtering unit to filter the polluted air sucked from the suction device consisting of a battery of filtering elements, functionally interposed between the continuous chamber and the suction device. The number of filtering elements in the battery of filtering elements being greater then 4 and lower then 12, one being closed to the other and extending horizontally and parallel one to the other. The filtering elements being fitted transversally to the longitudinal centre line of the conveying device supporting them. a side collecting duct collecting the air from each of the filtering elements, the side collecting duct is hinged and openable. a collector, connected to the suction device collecting the air from the collecting duct. a cleaning device for the filtering elements periodically pulsing blows of compressed air in contra-flow. The compressed air to each of the filtering elements being distributed by a side conduit and/or a cleaning device for the filtering elements periodically mechanically shaking or vibrating the filtering elements. The dust cake which is formed in said filtering elements disposed by the cleaning devices falling onto the conveying device placed below. one or more protection nets in the continuous chamber above the advancing material on the upper part of the continuously advancing belt.
[0046] With this solution a no-pollutant, better performing road planer is realized.
[0047] The invention will be better understood with the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] The features of the present invention are set forth in particulars in the appended claims. The invention itself, together with further features and attendant advantages, will become apparent from consideration of the following detailed description, taken in conjunction with the accompanying drawings.
[0049] An embodiment of the invention is now described, by way of example only, with reference to the accompanying drawings in which:
[0050] FIG. 1 discloses a side view of a planer of known type.
[0051] FIG. 2 discloses a longitudinal view of a planer of known type.
[0052] FIG. 3 discloses a longitudinal section view of the planer of the present invention.
[0053] FIG. 4 discloses a side view of the planer of the present invention.
[0054] FIG. 5 discloses a section view of a typical conveyor belt.
[0055] FIG. 6 discloses a section view of the conveyor belt equipped with the filtering-suction group of the present invention.
[0056] FIG. 7 discloses a schematic top view of the filtering-suction group.
[0057] FIG. 8 discloses a section view according to A-A in FIG. 3 .
[0058] FIG. 9 discloses a section view of the sealing devices in the discharge zone of the collecting conveyor onto the loading conveyor.
DETAILED DESCRIPTION OF THE INVENTION
[0059] The machine of FIG. 1 , FIG. 2 consists of a self propelled chassis ( 1 ), supported by crawler tracks ( 2 ), generally equipped with hydraulic actuators, powered by a diesel engine.
[0060] A milling drum ( 3 ) is supported by the chassis ( 1 ) transversally to the direction of travel, being directly operated by the diesel engine through a mechanical transmission, or by a hydraulic transmission.
[0061] The crawler tracks ( 2 ) are connected to telescopic columns ( 4 ), which consent the chassis to achieve the correct height and attitude to get the requested milling profile.
[0062] The material, milled by the drum ( 3 ), is removed by one or more conveyor belts ( 5 ), ( 6 ) and is finally discharged at the front section of the machine (in another solution this can be at its rear section). In the present case the milled material is discharged into a transport vehicle which precedes the milling machine, whilst in the opposed case the vehicle follows the milling machine, running backward.
[0063] The milling drum ( 3 ) is located inside a drum housing ( 7 ). With reference to the work driving direction, said drum housing ( 7 ) is provided with a rear mobile moulder ( 8 ), fitted with scraping tools, and with two mobile side plates ( 9 a ), ( 9 b ), kept in contact with the road surface, and having a floating or a slightly downward forced action.
[0064] In the front section of the milling drum housing ( 7 ) an opening ( 10 ) is provided, which consents the milled material to be discharged onto a first conveyor belt ( 5 ) (collecting conveyor). Said collecting conveyor ( 5 ) is provided at its driven pulley section with a support device ( 11 ) (pressure bar), generally sliding over the road surface, in contact with the same. The driving pulley section of said collecting conveyor ( 5 ) slides over a support ( 12 ) which is part of the machine chassis ( 1 ). As a consequence the frame of the collecting conveyor ( 5 ) moves vertically and longitudinally, depending upon the working milling depth.
[0065] The collecting conveyor ( 5 ) discharges the milled material onto a second conveyor belt ( 6 ) (loading conveyor) which can be slewed vertically and horizontally to adapt its discharge head ( 36 ) to the height and position of the transport vehicle.
[0066] The typical section view of the conveyor belts, of known technology, is schematically shown in FIG. 5 . Each conveyor consists of a mobile rubber belt ring ( 13 ), supported in the transport section by “V” shaped rollers ( 14 ) and supported by other rollers ( 15 ) in the return section. The frame ( 16 ) of the conveyor is fitted with side walls ( 17 a ), ( 17 b ) and with a cover ( 18 ). Said side walls ( 17 a ), ( 17 b ) support flexible skirts ( 19 a ), ( 19 b ) in positive contact with the upper surface of the rubber belt ( 13 ). The milled material is therefore transported inside a channel ( 21 ) enclosed by said walls ( 17 a ), ( 17 b ), ( 19 a ), ( 19 b ), by said cover ( 18 ) and by said mobile rubber belt ( 13 ).
[0067] During the milling operation dusts arise, caused by the partial crushing of the aggregates included in the road pavement.
[0068] If the road pavement consists of an asphalt mixture also bitumen vapours are produced, due to the high temperature caused by the friction of the cutting tools, so dust and vapours escape from the drum housing and from the conveyor belts and are emitted into the surrounding environment and particularly close to the driving platform ( 28 ) with potential health risk for the operator.
[0069] The description of the invention refers to a road planer improved with suction and disposal devices for dust and vapours as for FIG. 3 and FIG. 4 , where the milling drum ( 3 ) is located inside a drum housing ( 7 ) and where the suction-filtering unit ( 29 ) is located over the loading conveyor ( 6 ).
[0070] With reference to FIG. 3-6 the invention concerns the continuity of channel ( 21 a ) and ( 21 b ), respectively identifiable on conveyors ( 5 ) and ( 6 ), and the effective sealing of the discharge area ( 22 ) of the collecting conveyor ( 5 ) onto the loading conveyor ( 6 ). Said channels ( 21 a ), ( 21 b ) on conveyors ( 5 ), ( 6 ) and the discharge area ( 22 ) of conveyor ( 5 ) onto conveyor ( 6 ), constitute one continuous channel ( 23 ).
[0071] Said channel ( 23 ) is closed in its lower section by the walls of the milling drum housing ( 7 ), by the rear mouldboard ( 8 ) and by the side plates ( 9 a ), ( 9 b ), whilst its upper section is closed by one or more sets of overlapped flexible flaps ( 24 ), which oppose the entry of external air but do not oppose the flow ( 20 ) of the milled material. Said flexible flaps ( 24 ) slide over the milled material ( 20 ) in contact with it.
[0072] Said channel ( 23 ) is kept in depression by a suction device ( 25 ), preferably consisting of a radial centrifugal ventilator.
[0073] Said ventilator ( 25 ) sucks the air polluted by dust and vapours from said channel ( 23 ) through a filtering device ( 30 ), consisting in a battery of filtering elements ( 26 ) (pockets, hoses, cartridges).
[0074] Said filtering elements ( 26 ) are generally, but not necessarily, individually supported by an internal frame which prevents the filtering element from being squashed by the differential pressure existing between the external and the internal surfaces of the filtering medium.
[0075] The polluted air is forced to pass through the filtering elements ( 26 ) whilst the dust is retained on their external surfaces forming a cake.
[0076] This solution advantageously prevents the suction ventilator ( 25 ) from being crossed by dust-laden air which would affect the efficiency of the unit in a short time.
[0077] While in the drawings reference is made to a preferred solution with a battery of eight filtering elements, it will be apparent to experts in the art that different configurations with more or fewer filtering elements can be used.
[0078] Said battery of filtering elements ( 26 ) is advantageously disposed over said conveyor ( 6 ), the filtering elements ( 26 ) being subsequently disposed one after the other longitudinally to said conveyor ( 6 ).
[0079] A protection net ( 27 ) is also advantageously provided between the flow ( 20 ) of the milled material and the filtering elements ( 26 ). Said net ( 27 ) prevents the milled material from bouncing against the filtering elements ( 26 ) and reduces the risk of damage to a minimum.
[0080] During the milling operation the dust accumulates on the external surface of the filtering elements forming a sticking layer, the thickness of which tends to oppose the continuity and efficiency of the air suction.
[0081] Said dust layer is periodically removed by means of known techniques, which use pulse jets ( 35 ) of compressed air into the filtering elements ( 26 ), or vibrating devices to shake them.
[0082] With reference to FIG. 6 and FIG. 7 , said pulse jets ( 35 ) are distributed to each filtering element ( 26 ) by a conduit ( 38 ) running parallel to the longitudinal arrangement of said filtering elements ( 26 ). It will be apparent to experts in the art that different but equivalent configurations can be used.
[0083] The dusts removed from the filtering elements are efficaciously agglomerated and drop onto the milled material flow ( 20 ) carried by the loading conveyor ( 6 ), to be finally jointly discharged onto the transport vehicle.
[0084] At the discharge head ( 36 ) of the loading conveyor ( 6 ) other dust is inevitably produced, which however spreads around in the atmosphere far away from the operator's platform ( 28 ).
[0085] Close to the discharge head ( 36 ) of the loading conveyor ( 6 ) a spray bar ( 37 ) is provided. Said spray bar ( 37 ), consists of a set of water atomizing nozzles, having the scope to further support the dust agglomeration and its fall.
[0086] The suction efficiency depends upon the sealing degree of channel ( 23 ). In particular the sealing media of the critical discharge area ( 22 ) of the collecting conveyor ( 5 ) onto the loading conveyor ( 6 ) must be efficient enough so as to maintain the channel ( 23 ) depressurized at any position of conveyor ( 6 ) in respect of conveyor ( 5 ) and at any position of conveyor ( 5 ) in respect of the machine chassis ( 1 ).
[0087] The sealing means of the discharge area ( 22 ) of the collecting conveyor ( 5 ) onto the loading conveyor ( 6 ) are preferably made as schematically shown in FIG. 3 , where:
the sealing device ( 33 ) compensates the vertical slew of the loading conveyor ( 6 ), the sealing device ( 34 ) compensates the horizontal slew of the loading conveyor ( 6 ).
[0090] A preferred solution of the filtering-suction group ( 25 ), ( 30 ) is schematically shown in FIG. 6 , FIG. 7 and FIG. 8 .
[0091] The air, polluted by dusts and vapours produced by the milling operation, is sucked from the inside of the aforementioned channel ( 23 ), which forms a continuous connection between the drum housing ( 7 ) and the filtering-suction group ( 25 ), ( 30 ), said filtering-suction group ( 25 ), ( 30 ) being directly installed over the lower section of the frame of the collecting conveyor ( 6 ).
[0092] The suction, supported by the ventilator ( 25 ), produces a depression inside the channel ( 23 ), which causes a continuous intake of external air and prevents the polluted air from escaping.
[0093] The polluted air first passes through the protection net ( 27 ) and then through the filtering elements ( 26 ); said filtering elements ( 26 ) being preferably fitted horizontally and transversally to the longitudinal centre line of the loading conveyor ( 6 ).
[0094] The filtering elements ( 26 ) oppose a resistance to the air flow, which results in a pressure drop through the filtering media. This forces the dust to be retained on the external surface of the filtering elements ( 26 ), causing a slight compression of the dust and its agglomeration. The dust cake itself contributes to increase the pressure drop through the filtering elements, thus improving the dust agglomeration.
[0095] An automatic cleaning system ( 35 ), of known technology, periodically pulses blows of compressed air in contra-flow to detach the dust cake and makes it to drop onto the milled material flow ( 20 ). Only the dust particles with a size of a few microns and part of the asphalt vapours can pass through the filtering media and are not retained.
[0096] Said filtering-suction group ( 29 ) is advantageously located over the secondary chamber ( 21 b ) so that during the cleaning procedure of the filtering elements ( 26 ), the dusts removed from them drop directly on the loading conveyor ( 6 ), being then carried to the discharge head together with the milled material flow ( 20 ).
[0097] Said filtering-suction group ( 29 ) is advantageously located in correspondence of the lower section of the frame of the collecting conveyor ( 6 ), namely the section of the frame which is closer to the self propelled road milling machine body, so that the weight of the filtering-suction group does not bear down on the top end of the frame itself arising stability problems.
[0098] The filtered air is conveyed into a side collecting duct ( 31 ) and then into a collector ( 32 ), connected to the suction ventilator ( 25 ). Said side collecting duct ( 31 ), can be advantageously opened to remove the filtering elements for maintenance operation.
[0099] The negligible amount of dust, still remaining in the filtered air flow, does not affect in any way the efficiency of the system and the work continuity of the machine.
[0100] Advantageously said sets of flexible sealing means ( 24 ) applied at the end top of the second conveyor are made of a plurality of closed vertical straps in which each strap overlaps with its border the adjacent one. In this way the advancing material on the continuous belt does not create openings between said straps deflected upwards by the variation in size of the continuous advancing material ( 20 ). | A self propelled road milling machine including: a chassis mobile on crawler-tracks; a milling drum supported by the chassis and located inside a drum housing; at least first and second conveying devices, supported by the machine chassis, receiving the material milled by the milling drum, and transporting it to a discharge point; a suction-filtering device of the air polluted by dust and vapours produced by the milling process; upper and side sealing mechanisms on the conveying devices, the sealing mechanisms being able to realize one continuous chamber above the conveying devices; suction device connected to the continuous chamber able to realize a maintained depression relative to the outside, the suction device being conceived for sucking the polluted air from the continuous chamber; a filtering unit to filter the polluted air, consisting of a battery of filtering elements, interposed between the continuous chamber and the suction device. | 4 |
REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 61/185,685 filed on Jun. 10, 2009, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to an improved rewind apparatus for a flexible member. Specifically, the invention provides a retractable spool and a mechanism which allows a user to move a switch so that he/she has a choice of having the spool always pulling on the flexible member, a Tension mode of operation, or using a No Tension mode of operation that allows the flexible member to relax, and then, with a brief tug on the flexible member, retraction forces of a spring causes the flexible member to be wound around the spool.
[0004] 2. Description of Related Art
[0005] Apparatus for rewinding a flexible member such as a pet leash, tape measure, string with a writing instrument or keys is known in the prior art. More specifically, by way of example, U.S. Pat. No. 7,270,289 to Kish discloses a writing instrument holder having a substantially funnel-shaped body configured to hold concurrently a writing instrument internally and another writing instrument externally.
[0006] U.S. Pat. No. 7,131,401 to Huff, et al. discloses a retracting and locking leash housing includes a casing and a handle. A spool is rotatably disposed in the casing and includes a circle of teeth and a finger which extends from the locking portion to engage the circle of teeth when the trigger is moved to a locking position to prevent rotation of the spool.
[0007] U.S. Pat. No. 7,040,257 to Waxman, et al. discloses a retractable leash device having a housing with a leash wound around an internal reel. The reel is biased by a spring to automatically retract the leash. A lock in the housing is normally disengaged from teeth on the reel. When the lock is actuated, the reel is engaged by a ratchet to prevent rotation in the release direction but permit rotation in the retract direction.
[0008] U.S. Pat. No. 6,854,681 to Kish discloses a retractable device for retaining a writing instrument at an accessible location for an individual. The retractable device has a retractable reel coupled to a flexible member which engages the instrument. The flexible member includes a first bore and a second bore. The first bore is sized to receive a connector from the retractable reel. The second bore has a varying inner diameter which allows instruments of various sizes to be held within the flexible member.
[0009] U.S. Pat. No. 6,845,736 to Anderson discloses a spool rotatably mounted on a support and a flexible cord wound on the spool where the flexible cord has an end connected to the spool and a second end connected with an animal. The application of a first force to the free end of the flexible cord causes a portion of the flexible cord to unwind from the spool. The remainder of the flexible cord is prevented from unwinding from the spool unless a second force is applied to the free end of the flexible cord where the second force is greater than the first force.
[0010] U.S. Pat. No. 6,405,683 to Walter, et al. discloses a leash handle having a spool rotatably mounted in a housing, a trigger, and a dual-position switch. The trigger is operated to prevent the leash cord from extending or retracting, and released to enable the leash cord to extend out of the housing in response to an external force. The spooling assembly is spring biased to cause the leash cord to retract in the absence of trigger actuation and the presence of a preset external force.
[0011] U.S. Pat. No. 6,073,875 to Paugh discloses a retraction unit for keys and the like having a housing with a reel mounted in the housing for rotation, a retraction spring for the reel, and a cable carried on the reel, with the inner end of the cable connected to the reel, and a cable end fitting carried on the outer end of the cable where the fitting has an inner end, a central portion and an outer end, with the central portion of a lesser cross section than the inner and outer ends.
SUMMARY OF THE INVENTION
[0012] In an exemplary embodiment of the present invention, there is disclosed a retraction apparatus for a flexible member, where the retraction apparatus has a housing with a reel mounted in the housing for rotation, a rewinding spring coupled to the housing and the reel, and the flexible member has an inner end and an outer end where the flexible member is wound around the reel with the inner end being connected to the reel and the outer end being unattached or attached to a writing instrument or other item, the improvement comprising:
tracks located on a side surface of the reel, a track arm having an outer end and an inner end, the inner end being pivotally coupled to an elevation post; and an arm post attached to the outer end of the track arm for engaging the tracks on the side surface of the reel; wherein the inner end of the track arm can be raised or lowered to provide a no tension mode of operation or a tension mode of operation.
[0017] It is an object of the invention is to provide a means of interrupting the retracting force of the spring loaded spool and re-engaging the retracting force of the spool with a one handed operation on the flexible member without requiring a switch to stop the retracting force or to engage it.
[0018] It is an object of the invention to provide a user with a mechanical means of controlling amount of force required to start or stop rotation of the spool.
[0019] It is an object of the invention is to permit the user to allow the spool -and its biasing spring member to continuously apply a rewinding force to the flexible member.
[0020] It is an object of the invention is to allow the user to select a mode that will interrupt the pulling force and allow the flexible member to relax, and then allow the user to pull slightly on the flexible member and cause the rewind spool to start applying a retracting force.
[0021] It is an object of the invention to construct a track that rotates synchronously with a rewind spool as the rewind spool is rotated by the pulling force on the flexible member or as the rewind spool is rotated by the inward force of the rewind spring.
[0022] It is an object of the invention to construct an arm that is pivotally mounted on a pin and has an arm-post which is a part of the arm that engages a track as the track rotates so that the track predominately causes the arm-post to substantially follow the prescribed path of the track.
[0023] It is an object of the invention to use the shape of the track to substantially engage the arm-post to cause the arm to pivot as the arm-post follows the direction of the track.
[0024] It is an object of the invention to shape the tracks with elevation changes to affect the movement of the post-arm and to capture and secure the arm-post when needed to stop the rotation of the spool.
[0025] An object of the invention is that when the post-arm is captured in a designed place such as a latch-position in the track, the post-arm applies a force that counteracts the rewind force of the spring and causes the rewind spool to stop its rotation and stop the pulling forces on the flexible member.
[0026] It is an object of the invention to shape the track so that it can guide the arm-post in both the rewind and opposite rotation.
[0027] It is an object of the invention to apply a biasing force to the arm-post using a switch-locking-track-lever and lever-rib to insure engagement with the path of the tracks and the elevation levels of the path.
[0028] It is an object of the invention to use a secondary lever-rib in conjunction with the primary locking-lever-switch to further apply or alleviate the forces on the post and arm.
[0029] It is an object of the invention to alleviate tension on the flexible member so that the user can manipulate the flexible member or an object connected to the end of the flexible member without the user having to contend with the rewind force.
[0030] It is an object of the invention to secure an object to the end of the flexible member such as a holder for a writing instrument, tool, badge, utensil or other item useful to the user.
[0031] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0032] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0033] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0034] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
[0036] FIG. 1 is a perspective view of a spring loaded rewind mechanism for a flexible member with the top cover removed in accordance with the principles of the invention;
[0037] FIG. 2 is an exploded perspective view of the spring loaded rewind mechanism for a flexible member of FIG. 1 ;
[0038] FIG. 3 is a perspective view of a spring loaded rewind mechanism for a flexible member with the top cover removed showing the arm post captured in latch position of the spool track and the track arm lowered in no tension mode;
[0039] FIG. 4 is a perspective view of a spring loaded rewind mechanism for a flexible member with the top cover removed showing the arm post tgghe outer track when in the tension mode and the track arm raise by the switch locking lever; and
[0040] FIG. 5 is a perspective view of a device for rewinding a flexible member attached to a writing instrument in accordance with the principles of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] Referring to FIG. 1-5 , the main elements of the invention and a description of their functions are as follows:
[0042] Housing 11 , Bottom Half:
[0043] The bottom half of the housing 11 provides support for the spool 1 , arm 8 , switch, switch-locking-track-lever 9 and tracks, and provides a protection to the components. The housing also provides the outward appearance and support for functional attachments such as a slide belt clip and carabiner hook 14 . The housing is attached to one end of a spiral power spring and includes a “lever-rib” that enhances the downward force on the arm-post 7 at critical times in order to insure that the arm-post 7 engages the track.
[0044] Spool:
[0045] The spool, 1 is configured to be captured within the housing so that the spool is free to rotate. The spool holds one end of the biasing member such as a spiral power spring, or a spring and is configured to be attached to one end of a flexible member 17 . As the flexible member 17 is pulled out of the housing by the user, the spool 1 winds against the inward pull of the biasing member, thus storing energy that will be released when the user releases his/her pulling force.
[0046] Track: The tracks, 16 , see FIG. 2 , are shaped to best engage the shape of the arm-post 7 in order to maximally apply forces to move the arm-post 7 in the desired direction. The tracks can be a separate component mounted on the top of the spool 1 , or molded as an integral part of the spool 1 , or be joined separately, as long as it is positioned to accept the arm-post 7 and to rotate synchronously with the spool.
[0047] As the spool 1 rotates, features of the track apply forces that move the arm-post 7 in directions dictated by the directional rotation of the spool 1 . In addition, a desired downward force can direct the arm-post 7 to engage with elevation changes in the track.
[0048] These elevation changes are important in guiding the arm-post 7 . For example, an important section of the track is the “latch-position 5 ”. This location is configured and shaped in such a way to insure that the arm-post 7 is captured at the right moment. The post 7 is guided into and out of this latch-position 5 using strategically placed and shaped tracks 16 and elevation changes.
[0049] There is a substantial Inner-track 6 and Outer-track 2 .
[0050] When desired, with the switch in the No-Tension mode, the shape and elevation levels in the outer-track 2 guide the arm-post 7 from the outer-track 2 and into the critical latch-position 5 : This can only happen when the track is rotating in a certain direction such as in the direction of the spring-rewind force. When the arm-post 7 is in this latch-position 5 , it is captured substantially by the rewind/retraction force of spool 1 and the shape of the track in this position. The arm-post 7 applies the stopping force that prevents the spool from rotating in the retraction direction. The flexible member will relax.
[0051] With the arm-post 7 secure in the latch-position, 5 —when the user tugs on the flexible member 17 , the arm-post 7 is guided out of the latch-position 5 (because of the track shape and elevation changes), to the inner-track 6 , and then, when the user immediately releases his force, the spool 1 moves in the rewind/retraction direction. As it rotates in this direction, the shape of the path and elevation changes have little influence on the post and vice-versa: so the rewind forces of the spool allow the spool to retract.
[0052] When the post is in this inner-track 6 , and the user pulls on the string causing the spool to rotate in the opposite direction to rewind, another critical path is engaged—one that moves the arm-post 7 from the inner to the outer-track 2 . This inner-outer transition area 12 of track 6 is determined by the shape and elevation changes on the spool. As the user pulls the flexible member, the arm-post 7 is guided into this inner-outer transition 12 track and the arm-post 7 moves to the outside track.
[0053] Tracking Arm:
[0054] The track-arm 8 can have different styles and shapes. A key feature of the track-arm 8 is the part that engages with the track, and is referred to as the arm-post 7 , see FIGS. 1-4 . In this embodiment the arm is engaged with a base that is in turn mounted on pins which allows the arm to pivot around the pin pivot axis. The arm-post 7 is perpendicular to the arm, directed at the tracks 16 , and located near the outer part of the arm. The pivot axis of the arm can also slide up and down perpendicular to the plane of the pivot. This allows the arm-post 7 to be moved closer or further from the surface of the track by use of the switch-locking-track-lever 9 . An elevation-post on the base of the arm engages a switch-locking-track-lever 9 —it is the switch-locking-track-lever 9 combination that raises and lowers the arm and moved the arm-post 7 closer or further from the tracks 16 , see FIG. 1-4 .
[0055] Switch-locking-track-lever:
[0056] The function of the switch-locking-track-lever 9 is to allow two modes of operation: the No-tension mode (also called tug-n-back mode) and the Tension mode (also called Pencil Pull mode).
[0057] The switch-locking-track-lever 9 combination raises and lowers the arm, so that the arm-post 7 either engages (no-tension mode) with the track's features or disengages (tension-mode) with the track's features.
[0058] The inner part of the switch has a two level locking-track that engages with the “elevation-post” on the base of the arm. At each level of locking-track, the arm is allowed to pivot when the arm-post 7 is moved by the track. When the switch is moved into the tension-mode, the elevation-post on the base of the arm follows that locking-track and the entire arm is raised so that the arm-post 7 is moved substantially away from the tracks 16 on the spool which causes disengagement between the arm-post 7 and the track.
[0059] As the arm is raised, a part of the arm is pushed against a innovative lever-rib (not shown) on the inner surface of the top housing. As it pushes on this lever-rib, a additional downward force is applied to the arm-post 7 and this further insures that the post engages with the features the track.
[0060] As the post-arm 7 approaches the outer-track 2 , the arm slides off this lever-rib and the arm/post is forced to its most elevated position which is substantially away from the track. In this position, arm-post 7 has little influence on the track features and the spool can move freely under the influence of the user's force on the flexible member 17 or the spool will move as a result of the spring energy that applies an inward pulling/rewind force on the spool and hence on the flexible member.
[0061] When the switch is slid in the direction of the No-tension mode, the elevation-post on the arm's base that is engaged with the locking-track causes the arm to lower and causes the arm-post 7 to strongly engage with the track and then the arm-post 7 will follow the tracks 16 and elevations. Because the arm is substantially lower in this mode, the arm can move and pivot beneath the lever-rib and enter the latch-position 5 . At times, the lever-rib and switch action combination will create further downward pressure on the arm—insuring that the post follows the tracks 16 .
[0062] Flexible Member:
[0063] The flexible member 17 can be a string, tape measure, ribbon, cord, tubing, hose, cable etc. It is connected to the spool at the drum 17 , then wound around the spool and exits the enclosure 11 . When pulled, this flexible member causes the Spring/biasing element to store energy—energy that when released, causes the flexible member 17 to be rewound around the spool. A pulling or tugging action on the flexible member is the action that triggers the rotation of the spool and tracks 16 and causes the ensuing movement of the arm-post.
[0064] Biasing Element (not shown):
[0065] Typically a power spring having one end attached to the center post 20 /axis of the spool and the other end attached to the spool drum. When the flexible member is pulled/extended from the enclosure, it causes the power spring to wind around this axis and stores energy. When the pulling force is released from the flexible member, the spring causes the spool to rewind, which winds the flexible member around the spool.
[0066] Alternate Embodiments:
[0067] In an embodiment the arm can be mounted on one solid perpendicular post rather than in sections as disclosed above.
[0068] In an embodiment the track shape and elevation changes can be designed so that the arm-post 7 either applies force or reacts to forces depending on the rotation of the spool. For example, when the arm-post 7 enters the latch-location, the outer end of the arm-post 7 is pushing against the stopping wall. It can be designed so that the inner side of the arm-post 7 is engaged with this stopping wall. This can be done by changing the direction of the spring forces on the spool rotation and/or the orientation of the arm to the spool.
[0069] In an embodiment the arm can be a metal or other spring material such as a molded plastic with flexibility characteristics that can be adjusted. These characteristics apply critical amounts of forces to take advantage of the elevation changes in the tracks 16 and against the sides of the track.
[0070] In another embodiment the lever-lock-switch can be oriented differently to the arm.
[0000] The arm can be oriented perpendicular to the reel. Then the force of a post against the tracks 16 will be oriented accordingly and other forces and can be oriented to apply pressure against the tracks 16 .
[0071] In another embodiment the track can be physically separated from the spool but connected to the spool by means of a belt or gears. The track would still rotate synchronously with the spool.
[0072] In another embodiment the arm can be mounted to other locations in the housing.
[0073] In another embodiment the switch can have indents requiring another object to move it—rather than by a finger.
[0074] In another embodiment the end of the flexible member can be one of a wide range of metals or molded plastics with functional use or decorative/advertising use.
[0075] In another embodiment the arm base can be mounted on a ramp or other lever—similar to a click pen.
[0076] In another embodiment the spool can be mounted in such a way so that it is moved closer to a pivoting arm or arm-post 7 that may or may not be fixed.
[0077] In another embodiment the lever-rib may be located on top of the tracking arm. This rib configuration would then mate with an indention on the top enclosure when the tracking arm is stored in no-tension mode.
[0078] Operation:
[0079] There are two modes of operation which can be chosen by a user:
[0000] A. The Tension-mode (the tension/inward-rewind force is continuously applied to the flexible member by the rewind spring and is controlled to be on or off, by an outward pulling force on the flexible member; and
B. The No-Tension mode.
[0080] No-Tension-Mode Operation
[0081] With the flexible member fully retracted and the switch-locking-track-lever 9 in No-Tension mode, the switch-locking-track-lever 9 causes the arm-post 7 to apply pressure to the track, which causes the arm-post 7 to substantially follow the elevation levels and other track features when dictated by the rotational direction of the spool.
[0082] The user, or other entity, pulls on the free end or other part of the flexible member, and withdraws the flexible member out to a desired distance. No matter the location of the arm-post 7 at this time, the arm-post 7 is forced to the outer-track 2 by the rotation of the spool and the features of the track. As the spool continues to rotate in this direction - the arm-post 7 will stay in that outer-track 2 .
[0083] The user releases his pulling force and the spool starts to retract due to the inward-rewind force of the spool spring.
[0084] As the spool retracts, the arm-post 7 follows the track because of the unique shape and elevation changes of the outside-track. The arm-post 7 is eventually guided into the latch-position 5 . The arm-post 7 firmly contacts the stopping wall/detent in the latch-position 5 and this interaction stops the rotation of the spool and hence, the flexible member is tension free. The user can easily manipulate the flexible member or attached item.
[0085] The user gives an outward “tug” or pull on the flexible member, in opposition of the inward-spring force, on the flexible member. The spool is forced to rotate and as it does, the arm-post 7 moves away from the stopping wall and the arm-post 7 must now follow the unique exit path and elevation change and the arm-post 7 moves to the inside track. The design of the entry and exit tracks 16 and elevations of the latch-position 5 insure that the arm post can only move in the described direction—it cannot move backwards to the outer-track 2 after entering this transition area.
[0086] With the arm-post 7 in the inner-track 6 and when the user releases his pull/tug, the spring forces cause the spool to rewind. When the spool rotates in this direction the arm-post 7 is not substantially influenced (because of the shape of the track) and the inward/rewinding force of the spring on the spool will cause complete rewind of the flexible member. Since the post is not influenced by the track when the spool rotates in this direction, the post stays in the inner-track 6 .
[0087] When the user pulls the string out again, the arm-post 7 then follows the track, and the elevation and shape of the track now forces the post to move through the inner-track 6 -to-outer-track 2 -inner-outer transition 12 all the way to the outer-track 2 . This is helped somewhat by the lever-rib. The user pulls the string to the desired length the process is repeated.
[0088] Tension-Mode Operation
[0089] Starting with the switch in the Tension mode:
[0090] The switch-locking-track-lever 9 raises the arm away from the tracks 16 by moving the arm up toward the ceiling—moving the arm-post 7 away from the tracks 16 .
[0091] If the arm is in the outer-track 2 , it will be kept in that position—over the outer-track 2 —by the precisely located ending of the lever-rib on the ceiling. The arm-post 7 will be above the track and the flexible member can be pulled out to any length and when the user/other forces stop pulling on the flexible member, the rewind forces will pull the flexible member and cause it to rewind around the spool.
[0092] If the user moves the switch to Tension-mode when the arm is under the lever-rib (the arm-post 7 will be either in the latch-position 5 or in the inner-track 6 or in one of those transition areas). The lever-rib applies a force to the arm and the arm-post 7 is pressed against the track—engaging the arm-post 7 to the track—and when the user pulls the flexible member, the post follows the elevation and shape of the track all the way to the outer-track 2 position.
[0093] When the arm reaches the outer-track 2 position, the arm snaps away from the track and towards the ceiling (because of the upward pressure on the flexible arm that is applied by the switch-locking-track-lever 9 ). From that position, the spool will again be un-encumbered and the spool will be under the influence of the user's pulling force or the spring's inward force.
[0094] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled. | The present invention is directed to an improved rewind apparatus for a flexible member. Specifically, the invention provides a retractable spool and a mechanism which allows a user to move a switch so that he/she has a choice of having the spool always pulling on the flexible member, a Tension mode of operation, or using a No Tension mode of operation that allows the flexible member to relax, and then, with a brief tug on the flexible member, retraction forces of a spring causes the flexible member to be wound around the spool. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to an assembly for producing a laminated card, and more particularly to an invention which allows a user to record pertinent information onto a provided card, which can then be folded over to provide a front and rear side and then be instantly laminated. The invention is applicable, for example, for providing emergency medical information or quick reference contact information on a laminated card.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a self-laminating, two-sided card which provides important information about its user. The assembly disclosed and claimed herein has particular, although not exclusive, application to providing information relating to critical health, medical and emergency contact information, or a temporary identification card, for general purposes.
[0003] In a situation where a patient is unconscious or otherwise unable to communicate, a card with the patient's emergency medical information can prove valuable. If a patient is unconscious, an emergency responder may look for any items on a patient which would disclose medical information. Therefore, having a laminated card which can always be carried by a person in their wallet or purse can prove useful in emergency situations.
[0004] If the information contained on the card were smudged or otherwise inadvertently altered the car would be less useful. Therefore, it is advantageous to have this information protected within a transparent enclosure, such as plastic film or other web material.
[0005] Biddle, U.S. Pat. No. 3,068,140 discloses a method for creating a plastic identification device by typing, writing or otherwise inscribing information onto a base which is then cut and folded in half along a center line. The folded base sheet is then covered with transparent plastic material. Biddle teaches a lamination process which requires fusing a plastic sheet together by applying a combination of heat and pressure.
[0006] Goeken, U.S. Pat. No. 5,658,016 teaches an attachment for an identification card providing for example, medical information. However, Goeken discloses a transparent attachment which can only be used with and secured onto a separate, user provided identification card.
[0007] Simpson et al., U.S. Pat. No. 7,005,170 teaches an assembly for placing an information sheet or card into an envelope, which is then secured with adhesive to close the envelope. However, the envelope does not create a permanent seal as the invention discloses the option for the envelope to be opened to obtain information on the card.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present invention generally provide a self-laminating enclosure with an informational card predisposed within the enclosure, which can then be folded along a perforation in its center. A construction for a card or label is provided within the self-contained unit and components thereof may be quickly utilized to provide a secure repository of information
[0009] As will be seen below, the invention includes an assembly incorporating components which allows a user to input vital information onto multiple sides of a blank card and then fold the card along a perforation before permanently sealing the card within a transparent plastic film enclosure. This plastic film enclosure sometimes referred to herein as a laminated enclosure, helps eliminate smudging of the written information, and provides a strong, durable and water resistant card.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front view of the self-laminating card prior to use.
[0011] FIG. 2 is a perspective view of the self-laminating card, showing the four distinct layers of the present invention.
[0012] FIG. 3 is a perspective view of the self-laminating card showing the laminate layer being lifted from the card to allow a user to input their information.
[0013] FIG. 4 is a perspective view of the self-laminating card showing the rear backing layer being removed from the front laminate layer.
[0014] FIG. 5 is a front, perspective view of the self-laminating card and showing the front laminate layer adhesively secured to the information card.
[0015] FIG. 6 is a front, perspective view of the self-laminating card showing the card release liner being separated from the laminated information card.
[0016] FIG. 7 is a perspective view of the self-laminating card in partial folded condition.
[0017] FIG. 8A shows front and rear views of the self-laminating card after it has been completely assembled.
[0018] FIG. 8B shows front and rear views of another embodiment of the self-laminating card after it has been completely assembled.
[0019] FIG. 9 shows an alternative embodiment of the self-laminating card when used with a business card.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] While embodiments of this invention can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, as well as the best mode of practicing same, and is not intended to limit the invention to the specific embodiment illustrated.
[0021] Referring now to the drawings, a self-laminating card and assembly construction in accordance with the teachings of the present invention is shown in its entirety and in the condition it is in prior to use in FIGS. 1-2 . FIGS. 3-7 show the steps of assembling the self-laminating card and FIGS. 8A and 8B show a completed embodiment of the present invention. FIG. 9 shows an alternate embodiment of the self-laminating card where it can be used to laminate any comparably sized card such as a business card.
[0022] FIG. 1 is a front view of one embodiment of the self-laminating card 1 . In this embodiment, there are four main layers to the assembly and portions of each layer are shown on FIG. 1 . Also, the front and rear sides of the completely assembled laminated card 20 are shown positioned adjacent to each other prior to assembly of the self-laminating card 1 .
[0023] The top layer of the self-laminating card 1 is composed of a transparent laminate layer 2 . The layer is a plastic web such as a plastic film or sheet. The transparent laminate layer 2 has an opaque-colored backing 4 which is temporarily held in place by adhesive on the inner face of the laminate layer 2 . The backing 4 , which can also be referred to as laminate release liner 4 , forms the second layer of the self-laminating card 1 and allows the transparent laminate layer 2 to be easily separated and lifted from the card layer 6 . As shown in FIG. 3 , this allows for a user to input information onto the card 6 .
[0024] The card 6 is provided within the self-laminating card assembly 1 and has a writable surface to allow a user to record their personal information onto the card 6 such as by printing. In one embodiment, check boxes and blank lines are provided on the card 6 to allow a user to quickly and more efficiently enter their pertinent information. In another embodiment, the card 6 can be brightly colored in order to alert an emergency responder to the fact that important information is available on the card 6 .
[0025] The card 6 also has an adhesive backing which is temporarily held in place by second backing 8 which can also be referred to as a card release liner 8 . The card release liner 8 is the fourth and final layer and can be removed to reveal adhesive behind the card 6 . The card release liner 8 can be larger than the card 6 to allow for easier removal of the liner 8 . Once the card 6 is folded in half, the adhesive attaches the front and rear sides of the card 6 onto themselves in a secure and permanent manner. The card assembly 1 is now completely assembled as a completed card 20 which is now approximately the size of a credit card and laminated on both its front and rear side. Put another way the card has a transparent plastic web, such as a plastic film or sheet, adhesively fixed to the front and rear side of the card.
[0026] FIG. 2 is a perspective view of the self-laminating card 1 . The transparent laminate layer 2 is attached to the card layer 6 by an adhesive which is applied from the outer edge of the laminate layer 2 to a point which forms the attachment edge 3 . The attachment edge 3 is offset from the outer edge of the laminate layer 2 , to allow for a sufficient amount of adhesive to connect the two layers to each other. The adhesive which attaches the transparent laminate layer 2 to the card layer 6 may be stronger than the adhesive which attaches the release liners 4 , 8 to the laminate layer 2 and card layer 6 respectively. The attachment edge 3 runs the entire length of the self-laminating card 1 . Further, there is a perforated line which runs vertically along the center of the laminate layer 2 and card layer 6 which forms a fold center line 10 . The fold center line 10 will act as a guide for folding the self-laminating card 1 in half
[0027] FIG. 4 is a perspective view of the self-laminating card 1 showing the first step in assembling the completed card 20 . After the necessary information has been entered onto the card 6 , a user can proceed to begin assembling the self-laminating card 1 . The first step is to lift and remove the laminate release liner 4 from the inner face of the laminate layer 2 , revealing a layer of adhesive. With this adhesive, the laminate layer 2 can now be pressed firmly onto the card 6 to securely and permanently laminate the card 6 . FIG. 5 is a perspective view of the self-laminating card 1 with the transparent laminate layer 2 applied to the card 6 . Put another way card 6 has a plastic film 2 adhesively fixed thereto which completely covers the card.
[0028] FIG. 6 shows the next step in assembling the self-laminating card 1 . After applying the transparent laminate layer 2 , the card 6 is now ready to be folded upon itself to create a double-sided card. To accomplish this, the card release liner 8 is separated from the card 6 , revealing a layer of adhesive. In an alternate embodiment of the invention, laminate release liner 4 and the card release liner 8 can have printed instructions alerting a user on instructions on how to assemble the self-laminating card 1 . For example, these instructions can provide detailed step by step directions on how to assemble the self-laminating card 1 or may just provide an instruction to remove one or both of the release liners.
[0029] As illustrated in FIG. 7 , the card 6 can now be folded in half along a perforated centerline 10 provided in the center of the card 6 . With its adhesive backing, the card 6 can be firmly pressed together, permanently joining its two sides. With the card now laminated, i.e., covered in plastic film, the written information is sealed within. The end result is a strong, durable, water resistant card which resists smudging.
[0030] FIGS. 8A and 8B illustrate front and rear views of various embodiment of the completely assembled card 20 .
[0031] FIG. 9 illustrates another use for the invention. FIG. 9 illustrates how the present invention can be used with a business card. However any comparably-sized flat object can be utilized. To be used with a card other than the provided card 6 , the card 6 and card release liner 8 are first removed and discarded, leaving only the transparent laminate layer 2 and laminate release liner 4 . The assembly could of course be manufactured without card 6 and release liner 8 . As before, the laminate release liner 4 is removed from the inner face of the laminate layer 2 , revealing a layer of adhesive. The laminate layer 2 can now be applied to both the front and rear of the business card. This alternate use of the present invention allows a user to instantly and permanently laminate any card, thereby adding to the overall flexibility of the invention.
[0032] From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. | A self-laminating assembly for providing information, such as emergency medical or contact information, or a temporary identification card, for general purposes. Medical data or contact information is entered on a card which is predisposed within the assembly. The card can then be covered with a transparent plastic sheet and folded in half, along a perforation in its center to permanently seal the card within the transparent plastic enclosure. | 8 |
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/714,911 filed Sep. 7, 2005, the contents of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] This invention relates to an improved syringe construction; more particularly, this invention relates to a syringe construction exhibiting reduced plunger movement forces.
[0004] 2. Background of the Related Art
[0005] Syringes are typically constructed of an annular syringe body, a plunger adapted to travel within the syringe body in response to manually applied force, and an annular needle removably attached to the distal portion of the syringe body. The plunger is basically a piston terminating in an elastomeric seal. The syringe can either be pre-filled or can be filled by inserting the needle into a vial of the liquid to be drawn into the syringe and withdrawing the plunger to thereby draw the liquid into the syringe body in the region between the elastomeric seal and the needle.
[0006] Plungers in syringes are know to exhibit greater than desired movement forces especially when the syringes have been pre-filled and stored for a period of time. The movement forces include what is known as the breaking force, i.e., the relatively high force needed to move the plunger after is has been positioned in one location in the syringe body for an extended period of time. The movement forces also include the extrusion of running force, i.e., the force required to move the plunger within the syringe body at a desired rate. Since syringes are used primarily to administer drugs in specified doses, reduced plunger movement forces are desirable to provide better control of the dose delivered. Reduction in movement forces is especially desired in syringes that are pre-filled with a liquid.
[0007] In the past, efforts have been made to reduce movement forces primarily by applying lubricant coatings to the interior surface of the syringe body and the surface of the elastomeric seal of the plunger which contacts the syringe body. For example, most medical syringes employ a coating of silicone oil on the interior of the syringe body and the seal of the plunger. While the silicone coating reduces plunger movement forces, it is not acceptable for all applications because of potential contamination of the medicinal liquid within the syringe. Further efforts have been made to reduce plunger movement forces by coating the interior surface of the syringe body with a polymeric coating such as with a coating of a para-xylylene polymer (“parylene”) (see, U.S. patent application Publication No. US 2005/0010175 A1 published Jan. 13, 2005). Applying parylene to the elastomeric seal and/or the interior surface of the syringe body significantly reduces plunger movement forces as compared to simply coating the seal and/or interior surface of the syringe body with silicone oil. The parylene coating, however, is applied by vapor deposition which is not only an additional process step but also presents a significant added expense.
SUMMARY
[0008] Accordingly, it is an object of the present invention to provide an improved syringe construction which enables reduced plunger movement forces to be obtained in a simple, low cost manner.
[0009] This, as well as other objects and advantages are accomplished by the present invention which provides a syringe assembly comprising an annular syringe body and a plunger adapted to travel therein, said plunger terminating in an elastomeric seal, said seal having admixed therein during fabrication of the seal, a lubricant capable of migrating through the elastomeric seal to bloom on the surface thereof thereby imparting enhanced lubricity thereto reducing the movement forces necessary to enable controlled plunger movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention is illustrated in the accompanying drawings, wherein:
[0011] FIG. 1 is a cross sectional elevation view of one embodiment of a syringe of the present invention; and
[0012] FIG. 2 is an enlarged cross sectional partial elevation view of the syringe of FIG. 1 illustrating the migration and blooming of the lubricant in the elastomeric seal;
DETAILED DESCRIPTION OF THE INVENTION
[0013] While this invention is susceptible of many different embodiments, certain preferred embodiments will be described herein in detail with the understanding that the present disclosure is to be considered as providing various exemplifications of the principles of the present invention and is not intended to limit the invention to be specific embodiments illustrated herein.
[0014] Referring now to FIG. 1 , a syringe 10 of the present invention is shown as comprising an annular syringe body 12 , a plunger 14 adapted to travel within the syringe body 12 in response to manually applied force, and an annular needle 16 removably attached to the distal portion 18 of the syringe body 12 . The plunger 14 is basically a piston terminating in an elastomeric seal 20 . The region 22 bounded by the syringe body 12 , the distal portion 18 of the syringe body 12 and the distal portion of the elastomeric seal 20 can either be pre-filled with a liquid 24 which is typically a medicinal solution or can be filled with such liquid 24 by inserting the needle 16 into a vial containing the liquid 24 (not shown) and withdrawing the plunger 14 to thereby draw the liquid 24 into region 22 .
[0015] Syringe bodies are typically manufactured from glass or polymeric resins. Typical polymeric resins used in the manufacture of syringe bodies include olefin polymers and copolymers, polystyrene, polycarbonate, acrylate or methacrylate copolymers, cyclic olefin-containing polymers, bridged polycyclic hydrocarbon containing polymers, (see, for example, U.S. Pat. No. 6,085,270), and the like. Similarly, the plunger also can be manufactured from glass or polymeric resins. The plunger terminates in an elastomeric seal which deforms in use to provide a seal against the inner surface of the syringe body. The elastomeric seal can be affixed to the distal end of the plunger in any known manner, e.g., it can be adhesively secured thereto, threadably engaged thereto, frictionally engaged thereto, and the like.
[0016] The elastomeric seal can be formed from any elastomeric material which is generally inert and impervious with regard to the medicinal fluids anticipated to be used in conjunction with the syringes of the present invention. Suitable elastomers include natural rubber, styrene-butadiene rubber, acrylonitrile-butadine copolymers, neoprene, butyl rubber, polysulfide elastomers, urethane rubbers, ethylene-propylene diene (EPDM) elastomers, and the like.
[0017] In the fabrication of the elastomeric seal, the elastomeric material can be compounded with a variety of additives in, for example a Banbury mixer, to incorporate therein antioxidants, UV stabilizers, colorants, metallic stearates such as zinc, calcium, magnesium, lead and lithium stearates, fluoropolymers such as powered poly (tetrafluoroethylene) (TEFLON), and the like.
[0018] It has been found that when fluoropolymer additives are employed, unlike the lubricants useful in the present invention, the fluoropolymers do not migrate to the surface of the elastomeric material. Instead, the fluoropolymer additives become part of the matrix of the molded elastomeric material. The fluoroploymer additives are compounded with the elastomeric material in amounts ranging from about 10 to 50% by weight and preferably, from about 20 to 30% by weight based on the weight of elastomer. Incorporation of the fluoropolymer additives has been found to result in an elastomeric material exhibiting a reduced coefficient of friction.
[0019] In accordance with the present invention, during the compounding operation, one or more lubricants can be admixed with the elastomeric material to incorporate the lubricant(s) therein. Suitable lubricants are those that are not compatible with the elastomer and will migrate through the elastomer and bloom on the surface thereof. Continued blooming of the lubricant will provide the necessary lubricity to reduce the coefficient of friction of the seal and thereby reduce plunger movement forces providing an improved syringe construction. Lubricants useful in the present invention include, for example, both organic and inorganic lubricants. Exemplary organic lubricants include amides, especially oleamides, waxes, both natural and synthetic, for example, bees wax and derivatives of hydrogenated castor oil such as methyl 12-hydroxystearate, esters, oils such as mineral oils and the like. Inorganic lubricants include, for example graphite in flake or powered form, molybdenum disulfide, and the like.
[0020] The lubricant can be admixed with the elastomeric material in amounts ranging from about 0.05 to 0.50 wt % based on the weight of the elastomeric material and preferably, from about 0.2 to 0.4 wt %.
[0021] As shown in FIG. 2 , the plunger 14 terminates in elastomeric seal 20 . The elastomeric seal comprises elastomeric material 26 having a lubricant 28 admixed therein. The lubricant 28 migrates through the elastomeric material and blooms on the surface thereof forming a lubricious coating 30 . After compounding, the resulting elastomer can be thermoformed to the desired size and shape and affixed to the distal end of the plunger 14 . The resulting plunger assembly can be inserted into syringe body 12 to form the improved syringe construction of the present invention.
[0022] Syringes fabricated in accordance with the present invention have been found to exhibit a plunger breaking force reduction of about 75% and a running force reduction ranging between about 10 and 20%.
[0023] It will be understood that the invention may be embodied in other specific forms without departing from the spirit of scope thereof. The presently disclosed embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details set forth herein. | A syringe assembly is provided comprising an annular syringe body, a plunger adapted to travel therein in response to manual force, said plunger terminating in an elastomeric seal in sealing engagement with the interior surface of the syringe body, said seal having admixed therein a lubricant capable of migrating through the elastomeric seal to bloom on the surface thereof, thereby imparting enhanced lubricity thereto reducing the movement forces necessary to enable controlled plunger movement. | 0 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to image processing, and more particularly to converting a digital image or picture represented in one colorspace to a video signal represented in another colorspace for display on a computer monitor.
BACKGROUND OF THE INVENTION
Many image processing applications, such as image capture from a video signal, involve the conversion of a source image signal to a different signal for display on a computer monitor. For example, in some applications, incoming data is captured from a multi-dimensional colorspace signal, such as a YIQ signal or a Y, R-Y, B-Y signal, both of which are standard television transmission signals. The data is processed in that format. Before display, the data must be converted to a red, green, blue (RGB) format because the computer monitor, typically a cathode ray tube (CRT), expects the computer or other display driver to provide separate RGB signals.
The mathematical transformation required for this type of conversion from one colorspace to another requires a substantial amount of processing power. For YIQ to RGB conversion, 9 multiplies and 6 adds are required per pixel. Thus, 640×480×30×9 multiplies and 55 million adds per second are required to convert a YIQ television signal following the NTSC standard to an RGB signal for a typical monitor. For Y, R-Y, B-Y to RGB conversion, 3 multiplies and 4 adds are required per pixel.
The matrix calculations for such mathematical transformations are known in the art of image processing. An example of the mathematics for a YIQ to RGB conversion is set out in Hall, Illumination and Color in Computer Generated Imaging, p. 133, Springer-Verlag (1989).
One approach to image data conversion is the use of palettes, which are essentially look-up tables. In applications that do not involve colorspace to colorspace conversions, palettes are used to convert one-dimensional computer generated image data to other one dimensional data, i.e., greyscale data, or to convert one dimensional data to three dimensional data, i.e., RGB data.
However, for color conversion for photographic type pictures, conversion from a three dimensional color space to a different three dimensional space is required.
A need exists for a method of colorspace conversion that does not unduly burden the overall processing capacity of the computer system.
SUMMARY OF THE INVENTION
One aspect of the invention is a colorspace converter for transforming data representing one colorspace into data representing another colorspace. An array of transformation look-up tables receives digitized image data, such as YIQ data, representing an input colorspace. The dimensions of this array are the same as the number of components of the input colorspace and the number of components of the output colorspace. Thus, for YIQ to RGB conversion, the array has nine look-up tables. Each address of each look-up table represents a value of input data, and the look-up tables are loaded with a transformation value at each address. A number of adder units add the output of look-up tables producing like color data of the output colorspace. The result is a sum of values for each color in the output colorspace. Each sum is delivered to a saturation unit, which limits each sum to a saturation value.
A technical advantage of the invention is that conversion from one colorspace to another is performed in a palette instead of by a host or a graphics processor. This is particularly important when displaying moving pictures, which requires a colorspace conversion for each screen refresh. At a 72 Hz refresh rate and using a 640×480 pixel display, there are far more multiplies and adds per second than most existing image processing systems can handle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an image processing system having a palette that includes a colorspace converter.
FIG. 2 is a block diagram of an example of using the colorspace converter for YIQ to RGB conversion.
FIG. 3 illustrates an implementation of the invention in an integrated circuit.
FIG. 4 illustrates a circuit that is used with the colorspace converter to interleave subsampled and interpolated color components of YIQ data.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a color conversion system, used for image capture and processing applications. It provides real-time conversion from one colorspace to another colorspace during a CRT display process.
A data acquisition unit 10 is used to capture and digitize a video signal, or to otherwise provide digital image data, which is to be processed by processor 11. For purposes of this description, "image data" includes video, photographic, or any other type of data representing graphic information, whether moving or not. However, because of its real-time capability, the colorspace converter described herein is especially useful for moving pictures, such as from a television camera.
Dynamic random access memory 12 is used in a conventional manner for program and data storage. Refresh and timing control unit 17 provides control for refreshing the computer monitor 18, and for other conventional timing functions.
Video random access memory 13 acts a frame buffer. The output of video random access memory 13 goes to a serial register 14, and then to a palette 15.
The function of palette 15 is two-fold. First, it converts digital data in one colorspace to data in another colorspace, using colorspace .converter 16 in accordance with the description herein. Second, it converts digital data to analog signals for use by monitor 18. For purposes of example, the conversion described herein is a YIQ to RGB conversion, but the same techniques could be applied to other colorspace conversions.
The converted data is delivered to a computer monitor 18. Although not shown in FIG. 1, timing signals are also provided, using known techniques.
FIG. 2 illustrates the operation of colorspace converter 16. The general scheme of the colorspace converter 16 is the use of look-up tables (LUT's) 21 to perform three dimensional colorspace transformations.
Colorspace converter 16 has multiple inputs, with N LUT's 21 for each input, where N is the number of outputs. Each input is typically 8 bits. In the YIQ to RGB conversion described herein, three inputs correspond to the YIQ components, and each input is associated with three LUT's 21 which represent three RGB output signals. In this case, the LUT's 21 perform the function of multipliers.
LUT's 21 are implement with random access memory (RAM) devices. For 8 bits in and 8 bits out, each LUT 21 is a 256×8 memory. For fixed conversion computations, fixed logic devices, such as a read only memory, may be used. Referring again to FIG. 1, colorspace converter 16 is are in communication with processor 11, so that each LUT 21 may be loaded with values that will permit the YIQ input to be mapped to a desired RGB output.
Adders 22 add the output of each LUT 21 to like output of other LUT's 21. Thus, the R components from the R LUT's 21 are added together, as are the G and B components of G and B LUT's 21. Adders 22 are standard logic devices.
Saturate units 23 ensure that the results of the addition of each color component are add with saturate, to avoid the results of arithmetic overflow. Thus, for example, if the results of adding the 3 R components results in a value that exceeds a saturation value, the R saturation unit 23 reduces the sum to the saturation value. Saturation units 23 are also implemented with logic devices. In the case of positive and negative output values of LUT's 21, saturation units 23 saturate both maximum and minimum values.
In operation, colorspace converter 16 receives data representing a pixel during a given time period. Each component of the input colorspace data is transformed into an output colorspace value, using look-up tables 21. The data representing like components of the output colorspace are added together, using adder units 22. Each sum is tested for saturation by a saturation unit 23, and any sums that exceed a predetermined saturation value are limited to that value. Thus, for each pixel, the arithmetic computations are limited to six adds, with all other operations being simple compare and memory access operations.
A feature of the invention is that it permits negative as well as positive values to be transformed. In the case of negative values, saturation units 23 are modified to support appropriate computations, such as two's complement addition.
Input extension LUT's 24 may be used to compensate for nonlinearities associated with the input. Likewise, output extension LUT's may be used to compensate for nonlinearities associated with the output device or with the human vision system. These LUT's 24 and 25 may be loaded with any desired transfer function.
FIG. 3 illustrates how colorspace converter 16 may be implemented in an integrated circuit. For conversion from one three dimensional colorspace to another, three input ports, represented by DA0-DA7, DB0-DB7, and DC0-DC7, each receive a component of image data, such as YIQ data. Each input data line is associated with a row of look-up tables, such that colorspace converter 16 has the configuration of FIG. 2, and is loaded with transform values, using address and data input registers 33 and 34, or other interface means with processor 11.
The input data to be transformed is latched into input latches 31. The output of these latches 31 is fed into colorspace converter 16, which transforms the data. The transformed data is delivered to digital to analog converters 32, whose output is sent to monitor 18.
An advantage of the invention is that it permits subsampling of the chroma component of an input colorspace within colorspace converter 16. For example, a different data rate may be used for the Y component than for the I and Q components of a YIQ signal, using a latch in the I and Q data paths prior to delivery of the data to LUT's 21. This latch is clocked at some ratio of the clocking frequency of the Y component.
FIG. 4 illustrates a circuit that interpolates I or Q values. A first latch 41 receives chroma, i.e., I or Q data. The chroma data is clocked at a chroma clock rate, and delivers the data to a second latch 42, an adder 43, and a multiplexer 44. Latch 42 and adder 43 are used to interpolate spatially proximate data, and multiplexer 44 is used to interleave subsampled and interpolated data. Latch 42 is also clocked at the chroma clock rate. Adder 43 prevents overflow by discarding the least significant bit. The output of multiplexer 45 is delivered to a third latch 45, which is clocked at a luma, i.e., Y, clock rate, such that the output of the subsampling circuit is at the luma rate. For this implementation, the chroma clock rate of latches 41 and 42 is one-half the luma clock rate, thus the input I and Q components are subsampled at 2:1, as compared to the sampling of the Y component.
Other Embodiments
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments, will be apparent to persons skilled in the art. It is, therefore, contemplated that the appended claims will cover all modifications that fall within the true scope of the invention. | A colorspace converter for use with image processing systems. The colorspace converter transforms digitized image data in one colorspace into image data in another colorspace, for use by a computer monitor. The colorspace converter uses look-up tables and other logic devices, and avoids the need for processor intervention. The look-up tables may be loaded for simple mapping, and extension look-up tables may be loaded for nonlinear extension transformations. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to a water-soluble polymer composition, a composition for forming a plaster layer of a skin patch, production methods therefor, and a skin patch prepared using the composition for forming a plaster layer.
BACKGROUND ART
[0002] A poultice, cooling sheet, or like skin patch is produced by applying a gell-like plaster, which has been prepared by adding various medicaments, water, or other ingredients to a composition containing a water-soluble polymer, to the surface of a nonwoven fabric or like support, and curing and aging the composition, thereby forming the plaster layer on the support. Examples of water-soluble polymers that may be added to such a composition include poly(meth)acrylic polymers, such as poly(meth)acrylic acid or a salt thereof.
[0003] A composition for forming a plaster layer that contains a water-soluble polymer and that is used for a skin patch is required to have sufficient adhesiveness to the skin, elasticity for application to a bending part, and other properties. It is also required to have various other properties adopted to the skin patch production process.
[0004] A typical process for producing a poultice or cooling sheet comprises the steps of preparing a gell-like plaster by mixing various additive ingredients to a composition containing a water-soluble polymer, applying the gell-like plaster to a nonwoven fabric or like support, covering the surface thereof with a polyethylene film or like liner, cutting and packing the result, and then curing and aging the composition in the pack.
[0005] In such a method, when a gell-like plaster is prepared from the water-soluble polymer composition, aluminum or a like polyvalent metal compound is added to the water-soluble polymer composition as a cross linking agent. If the water-soluble polymer easily reacts with the polyvalent metal compound and the curing speed is too fast, gelation proceeds during the application of the water-soluble polymer to the support, making it difficult to apply it to the support. Therefore, in order to control the reaction speed between the water-soluble polymer and the polyvalent metal compound, a method is employed wherein disodium ethylenediaminetetraacetate is also added as a gelation rate retarding agent when adding the polyvalent metal compound (Patent Literature 1).
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Unexamined Patent Publication No. H03-188149
SUMMARY OF INVENTION
Technical Problem
[0007] However, it is difficult to control the curing speed of the gel by the method disclosed in PTL 1 wherein a polyvalent metal compound and a gelation rate retarding agent are added simultaneously. This makes it difficult to obtain a desirable curing speed, and may hinder operations such as mixing additive ingredients and applying the plaster to a support.
[0008] The present invention was made in view of the current status of conventional techniques described above. One of the main objects thereof is to provide a composition that is usable in forming a plaster layer for a skin patch, such as a poultice, a cooling sheet, or the like. More specifically, the present invention aims to provide a composition containing a water-soluble polymer for which the gelation speed is easily controllable and which can readily be applied to a support, and a skin patch formed by using the composition.
Solution to Problem
[0009] The present inventors conducted extensive research to achieve the above objects. As a result, they found that when a polyvalent metal compound as a cross linking agent is added to a water-soluble polymer composition containing a gelation rate retarding agent together with poly(meth)acrylic acid or a salt thereof, and the resulting composition is used as a composition for forming a plaster layer of a skin patch, the gelation speed of the gell-like plaster can be easily controlled and the induction period until the hardening of the gell-like plaster proceeds can be desirably arranged. This facilitates the operation of mixing additive ingredients with the composition and applying the plaster to a support. The present invention has been accomplished based on the above findings.
[0010] Specifically, the present invention provides a water-soluble polymer composition, a composition for forming a plaster layer of a skin patch, production methods thereof, and a skin patch prepared using the composition for forming a plaster layer, as described below.
[0011] Item 1. A water-soluble polymer composition comprising a water-soluble poly(meth)acrylic polymer and a gelation rate retarding agent.
[0012] Item 2. The water-soluble polymer composition according to Item 1, which is prepared by polymerizing at least one (meth)acrylic compound selected from the group consisting of (meth)acrylic acid and salts thereof to obtain a hydrated gel of a water-soluble poly(meth)acrylic polymer, adding a gelation rate retarding agent before or while drying the resulting hydrated gel, and drying the result.
[0013] Item 3. The water-soluble polymer composition according to Item 1 or 2, wherein the amount of the gelation rate retarding agent added is 0.1 to 10 parts by mass relative to 100 parts by mass of the (meth)acrylic compound, which is at least one compound selected from the group consisting of (meth)acrylic acid and salts thereof, that is used to prepare the water-soluble poly(meth)acrylic polymer.
[0014] Item 4. A composition for forming a plaster layer of a skin patch comprising the water-soluble polymer composition of any one of Items 1 to 3 and a polyvalent metal compound.
[0015] Item 5. The composition for forming a plaster layer according to Item 4, wherein the amount of the polyvalent metal compound is 0.01 to 20 parts by mass relative to 100 parts by mass of the water-soluble polymer composition.
[0016] Item 6. A skin patch comprising a plaster layer formed from the composition for forming a plaster layer of Item 4 or 5.
[0017] Item 7. The skin patch according to Item 6, which is a poultice or a cooling sheet.
[0018] Item 8. A method for producing a water-soluble polymer composition comprising:
[0019] polymerizing at least one (meth)acrylic compound selected from the group consisting of (meth)acrylic acid and salts thereof to obtain a hydrated gel of a water-soluble poly(meth)acrylic polymer;
[0020] adding a gelation rate retarding agent before or while drying the resulting hydrated gel; and
[0021] drying the result.
[0022] Item 9. A method for producing a composition for forming a plaster layer of a skin patch comprising a step of adding a polyvalent metal compound to the water-soluble polymer composition obtainable by the method of Item 8.
[0023] The water-soluble polymer composition and the composition for forming a plaster layer of a skin patch of the present invention are explained in detail below.
(I) Water-Soluble Polymer Composition
[0024] The water-soluble polymer composition of the present invention comprises a water-soluble poly(meth)acrylic polymer and a gelation rate retarding agent as active ingredients. The water-soluble poly(meth)acrylic polymer and gelation rate retarding agent contained in the composition are explained below.
[0000] (1) Water-Soluble Poly(meth)acrylic polymer
[0025] There is no limitation to the water-soluble poly(meth)acrylic polymer used in the present invention as long as it is obtainable by using at least one (meth)acrylic compound selected from the group consisting of (meth)acrylic acid and salts thereof as a monomer component and polymerizing it. The polymerization method is not particularly limited, and typical methods for polymerizing a (meth)acrylic compound, such as a reversed-phase suspension polymerization method or an aqueous solution polymerization method, can be employed. Preferable examples of polymerization methods include those in which the polymerization degree is controlled when polymerizing a monomer component so that extremely low-molecular-weight polymers and extremely high-molecular-weight polymers are not formed. In this specification, “(meth)acrylic acid” includes both “acrylic acid” and “methacrylic acid.”
[0026] Hereunder, the reversed-phase suspension polymerization method and the aqueous solution polymerization method are explained in detail as examples for producing a water-soluble poly(meth)acrylic polymer.
(i) Reversed-Phase Suspension Polymerization Method
[0027] The reversed-phase suspension polymerization method is conducted by, for example, subjecting at least one (meth)acrylic compound selected from the group consisting of (meth)acrylic acid and salts thereof as a monomer component to water-in-oil reversed-phase suspension polymerization using a radical polymerization initiator in a petroleum hydrocarbon dispersion medium that contains at least one component selected from the group consisting of surfactants and polymeric dispersion agents. The reversed-phase suspension polymerization method may be conducted in two or more steps, wherein a (meth)acrylic compound is further added to a slurry of a water-soluble poly(meth)acrylic polymer obtained by reversed-phase suspension polymerization.
[0028] The (meth)acrylic compound used as the monomer component is generally used in the form of an aqueous solution. The concentration of the (meth)acrylic compound in the aqueous solution is preferably 15 mass % to a saturated concentration in order to quickly advance the polymerization reaction.
[0029] In the present invention, in order to render an appropriate water-soluble property to the resulting poly(meth)acrylic polymer, it is preferable that a (meth)acrylic acid salt be used singly or a mixture of a (meth)acrylic acid salt and (meth)acrylic acid be used as the (meth)acrylic compound that is used as the monomer component. A poly(meth)acrylic polymer having an appropriate water-soluble property can be produced by, for example, neutralizing a part or all of the (meth)acrylic acid in an aqueous solution using a base to prepare an aqueous solution containing (meth)acrylic acid salt, and causing a polymerization reaction in the aqueous solution. In this case, the neutralization degree of the (meth)acrylic acid is preferably about 5 to 100 mol %, and more preferably about 20 to 100 mol % in order to obtain a satisfactory solubility of the resulting water-soluble poly(meth)acrylic polymer.
[0030] Specific examples of salts of (meth)acrylic acid include lithium (meth)acrylate, sodium (meth)acrylate, potassium (meth)acrylate, and ammonium (meth)acrylate. Among these salts of (meth)acrylic acid, sodium (meth)acrylate and potassium (meth)acrylate are preferable, and sodium (meth)acrylate is particularly preferable. In order to prepare such salts of (meth)acrylic acid, bases such as lithium hydroxide, sodium hydroxide, potassium hydroxide, and ammonia can be used.
[0031] Examples of radical polymerization initiators include potassium persulfate, ammonium persulfate, sodium persulfate, and like persulfates; methyl ethyl ketone peroxide, methyl isobutyl ketone peroxide, di-tert-butyl peroxide, tert-butyl cumyl peroxide, tert-butyl peroxyacetate, tert-butyl peroxyisobutyrate, tert-butyl peroxypivalate, hydrogen peroxide, and like peroxides; and 2,2′-azobis(2-amidinopropane)dihydrochloride, 2,2′-azobis[2-(N-phenylamidino)propane]dihydrochloride, 2,2′-azobis[2-(N-allylamidino)propane]dihydrochloride, 2,2′-azobis{2-[1-(2-hydroxyethyl)-2-imidazolin-2-yl]propane}dihydrochloride, 2,2′-azobis{2-methyl-N-[1,1-bis(hydroxymethyl)-2-hydroxyethyl]propionamide}, 2,2′-azobis[2-methyl-N-(2-hydroxyethyl)-propionamide], 4,4′-azobis(4-cyanovaleric acid), and like azo compounds. These radical polymerization initiators may be used singly or in a combination of two or more. Among these radical polymerization initiators, potassium persulfate, ammonium persulfate, sodium persulfate and 2,2′-azobis(2-amidinopropane)dihydrochloride are suitably used as they are easily available from an industrial perspective and have good storage stability.
[0032] The amount of radical polymerization initiator used is preferably 0.015 to 0.15 parts by mass relative to 100 parts by mass of (meth)acrylic compound in order to shorten the polymerization reaction time, prevent an excessively rapid polymerization reaction, and easily control the degree of polymerization as desired. When the amount of radical polymerization initiator used is too small, the polymerization reaction may be undesirably prolonged. When the amount of radical polymerization initiator used is too large, the polymerization reaction proceeds too quickly, resulting in an excessively rapid reaction. This may make it impossible to control the polymerization reaction.
[0033] The radical polymerization initiator may be used as a redox-polymerization initiator in combination with sodium sulfite, sodium hydrogensulfite, ferrous sulfite, and like sulfites; D-ascorbic acid, L-ascorbic acid, rongalite, and like reducing agents; etc.
[0034] When the poly(meth)acrylic polymer is produced by the method described above, the addition of a water-soluble chain transfer agent is preferable in order to control the degree of polymerization so that the formation of an extremely low-molecular-weight polymer or an extremely high-molecular-weight polymer can be prevented. Examples of water-soluble chain transfer agents include hypophosphite compounds, phosphorous compounds, thiol compounds, secondary alcohol compounds, and amine compounds. These water-soluble chain transfer agents may be used singly or in a combination of two or more. Among these water-soluble chain transfer agents, sodium hypophosphite, potassium hypophosphite, and like hypophosphite compounds are suitably used because they have no odor and are desirable in terms of sanitary and safety aspects.
[0035] In order to suitably control the degree of polymerization, the amount of water-soluble chain transfer agent used is preferably 0.001 to 2 parts by mass, and more preferably 0.001 to 1.7 parts by mass relative to 100 parts by mass of (meth)acrylic compound. When the amount of water-soluble chain transfer agent used is too small, the effect of the water-soluble chain transfer agent may not be fully exhibited. When the amount of water-soluble chain transfer agent used is too large, the proportion of the low-molecular-weight polymer undesirably increases and the gel curing rate of the composition for forming a plaster layer tends to become slow. Furthermore, when a poultice is produced using this composition, the adhesiveness of the gel of the poultice may be lowered because the salt content in the gel increases.
[0036] Examples of surfactants used for polymerizing a (meth)acrylic compound include polyglyceryl fatty acid esters, sucrose fatty acids esters, sorbitan fatty acid esters, polyoxyethylenesorbitan fatty acid esters, polyoxyethyleneglycerine fatty acid esters, sorbitol fatty acid esters, polyoxyethylenesorbitol fatty acid esters, polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, polyoxyethylene castor oil, polyoxyethylene hydrogenated castor oil, alkyl allyl formaldehyde condensed polyoxyethylene ethers, polyoxyethylene polyoxypropylene block copolymers, polyoxyethylene polyoxypropyl alkyl ethers, polyethyleneglycol fatty acid esters, polyoxyethylene alkylamine, phosphoric esters of polyoxyethylene alkyl ether, and phosphoric esters of polyoxyethylene alkyl allyl ether. These surfactants may be used singly or in a combination of two or more. Among these surfactants, sorbitan fatty acid esters, polyglyceryl fatty acid esters, and sucrose fatty acid esters are suitably used as they can render excellent dispersion stability to the aqueous solution containing the (meth)acrylic compound.
[0037] Examples of polymeric dispersion agents include maleic anhydride modified polyethylene, maleic anhydride modified polypropylene, maleic anhydride modified ethylene/propylene copolymers, maleic anhydride modified EPDM (ethylene/propylene/diene terpolymers), maleic anhydride modified polybutadiene, ethylene/maleic anhydride copolymers, ethylene/propylene/maleic anhydride copolymers, butadiene/maleic anhydride copolymers, oxidized polyethylene, ethylene/acrylic acid copolymers, ethylcellulose, and ethylhydroxyethyl cellulose. These polymeric dispersion agents may be used singly or in a combination of two or more. Among these, maleic anhydride modified polyethylene, maleic anhydride modified polypropylene, maleic anhydride modified ethylene propylene copolymers, oxidized polyethylene, and ethylene/acryl acid copolymers are suitably used as they can render excellent dispersion stability to the aqueous solution containing the (meth)acrylic compound.
[0038] Both or only one of the surfactant and polymeric dispersion agent may be used. The amount of these components used i.e., the total amount of surfactant and polymeric dispersion agent, is preferably 0.1 to 5 parts by mass and more preferably 0.2 to 3 parts by mass relative to 100 parts by mass of (meth)acrylic compound in order to maintain excellent dispersed state of an aqueous solution containing the (meth)acrylic compound, and to obtain a dispersion effect that achieves a good balance with the amount of these components used. When the amount of these components used is too small, the dispersibility of the (meth)acrylic compound becomes undesirably low, and this may result in irregular polymerization. When the amount of these components used is too large, a dispersion effect that is in good balance with the amount used may not be achieved.
[0039] Examples of petroleum hydrocarbon dispersion mediums include n-hexane, n-heptane, n-octane, ligroin, and like aliphatic hydrocarbons; cyclopentane, methylcyclopentane, cyclohexane, methylcyclohexane, and like alicyclic hydrocarbons; and benzene, toluene, xylene, and like aromatic hydrocarbons. These petroleum hydrocarbon dispersion mediums may be used singly or in a combination of two or more. Among these petroleum hydrocarbon dispersion mediums, n-hexane, n-heptane, and cyclohexane are preferable as they are easily available from an industrial perspective, stable in quality and inexpensive.
[0040] The amount of petroleum hydrocarbon dispersion medium used is preferably 50 to 600 parts by mass, and more preferably 80 to 550 parts by mass relative to 100 parts by mass of (meth)acrylic compound in order to easily control the polymerization temperature by removing the heat of polymerization.
[0041] The reaction temperature in the polymerization varies depending on the radical polymerization initiator used. The reaction temperature is preferably about 20 to 110° C. Having a reaction temperature within that range facilitates rapid polymerization to shorten the polymerization time, improves productivity, and allows easy removal of the polymerization heat to promote a smooth reaction. The reaction temperature is more preferably about 40 to 90° C. in order to easily control the polymerization temperature and degree of polymerization. When the reaction temperature is too low, the rate of polymerization becomes slow and prolongs the polymerization time, and is thus economically undesirable. When the reaction temperature is too high, removal of the polymerization heat becomes difficult. This may make it difficult to achieve a smooth reaction.
[0042] After the polymerization reaction is thus completed, a slurry is obtained in which a hydrated gel of water-soluble poly(meth)acrylic polymer is dispersed therein. Thereafter, water and the petroleum hydrocarbon dispersion medium are removed by heating, for example, at 80 to 200° C., to dry the resulting slurry, obtaining a water-soluble poly(meth)acrylic polymer.
(ii) Aqueous Solution Polymerization Method
[0043] An aqueous solution polymerization method is explained below as one embodiment. The aqueous solution polymerization method can be performed according to a conventional method using, for example, a (meth)acrylic compound as a monomer component, and a radical polymerization initiator.
[0044] In the aqueous solution polymerization method, the types, amounts, etc., of the (meth)acrylic compound, radical polymerization initiator, other optional components, and the like are the same as those used in the reversed-phase suspension polymerization method explained above.
[0045] In the aqueous solution polymerization method, the reaction temperature, reaction time, and the like during the polymerization reaction are the same as those of the reversed-phase suspension polymerization method explained above.
[0046] After the polymerization reaction is completed, a hydrated gel of water-soluble poly(meth)acrylic polymer is obtained. Thereafter, water is removed and the hydrated gel is dried by heating, for example, at 80 to 200° C., to obtain a water-soluble poly(meth)acrylic polymer.
(2) Gelation Rate Retarding Agent
[0047] In the present invention, compounds having a chelation ability or a coordination ability with regard to metal ions can be used as a gelation rate retarding agent. There is no limitation to the gelation rate retarding agents, and known compounds usable as a gelation rate retarding agent for a poly(meth)acrylic polymer can be used. Examples thereof include organic acids such as ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, acetic acid, citric acid, fumaric acid, tartaric acid, lactic acid, and malic acid; salts of these organic acids; inorganic acids such as boric acid and carbonic acid; and salts of inorganic acids, such as borate, carbonate, and hydrogen carbonate. There is no particular limitation to the types of the organic acid salts and inorganic acid salts as long as they are water soluble, and examples thereof include alkali metal salts, alkaline earth metal salts, and ammonium salts.
[0048] These gelation rate retarding agents may be used singly or in a combination of two or more. Among these gelation rate retarding agents, ethylenediaminetetraacetic acid and salts thereof are suitably used because they have no odor and are desirable in terms of sanitary and safety aspects.
[0049] The amount of the gelation rate retarding agent added is preferably about 0.1 to 10 parts by mass relative to 100 parts by mass of the (meth)acrylic compound used as a monomer component to attain the appropriate induction period for hardening the gel. When the amount of the gelation rate retarding agent is too small, an induction period sufficient for fully kneading the additive ingredients added to the composition may not be attained when poultices or the like are produced using the composition containing the water-soluble poly(meth)acrylic polymer. In case that the amount of the gelation rate retarding agent is too large, when a polyvalent metal compound is added to the composition as a cross linking agent to form a gell-like plaster, the masking action to the polyvalent metal ions is too strong and the gelation reaction is readily hindered. This tends to prolong the gelation time and is thus not efficient; furthermore, the final strength of the formed plaster layer may become undesirably low.
(3) Method for Producing a Water-Soluble Polymer Composition
[0050] The water-soluble polymer composition of the present invention comprises the water-soluble poly(meth)acrylic polymer and the gelation rate retarding agent described above as active ingredients. By forming a composition comprising a water-soluble poly(meth)acrylic polymer and a gelation rate retarding agent in advance, the water-soluble polymer and the gelation rate retarding agent are present in a uniform manner.
[0051] This allows the curing speed to be easily controlled when such a composition is reacted with a polyvalent metal compound used as a cross linking agent. Therefore, when a plaster layer for a skin patch is formed by adding a polyvalent metal compound to promote gelation, a desirable induction period can be attained before the initiation of the hardening of the gell-like composition. As a result, this causes the additive ingredients to be uniformly mixed and facilitates the application of the composition to a support.
[0052] The method for mixing the water-soluble poly(meth)acrylic polymer with the gelation rate retarding agent is not particularly limited as long as it can mix the water-soluble poly(meth)acrylic polymer with the gelation rate retarding agent as uniformly as possible.
[0053] Examples of such methods include: polymerizing a (meth)acrylic compound in the presence of the gelation rate retarding agent during the polymerization process of the poly(meth)acrylic polymer described above; and polymerizing a (meth)acrylic compound to form a hydrated gel of poly(meth)acrylic polymer, and adding a gelation rate retarding agent before or while drying the hydrated gel. By using such methods, the water-soluble polyacrylic polymer and the gelation rate retarding agent can be mixed. In particular, in order to smoothly conduct the polymerization reaction for the poly(meth)acrylic polymer, the water-soluble polymer composition of the present invention is preferably produced by a method comprising polymerizing the (meth)acrylic compound to prepare a hydrated gel, then adding a gelation rate retarding agent to the resulting hydrated gel, and drying the result, or adding a gelation rate retarding agent while drying the hydrated gel.
(II) Composition for Forming a Plaster Layer of a Skin Patch
[0054] A composition prepared by adding a polyvalent metal compound, as a cross linking agent, to the water-soluble polymer composition comprising the water-soluble poly(meth)acrylic polymer and gelation rate retarding agent described above has a property such that gelation gradually proceeds. Such a composition can be used for forming a plaster layer of a skin patch. A plaster layer of a skin patch can be formed by, for example, applying a gell-like composition, which has been obtained by adding a polyvalent metal compound, to a support for a skin patch, and then curing and aging it.
[0055] A polyvalent metal compound added to the composition for forming a plaster layer functions as a cross-linking agent to the water-soluble poly(meth)acrylic polymer. Examples of polyvalent metal compounds include salts of bivalent to hexavalent metal ions with anions, such as chloride ions, sulphate ions, silicate ions, and phosphate ions. Specific examples of polyvalent metal ions include aluminum ions, calcium ions, iron ions and the like. Specific examples of polyvalent metal compounds include aluminum hydroxide, aluminum sulfate, aluminum silicate, aluminum phosphate, aluminum glycinate, calcium hydroxide, and ferric sulfate. These polyvalent metal compounds may be used singly or in a combination of two or more.
[0056] The amount of the polyvalent metal compound added is preferably about 0.01 parts by mass or more, more preferably 0.05 parts by mass or more, and particularly preferably 0.1 parts by mass or more relative to 100 parts by mass of the water-soluble poly(meth)acrylic polymer in order to render excellent shape retention to the plaster layer to be prepared by applying the gell-like plaster formed from a composition, to which a polyvalent metal compound has been added, to a support, followed by curing and aging. The upper limit of the amount of the polyvalent metal compound used is preferably about 20 parts by mass or less, more preferably 15 parts by mass or less, and particularly preferably about 10 parts by mass or less relative to 100 parts by mass of water-soluble poly(meth)acrylic polymer in order to render excellent elasticity and adhesiveness to the plaster layer to be formed.
[0057] In addition to the water-soluble poly(meth)acrylic polymer composition and polyvalent metal compound, polyhydric alcohols, pH adjusters and the like may be added to the composition for forming a plaster layer of a skin patch according to the present invention.
[0058] Among these, the polyhydric alcohols function as a water retention agent. Specific examples of polyhydric alcohols include glycerol, polypropylene glycol, sorbitol, and butylene glycol. These polyhydric alcohols may be used singly or in a combination of two or more.
[0059] The amount of the polyhydric alcohol is preferably 50 mass % or less relative to the total amount of the composition for forming a plaster layer, including polyhydric alcohol, water, other optional additive ingredients, and the like. If the amount of the polyhydric alcohol exceeds 50 mass %, the curing speed may be undesirably lowered when the gell-like plaster is formed into a plaster layer by applying it to a support, followed by curing and aging.
[0060] The pH adjuster promotes the separation of metal ions from a polyvalent metal compound and functions as a pH-controlling agent for a composition for forming the plaster layer itself. Specific examples of pH adjusters include tartaric acid, lactic acid, citric acid, and like organic acids. The pH adjusters may be used singly or in a combination of two or more. The amount of the pH adjuster is preferably such that when a composition for forming a plaster layer is obtained by adding water, polyhydric alcohol, other optional additive ingredients, and the like, the resulting composition has a pH of about 3 to 7.
[0061] The composition for forming a plaster layer of the present invention comprises the components described above. The composition is usually used in the form of an aqueous dispersion by adding water thereto. There is no particular limitation to the method for preparing the composition, and the composition can be prepared, for example, as follows. A polyhydric alcohol is added, as necessary, to a polyvalent metal compound and a water-soluble polymer composition containing a gelation rate retarding agent, and then these components are mixed to prepare a dispersion. Separate from this dispersion, an aqueous solution in which a pH adjuster and water are mixed is prepared. Thereafter, the dispersion prepared above is mixed with the aqueous solution to obtain the composition for forming a plaster layer.
[0062] The amount of water used is not particularly limited. The preferable amount of water is 50 mass % or more relative to the total amount of the composition for forming a plaster layer including water, polyhydric alcohol, other optional additive ingredients, etc. When the amount of water is less than 50 mass %, the application of the gell-like plaster to a support may become difficult, and the curing speed may become difficult to control when a plaster layer is formed by curing and aging the gell-like plaster.
(III) Skin Patch
[0063] A skin patch can be obtained as follows. A polyvalent metal compound, as a cross linking agent, and optional additive ingredients, if necessary, are added to the aforementioned water-soluble polymer composition comprising a water-soluble poly(meth)acrylic polymer and a gelation rate retarding agent to form a gell-like plaster. The gell-like plaster is then applied to a nonwoven fabric or like support, and the result is subjected to curing and aging to form a plaster layer, thereby obtaining a skin patch. Specific examples of skin patches include poultices and cooling sheets.
[0064] The method for producing a skin patch is not particularly limited, and may, for example, comprise the steps of adding a polyvalent metal compound and optional additives to the water-soluble polymer composition of the present invention to prepare a gell-like composition, applying the gell-like composition to a nonwoven fabric or like support, covering the surface thereof with a polyethylene film or like liner, cutting the result into a desirable size if necessary, packing the result, and curing and aging the gel in the pack.
[0065] The additives may be suitably selected from known components depending on the application of the skin patch. Examples of additives for producing a poultice include methyl salicylate, L-menthol, D,L-camphor, and tocopheryl acetate. Examples of additives for producing a cooling sheet include paraben, a pigment, and a fragrance. The amounts of these additives may be the same as those of general plaster layers.
[0066] A polyester nonwoven fabric is an example of a nonwoven fabric that is used as a support. Nonwoven fabrics are commercially available, such as a plaster base fabric (produced by Japan Vilene Company, Ltd.).
Advantageous Effects of Invention
[0067] The composition prepared by adding a polyvalent metal compound to the water-soluble polymer composition of the present invention has an appropriate induction period before the start of the hardening of the gel. Therefore, when additive ingredients are added to the composition to prepare a gell-like plaster, the additive ingredients can be smoothly and uniformly mixed with the composition. This also allows the gell-like plaster to be easily applied to a support.
DESCRIPTION OF EMBODIMENTS
[0068] The present invention is explained in detail below with reference to Examples and Comparative Examples. However, the scope of the invention is not limited to these Examples.
Example 1
Preparation of a Water-Soluble Polymer Composition
[0069] A 1,000-mL five-necked cylindrical round-bottom flask equipped with a reflux condenser, a dropping funnel, a nitrogen introduction tube, a stirrer, and a stirring blade was prepared. n-Heptane (340 g) was placed in this flask, and 0.92 g of sucrose stearate having HLB of 3 (produced by Mitsubishi-Kagaku Foods Corporation, Ryoto Sugar Ester S-370) and 0.92 g of maleic anhydride modified ethylene propylene copolymer (produced by Mitsui Chemicals, Inc., Hi-wax 1105A) were added thereto. The mixture was heated to 80° C. while stirring to dissolve the surfactant, and then cooled to 55° C.
[0070] An 80 mass % aqueous solution of acrylic acid (92 g, 1.02 mol) was then placed in a 500-mL Erlenmeyer flask. While cooling the flask from the outside, a 30 mass % aqueous solution of sodium hydroxide (68.1 g, 0.51 mol) was added dropwise thereto to perform 50 mol % neutralization. To the thus neutralized solution, 1.15 g of a 2.0 mass % aqueous solution of 2,2′-azobis(2-amidinopropane)dihydrochloride as a radical polymerization initiator, 0.92 g of a 1.0 mass % aqueous solution of sodium hypophosphite monohydrate, and 51.6 g of ion-exchanged water were added, giving a monomer aqueous solution.
[0071] The entire quantity of this monomer aqueous solution was added to the cylindrical round-bottom flask. The flask was dipped in a 60° C. water bath to heat it to 58° C. The atmosphere inside the flask was replaced with nitrogen, followed by conducting a polymerization reaction. The contents reached the peak temperature (79° C.) 30 minutes after the initiation of the polymerization reaction. The flask was maintained in the state of being dipped in the 60° C. water bath for 0.5 hours, and the reaction was continued. The temperature of the internal solution after 0.5 hours was 59° C.
[0072] After the polymerization was completed, 30 g of a 3 mass % aqueous solution of disodium ethylenediaminetetraacetate was added to a slurry containing a hydrated gel of a water-soluble polyacrylic polymer. After stirring for 0.5 hours, the slurry was heated in a 125° C. oil bath. Azeotropic distillation of n-heptane and water was conducted to remove 138 g of water from the flask while refluxing the n-heptane. Thereafter, the n-heptane in the flask was removed by distillation to make the contents dry, obtaining 90.1 g of a water-soluble polymer composition.
[Preparation of a Composition for Forming a Plaster Layer]
[0073] 0.25 parts by mass of tartaric acid was added to 86.55 parts by mass of distilled water, giving Liquid A.
[0074] Subsequently, a mixed solvent of 4 parts by mass of glycerol and 4 parts by mass of propylene glycol was placed in a 500-mL beaker, and 0.2 parts by mass of a dried aluminum hydroxide gel (produced by Kyowa Chemical Industry Co., Ltd.; model number: S-100, acid reactivity: 0.1 N—HCl=180 seconds) was added and dispersed, giving Liquid B.
[0075] While stirring Liquid B at 100 rpm using a pitched paddle having a blade diameter of 75 mm, 5 parts by mass of the aforementioned water-soluble polymer composition was added thereto in 2 seconds and stirring continued for 3 seconds. The total amount of the aforementioned Liquid A was then added thereto in 2 seconds. Thereafter, the mixture was stirred for 15 seconds, and then stirring was halted, obtaining a composition for forming a plaster layer.
Example 2
[0076] A 1,000-mL five-necked cylindrical round-bottom flask equipped with a reflux condenser, a dropping funnel, a nitrogen introduction tube, a stirrer, and a stirring blade was prepared. n-Heptane (340 g) was placed in this flask, and 0.92 g of sucrose stearate having HLB of 3 (produced by Mitsubishi-Kagaku Foods Corporation, Ryoto Sugar Ester S-370) and 0.92 g of a maleic anhydride modified ethylene-propylene copolymer (produced by Mitsui Chemicals, Inc., Hi-wax 1105A) were added thereto. The mixture was heated to 80° C. while stirring to dissolve the surfactant, and then cooled to 55° C.
[0077] An 80 mass % aqueous solution of acrylic acid (92 g, 1.02 mol) was then placed in a 500-mL Erlenmeyer flask. While cooling the flask from the outside, a 30 mass % aqueous solution of sodium hydroxide (68.1 g, 0.51 mol) was added dropwise thereto to perform 50 mol % neutralization. To the thus neutralized solution, 1.15 g of a 2.0 mass % aqueous solution of 2,2′-azobis(2-amidinopropane)dihydrochloride as a radical polymerization initiator, 0.92 g of a 1.0 mass % aqueous solution of sodium hypophosphite monohydrate, and 51.6 g of ion-exchanged water were added and dissolved, giving a monomer aqueous solution.
[0078] The entire quantity of this monomer aqueous solution was added to the cylindrical round-bottom flask. The flask was dipped in a 60° C. water bath to heat it to 58° C. The atmosphere inside the flask was replaced with nitrogen, followed by conducting a polymerization reaction. The contents reached the peak temperature (79° C.) 30 minutes after the initiation of the polymerization reaction. Thereafter, the flask was placed in a 55° C. water bath for 1 hour, and the reaction was continued. The temperature of the internal solution after 1 hour was 53° C.
[0079] After the polymerization was completed, 80 g of a 10 mass % aqueous solution of disodium ethylenediaminetetraacetate was added to a slurry containing a hydrated gel of water-soluble polyacrylic polymer. After stirring for 0.5 hours, the slurry was heated in a 125° C. oil bath. Azeotropic distillation of n-heptane and water was conducted to remove 181 g of water from the flask while refluxing the n-heptane. Thereafter, the n-heptane in the flask was removed by distillation to make the contents dry, obtaining 97.7 g of a water-soluble polyacrylic polymer composition.
[0080] Using the resulting water-soluble acrylic polymer composition, a composition for forming a plaster layer was prepared in the same manner as in Example 1.
Example 3
[0081] An 80 mass % aqueous solution of acrylic acid (27 g, 0.3 mol) was placed in a 300-mL Erlenmeyer flask. While cooling the flask from the outside, a 30 mass % aqueous solution of sodium hydroxide (20 g, 0.15 mol) was added dropwise thereto to perform 50 mol % neutralization. To the thus neutralized solution, 22.6 g of ion-exchanged water was added, giving a monomer aqueous solution.
[0082] To a 500-mL five-necked cylindrical round-bottom flask equipped with a reflux condenser, a dropping funnel, a nitrogen introduction tube, a stirrer, and a stirring blade, the entire quantity of this monomer aqueous solution was added. The atmosphere inside the flask was replaced with nitrogen, and the flask was dipped in a 60° C. water bath and heated to 58° C. 30 g of a 3 mass % aqueous solution of disodium ethylenediaminetetraacetate was added to the resulting solution, followed by stirring for 0.5 hours. Thereafter, 0.54 g of a 2.0 mass % aqueous solution of 2,2′-azobis(2-amidinopropane)dihydrochloride as a radical polymerization initiator, and 0.72 g of a 1.0 mass % aqueous solution of sodium hypophosphite monohydrate were added, followed by conducting a polymerization reaction. The contents became thicker one minute after the initiation of the polymerization reaction, and stirring was stopped when 2 minutes had passed. The contents reached the peak temperature (75° C.) 4 minutes after the initiation of the polymerization reaction. The flask was maintained in the state of being dipped in the 60° C. water bath for 3 hours, and the reaction was continued. The temperature of the internal solution after 3 hours was 58° C.
[0083] After the polymerization was completed, the unified hydrated gel of water-soluble polyacrylic polymer was dried at 120° C. for 2 hours. The dried polymer was pulverized and dried at 110° C. for 2 hours, obtaining 24.4 g of a water-soluble polyacrylic polymer composition.
[0084] Using the resulting water-soluble polyacrylic polymer composition, a composition for forming a plaster layer was produced in the same manner as in Example 1.
Example 4
[0085] A 1,000-mL five-necked cylindrical round-bottom flask equipped with a reflux condenser, a dropping funnel, a nitrogen introduction tube, a stirrer, and a stirring blade was prepared. n-Heptane (340 g) was placed in this flask, and 0.92 g of sucrose stearate having HLB of 3 (produced by Mitsubishi-Kagaku Foods Corporation, Ryoto Sugar Ester S-370) and 0.92 g of a maleic anhydride modified ethylene-propylene copolymer (produced by Mitsui Chemicals, Inc., Hi-wax 1105A) were added thereto. The mixture was heated to 80° C. while stirring to dissolve the surfactant, and then cooled to 55° C.
[0086] An 80 mass % aqueous solution of acrylic acid (92 g, 1.02 mol) was then placed in a 500-mL Erlenmeyer flask. While cooling the flask from the outside, a 30 mass % aqueous solution of sodium hydroxide (68.1 g, 0.51 mol) was added dropwise thereto to perform 50 mol % neutralization. To the thus neutralized solution, 1.15 g of a 2.0 mass % aqueous solution of 2,2′-azobis(2-amidinopropane)dihydrochloride as a radical polymerization initiator, 0.92 g of a 1.0 mass % aqueous solution of sodium hypophosphite monohydrate, and 51.6 g of ion-exchanged water were added, giving a monomer aqueous solution.
[0087] The entire quantity of this monomer aqueous solution was added to the cylindrical round-bottom flask. The flask was dipped in a 60° C. water bath to heat it to 58° C. The atmosphere inside the flask was replaced with nitrogen, followed by conducting a polymerization reaction. The contents reached the peak temperature (79° C.) 30 minutes after the initiation of the polymerization reaction. The flask was maintained in the state of being dipped in the 60° C. water bath for 0.5 hours, and the reaction was continued. The temperature of the internal solution after 0.5 hours was 59° C.
[0088] After the polymerization was completed, 100 g of a 10 mass % aqueous solution of disodium ethylenediaminetetraacetate was added to a slurry containing a hydrated gel of a water-soluble polyacrylic polymer. After stirring for 0.5 hours, the slurry was heated in a 125° C. oil bath. Azeotropic distillation of n-heptane and water was conducted to remove 199 g of water from the flask while refluxing the n-heptane. Thereafter, the n-heptane in the flask was removed by distillation to make the contents dry, obtaining 99.4 g of a water-soluble polyacrylic polymer composition.
[0089] Using the resulting water-soluble polyacrylic polymer composition, a composition for forming a plaster layer was produced in the same manner as in Example 1.
Comparative Example 1
[0090] A 1,000-mL five-necked cylindrical round-bottom flask equipped with a reflux condenser, a dropping funnel, a nitrogen introduction tube, a stirrer, and a stirring blade was prepared. n-Heptane (340 g) was placed in this flask, and 0.92 g of sucrose stearate having HLB of 3 (produced by Mitsubishi-Kagaku Foods Corporation, Ryoto Sugar Ester S-370) and 0.92 g of a maleic anhydride modified ethylene-propylene copolymer (produced by Mitsui Chemicals, Inc., Hi-wax 1105A) were added thereto. The mixture was heated to 80° C. while stirring to dissolve the surfactant, and then cooled to 55° C.
[0091] An 80 mass % aqueous solution of acrylic acid (92 g, 1.02 mol) was then placed in a 500-mL Erlenmeyer flask. While cooling the flask from the outside, a 30 mass % aqueous solution of sodium hydroxide (68.1 g, 0.51 mol) was added dropwise thereto to perform 50 mol % neutralization. To the thus neutralized solution, 1.15 g of a 2.0 mass % aqueous solution of 2,2′-azobis(2-amidinopropane)dihydrochloride as a radical polymerization initiator, 0.92 g of a 1.0 mass % aqueous solution of sodium hypophosphite monohydrate, and 51.6 g of ion-exchanged water were added and dissolved, giving a monomer aqueous solution.
[0092] The entire quantity of this monomer aqueous solution was added to the cylindrical round-bottom flask. The flask was dipped in a 60° C. water bath to heat it to 58° C. The atmosphere inside the flask was replaced with nitrogen, followed by conducting a polymerization reaction. The contents reached the peak temperature (79° C.) 30 minutes after the initiation of the polymerization reaction. The flask was maintained in the state of being dipped in the 60° C. water bath for 0.5 hours, and the reaction was continued. The temperature of the internal solution after 0.5 hours was 59° C.
[0093] After the polymerization was completed, a slurry containing a hydrated gel of a water-soluble polyacrylic polymer was heated in a 125° C. oil bath. Azeotropic distillation of n-heptane and water was conducted to remove 108 g of water from the flask while refluxing the n-heptane. Thereafter, the n-heptane in the flask was removed by distillation to make the contents dry, obtaining 89.1 g of a water-soluble polyacrylic polymer.
[0094] Using the resulting water-soluble polyacrylic polymer, a composition for forming a plaster layer was produced in the same manner as in Example 1.
Comparative Example 2
[0095] The water-soluble polyacrylic polymer obtained in Comparative Example 1 was used for preparing a gell-like composition as follows. That is, a composition for forming a plaster layer was produced in the same manner as in Example 1 except that 0.2 parts by mass of disodium ethylenediaminetetraacetate was added together with 5 parts by mass of water-soluble polyacrylic polymer.
[0096] The gel strengths of the compositions for forming a plaster layer obtained in Examples 1 to 4 and Comparative Examples 1 and 2 were evaluated by the procedure described below. Table 1 shows the evaluation results.
[Gel Aging]
[0097] Each of the above prepared compositions for forming a plaster layer (95 to 100 g) was placed in a polyethylene container (produced by AS ONE Corporation, product name: Tight Boy TB-2) and then placed in a thermo-hygrostat (produced by ESPEC Corp., product name: LHU-113) that was adjusted to 25° C. and relative humidity of 60%, and then allowed to age for a predetermined period of time (1, 2, 3, 6, 9, 12, 15, 18, 24, 30, 36, and 48 hours).
[Gel Strength]
[0098] The gel strengths immediately after production and after being aged for a predetermined period of time were measured using a curdmeter (produced by I TECHNO Co., Ltd., product name: Curdmeter MAX, model number: ME-303). The measurement conditions were as shown below:
[0099] Load: 100 g, diameter of pressure-sensitive shaft: 16 mm, carriage speed: 7 seconds/inch, and measurement mode: viscous.
Example 5
Preparation of Poultices
[0100] The composition for forming a plaster layer obtained in Example 1 was applied and spread over one surface of a polyester nonwoven fabric (produced by Japan Vilene Company, Ltd., product name: plaster base fabric) in such a manner that the thickness of the coating became 5 mm. The coated surface of the gel was covered with nylon film. The result was cut into a size of 100×50 mm, obtaining a poultice.
Examples 6 to 8 and Comparative Examples 3 and 4
[0101] Poultices were produced in the same manner as in Example 5 except that each of the compositions for forming plaster layers obtained in Examples 2 to 4 and Comparative Examples 1 and 2 shown in Table 1 were used.
[0102] The appearance of the poultices obtained in Examples 5 to 8 and Comparative Examples 3 and 4 was evaluated by the following procedure. Table 1 shows the evaluation results.
[Gel Condition]
[0103] In the production of poultices, the gel condition of the composition for forming a plaster layer immediately after application was evaluated by visually observing the presence or absence of unswollen lump.
[0104] A: No unswollen lump observed
[0105] B: Unswollen lump observed
[0000]
TABLE 1
Gel Strength [N/m 2 ]
Aging Time [hours]
Gel
0
1
2
3
6
9
12
15
18
24
30
36
48
Condition
Example 1
147
98
99
101
223
321
405
448
458
480
484
484
487
Example 5
A
Example 2
143
96
96
98
98
99
105
158
270
401
430
444
452
Example 6
A
Example 3
111
93
94
95
95
148
255
360
432
467
471
480
480
Example 7
A
Example 4
141
95
97
95
98
97
98
99
189
340
389
390
390
Example 8
A
Comparative
155
178
201
223
345
429
456
465
473
488
491
493
495
Comparative
A
Example 1
Example 3
Comparative
148
160
172
188
253
322
371
403
423
445
462
467
468
Comparative
B
Example 2
Example 4
[0106] As is clear from Table 1, the water-soluble polyacrylic polymer compositions of Examples 1 to 4 exhibited a low gel strength of 200 N/m 2 or lower for more than 3 hours from the production of the composition for forming a plaster layer. Therefore, it is confirmed that these compositions have an appropriate induction period before the start of the hardening of the gel.
[0107] When the poultices of Examples 5 to 8 of the present invention are produced, unswollen lump is not observed in the composition for forming a plaster layer; therefore, the resulting poultices have an excellent appearance. | The present invention relates to a water-soluble polymer composition which comprises a water-soluble poly(meth)acrylic polymer and a gelation rate retarding agent, and a composition for forming a plaster layer of a skin patch which is obtainable by adding a polyvalent metal compound to the water-soluble polymer composition. When a polyvalent metal compound is added, the aforesaid water-soluble polymer composition shows an appropriate induction period before the start of the hardening of the gel. When the water-soluble polymer composition is used for forming a plaster layer of a skin patch, therefore, additive ingredients can be uniformly mixed and the procedure for coating to a support can be facilitated. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a divisional application of application Ser. No. 12/725,184, filed Mar. 16, 2010, which is incorporated by reference
FIELD OF THE INVENTION
[0002] The present invention relates to a retard roller, and more particularly to a retard roller for use in an automatic document feeder.
BACKGROUND OF THE INVENTION
[0003] In the early stage, a scanning apparatus is used to scan the image of a single document. For scanning both sides of the document, the document should be manually turned over after one side of the document has been scanned in order to sequentially scan the other side of the document. For scanning a stack of documents, after one document has been scanned, the document should be removed from the scanning apparatus and then a next document could be placed on the scanning apparatus in order to be further scanned. Since the process of manually turning over the document or manually replacing the document is very troublesome, the conventional scanning apparatus is not feasible. Recently, an automatic document feeder is usually integrated into the scanning apparatus. The automatic document feeder is suitable to perform a duplex scanning operation and successively scan plural documents without the need of manually turning over or replacing the documents.
[0004] Generally, the automatic document feeder has a sheet input tray for placing a stack of documents. The automatic document feeder also has a sheet pick-up module for successively feeding the stack of documents from the sheet input tray to the internal portion of the automatic document feeder in a sheet-feeding direction. For allowing only one document to be fed into the internal portion of the automatic document feeder at each feeding time, the sheet pick-up module has a sheet separation roller and a separation pad. The separation pad is disposed under the sheet separation roller. The sheet separation roller may provide a frictional force to the document that is contacted with the separation pad. The frictional forces between the sheet pick-up module, the separation pad and the documents should be elaborately controlled. Generally, the frictional force between the sheet pick-up module and the document contacted with the sheet pick-up module is greater than the frictional force between the documents. In addition, the frictional force between the separation pad and the document contacted with the separation pad is also greater than the frictional force between the documents. As a consequence, only one document is allowed to be fed into the internal portion of the automatic document feeder at each feeding time. As the automatic document feeder is used for a long time, the separation pad is usually abraded, or even losses the function of separating documents. In this situation, the separation pad needs to be replaced with a new one. Since the separation pad is usually securely fastened on the automatic document feeder, the process of replacing the separation pad is very complicated.
[0005] For solving the above drawbacks, U.S. Pat. No. 6,659,450 disclosed an automatic document feeder with an easily disassembled separation pad and retard roller. During the sheet-feeding process, the retard roller generates a damping torque in a sheet-feeding rotating direction. In response to the damping torque, the retard roller provides a frictional force to the document. Although the separation pad and the retard roller of the automatic document feeder described in U.S. Pat. No. 6,659,450 are disassembled more easily when compared with the prior art, there are still some drawbacks. For example, after the retard roller is disassembled, the spring for providing a normal force on the retard roller is still retained in the automatic document feeder. During the process of assembling the retard roller, the retard roller needs to be installed in the automatic document feeder while aligning the retard roller with the spring. In other words, the retard roller needs to be precisely combined with the spring in order to achieve a normal function of the retard roller. The process of assembling the retard roller is not user-friendly.
[0006] Moreover, in a case that the documents are jammed in the internal portion of the automatic document feeder, the installation of the retard roller or separation pad incurs some drawbacks. For example, due to the frictional force between the jammed documents and the retard roller (or separation pad), the jammed documents fail to be pulled out of the automatic document feeder in a sheet-returning direction, which is opposed to the sheet-feeding direction. For releasing the jammed documents, the user needs to open the upper cover of the automatic document feeder to uplift the sheet pick-up module. As such, the sheet pick-up module is separated from the upper sides of the jammed documents and the frictional force between the jammed documents and the retard roller (or separation pad) is eliminated. Meanwhile, the jammed documents could be effectively released.
[0007] Since the process of removing the document from the automatic document feeder is very troublesome, there is a need of providing a retard roller for moving the document in the sheet-feeding direction and the sheet-returning direction without the need of opening the upper cover.
SUMMARY OF THE INVENTION
[0008] An object of the present invention provides a retard roller for moving the document in the sheet-feeding direction and the sheet-returning direction.
[0009] Another object of the present invention provides an easily disassembled/assembled retard roller module.
[0010] In accordance with an aspect of the present invention, there is provided a retard roller of an automatic document feeder for providing a frictional force to separate a first document and a second document from each other. The first document lies on the second document. The retard roller includes a sleeve, a separation pad, a helical spring and a rotating shaft. The sleeve has a sleeve inner wall. The separation pad is sheathed around the sleeve, and contacted with the second document. The helical spring is disposed within the sleeve, and includes a first spring segment and a second spring segment. The first spring segment has a first spring inner diameter. The second spring segment has a second spring inner diameter smaller than the first spring inner diameter. The first spring segment is contacted with the sleeve inner wall. The rotating shaft is penetrated through the helical spring and contacted with the second spring segment. When the second document is moved in a first direction, the sleeve is rotated in a first rotating direction, the first spring segment is twisted in the first rotating direction, and the first spring inner diameter of the first spring segment is widened, so that the first spring segment is fixed on the sleeve inner wall and the second spring segment is twisted with respect to the rotating shaft to generate a first damping torque. After the first spring inner diameter of the first spring segment is widened and the second document is moved in a second direction opposed to the first direction, the sleeve is rotated in a second rotating direction, so that the second spring segment is fixed on the rotating shaft and the first spring segment is twisted to generate a second damping torque. The first damping torque is greater than the second damping torque.
[0011] In an embodiment, the sleeve inner wall includes a first inner wall part and a second inner wall part. The first inner wall part is near a first end of the sleeve, and has a first sleeve inner diameter. The second inner wall part is near a second end of the sleeve, and has a second sleeve inner diameter. The first sleeve inner diameter is smaller than the second sleeve inner diameter.
[0012] In an embodiment, the sleeve inner wall is an inclined wall.
[0013] In an embodiment, the first spring segment is contacted with the first inner wall part. The second spring segment is separated from the second inner wall part but contacted with the rotating shaft. When the sleeve is rotated in the first rotating direction, the first spring segment is twisted in the first rotating direction, and the first spring inner diameter of the first spring segment is widened, so that the first spring segment is fixed on the first inner wall part and the second spring segment is twisted with respect to the rotating shaft to generate the first damping torque. After the first spring inner diameter of the first spring segment is widened and the second document is moved in the second direction, the sleeve is rotated in the second rotating direction, so that the second spring segment is fixed on the rotating shaft and the first spring segment is twisted to generate the second damping torque.
[0014] In an embodiment, the first spring segment is eccentrically connected with the second spring segment.
[0015] In an embodiment, the retard roller further includes a receiving shaft inserted into the first end of the sleeve. The rotating shaft is inserted into the second end of the sleeve and received within the receiving shaft.
[0016] In accordance with another aspect of the present invention, there is provided a retard roller of an automatic document feeder for providing a frictional force to separate a first document and a second document from each other. The first document lies on the second document. The retard roller includes a first sleeve, a second sleeve, a separation pad, a helical spring, a one-way clutch and a rotating shaft. The first sleeve has a sleeve inner tube. The second sleeve is accommodated within the first sleeve, and has a sleeve outer tube. The sleeve outer tube is arranged at an end of the second sleeve and contacted with an end of the sleeve inner tube. The separation pad is sheathed around the first sleeve, and contacted with the second document. The helical spring is accommodated within the first sleeve. A first end of the helical spring is sheathed around the sleeve outer tube to define a first spring segment. A second end of the helical spring is sheathed around the sleeve inner tube to define a second spring segment. The first spring segment has a first spring inner diameter. The second spring segment has a second spring inner diameter smaller than the first spring inner diameter. The one-way clutch is accommodated within the second sleeve for preventing the second sleeve from rotating in a first rotating direction. The rotating shaft is penetrated through the first sleeve, the second sleeve and the one-way clutch. When the second document is moved in a first direction, the first sleeve is rotated in the first rotating direction, and the second sleeve fails to be rotated in response to the one-way clutch, so that the first spring segment is fixed on the sleeve outer tube and the second spring segment is twisted with respect to the sleeve inner tube to generate a first damping torque. When the second document is moved in a second direction opposed to the first direction, the first sleeve is rotated in a second rotating direction, the first spring segment is fixed on the sleeve outer tube, and the second spring segment is fixed on the sleeve inner tube, so that the second sleeve is rotated with the first sleeve and the one-way clutch is rotated with respect to the rotating shaft to generate a second damping torque. The first damping torque is greater than the second damping torque.
[0017] In an embodiment, a tube diameter of the sleeve inner tube is smaller than that of the sleeve outer tube, so that the interference between the first spring segment and the sleeve outer tube is greater than the interference between the second spring segment and the sleeve inner tube.
[0018] In accordance with a further aspect of the present invention, there is provided a retard roller module of an automatic document feeder. The retard roller module has a retard roller for providing a frictional force to separate a first document and a second document from each other. The first document lies on the second document. The retard roller module includes a retard roller frame, the retard roller and an elastic element. The retard roller is installed on the retard roller frame. The retard roller includes a sleeve, a separation pad, a helical spring and a rotating shaft. The sleeve has a sleeve inner wall. The separation pad is sheathed around the sleeve, and contacted with the second document. The helical spring is disposed within the sleeve, and includes a first spring segment and a second spring segment. The first spring segment has a first spring inner diameter. The second spring segment has a second spring inner diameter smaller than the first spring inner diameter. The first spring segment is contacted with the sleeve inner wall. The rotating shaft is penetrated through the helical spring and contacted with the second spring segment. When the second document is moved in a first direction, the sleeve is rotated in a first rotating direction, the first spring segment is twisted in the first rotating direction, and the first spring inner diameter of the first spring segment is widened, so that the first spring segment is fixed on the sleeve inner wall and the second spring segment is twisted with respect to the rotating shaft to generate a first damping torque. After the first spring inner diameter of the first spring segment is widened and the second document is moved in a second direction opposed to the first direction, the sleeve is rotated in a second rotating direction, so that the second spring segment is fixed on the rotating shaft and the first spring segment is twisted to generate a second damping torque. The first damping torque is greater than the second damping torque. The elastic element is disposed on the retard roller frame and contacted with the retard roller for providing an elastic force on the retard roller, so that the retard roller is movable upwardly and downwardly with respect to the retard roller frame.
[0019] In an embodiment, the sleeve inner wall includes a first inner wall part and a second inner wall part. The first inner wall part is near a first end of the sleeve, and has a first sleeve inner diameter. The second inner wall part is near a second end of the sleeve, and has a second sleeve inner diameter. The first sleeve inner diameter is smaller than the second sleeve inner diameter.
[0020] In an embodiment, the sleeve inner wall is an inclined wall.
[0021] In an embodiment, the first spring segment is contacted with the first inner wall part. The second spring segment is separated from the second inner wall part but contacted with the rotating shaft. When the sleeve is rotated in the first rotating direction, the first spring segment is twisted in the first rotating direction, and the first spring inner diameter of the first spring segment is widened, so that the first spring segment is fixed on the first inner wall part and the second spring segment is twisted with respect to the rotating shaft to generate the first damping torque. After the first spring inner diameter of the first spring segment is widened and the second document is moved in the second direction, the sleeve is rotated in the second rotating direction, so that the second spring segment is fixed on the rotating shaft and the first spring segment is twisted to generate the second damping torque.
[0022] In an embodiment, the first spring segment is eccentrically connected with the second spring segment.
[0023] In an embodiment, the retard roller further includes a receiving shaft inserted into the first end of the sleeve. The rotating shaft is inserted into the second end of the sleeve and received within the receiving shaft.
[0024] In an embodiment, the elastic element further includes a torsion spring arm, which is contacted with the retard roller for providing the elastic force on the retard roller, so that the retard roller is movable upwardly and downwardly with respect to the retard roller frame.
[0025] In an embodiment, the elastic element is a supporting torsion spring.
[0026] In an embodiment, the rotating shaft further comprises a confining edge. When the confining edge is fixed on the retard roller frame, the rotating shaft is fixed and fails to be rotated.
[0027] In accordance with a further aspect of the present invention, there is provided a retard roller module of an automatic document feeder. The retard roller module has a retard roller for providing a frictional force to separate a first document and a second document from each other. The first document lies on the second document. The retard roller module includes a retard roller frame, the retard roller and an elastic element. The retard roller is installed on the retard roller frame. The retard roller includes a first sleeve, a second sleeve, a separation pad, a helical spring, a one-way clutch and a rotating shaft. The first sleeve has a sleeve inner tube. The second sleeve is accommodated within the first sleeve, and has a sleeve outer tube. The sleeve outer tube is arranged at an end of the second sleeve and contacted with an end of the sleeve inner tube. The separation pad is sheathed around the first sleeve, and contacted with the second document. The helical spring is accommodated within the first sleeve. A first end of the helical spring is sheathed around the sleeve outer tube to define a first spring segment. A second end of the helical spring is sheathed around the sleeve inner tube to define a second spring segment. The first spring segment has a first spring inner diameter. The second spring segment has a second spring inner diameter smaller than the first spring inner diameter. The one-way clutch is accommodated within the second sleeve for preventing the second sleeve from rotating in a first rotating direction. The rotating shaft is penetrated through the first sleeve, the second sleeve and the one-way clutch. When the second document is moved in a first direction, the first sleeve is rotated in the first rotating direction, and the second sleeve fails to be rotated in response to the one-way clutch, so that the first spring segment is fixed on the sleeve outer tube and the second spring segment is twisted with respect to the sleeve inner tube to generate a first damping torque. When the second document is moved in a second direction opposed to the first direction, the first sleeve is rotated in a second rotating direction, the first spring segment is fixed on the sleeve outer tube, and the second spring segment is fixed on the sleeve inner tube, so that the second sleeve is rotated with the first sleeve and the one-way clutch is rotated with respect to the rotating shaft to generate a second damping torque. The first damping torque is greater than the second damping torque. The elastic element is disposed on the retard roller frame and contacted with the retard roller for providing an elastic force on the retard roller, so that the retard roller is movable upwardly and downwardly with respect to the retard roller frame.
[0028] In an embodiment, a tube diameter of the sleeve inner tube is smaller than that of the sleeve outer tube, so that the interference between the first spring segment and the sleeve outer tube is greater than the interference between the second spring segment and the sleeve inner tube.
[0029] In an embodiment, the rotating shaft further comprises a confining edge. When the confining edge is fixed on the retard roller frame, the rotating shaft is fixed and fails to be rotated.
[0030] In an embodiment, the elastic element further includes a torsion spring arm, which is contacted with the retard roller for providing the elastic force on the retard roller, so that the retard roller is movable upwardly and downwardly with respect to the retard roller frame.
[0031] In an embodiment, the elastic element is a supporting torsion spring.
[0032] The above objects and advantages of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a schematic side view illustrating a retard roller module in a sheet-feeding status according to a first embodiment of the present invention;
[0034] FIG. 2 is a schematic exploded view illustrating the retard roller module according to the first embodiment of the present invention;
[0035] FIG. 3 is a schematic assembled view illustrating the retard roller module according to the first embodiment of the present invention;
[0036] FIG. 4 is a schematic cross-sectional view illustrating the retard roller of the retard roller module according to the first embodiment of the present invention;
[0037] FIG. 5 is a schematic side view illustrating the retard roller module in a sheet-returning status according to the first embodiment of the present invention;
[0038] FIGS. 6A , 6 B and 6 C are schematic views illustrating the process of disassembling/assembling the retard roller module according to the first embodiment of the present invention;
[0039] FIG. 7 is a schematic cross-sectional view illustrating the retard roller of the retard roller module according to a second embodiment of the present invention;
[0040] FIG. 8 is a schematic exploded view illustrating the retard roller module according to a third embodiment of the present invention; and
[0041] FIG. 9 is a schematic cross-sectional view illustrating the retard roller module according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] The present invention provides a retard roller module for use in an automatic document feeder. FIG. 1 is a schematic side view illustrating a retard roller module in a sheet-feeding status according to a first embodiment of the present invention. The retard roller module is mounted in an automatic document feeder. As shown in FIG. 1 , the automatic document feeder 1 comprises a retard roller module 10 and a sheet pick-up mechanism 20 . The sheet pick-up mechanism 20 is used for feeding a first document S 1 and a second document S 2 into an internal portion of the automatic document feeder 1 . The retard roller module 10 is used to provide a frictional force to the second document S 2 . Due to the frictional force, the first document S 1 lying on the second document S 2 could be separated from the second document S 2 .
[0043] Hereinafter, the configurations of the retard roller module 10 will be illustrated with reference to FIGS. 2 and 3 . FIG. 2 is a schematic exploded view illustrating the retard roller module according to the first embodiment of the present invention. FIG. 3 is a schematic assembled view illustrating the retard roller module according to the first embodiment of the present invention. The retard roller module 10 comprises a retard roller frame 101 , a retard roller 102 and an elastic element 103 . The retard roller 102 is installed on the retard roller frame 101 . The elastic element 103 is disposed on the retard roller frame 101 . The elastic element 103 has a torsion spring arm 1031 . The torsion spring arm 1031 is contacted with the retard roller 102 for providing an elastic normal force on the retard roller 102 , so that the retard roller 102 is movable upwardly and downwardly with respect to the retard roller frame 101 . In this embodiment, the elastic element 103 is a supporting torsion spring.
[0044] The configurations of the retard roller 102 will be illustrated in FIG. 4 , which is a schematic cross-sectional view illustrating the retard roller of the retard roller module according to the first embodiment of the present invention. The retard roller 102 , which is installed on the retard roller frame 101 , comprises a sleeve 1021 , a separation pad 1022 , a helical spring 1023 and a rotating shaft 1024 . The sleeve 1021 has a sleeve inner wall 10211 . The separation pad 1022 is sheathed around the sleeve 1021 . When the separation pad 1022 is contacted with the second document S 2 , a frictional force is generated. In this embodiment, the separation pad 1022 is a rubbery wheel. The helical spring 1023 is disposed within the sleeve 1021 . The helical spring 1023 comprises a first spring segment 10231 and a second spring segment 10232 . The first spring segment 10231 has a first spring inner diameter r 1 . The second spring segment 10232 has a second spring inner diameter r 2 . The first spring segment 10231 is contacted with the sleeve inner wall 10211 . The second spring segment 10232 is separated from the sleeve inner wall 10211 . The second spring inner diameter r 2 is smaller than the first spring inner diameter r 1 . The first spring segment 10231 is eccentrically connected with the second spring segment 10232 . The rotating shaft 1024 is penetrated through the helical spring 1023 and contacted with the supporting torsion spring 103 for receiving the elastic normal force, which is provided by the supporting torsion spring 103 . The rotating shaft 1024 further comprises a confining edge 10241 . When the confining edge 10241 is fixed on the retard roller frame 101 , the rotating shaft 1024 is fixed and fails to be rotated (see FIGS. 2 and 3 ).
[0045] Please refer to FIG. 1 again. For feeding the first document S 1 and the second document S 2 by the automatic document feeder 1 , the sheet pick-up roller and the sheet separation roller of the sheet pick-up mechanism 20 are rotated in a second rotating direction C 2 to transport the first document S 1 and the second document S 2 . As such, the first document S 1 and the second document S 2 are moved in a first direction A 1 . The separation pad 1022 of the retard roller 102 is contacted with the second document S 2 , so that the retard roller 102 is rotated in a first rotating direction C 1 . The first rotating direction C 1 is opposed to the second rotating direction C 2 . In this embodiment, the first direction A 1 is a sheet-feeding direction, the first rotating direction C 1 is an anti-clockwise direction, and the second rotating direction C 2 is a clockwise direction. When the first document S 1 and the second document S 2 are transported and moved in the first direction A 1 , the first document S 1 and the second document S 2 are sustained against the retard roller 102 , so that the retard roller 102 is moved downwardly with respect to the retard roller frame 101 . As such, the first document S 1 and the second document S 2 are allowed to be fed into the internal portion of the automatic document feeder 1 through the region between the sheet pick-up mechanism 20 and the retard roller module 10 .
[0046] When the separation pad 1022 of the retard roller 102 is contacted with the second document S 2 and the retard roller 102 is rotated in the first rotating direction C 1 , the sleeve 1021 of the retard roller 102 is also rotated in the first rotating direction C 1 . Since the first spring segment 10231 is contacted with the sleeve inner wall 10211 , the first spring segment 10231 is twisted in the first rotating direction C 1 upon rotation of the sleeve inner wall 10211 . Due to the twisting direction of the helical spring 1023 , the first spring segment 10231 is stretched. As such, the inner diameter of the first spring segment 10231 is widened to be larger than the original first spring inner diameter r 1 . As such, the gap between the first spring segment 10231 and the sleeve inner wall 10211 is shortened, and the interference between the first spring segment 10231 and the sleeve inner wall 10211 is increased, so that the first spring segment 10231 is fixed (tightened) on the sleeve inner wall 10211 . At the same time, the second spring segment 10232 is twisted with respect to the rotating shaft 1024 . In addition, for overcoming an inner stress resulted from the interference between the second spring segment 10232 and the rotating shaft 1024 , the second spring segment 10232 generates a first damping torque T 1 . In response to the first damping torque T 1 , the retard roller 102 provides a first frictional force to the second document S 2 , so that the second document S 2 fails to be transported. At the same time, the first document S 1 is allowed to be transported in the first direction A 1 by the sheet pick-up mechanism 20 .
[0047] FIG. 5 is a schematic side view illustrating the retard roller module in a sheet-returning status according to the first embodiment of the present invention. In a case that the first document S 1 is jammed in the internal portion of the automatic document feeder 1 , the jammed first document S 1 needs to be removed from the automatic document feeder 1 . For removing the jammed first document S 1 , the jammed first document S 1 needs to be moved in a second direction A 2 , which is opposed to the first direction A 1 . In this embodiment, the second direction A 2 is a sheet-returning direction. When the first document S 1 is moved in the second direction A 2 , the retard roller 102 is rotated in the second rotating direction C 2 because the separation pad 1022 of the retard roller 102 is contacted with the second document S 2 . As such, the sleeve 1021 of the retard roller 102 is also rotated in the second rotating direction C 2 . Due to the twisting direction of the helical spring 1022 , the second spring segment 10232 is fixed (tightened) on the rotating shaft 1024 . Since the first spring segment 10231 is contacted with the sleeve inner wall 10211 , the first spring segment 10231 is twisted in the second rotating direction C 2 upon rotation of the sleeve inner wall 10211 . In addition, for overcoming an inner stress resulted from the interference between the first spring segment 10231 and the sleeve inner wall 10211 , the first spring segment 10231 generates a second damping torque T 2 . In response to the second damping torque T 2 , the retard roller 102 provides a second frictional force to the second document S 2 . Since the interference between the first spring segment 10231 and the sleeve inner wall 10211 is very low, the second damping torque T 2 is very low. In other words, the second frictional force corresponding to the second damping torque T 2 is also very low. Without obvious obstruction, the second document S 2 could be smoothly moved in the second direction A 2 to be removed from the automatic document feeder 1 .
[0048] It is noted that the damping torque is in direct proportion to the frictional force. As the first damping torque T 1 is increased, the first frictional force is increased. Whereas, as the second damping torque T 2 is decreased, the second frictional force is decreased.
[0049] FIGS. 6A , 6 B and 6 C are schematic views illustrating the process of disassembling/assembling the retard roller module according to the first embodiment of the present invention. For disassembled the retard roller module 10 from the automatic document feeder 1 , the bilateral sides of the retard roller 102 are firstly held by the user's hands, then the retard roller module 10 is turned, and finally the retard roller module 10 is detached. On the other hand, the user may assemble the retard roller module 10 in the automatic document feeder 1 in the sequence of the steps shown in FIG. 6C , FIG. 6B and FIG. 6A .
[0050] Another exemplary retard roller and another exemplary retard roller assembly will be illustrated with reference to FIG. 7 . FIG. 7 is a schematic cross-sectional view illustrating the retard roller of the retard roller module according to a second embodiment of the present invention. Except for the retard roller, the configurations of the other components included in the automatic document feeder of this embodiment are similar to those illustrated in the first embodiment, and are not redundantly described herein. As shown in FIG. 7 , the retard roller 202 comprises a sleeve 2021 , a separation pad 2022 , a helical spring 2023 , a rotating shaft 2024 and a receiving shaft 2025 . The sleeve 2021 comprises a first inner wall part 20211 and a second inner wall part 20212 . The first inner wall part 20211 has a first sleeve inner diameter d 1 . The first inner wall part 20211 is near a first end of the sleeve 2021 . The second inner wall part 20212 has a second sleeve inner diameter d 2 . The second inner wall part 20212 is near a second end of the sleeve 2021 . The first sleeve inner diameter d 1 is smaller than the second sleeve inner diameter d 2 . The inner wall of the sleeve 2021 is an inclined wall. That is, the inner wall of the sleeve 2021 is cone-shaped wall.
[0051] The separation pad 2022 is sheathed around the sleeve 2021 . When the separation pad 2022 is contacted with the second document S 2 , a frictional force is generated. In this embodiment, the separation pad 2022 is a rubbery wheel. The helical spring 2023 is disposed within the sleeve 2021 . The helical spring 2023 comprises a first spring segment 20231 and a second spring segment 20232 . The first spring segment 20231 has a first spring inner diameter r 1 . The second spring segment 20232 has a second spring inner diameter r 2 . The first spring segment 20231 is contacted with the sleeve inner wall 20211 . The second spring segment 20232 is separated from the sleeve inner wall 20211 . The second spring inner diameter r 2 is smaller than the first spring inner diameter r 1 . The first spring segment 20231 is eccentrically connected with the second spring segment 20232 . The rotating shaft 2024 is penetrated through the helical spring 2023 and inserted into the second end of the sleeve 2021 . The receiving shaft 2025 is inserted into the first end of the sleeve 2021 for receiving the rotating shaft 2024 .
[0052] Hereinafter, the operating principles of the retard roller 202 when the automatic document feeder is in the sheet-feeding status will be illustrated in more details. Except for the retard roller, the operating principles of the other components included in the automatic document feeder of this embodiment are similar to those illustrated in the first embodiment, and are not redundantly described herein. When the first document and the second document are fed, the separation pad 2022 of the retard roller 202 is contacted with the second document. As such, the retard roller 202 is rotated in the first rotating direction, and the sleeve 2021 of the retard roller 202 is also rotated in the first rotating direction. Since the first spring segment 20231 is contacted with the first inner wall part 20211 , the first spring segment 20231 is twisted in the first rotating direction upon rotation of the first inner wall part 20211 . Due to the twisting direction of the helical spring 2022 , the first spring segment 20231 is stretched. As such, the first spring segment 20231 is fixed on the first inner wall part 20211 . At the same time, the second spring segment 20232 is twisted with respect to the rotating shaft 2024 . In addition, for overcoming an inner stress resulted from the interference between the second spring segment 20232 and the rotating shaft 2024 , the second spring segment 10232 generates a first damping torque. In response to the first damping torque, the retard roller 202 provides a first frictional force to the second document, so that the second document fails to be transported. At the same time, the first document is allowed to be transported in the first direction by the sheet pick-up mechanism 20 .
[0053] In a case that the first document is jammed in the internal portion of the automatic document feeder, the jammed first document needs to be removed from the automatic document feeder. For removing the jammed first document, the jammed first document needs to be moved in a second direction, which is opposed to the first direction. When the first document is moved in the second direction, the retard roller 202 is rotated in the second rotating direction opposed to the first rotating direction because the separation pad 2022 of the retard roller 202 is contacted with the second document. As such, the sleeve 2021 of the retard roller 202 is also rotated in the second rotating direction. Due to the twisting direction of the helical spring 2022 , the second spring segment 20232 is fixed (tightened) on the rotating shaft 2024 . Since the first spring segment 20231 is contacted with the sleeve inner wall 20211 , the first spring segment 20231 is twisted in the second rotating direction upon rotation of the first inner wall part 20211 . In addition, for overcoming an inner stress resulted from the interference between the first spring segment 20231 and the first inner wall part 20211 , the first spring segment 20231 generates a second damping torque T 2 . In response to the second damping torque T 2 , the retard roller 202 provides a second frictional force to the second document. The second frictional force is nearly zero. As such, the second document could be smoothly moved in the second direction to be removed from the automatic document feeder without obvious obstruction.
[0054] In this embodiment, the sleeve 2021 comprises a first inner wall part 20211 and a second inner wall part 20212 . The inner wall of the sleeve 2021 is substantially an inclined wall. Since the first inner wall part 20211 of the sleeve 2021 is gradually tapered, the interference between the first inner wall part 20211 and the first spring segment 20231 within the sleeve 2021 becomes more uniform. In other words, the damping torque is generated more smoothly and stably.
[0055] A more preferred embodiment is illustrated with reference to FIGS. 8 and 9 . FIG. 8 is a schematic exploded view illustrating the retard roller module according to a third embodiment of the present invention. FIG. 9 is a schematic cross-sectional view illustrating the retard roller module according to the third embodiment of the present invention. The retard roller module 30 comprises a retard roller frame 301 , a retard roller 302 and an elastic element 303 . The retard roller 302 is installed on the retard roller frame 301 . The elastic element 303 is disposed on the retard roller frame 301 , and contacted with the retard roller 302 . The elastic element 303 is used for providing an elastic normal force on the retard roller 302 , so that the retard roller 302 is movable upwardly and downwardly with respect to the retard roller frame 301 . In this embodiment, the elastic element 303 is a supporting torsion spring. The structure of the retard roller 302 will be illustrated as follows. The retard roller 302 comprises a first sleeve 3021 , a second sleeve 3022 , a separation pad 3023 , a helical spring 3024 , a one-way clutch 3025 and a rotating shaft 3026 . The first sleeve 3021 has a sleeve inner tube 30211 . The second sleeve 3022 is accommodated within the first sleeve 3021 . The second sleeve 3022 has a sleeve outer tube 30221 . The sleeve outer tube 30221 is arranged at an end of the second sleeve 3022 , and contacted with an end of the sleeve inner tube 30211 . The tube diameter d 2 ′ of the sleeve inner tube 30211 is smaller than the tube diameter d 1 ′ of the sleeve outer tube 30221 . As such, the interference between the first spring segment 30241 and the sleeve outer tube 30221 is greater than the interference between the second spring segment 30242 and the sleeve inner tube 30211 .
[0056] The separation pad 3022 is sheathed around the first sleeve 3021 . When the separation pad 3022 is contacted with the second document S 2 , a frictional force is generated. In this embodiment, the separation pad 3022 is a rubbery wheel. The helical spring 3024 is disposed within the first sleeve 3021 . An end of the helical spring 3024 is sheathed around the sleeve outer tube 30221 to define a first spring segment 30241 . The other end of the helical spring 3024 is sheathed around the sleeve inner tube 30211 to define a second spring segment 30242 . The first spring segment 30241 has a first spring inner diameter r 1 ′. The second spring segment 30242 has a second spring inner diameter r 2 ′, which is smaller than the first spring inner diameter r 1 ′. The one-way clutch 3025 is accommodated within the second sleeve 3022 for preventing the second sleeve 3022 from rotating in the first rotating direction. That is, due to the one-way clutch 3025 , the second sleeve 3022 is allowed to be rotated in the second rotating direction. The rotating shaft 3026 is penetrated through the first sleeve 3021 , the second sleeve 3022 and the one-way clutch 3025 . The rotating shaft 3026 further comprises a confining edge 30261 . When the confining edge 30261 is fixed on the retard roller frame 301 , the rotating shaft 3026 is fixed and fails to be rotated.
[0057] The operating principles of the retard roller module will be illustrated as follows. For feeding the first document (not shown) and the second document (not shown) by the automatic document feeder, the sheet pick-up mechanism (not shown) is rotated in a second rotating direction to transport the first document and the second document. As such, the first document and the second document are moved in a first direction (not shown). When the first document and the second document are transported and moved in the first direction, the first document and the second document are sustained against the retard roller 302 , so that the retard roller 302 is moved downwardly with respect to the retard roller frame 301 . When the separation pad 3022 of the retard roller 302 is contacted with the second document and the retard roller 302 is rotated in the first rotating direction, the first sleeve 3021 is also rotated in the first rotating direction. Due to the one-way clutch 3025 , the second sleeve 3022 fails to be rotated, so that the first spring segment 30241 is fixed on the sleeve outer tube 30221 . In addition, the second spring segment 30242 is twisted with respect to the sleeve inner tube 30211 to generate a first damping torque. In response to the first damping torque, the retard roller 302 provides a first frictional force to the second document, so that the second document fails to be moved. At the same time, the first document is allowed to be transported in the first direction.
[0058] In a case that the first document is jammed in the internal portion of the automatic document feeder, the jammed first document needs to be removed from the automatic document feeder. For removing the jammed first document, the jammed first document needs to be moved in a second direction, which is opposed to the first direction. When the first document is moved in the second direction, the retard roller 302 is rotated in the second rotating direction because the separation pad 3022 of the retard roller 302 is contacted with the second document. As such, the first sleeve 3021 is also rotated in the second rotating direction. The first spring segment 30241 is fixed on the sleeve outer tube 30221 , and the second spring segment 30242 is fixed on the sleeve inner tube 30211 . The second sleeve 3022 is rotated with the first sleeve 3021 . In addition, the one-way clutch 3025 is rotated with respect to the rotating shaft 3026 , so that a second damping torque is generated. The first damping torque is greater than the second damping torque. Since the one-way clutch 3025 is smoothly rotated with respect to the rotating shaft 3026 , the interference between the one-way clutch 3025 and the rotating shaft 3026 is nearly zero. In other words, the second damping torque is nearly zero, and the second frictional force corresponding to the second damping torque is nearly zero. As such, the second document could be smoothly moved in the second direction to be removed from the automatic document feeder without obvious obstruction.
[0059] From the above description, since the helical spring of the retard roller of the present invention comprises a first spring segment with a larger inner diameter and a second spring segment with a smaller inner diameter, different interference magnitudes are generated by the first spring segment and the second spring segment when the helical spring is twisted. In response to different interference magnitudes, the first damping torque and the second damping torque with different torque magnitudes are generated, wherein the first damping torque is greater than the second damping torque. By mean of the above configurations, the retard roller of the present invention can provides two damping torques with different directions and different magnitudes. In a case that the document is jammed in the automatic document feeder, the automatic document feeder is capable of returning the document in the sheet-returning direction to remove the document without the need of opening the upper cover.
[0060] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. | A retard roller of an automatic document feeder provides a frictional force to separate plural documents from each other. The retard roller can provide a first damping torque and a second damping torque with different directions. The second damping torque is smaller than the first damping torque. As such, the frictional force exerted on the document is reduced for returning the document out of the automatic document feeder. A retard roller module having such a retard roller is also provided. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a fuel injection system with fuel pressure intensification, in which there is arranged, at the transition from a pressure source, which is formed in particular by a pressure accumulator, to a fuel injection injector, a pressure intensifier having a control space whose pressure level determines the degree of intensification and, consequently, the pressure increase over the initial pressure in the pressure accumulator and the operating pressure for the injector. The nozzle needle is loaded in the closing direction by the fuel pressure in a pressure chamber formed at the rear side of the nozzle needle.
In a known system of this type, the control space and also the pressure chamber are connected to a fuel return independently of one another, in each case by way of a control valve so that, by control of the pressure intensifier, a particular shape for the pressure curve can be established. By controlling the injector independently a range of the pressure curve suitable for injection can be selected. A mutually independent control of the pressure intensifier and of the injector is provided by magnetically actuated 2/2-way valves. This requires in addition to space and costs, a highly accurate coordination in the activation of the injectors and the valves since even small tolerances result in marked differences in the injection behavior.
In order to reduce the space requirement and the costs, and also to simplify the control so as to be able to sufficiently affect the engine combustion, in a first solution according to the invention, the connection of the control space and of the actuation space to the fuel return is controlled in a combined manner via a common valve connection. As a result, although the breadth of variation is restricted, the expenses are considerably reduced and space is saved, still wide-ranging possibilities for exerting influence are afforded. That is the combustion behavior of the internal combustion engine can be sufficiently influenced particularly with regard to obtaining favorable exhaust gas values.
A further solution according of the invention utilizes the fuel injector itself as a control element or control valve in that a part, which is involved in actuating the nozzle needle and moveable together with the nozzle needle, is a spool valve, which, by the design of the control cross-section thereof, particular the rising flank of the pressure profile can be varied in relation to the pressure prevailing at the nozzle needle seat.
Finally, in a further solution according to the invention the connection of the control space or of the action space to the return is influenced by a control valve in the form of a pressure balance with connections which branch off, on one hand, from the inlet and, on the other hand, from a connection between the inlet and the connection of the actuator space or of the control space to the return. In this solution, a separate valve control is implemented for connecting the control space and the actuation space to the return, but the control outlay is substantially reduced depending on the hydraulic conditions. The other valve control, which is disposed in the connection of the actuation space or of the control space to the return and which is established via the directional valve, affords the possibility of influencing the hydraulic conditions and consequently the control behavior of the pressure balance by a corresponding timing of the directional valve.
In a preferred design, one of the connections is branched off from the inlet and the other is branched off from a throttled connection between the inlet and the connection of the actuation space to a downstream control valve.
In such a design, the injector and the pressure intensifier are activated virtually simultaneously. A rising pressure profile during injection is thereby ensured.
This, in turn, makes it possible to provide for a process sequence which makes it possible, in particular, to affect the rising ramp of the pressure profile at the nozzle seat and which leads to a virtually rectangular pressure profile, in particular in the region of the rising ramp.
For this process sequence, it is assumed that the closing position of the magnetically activated control valve corresponds to a closing position of the nozzle needle due to the high pressure prevailing in the actuation space and due to the blocking of the control space to the return as determined by the pressure balance. When the magnetically activated control valve, which is in particular a 2/2-way valve, is briefly opened, the pressure drops in the actuation space and, with some delay, also in the control space. As a result, the pressure on the control piston of the pressure balance in the direction of its closing position is reduced. In this intermediate phase, however, the nozzle needle is still closed, so that, in the event of a correspondingly brief opening of the control valve, the pressure in the actuation space is reduced, but not the pressure prevailing at the inflow side, assuming corresponding dimensioning of the throttle cross-sections in the inlet and in the outlet to the actuation space. If, then, the control valve is once again opened, initially the pressure in the action space is reduced along with the high pressure at the inlet side, so that, during the opening of the nozzle needle, a correspondingly steep pressure rise at the nozzle-needle seat, and consequently, a steep pressure ramp, is obtained. This occurs especially since the previous lowering of pressure as a result of the preceding brief opening of the control valve also causes a reduction of the pressure acting on the control spool of the pressure balance in a closing direction. Consequently, when the control valve is once again opened in order to initiate fuel injection, there is a rapid displacement of the control spool of the pressure balance to the opening position connecting the control space to the return line.
In a further design, in which the pressure balance is branched off, on the one hand, from the inflow and, on the other hand, from a throttled connection between the inflow and the connection of the control space to the following control valve, when injection is initiated by opening of the control valve, the pressure intensifier is cut in before the injector is released. The result of this is a high pressure prevailing at the injector when the latter responds, this, in turn, entailing a steep, virtually rectangular pressure profile during injection.
Overall, therefore, in the solutions according to the invention, with only one magnetically activated control valve, an operating behavior is achieved, in which tolerances in the operation of the valve are avoided and the space requirements and also the control requirements are reduced overall, and in which, irrespective of these simplifications, both, fuel preinjection and fuel post injection are possible and the injection pressure is freely selectable.
Further details and features of the invention will become apparent from the following description of the invention with reference to the accompanying drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows diagrammatically an injection system with pressure intensification, in which the communication between the control space of the pressure intensifier and of the actuation space of the injector is controlled via a control valve,
FIG. 2 is a diagrammatic illustration of the pressure profile at the nozzle-needle seat over time,
FIG. 3 shows an embodiment of an injection system with pressure intensification wherein the stroke movement of the nozzle needle of the fuel injector is utilized for controlling communication between the control space of the pressure intensifier and the fuel return, and
FIGS. 4 and 5 show other embodiments of an injection system with pressure intensification according to the invention, in which communication between the control space of the pressure intensifier or the communication between the actuator space of the fuel injector and the return are controlled via a pressure balance.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the figures, 1 designates an injection system which comprises a pressure source 2 in the form of a pressure accumulator, as is customary, particularly in common rail systems, and a fuel injector 3 . The fuel injector 3 is illustrated merely diagrammatically and has a nozzle-needle bore which extends to a nozzle seat 4 which is provided with injection holes and in which a nozzle needle 5 is supported. The nozzle needle 5 is spring-loaded towards it closing position as indicated diagrammatically at 6 . At the rear side, an actuation space 7 is provided which is connected in a throttled manner, indicated by a diaphragm or throttle 8 , to a fuel supply line 9 and which also has a connection 10 to the fuel return 11 . A throttle 12 , which may also be in the formal a diaphragm, is provided at the transition between the actuation space 7 and the connection 10 .
A pressure intensifier 13 is connected to the fuel supply line 9 from the pressure source 2 to the fuel injector 3 , specifically in the portion 14 of the fuel supply line 9 and a non-return valve 15 is disposed in the line portion 14 .
The pressure intensifier 13 comprises a stepped piston arrangement including a pressure receiver 16 and a pressure transmitter 17 . The pressure receiver 16 has a larger action surface 18 than the pressure transmitter 17 , the action surface of which is designated by 19 .
Opposite the action surface 18 , the pressure receiver 16 includes a control space 20 in which a spring 47 is disposed. The control space 20 is connected in a throttled manner, illustrated symbolically by the throttle 21 , to the inflow line 22 between the pressure source 2 and the working space 23 over the action surface 18 of the pressure receiver 16 .
The control space 20 is in communication by a line 24 to the fuel return 11 . The communication line 24 from the control space 20 to the return 11 extends to the return 11 by way of a control valve 25 which is a magnetically controlled 2/2-way valve. Also, the fuel injector 3 is connected to the line 24 so that the control space 20 and the fuel injector, that is the actuation space 7 thereof, can be in communication with the return line 11 under the control of the valve 25 .
In the illustrated initial position of the control valve 25 , the lines 10 and 24 which lead to the return 11 are blocked with the result that the pressure intensifier 13 is not activated and the nozzle needle 5 is held in its closed position by the pressure maintained in the actuation space 7 .
When the control valve 25 is opened, the control space 20 and also the actuation space 7 are simultaneously connected to the return 11 and are consequently relieved of pressure. As a result, the pressure intensifier 13 is activated and the nozzle needle 5 is raised into the opening position via the injection medium, which is present under high pressure. With the pressure intensifier 13 interposed, the pressure prevailing on the inlet side via the pressure source 2 is increased so that, depending on the degree of intensification, very high injection pressures are available. The pressure intensification however is restricted to that part of the injection medium, which flows to the fuel injector 3 . The response times in the connection between the control space 20 and the return 11 or respectively, between the actuation space 7 and the return 11 can be influenced via the respective flow cross sections, as illustrated for the line 10 by the throttle 12 .
FIG. 2 illustrates the profile of the pressure P at the nozzle-needle seat 4 over time, t, P 1 designating the pressure provided by the pressure source and P 2 designating the pressure which prevails at the inlet side during activation of the pressure intensifier 13 . t 1 designates the point in time of the opening of the control valve 25 and t 2 its subsequent closing point of time. The opening-side ramp of the pressure-profile curve is designated by 26 and the ramp occurring during closing is designated by 27 . A steeper or flatter profile of the ramps 26 , 27 is obtained as a function of the pressure reduction in the actuation space 7 and of the level of the high pressure prevailing on the inlet side. It is the aim to have a steep, preferably virtually rectangular profile particularly at the opening side.
FIG. 3 shows another embodiment, corresponding parts or connections being given the same reference numerals.
Contrary to the illustration according to FIG. 1, the connection from the control space 20 to the return 11 designated by 28 extends to a control spool 29 , which is an integral part of the nozzle needle operating mechanism disposed above the actuation space 7 of the nozzle needle 5 and which delimits the actuation space 7 at on the nozzle-needle side. The control spool 29 has a control groove 30 for controlling the fuel flow to the return 11 .
Via the control groove 30 and its position in relation to the connection cross sections of the connection 28 to the injector 3 , the control times can be adjusted. The control groove 30 may also form a throttle cross-section.
In the embodiment according to FIG. 4, as in the previous versions, the control valve 25 is disposed in the connection line 10 to the return line 11 . The connection line 31 between the control space 20 and the return line 11 extends through a pressure control valve 32 containing a control spool 33 , which has a control groove 34 and which is spring-biased toward one end position by a spring 35 . The pressure control valve 32 is connected, at the end opposite the spring 35 , to the fuel supply line 9 , and a throttled connection 36 extending via the throttle 37 from the inflow 9 to the connection line 10 of the actuation space 7 to the return line 11 . The connection for that end of the control spool 33 , which is acted upon by the spring 35 , is branched off from the connection 36 . Depending on the pressure, the control groove 34 is in alignment with the connection 31 of the control space 20 providing for connection with the return 11 or alternately blocking off this connection.
When the control valve 25 is opened, the pressure in the actuation space 7 and also the spring-side action of pressure on the control spool 33 of the pressure control valve 32 drops, so that the pressure intensifier 13 is activated. The corresponding time sequences can be influenced in a more or less throttling manner by means of appropriate connection line cross sections. A corresponding influence is also possible by the timing of the control valve 25 , for example such that the latter is first opened briefly, so that the pressure in the action space 7 , is lowered but the nozzle needle 5 does not lift off the nozzle seat 4 . When the control valve 25 is re-opened after a brief closing phase, an initial period is provided in which there is a lower pressure in the actuation space 7 and therefore the high pressure built up via the pressure intensifier 13 acts upon the nozzle needle 5 against a lower counter-pressure thus leading to a virtually immediate opening of the nozzle needle 5 along with a correspondingly steep pressure rise at the nozzle seat 4 .
In the embodiment according to FIG. 5, once again a pressure control valve 38 is used for operation, the valve having a control spool 39 which is biased towards one end position via a spring 40 and which has a control groove 41 .
The control space 20 of the pressure intensifier 13 is connected to the return line 11 via the connection line 24 and the control valve 25 . The pressure control valve 38 is disposed between the inlet line 9 and the connection line 24 extending from the control space 20 to the return 11 . The spring-side end of the pressure control valve 38 is connected to a connection line 42 , which extends to the inlet line 9 via a throttle 43 and to the connection line 24 via a throttle 44 . The connection 45 to the spring side of the pressure control valve 38 is branched off between the throttles 43 and 44 . The opposite connection designated by numeral 46 is connected, unthrottled to the inlet line 9 . In this embodiment, during the opening of the valve 25 , the pressure intensifier 13 is first activated and there is a relatively small delay in the response of the injector 3 , so that, at the start of injection, a high pressure is rapidly available at the nozzle needle 5 and an approximately rectangular profile of the pressure curve is obtained. | In an injection system with pressure intensification with a simple and space-saving design, control means are provided permitting a large range fuel injection pressure control, which also permits rapid adaptation of the fuel injection pressure to the various engine operating conditions. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a solution distribution arrangement for a portable cleaning machine.
[0003] 2. Background Information
[0004] It is known to have floor cleaning units that have a liquid distribution system for dispensing detergent to wash the floor and/or clean water to rinse the floor. Often when washing the floor, detergent from one supply tank is automatically mixed with clean water and then the mixed cleaning solution is distributed on the floor. It is desirable to maintain a constant mix ratio between the detergent and clean water, especially in a gravity flow system for its low cost benefits. However, as the level of the water and detergent lowers during the application of cleaning solution in a gravity flow system, the flow rates out of the tanks will decline and at disproportional rates from each other due to the different tank volumes. This is due to the different hydrostatic heads caused by the different levels of water and detergent in their respective tanks. These variable flow rates produces a variable mixing ratio. One solution is to pump the fluids from their respective tanks at a pressure that is much higher than the hydrostatic head, thus making the effect of the liquid level on flow rate insignificant. However, the pump is an added cost, consumes power, and is subject to failure.
[0005] It is an object of the present invention to provide a cleaning machine with clean water and detergent containers having a low cost and reliable automatic mixing system in which the mixing ratio of clean water and detergent is constant irrespective of the levels of clean water and detergent in their respective containers.
SUMMARY OF THE INVENTION
[0006] The foregoing and other objects of the present invention will be readily apparent from the following description and the attached drawings. In one aspect of the invention, a portable cleaning apparatus for cleaning a surface in which cleaning solution is dispensed to the surface and substantially simultaneously extracted along with the dirt on the surface in a continuous operation is provided. The portable cleaning apparatus includes a housing and a distributor operatively connected to the housing for distributing cleaning solution to the surface. A first solution container is removably mounted to the housing and fluidly connected to the distributor for supplying a flow of cleaning solution to the distributor. A recovery tank is removably mounted to the housing and a suction nozzle is secured to the housing and in fluid communication with the recovery tank for transporting the cleaning solution and dirt from the surface into the recovery tank. A suction source is in fluid communication with the suction nozzle and recovery tank for drawing the cleaning solution and dirt from the surface through the suction nozzle and to the recovery tank. A second solution container is provided inside the first solution container for supplying a flow of cleaning solution to the distributor.
[0007] In another aspect of the invention, a portable cleaning apparatus for cleaning a surface is provided and includes a housing. A distributor is operatively connected to the housing for distributing solution to the surface. A first solution container is mounted to the housing and contains a first solution. The first solution container has a bottom portion with an outlet portion fluidly connected to the distributor for supplying a flow of a first solution to the distributor. A second solution container is provided in the first solution container and contains a second solution. The second solution container has an outlet fluidly connected to the distributor for supplying a flow of a second solution to the distributor. The second solution container is design and constructed, to transfer the weight of the first solution above the second solution container to the second solution in the second solution container to produce substantially the same hydrostatic head at both the outlet of the first solution container and the outlet of the second solution container.
[0008] In still another aspect of the invention, a portable cleaning apparatus for cleaning a surface is provided and includes a housing. A distributor is operatively connected to the housing for distributing solution onto the surface. A first solution container having a bottom portion is mounted to the housing and fluidly connected to the distributor for supplying a flow of a first solution to the distributor. A second solution container is provided inside the first solution container for supplying a second solution to the distributor. The second solution container having a bottom portion, wherein the bottom portion of the second solution container having a fill opening for filling the second solution container with solution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The invention will now be described, by way of example, with reference to the attached drawings, of which:
[0010] FIG. 1 is a perspective view of a carpet extractor embodying the present invention;
[0011] FIG. 2 is a schematic view of the fluid distribution system of the embodiment shown in FIG. 1 with portions broken away for illustrative purposes;
[0012] FIG. 3 is a sectional view of taken along line 3 - 3 of FIG. 1 ; and
[0013] FIG. 4 is a vertical sectional view the solution release valve in the clean water tank.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to the drawings, FIG. 1 depicts a perspective view of a cleaning apparatus in the form of a upright carpet extractor 60 according to one embodiment of the present invention. The upright carpet extractor 60 comprises an upright handle assembly 62 pivotally connected to the rear portion of the floor-engaging portion or base assembly 64 that moves and cleans along a surface 74 such as a carpet 74 . The base assembly 64 includes two laterally displaced wheels 66 (only the left wheel 66 L being shown) rotatably attached thereto. A supply or solution tank assembly 76 is secured upon a bottom base 624 and removably mounted to the handle portion 62 of the extractor 60 . A combined air/water separator and recovery tank 80 with carrying handle 332 removably sets atop a motor/fan assembly 90 (FIG. 3. from co pending application having Ser. No. 10/165,731 and publication no. 20030226230; the disclosure being incorporated herein by reference) of base assembly 64 and is surrounded by a hood portion 82 . A floor suction nozzle assembly 124 is removably mounted to the hood portion 82 of the base assembly 64 and in fluid communication with the recovery tank 80 for transporting air and liquid into the recovery tank 80 . The floor suction nozzle assembly 124 includes a front plate secured to a rear plate that in combination define dual side ducts 130 , 132 separated by a tear drop shaped opening 134 .
[0015] As depicted in FIG. 2 , the base assembly 64 includes a brush assembly 70 having a plurality of rotating scrub brushes 72 for scrubbing the surface. A suitable brush assembly 70 is taught in U.S. Pat. No. 5,867,857, the disclosure which is incorporated herein by reference. Brush assembly 70 is operated by a suitable gear train (or other known means). A suitable air turbine driven gear train is taught in U.S. Pat. No. 5,443,362, the disclosure of which is incorporated by reference. Other brush assemblies could be used such as, for example, a horizontal brush roll or fixed brush assembly.
[0016] The supply tank assembly 76 comprises a clean water supply tank 620 and a smaller detergent supply container 622 provided in the clean water supply tank 620 as depicted in FIG. 1 . The supply tank assembly 76 includes a combination carrying handle and tank securement latch 78 providing a convenient means for carrying the tank and/or securing the tank to the extractor handle assembly 62 . The clean water tank 620 has a cap 720 (FIG. 27 from co pending application having Ser. No. 10/165,731 and publication no. 20030226230) covering a top opening for filling the corresponding clean water tank 620 with clean water. The clean water tank 620 has a bottom wall 713 with an outlet opening 541 , which receives a solution release valve 746 as seen in FIG. 4 .
[0017] Referring to FIG. 3 , the detergent container 622 is a flexible container in the form of a bladder. The material of the bladder is composed of vinyl that is chemical resistance to the detergent. However, other suitable flexible material can be used. A mounting member 211 is secured to the outer side of the bottom wall 713 and covers an opening 543 formed in the bottom wall 713 of the clean water tank 620 . The mounting member 211 has a flat attaching portion 213 that is attached to the bottom wall 713 by a pair of screws 215 threaded into bosses 217 formed in the bottom wall 713 . Seals 219 are inserted around the screws 215 and sandwiched between the mounting member 211 and bottom wall 713 to prevent the fluid in the clean water tank 620 from leaking. Other suitable means can be used to secure the mounting member 211 to the bottom wall 713 , such as, for example, by adhesives or welding.
[0018] The mounting member 211 has a neck 221 extending upwardly therefrom over which a bottom neck 223 of the bladder 622 fits tightly around it and is adhesively secured. An elastic band or clamp 225 fits snugly around the neck 223 of the bladder for additional securement. The neck 221 surrounds a solution release valve 746 provided in the mounting member and a fill opening 227 formed in the mounting member 211 for filling the detergent container 622 with liquid detergent. A threaded cap 231 is removably secured to the fill opening 227 . Alternatively, the neck 221 can be integrally formed with the bottom wall 713 of the clean water tank 620 with the outlet opening 545 and fill opening 227 being formed in the bottom wall 713 to eliminate the mounting member 211 .
[0019] The solution release valve 746 is normally in the closed position. However, when the tank assembly 76 is positioned in the handle 62 , the solution release valves 746 in the clean water tank 620 and detergent container 622 open permitting clean water from the clean water supply tank 620 and detergent from the detergent supply container 622 to flow to mixing Tee 796 . Upon removal of the tank assembly 76 from the handle 62 , the solution release valves 746 close prohibiting liquid from flowing out of the clean water tank 620 and detergent container 622 .
[0020] As seen in FIG. 3 , the solution release valve 746 is incorporated into an opening 545 of the mounting member 211 for the detergent container 622 . The other solution release valve 746 is incorporated into outlet 541 of the bottom plate 713 of the clean water tank 620 as seen in FIG. 4 , which is of similar construction. Thus, only the one for the detergent tank 622 will be described in more detail. The solution release valve 746 comprises a valve body 742 having an elongate plunger 744 extending coaxially upward therethrough. The plunger 744 having an outside diameter less than the inside diameter of the valve body 742 is provided with at least four flutes 745 (FIG. 27 from co pending application having Ser. No. 10/165,731 and publication no. 20030226230) to maintain alignment of the plunger 744 within the valve body 742 as the plunger 744 axially translates therein and permits the passage of fluid therethrough when the plunger 744 is in the open position.
[0021] A valve body 742 having a vertically extending bore 756 (FIG. 27 from co pending application having Ser. No. 10/165,731 and publication no. 20030226230) slidingly receives therein the upper shank portion of the plunger 744 . An elastomeric circumferential seal 748 circumscribes plunger 744 for sealingly engaging valve body 742 . The seal 748 is urged against the valve body 742 by action of the compression spring 752 , circumscribing plunger 744 . The spring 752 is positioned between the body 742 and the seal 748 . The solution release valve 746 is normally in the closed position. However, as the supply tank assembly 76 is placed upon the support shelf 743 of the handle 62 , the pin 738 of the reservoir 721 (FIG. 27 from co pending application having Ser. No. 10/165,731 and publication no. 20030226230) aligns with plunger 744 , thereby forcing plunger 744 upward to separate the seal 748 from the valve body 742 , compressing spring 752 , and opening the valve body 742 permitting detergent from the detergent supply container 622 to flow through bore 756 of the valve body 742 into the reservoir 721 . Upon removal of supply tank assembly 76 from the support shelf 743 , the energy stored within compression spring 752 urges the seal 748 down against the valve body 742 to close the valve 746 .
[0022] An elastomeric tank seal 500 has an annular groove 501 that receives the edge 503 of the opening 545 of the mounting member 211 to secure it to the edge 503 . For the solution release valve 746 of the clean water tank 620 , the tank seal 500 has the annular groove 501 receiving the edge 571 of the outlet opening 541 of the bottom wall 713 as seen in FIG. 4 . Upper and lower annular ribs 505 , 507 formed on the outer surface of the valve body 742 secure the elastomeric seal 500 to the valve body 742 . In particular, the lower rib 507 engages the underside of a lip 509 on the seal and the upper rib extends over and engages the top edge 511 of the outlet opening. The cap 231 is threadily secured around a complimentary threaded downwardly depending neck portion 233 of the fill opening 227 of the mounting member 211 . A seal 235 is sandwiched between the cap 231 and bottom end of the neck portion 233 to prevent fluid from leaking from the detergent container 622 . Alternatively, the neck portion 233 can depend downwardly from the outlet opening 545 , so that a threaded cap can be received thereon and also mount a solution release valve through the outlet opening 545 to eliminate the fill opening 227 . Further details of such a cap and solution valve arrangement are shown in U.S. Pat. No. 6,167,586; the disclosure of which is hereby incorporated by reference.
[0023] In operation, the detergent container 622 is filled with liquid detergent and the clean water tank 620 is filled with the clean water above the height of the detergent. In this arrangement, the weight of the water above the detergent container or bladder is transferred through the bladder wail 623 to the liquid detergent. The bladder wall 623 is designed to be flexible enough to collapse and allow this weight transfer. The equal weight produces approximately the same hydrostatic head at both the outlet 541 for the water and outlet 545 for the liquid detergent. Also, as water level drops due to the clean water flowing out of the clean water tank 620 , the pressures at each of the outlets changes by the same amount as long as the water level is above the detergent container 622 . This constant pressure ratio in turn causes the flow rates to change at generally the same amount and thus substantially reduces the variation of the detergent to water mixing ratio in mixing Tee 796 .
[0024] With continue reference to FIG. 2 , the carpet extractor 60 includes a solution hose 794 that fluidly connects outlet opening 541 of the clean water tank 620 to a shut off valve 800 used for selectively turning on and off the flow of clean water. Another solution hose 790 fluidly connects the outlet opening 541 of the water tank 620 to an inlet 812 of a pressure actuated shut off valve 804 . A solution hose 798 fluidly connects the outlet opening 545 of the detergent container 622 to an inlet 523 of the mixing Tee 796 . A second shut off valve 820 is used for selectively turning on and off the flow of mixed water and detergent cleaning solution through distributor 792 . Both shut off valves 800 , 820 are fluidly connected to the distributor 792 through their respective solution hoses 794 , 876 . The shut off valves 800 , 820 are in the form of solenoid valves, however, other types of valves also could be used.
[0025] The pressure actuated shut off valve 804 is fluidly connected between the clean water tank 620 and the mixing Tee 796 for turning off and on the flow of water. This shut off valve 804 is opened and closed by outside pressure via a conduit 806 connected between it and the outlet 807 of a pump 808 through a Tee 817 . The valve 804 includes a pressure port 822 fluidly connected to the outlet 807 of a pump 808 . The outlet of the valve 814 is fluidly connected to an inlet 521 of the mixing Tee 796 via hose 815 . It should be known that clean water tank 620 could be fluidly connect to the outlet 814 of the valve 804 with the inlet 812 of the valve 804 being fluidly connect to the mixing Tee 796 so that fluid could flow the opposite direction if desired.
[0026] In operation, when the pressure at the pressure port 822 is below a predetermined value such as between 7 to 10 psi, the valve 804 opens to allow water to flow in both directions. Such a pressure value at the pressure port 822 occurs when the main shut off valve 820 is opened and the pump 808 is turned on. The pump 808 also pressurizes the water mixed with detergent to draw it to the distributor 792 . When the pressure exceeds a second predetermined value such as between 20 to 30 psi, the valve 804 closes. This would occur if the main shut off valve 820 is closed and the pump is turned on. Thus, with the valve 804 closed, the cleaning solution is prevented from flowing through it. Various types of pumps can be used such as a piston pump, gear pump or centrifugal pump.
[0027] Outlet 525 of the mixing Tee 796 is fluidly connected via flexible hose 823 to the inlet of the pump 808 , which provides pressure to draw the cleaning solution to the distributor 792 , when it is turned on. A relief valve 809 is fluidly connected across the pump 808 to limit the pressure at the outlet 807 of the pump 808 to a predetermine value. The outlet 807 of the pump 808 is fluidly connected to the main shut off valve 820 via flexible hoses 825 , 874 and 876 .
[0028] The valves 800 , 820 are operated by a trigger switch 821 as depicted in FIG. 1 . The trigger switch 821 is pivotally connected to the upper handle portion 358 approximately near a closed looped handgrip 824 . Slide switch 858 is used to select one of the shut off valves 800 , 822 to be opened and closed by the trigger switch 821 . Slide switch 856 is the main power switch, which turns on and off the suction motor 90 (FIG. 3 from co pending application having Ser. No. 10/165,731 and publication no. 20030226230) and pump 808 . The cleaning solution containing the clean water or water mixed with detergent flows to their associated shut off valves 800 , 820 . The cleaning liquid distributor 792 evenly distributes the cleaning solution to each of the rotary scrub brushes 72 . The scrub brushes 72 then spread the cleaning solution onto the carpet (or bare floor), scrub the cleaning liquid into the carpet and dislodge embedded soil. A solution discharge valve 877 allows the mixed detergent and clean water to flow through an integrally formed nipple 218 and a detachable solution tube 216 to a hand-held cleaning attachment (not shown) and dispense by typical spray means.
[0029] As is commonly known, a user turns on the carpet extractor 60 and pivots the handle 62 in an incline position while moving the carpet extractor 60 over the surface to clean it. The user squeezes the trigger switch 821 so that the carpet extractor 60 distributes the cleaning solution to the surface and substantially simultaneously extracts it along with the dirt on surface in a continuous operation. In particular, soiled cleaning solution is extracted from the surface by the suction nozzle 124 and transported into the recovery tank 80 where the liquid and air are separated. A vacuum is created in the recovery tank 80 by the suction motor, which draws air from the recovery tank 80 and exhausts the air to the surface 74 . Further details of the carpet extractor are disclosed in co pending application having Ser. No. 10/165,731 and publication no. 20030226230; the disclosure being incorporated herein by reference.
[0030] The present invention has been described by way of example using the illustrated embodiments. Upon reviewing the detailed description and the appended drawings, various modifications and variations of the embodiments will become apparent to one of ordinary skill in the art. All such obvious modifications and variations are intended to be included in the scope of the present invention and of the claims appended hereto. For example, the mixed detergent and clean water cleaning solution can flow from the clean water tank and detergent container by gravity alone, without the use of the pump, to the distributor.
[0031] In view of the above, it is intended that the present invention not be limited by the preceding disclosure of the embodiments, but rather be limited only by the appended claims. | A portable cleaning apparatus for cleaning a surface is provided and includes a housing. A distributor is operatively connected to the housing for distributing solution to the surface. A first solution container is mounted to the housing and contains a first solution. The first solution container has a bottom portion with an outlet portion fluidly connected to the distributor for supplying a flow of a first solution to the distributor. A second solution container with an outlet is provided in the first solution container and contains a second solution. The outlet of the second solution container is fluidly connected to the distributor for supplying a flow of a second solution to the distributor. In at least one aspect of the invention, the second solution container is design and constructed to transfer the weight of the first solution above the second solution container to the second solution in the second solution container to produce substantially the same hydrostatic head at both the outlet of the first solution container and the outlet of the second solution container. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to an improvement in the base of a self-locking container assembly and a method for using the same. The base is adapted to have locking ears which lock the sides of the base in place during storage and shipment. The base locking ears are adapted to be unlockable to permit disengagement of the interlocking container sections without losing the ability to reassemble the base for subsequent use.
In the past, various means having been provided for joining sections of cardboard and corrugated containers for storing manufactured products. Adhesive tape, strapping, glue, stapling, various folding configurations and other arrangements have been employed. Many of these closure arrangements, especially those employing interlocking sections with destructive tear strips such as that taught by Kelly, U.S. Pat. No. 2,800, 266 and Houston U.S. Pat. No. Re. 26,557, provide for use of the container only one time since opening the container necessarily destroys the structural integrity of one of the interlocking sections. Consequently, when a self-locking container must be opened prior to final shipment, it generally necessitates repackaging the contents in a new container, adding the extra expense of labor and packaging. This added expense may be substantial when the containers involved are large or when a large number of containers must be opened for inspection or product recalls prior to shipment to the consumer. Furthermore, since only one set of packaging is generally calculated into the cost of goods, the cost of any additional packaging is taken directly out of gross profit.
Interlocking container arrangements which may be easily disengaged by access to the inner locking flange member, such as taught by Hammond, U.S. Pat. No. 1,130,271 and Anderson, U.S. Pat. No. 2,370,927, are generally not suitable for heavier packaging applications such as for washing machines and air conditioners where the base must be aggressively retained by the container body section. Such easily disengageable interlocking container arrangements also suffer from the inability to restrict access to the contents of a container since interlocking sections may be reinterengaged without signs of entry.
SUMMARY
The present invention is addressed to an improved apparatus and method for making the using a self-locking container which may be non-destructively disengaged and thereafter re-interengaged. The invention features a polygonal container and an interlocking base and is well-suited where the container is also provided with an interlocking lid closing configuration. The base includes inwardly directed folded flanges which interengage with outwardly directed folded flanges provided on the lower edge of the container body. Therefore, when the container body section is nestingly mated with the base section, the oppositely-disposed flanges on each of the two respective container sections become lockingly engaged without the need for adhesives or other binding materials. If at any time, prior to shipment to the consumer, it becomes necessary to gain access to the contents of the locked container, either the locking ear tabs provided in the base section or the flange portion adjacent to the locking tabs may be severed, permitting disengagement of the interlocked container sections.
To use the base section a subsequent time, it is simply a matter of first, refolding the previously lowered folded flange back into its original, vertical position and stapling the locking ears in place between the folds of the receiving walls. Then, the body section is once again nestingly mated with the base section and depressed until the oppositely-disposed folded flanges become lockingly engaged. The container is then ready for storage or shipment bearing the same interlocking structural properties as before the sections were disengaged.
Base sections may be provided with more than one hinged wall fitted with pivotable, tabbed locking ears enabling the container to be re-interengaged a proportional number of times.
The present invention is addressed to the method and apparatus for interlocking bases fitted with pivotable tabbed locking ears. However, the invention may be equally well adapted for use as an interlocking lid section, where access through the top of the container is suitable.
The present invention is particularly adapted to containers assembled from blanks of single wall corrugated fiberboard. However, it is apparent that other materials suitable for containers may be employed, if desired.
Therefore, a general feature of the present invention is the provision of an improved container locking mechanism which allows interlocking container sections to be nondestructively disengaged after being interengaged and thereafter re-interengaged.
A specific feature of the present invention is the provision of an improved locking mechanism for a rectangular container assembly having a walled base section which interlocks with a walled body section during shipment but which may be nondestructively removed and locked a second time for a subsequent shipment.
Another feature of the invention provides a method for forming a nondestructively disengageable container assembly of a walled body section and a walled base section, which comprises:
providing the walled body section to have folded flanges formed by folding a portion of the walls outwardly back on themselves;
providing the walled base section to have folded flanges formed by folding a portion of the walls inwardly back on themselves, each of a pair of opposing folded walls of the base section bearing a slot near an end thereof; the walled base section further provided with an intermediate hinged folded flange disposed between a pair of opposing folded walls terminated at both ends with hinged tabbed locking ears which are positioned between the folds of the pair of opposing folded walls such that the tabs are disposed through the slots.
lockingly engaging the sections by nestingly, abuttably engaging the folded flanges of the sections, the locking ears adapted to be nondestructively removed from the opposing folded walls while the sections are nestingly interengaged by severing the tab portion disposed through the slots.
Another feature of the invention provides an alternate method of non-destructively releasing the locking ears by severing the flange portions between the slots and the flange ends.
Other features of the invention will, in part, be obvious and will, in part, appear hereinafter. The invention, accordingly, comprises the mechanism and method possessing the construction of elements, arrangement of parts and steps which are exemplified in the following detailed description.
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 drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an assembled container with a cover and base therefor,
FIG. 2 is a perspective view, similar to FIG. 1, showing the hinged folded flange with locking ears in its distended position after severing the than retaining section of the end wall but prior to disengagement of the interlocking container sections;
FIG. 3 is a perspective view, similar to FIGS. 1 and 2, showing the container body section being slidingly disengaged from the base section;
FIG. 4 is a partial perspective view depicting the base locking mechanism after reassembly, stapling and re-interengagement of the interlocking container sections;
FIG. 5 is a partial sectional view taken along line 5--5 of FIG. 1 depicting the interengagement of the base and body sections prior to severing either the locking ear tab or tab retaining section;
FIG. 6 is a partial sectional view taken along line 6--6 of FIG. 4 depicting the interengagement of the base and body sections after severing the tab retaining section of the folded flange of the end wall;
FIG. 7 is a plan view of the container base blank in an unfolded configuration showing the placement of cut lines and fold lines; and
FIG. 8 is a partial sectional view taken along line 8--8 of FIG. 1 depicting the interengagement of the base and lid sections.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus and method of the present invention may be constructed of a variety of polygonal shapes as well as a variety of suitable materials including corrugated board, paperboard, plastic or other semi-flexible materials. Furthermore, the top of the container may be closed in a number of suitable means, including a separate locking lid arrangement or hinged folding flaps as part of the body section. For the purpose of the instant description, the apparatus and method are disclosed in conjunction with the formation of a rectangular container assembly, having a separate lid assembly and constructed of single wall corrugated paperboard.
Referring to the drawings, in particularity to FIG. 1, container assembly, generally depicted at 20, comprises a rectangular body section 10, a lid section 12 and a base section 14. Body 10 includes upstanding single thickness sidewalls 40 and 42, jointed to upstanding end walls 48 and 50, by wall angle fold lines, such as 44. End wall 50 is provided with hinged and inwardly directed wall joining flap 46. Where end wall 50 and side wall 42 abut, body section 10 is secured in a polygonal configuration by fixing wall joining flap 46 to the inside face of side wall 42 by a gluing, stapling or other affixing means.
Referring additionally to FIG. 2, the lower ends of side walls 40 and 42, and of end walls 48 and 50 form a perimeter of outwardly and upwardly directed locking flange portions, such as 58, providing a locking means for cooperatively retaining base 14. A similar perimeter flange of outwardly and downwardly folded flange portions is formed at the upper ends of side walls 40 and 42, and of end walls 48 and 50, providing a locking means for cooperatively retaining lid 12, generally depicted in FIG. 8.
As substantially shown in FIG. 1, lid section 12 of container assembly 20 comprises a top panel 22 having depending side walls, such as 24, arranged to telescope over the open end portion of container body 10. Lid side wall 24 is provided with hinged locking ear 26, shown in phantom, tucked into and held nestingly captive by double folded end wall 30, with locking tabs, such as 28, inserted into spaced openings provided along lower edge of top panel 22. Lid 12 includes means inwardly thereof for interengagement with the outwardly and downwardly directed flanges, such as 52, formed at the uppermost portions of body side walls 40 and 42 and end walls 48 and 50 when lid 12 is closingly placed over body 10, thereby providing a positive locking arrangement between body and cap 12. Such locking engagement being substantially depicted in FIG. 8.
Referring to FIG. 7, base section 14 of container 20 if formed from foldable blank 66. Parts of blank for base 14 of container 20 are identified with identical reference numbers used to identify the respective parts of fully assembled or partially disassembled container assembly as depicted in FIGS. 1, 2, 3 and 4. Blank 66 is shown in its final form after it has been die cut form a single sheet of corrugated paperboard. Blank 66 is prescored, as indicated by long broken lines, such as 146, with perforated score lines being depicted generally by short broken lines, such as 142, to provide proper folding of base subsections into base section 14. Cut portions of blank 66 are depicted by solid lines, such as at 124.
Still referring to FIG. 7, blank 66 is shown comprised of a rectangular bottom 68, oppositely disposed outer side walls 76 and 78 extending upwardly on fold lines 146 and 148, respectively, and oppositely disposed outer end walls 80 and 82 extending upwardly on fold lines 176 and 178 respectively. Side wall 78 is terminated at both its ends by hinged tabbed locking ears 104 and 106, which are inwardly directed along respective fold lines 150 and 152. Similarly, oppositely disposed side wall 76 is terminated at both its ends by hinged tabbed locking panels 108 and 110, which are inwardly directed along respective fold lines 154 and 156. Double folded base side wall locking flanges, such as 72 shown in FIG. 2, are formed along parallel, double perforated fold lines 142 and 144 after base side wall locking flange inner panels 134 and 136 are folded inwardly along their respective fold lines 138 and 140.
Body 10 and base 14 sections are used in the following manner by the manipulative steps exemplified below.
Referring to FIG. 3, beginning as a prescored and glued configuration in a flattened condition (not shown), body section 10 is prepared for interengagement with base 14 by folding lower body sidewall locking flanges, such as 58, and lower end wall locking flanges, such as 54, outwardly and upwardly back onto sidewalls 40 and 42 and end walls 48 and 50 themselves. Body 10, if container assembly 20 were to employ an interlocking lid configuration, would additionally require a similar folding of respective upper end wall and sidewall locking flanges, such as 52, to form edge for lockingly engaging oppositely disposed flange 34 of lid 12, as depicted in FIG. 8. Upon folding of all locking flanges, flattened body section 10 is opened into its polygonal shape, forming semi-perimetric flanges at the uppermost and lower most edges of container, being constituted of lower body end wall locking flange 54 and lower body sidewall locking flange 58 and of their oppositely disposed counterparts, 56 and 60 (not shown). These outwardly and upwardly directed semi-perimeter interlocking flanges also serve to reinforce the scored lower perimeter edge of body 10 and strengthen the lower corners thereof.
Blank 66, shown in FIG. 7, is assembled into fully set up base 14, shown in FIG. 1, by performing the steps herein below exemplified. First, base sidewalls 76 and 78 are formed by respectively folding base sidewall flange interior panels 134 and 136 substantially 180° upwardly along parallel, double fold lines 138 and 140, to lie inwardly and adjacent to the inner face of outer folds 130 and 132 of base sidewalls 76 and 78 and then additionally being folded substantially 180° upwardly along parallel, double perforated fold lines 142 and 144. Folded flanges 130 and 132 may then be affixed to the inner face of base sidewalls 76 and 78, by stapling or other securing means. Base sidewalls 76 and 78 are completed by bending the resulting double folded panels substantially 90` upwardly along respective fold lines 146 and 148, placing base sidewalls 76 and 78 in a vertical position. As the base sidewalls are being manipulated upwardly, respective tabbed locking flaps 108 and 110 and tabbed locking ears 104 and 106 are bent 90° along their respective fold lines 54, 156, 150, and 152 until perpendicular to base bottom 68 and in line with base end wall fold lines 176 and 178.
Each of the base end walls 80 ad 82 is formed by respectively folding end wall locking flanges interior panels 160 and 162 substantially 180° upwardly along parallel, double scored fold lines 168 and 170. End wall locking flange portions, such as 100, shown in phantom in FIG. 3, may then be stapled through its own double thickness to retain its folded configuration. End walls 80 and 82 are then folded 90° upwardly along scored fold lines 176 and 178 respectively until the inner faces of end walls 80 and 82 are facingly adjacent to the outer faces of tabbed locking members 104, 108 and 106, 110. Folded flange portions 100 and 102 (not shown) are then folded substantially 180° downwardly along respective parallel, double perforated fold lines 172 and 174 thereby respectively retaining tabbed locking members 104 and 108 and 106 and 110 between end wall 80 and end wall locking flange 100 and end wall 82 and end wall locking flange 102 (not shown), vertically disposing locking members tabs 112, 114, 116 and 118 through respective tab locking slots 84, 86, 88 and 90. Referring to FIGS. 5 and 6, it can be seen that the locking tab 112 of hinged locking ear 104 is retained by the tab retaining section 120 of the folded flange 100 formed between the slot 84 and the near end of the end wall 80. Although not shown in detail, a similar locking arrangement is respectively achieved at the opposite end of outer side wall 78 by locking tab 114, hinged locking ear 106 and tab retaining section 122 and end wall 82. Completely assembled end walls 80 and 82 are captively retained vertically by interlocking lateral notches, such as 190, formed at opposite ends of end walls 80 and 82 with corresponding laterally, perpendicularly disposed lateral tabs, such as 192, formed at opposite ends of side walls 76 and 78. Alternately, end walls 80 and 82 and their corresponding nestingly disposed locking flaps 108, 110 and locking ears 104, 106 may be secured in their vertical orientation by affixing staples through the complete thickness of the flanges 100 and 102 and end walls 80 and 82, such as medially along the length of end walls, care being taken not to staple through any wall portion of base 14 containing tabbed locking ears 104 and 106.
Referring to FIGS. 1-3, and 8, lid section 12 is shown in a closed and locked position on container body 10. Oppositely disposed lid locking flanges, such as 34, project inwardly and upwardly toward container 10, and lockingly engage along the bottom edge of corresponding downwardly folded flanges, such as 52, depending from the upper perimeter of body 10 when lid 12 is thereon matingly engaged. Tensioning of body flange 52 and lid flange 34 is such that once lid 12 has been placed in locking engagement with body section 10, disengagement of the matingly engaged sections requires the destruction of either.
Referring to FIGS. 1, 2, 3, and 5, FIG. 1 shows body 10 in a closed and locked position, nesting engaged within base 14. The perimetrical locking base flange formed by the combination of end walls flanges 100 and 102 and sidewall flanges 70 and 72, project inwardly and downwardly toward container body 10, and are lockingly engaged with the upper edges of the base perimeter flange, such as 62, formed by the combination of body sidewall locking flanges 58 and 60 (not shown) and body end wall locking flanges 54 and 56. The out-turned body sidewall locking flange 58 is dependingly coupled with body end wall locking flange 54, forming a continuous, semi-perimeter flange at the lower edge of body section 10. Sidewall flange 60 (not shown) and end wall flange 56 (not shown) form a semi-perimeter flange substantially around the remainder of the lower edge of body section 10. Being under tension, upturned lower body flanges 54, 56, 58 and 60 are maintained in face-to-face abutment with base sidewall and end wall spacing tabs, such as 124 and 126 shown in FIG. 3, provided to ensure proper engagement between the upturned body flange 58 and the down-turned base flange 72 and to prevent the over-engagement of flange edges, such as where body flange locking edge 62 and base end wall flange locking edge 128 meet, essentially as shown in FIGS. 5 and 6.
Referring to FIGS. 4, 5, 6 and 7, upon locking body section 10 into base section 14, the non-destructive disengagement of the sections is facilitated by severing tab retaining sections 120, 122 and folding sidewall 78 along fold line 148 substantially 90° downwardly, as shown in FIG. 2. Container body 10 may then be slidingly disengaged from the base section through the portal opened by distended sidewall 78, as in FIG. 3. Once base section 14 and body section 10 have been fully disengaged, body section may be lifted to gain full access to the contents of the container.
Alternately, base 14 and body 10 sections may be non-destructively disengaged by severing those portions of locking tabs 112 and 114 vertically disposed through tab locking slots 84 and 86. After locking tabs 112 and 114 have been severed, sidewall 78 may be pivotally distended 90° downwardly about fold line 148. Once sidewall 78 is completely, distended, as in FIG. 2, body 10 may be slidingly disengaged from base 14.
After locking ears 104 and 106 have been disengaged from their cooperative locking slots 84 and 86 by either heretofore described severing method, base section 14 may be reassembled to once again permit locking engagement with container body 10. With locking ears 101 and 106 directed inwardly, base sidewall 78 may be folded substantially 90° upwardly along fold line 148 until locking ears 104 and 106 are in sliding, nesting engagement between the inner faces of end walls 80 and 82 and end wall locking flanges 100 and 102, as in FIG. 6. Once base sidewall 78 is fully erect, locking ears are secured into place by affixing a staple, such as 38, through the portions of end walls 80 and 82 containing the nestingly engaged locking ears 104 and 106, essentially as depicted in FIGS. 4 and 6. After locking ears have been secured by staples, such as 38, base 14 is fully prepared for locking re-interengagement with container body 10 with structural integrity substantially equivalent to that before the body and base 14 sections were severingly disengaged.
Referring to FIG. 7, corrugations of base blank 66 is depicted by arrow A. Such vertical corrugations provide the downwardly and inwardly directed base sidewall locking flanges 70 and 72 with increased compression strength to resist flange failure from lateral pressure that may be applied to body sidewalls 40 and 42 during shipping and storage of a loaded container assembly. Reinforcing material, such as tape strip 180, is provided to strengthen short tab retaining sections 120 and 122 of base end walls 80 and 82, allowing the retaining sections to resist under the shearing pressure of locking tabs 112 and 114.
Since certain changes may be made in the above apparatus and method without departing from the scope of the invention herein involved, it is intended that all matter disclosed in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | The present invention is addressed to an improved apparatus and method for making and using a self-locking container which may be non-destructively disengaged and thereafter re-interengaged. The invention features a polygonal container and an interlocking base and is well-suited where the container is also provided with an interlocking lid closing configuration. The base includes inwardly directed folded flanges which interengage with outwardly directed folded flanges provided on the lower edge of the container body. Therefore, when the container body section is nestingly mated with the base section, the oppositely-disposed flanges on each of the two respective container sections become lockingly engaged without the need for adhesives or other binding materials. If at any time, prior to shipment to the consumer, it becomes necessary to gain access to the contents of the locked container, either the locking ear tabs provided in the base section or the flange portion adjacent to the locking tabs may be severed, permitting disengagement of the interlocked container sections. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of Design patent application Ser. No. 166,916 entitled PORTABLE ROTATING CLEANER filed Mar. 11, 1988, and now pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to improvements in drain cleaning apparatus, and more particularly, but not by way of limitation, to a portable drain cleaning apparatus having multiple combination usages for servicing a broad range of drain sizes and piping component combinations, including traps and short bends.
2. Discussion of Prior Art
Drain cleaning apparatuses of various types and arrangements have been known for many years. Bowlsby, U.S. Pat. No. 4,420,852, teaches the use of a rotating drum having a length of coiled spring snake with an internally extending flexible tube for carrying a flow of water to the free end of the snake. Tap water is passed at house pressure to the hub of the drum to which the near end of the snake is attached. However, this does not provide any cleaning efficacy, as the low pressures encountered in such service are simply ineffective to provide any practical benefit.
Sato, U.S. Pat. No. 3,959,840, is similar, but includes a pump which communicates with a water tank for delivering a high pressure water jet to the free end of the flexible tube.
Ciaccio, U.S. Pat. No. 3,045,547, is an earlier teaching of a wheel supported portable apparatus which deals with the matter of simultaneously feeding and rotatably driving a coiled rod with a cutting tool mounted thereon for cleaning municipal sewers, and with the imparting of variable rotating and payout speeds by means of power provided by a gasoline engine. Ciaccio, U.S. Pat. No. 3,370,599, also dealing with large municipal sewers, teaches a similar rotatable drum and power apparatus but adds a rotary hydraulic cleaning tool incorporating a forwardly-directed cleaning jet and rearwardly-directed propulsion jets to assist in propelling the tool along the sewer pipe.
Klein, Sr., U.S. Pat. No. 4,312,679, teaches a method for cleaning clogged pipes in which a snake hose having a free nozzle with radially directed jets is forced through a clogged pipe and withdrawn in flushing activation. The claimed purpose is to avoid dirty water backup in the pipe's internally positioned inlets.
Finger, U.S. Pat. No. 4,368,757, teaches a pressure cleaning apparatus having a pair of fluid containers used to blend detergent and water to the suction inlet of a pump. However, this patent, being of interest in the general area of pressurized cleaning devices, does not deal with the cleaning of sewer lines and the like.
These and all other known prior art teachings have faced specific problems associated with the cleaning of municipal, industrial and domestic lines. As discerned from the above mentioned patents, as well as from the experience in the field of drainage cleaning, a fairly wide array of cleaning devices is available to the craftsman faced with a particular stoppage difficulty. However, when called to a location, one is usually informed only vaguely as to what is to be expected in terms of line sizes, trap types and locations, and other such information necessary for the cleaning task at hand. Thus, the normal service operator may be ill equipped to adapt in terms of equipment to the problem encountered. In short, a drain cleaning apparatus which offers a wide range of systems that can be used in various combinations to accommodate and bring relief to a customer's plaintive but ill described request for assistance has attractive and useful possibilities in this field.
One item of equipment which would be most helpful is a lightweight, portable drain cleaning apparatus that can easily be taken to practically every location, including roof decks and the like.
SUMMARY OF THE INVENTION
The present invention comprises a drain cleaning apparatus featuring multiple use capability. A rotatable payout drum is supported by a small, easily carried frame which also supports a power source for selectively rotating the payout drum in either rotational direction. A coil spring snake is wound in the payout drum which has a central hollow hub through which the snake is extendable and rotatable concentrically with the drum.
The payout drum is supported for quick detachment and removal, for the purpose of mounting a substitute payout drum containing a different sized snake.
In one embodiment of the present invention, the free end of the snake is provided with a conventional spring coil which has proven to be quite successful in clearing most household stoppages. Yet another embodiment features a pair of cutter blades for removing more firmly established blockages such as are frequently caused by tree roots.
It is an object of the present invention to provide an improved drain cleaning apparatus having multiple use capability for a wide range of drain pipes and sizes.
Another object of the present invention, while achieving the above stated object, is to provide an improved drain cleaning apparatus which is sufficiently light in weight that one man can carry it easily, and which is in a small, compact package to permit it to be used in cramped, awkward spaces.
A further object of the present invention, while achieving the above stated objects, is to provide an improved drain cleaning apparatus which offers wide flexibility of servicing capability while enjoying economy of manufacturing, operating and maintenance costs.
Other objects, advantages and features of the present invention will be apparent from the following description when read in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which form part of the instant specification and which are to be read in conjunction therewith, and in which like reference numerals are used to indicate like parts of the various views:
FIG. 1 is a perspective view of a multiple use drain cleaning apparatus made in accordance with the present invention.
FIG. 2 is an elevational view of one side of the drain cleaning apparatus of FIG. 1.
FIG. 3 is an enlarged perspective view of an alternate chuck holder adapter mounted on a payout drum of the drain cleaning apparatus of FIG. 1 and which shows a pair of cutter blades affixed to the end of the coil spring snake.
FIG. 4, is a longitudinal cross-sectional view through the center of the drive shaft of the drain cleaning apparatus of FIG. 1.
DESCRIPTION
Referring to the drawings in general, and more particularly to FIGS. 1 and 2, shown therein is a drain cleaning apparatus 10 constructed in accordance with the present invention. The drain cleaning apparatus 10 comprises a main frame assembly 12 constructed of tubular material having a generally horizontal base 14, a motor support member 16, a drive shaft support member 18, and a carrying handle 20. The motor support member 14 and the drive shaft support member 18 (shown in FIG. 2) are assembled in such a manner as to be disposed in fixed spatial relation, and somewhat angularly, to each other. Cross braces 22 are provided in the main frame assembly 12 for strength and rigidity thereof.
In FIG. 2, a drum assembly 24 is shown mounted on main frame assembly 12, the drum assembly 24 comprising a generally cylindrically shaped hollow payout drum 26, a chuck holder adapter 28, and a contractable jaw chuck 30.
As will be appreciated, drum assemblies for coiled cleaning cable are known in the art, and the drum assembly 24 need not be described in detail, except to note that the drum assembly 24 is supported on a rotatable drive shaft 32. The drive shaft 32 is supported by appropriately disposed bearings 34 supported by the drive shaft support member 18. A coil spring cleaning snake 36 is wound up within the drum 26 in its storage mode and extends through the centrally located chuck holder adapter 28 and the jaw chuck 30 for concentric rotation therewith. A snake cleaning head 38 is supported by the extending end of the coil spring cleaning snake 36. A drum drive wheel 40 is mounted on the drive shaft 32 and a drive belt 42 extends thereover.
The payout drum 26 can be fitted with a variety of adapters and cleaning heads to accommodate different stoppage problems encountered on the customer's premises. FIG. 3 shows one such alternate configuration, with an alternate chuck holder adapter 44 bolted onto the payout drum 26. This alternate chuck holder adapter 44 accommodates a snake guide arm 46 through which extends the coil spring cleaning snake 36, and a snake cleaning head 48 is supported on the end thereof. A pair of cutter blades 50 are affixed to the snake cleaning head 48 by a hold down screw 52. A cable set screw 53 can be loosened or tightened to permit passage of the coil spring cleaning snake 36 or to grippingly secure same to the snake guide arm 46.
Referring again to FIG. 2, mounted on the appropriately located motor support member 16 is a power assembly 54. The power assembly 54 comprises an electric motor 56 which is preferably a variable speed unit, and a power sheave (not shown) for receiving the drive belt 42 for imparting rotational power to the drive wheel 40. A protective safety guard 58 is preferably provided over the power sheave and the upper portion of the drive belt 42. Conventional electrical switching and controls are provided, and may include a foot switch 60. A ground fault interrupter (not shown) can be provided to lessen the danger of electrical shock in the event of an electrical short circuit condition.
Referring now to FIG. 4, this cross-sectional view of the drive shaft 32 illustrates a novel fastening principle in drain cleaning machines. An outboard end 62 of the drive shaft 32 is machined in such a manner as to form a key which fits into a matching slot (not shown) on the inboard end of drum 26 (shown in FIGS. 1 and 2). Drive shaft 32 is also equipped with a locking ball 64 similar to that which is used in a socket wrench. When payout drum 26 is pushed onto drive shaft 32, hand pressure is sufficient to depress ball 64, thus permitting the machined drive shaft end 62 to be firmly seated into the matching slot (not shown) in the inboard end of drum 26. When the payout drum 26 is completely seated, a spring 66 thrusts the locking ball 64 into an appropriately disposed and sized indentation (not shown) formed in the interior diameter of the center hole on the inboard side (not shown) of payout drum 26, thus locking the payout drum 26 onto drive shaft 32.
In operation, the drain cleaning apparatus 10 is carried via its handle 20 to a position of conduit entry, such as in a basement or in a roof, and the base 14 of the drain cleaning apparatus 10 is set onto a convenient hard surface (such as a floor or a roof). Assuming that the drain cleaning apparatus 10 is equipped in the embodiment shown in FIGS. 1 and 2, the jaw chuck 30 is loosened and the coil spring cleaning snake 36 is pulled out of the payout drum 26 sufficiently to extend the snake cleaning head 38 into the conduit to be cleaned. With the snake cleaning head 38 in the conduit, the coil spring cleaning snake 36 is extended until the restriction in the conduit is reached by the snake cleaning head 38. At this point, the jaw chuck 30 is tightened and the power assembly 54 is energized to rotate the drum drive wheel 40 via the drive belt 42. This rotates the drive shaft 32 on which the payout drum 26 is supported. As the payout drum 26 is rotated, the coil spring cleaning snake 36 is caused to rotate concentrically about its longitudinal axis even if bent or curved within the conduit being cleaned.
Since the drain cleaning apparatus 10 is lightweight and portable, the operator can grippingly support the handle 20 while gently advancing the rotating coil spring cleaning snake 36 to push the snake cleaning head 38 against the blockage. As necessary, the drain cleaning apparatus 10 can be set down, the jaw chuck 30 again loosened and the coil spring cleaning snake 36 extended further, with or without stopping or slowing down the rotation of the drive shaft 32 by the electric motor 56. Once the extending length of the coil spring cleaning snake 36 has been adjusted as necessary, the drain cleaning apparatus 10 can again be lifted and the operation continued. This procedure can be repeated until the conduit blockage has been cleared.
To take up the coil spring cleaning snake 36, with the electric motor 56 deenergized, the jaw chuck 30 is loosened and the coil spring cleaning snake 36 is hand pulled from the conduit so as to be pushed back into the payout drum 26. Once this is accomplished, the drain cleaning apparatus 10 can be carried to another location of use.
The structure of the snake cleaning head 38 permits for quick removal of the drum assembly 24 and for quick remounting of a replacement drum assembly 24 thereon. This feature is very beneficial as several drum assemblies of varying sizes and configuration can be inventoried as required for the range of jobs encountered in any given service area.
From the above, it is clear that the present invention is well adapted to carry out the objects and to attain the ends and advantages mentioned herein as well as those inherent in the invention. While preferred embodiments of the invention have been described for the purposes of this disclosure, numerous changes can be made which will readily suggest themselves to those skilled in the art and which are encompassed within the spirit and scope of the invention disclosed herein and as defined in the appended claims. | A portable drain cleaning apparatus comprising a payout drum supporting a coil spring snake wound therein and supported for rotation on a support frame, the payout drum being detachable and replaceable with similar drums supporting different sized and configured snakes. | 1 |
TECHNICAL FIELD
[0001] This invention relates generally to a system for cooling axial flow turbines, particularly low-pressure steam turbines. More specifically it relates to a system for cooling last stage blades in low-pressure steam turbines, in particular where such last stage blades are made from composite materials.
BACKGROUND
[0002] The rotating blades of low-pressure steam turbines induce tremendous centrifugal forces into the rotor. This can be a limiting factor in designing the turbine for maximum efficiency. A solution is to use lower density blade materials as such blades exert less force into the rotor. This solution can, however, only be applied if the low-density material has adequate mechanical properties. While using titanium is presently regarded as the method of choice, future alternatives may have even better strength to weight ratios. Among the possible alternatives are blades of composite materials, examples of which is disclosed the published United States patent application US 2008/0152506 A1 and the published international patent applications WO 2011/039075 A1 and WO 2010/066648 and the Swiss Patent Number CH 547943.
[0003] Composite materials are typically less temperature resistant than metals. This can be a problem, in particular during low volume flow operation and full speed conditions. Under such conditions not enough heat is carried by the volume flow through the turbine and particularly the last stage blades become susceptible to windage heating of the blade tip area. Normal blade temperatures typically do not exceed 65° C. However, last stage blade tip temperatures can exceed 250° C. under windage conditions without corrective means. At such temperatures, the mechanical properties of composite material are significantly impacted and they may suffer permanent degradation.
[0004] A solution to windage heating is provided by Patent application No. US2007/292265 A1. The solution comprises injecting a cooling medium in the vicinity of the last stage tip region. The medium, which includes either steam or water, may be injected from the casing either fore or aft of the blade tip. As an alternative, or in addition, a small extraction groove for extracting flow through the outer sidewall may be provided near the blade tip just forward of the blade.
[0005] In view of the prior art it is seen as an object of the present invention to provide more efficient means and methods of cooling the tips of turbine blades, in particular last stage blades of composite materials.
SUMMARY
[0006] According to an aspect of the present invention, there is provided an axial flow turbine having a casing defining a flow path for a working fluid therein, a rotor co -axial to the casing, a plurality of stages, each including a stationary row of vanes circumferentially mounted on the casing a rotating row of blades, circumferentially mounted on the rotor, with an inner face of the casing exposed to the working fluid having one or more essentially circumferential grooves of increasing depth each ending in an extraction port with a bore.
[0007] The grooves follow typically a circumferential line around the inner face of the casing. However the may also deviate by preferably only up to 10 degrees from the circumferential line. If deviating, the grooves deviate preferably in general flow direction through the turbine.
[0008] The inner face of the casing in this invention can be the inner face of any part mounted onto the actual inner face of the casing such as diaphragms, vane carriers, heat shield etc. The grooves are machined into the face of the part which is exposed to the flow of the working fluid.
[0009] Preferably, the depth of the groove start at zero depth. The depth best increases smoothly to avoid the formation of vortices or other obstacles to a smooth extraction of working fluid.
[0010] The bore of the extraction port is preferably oriented tangentially to the groove to take advantage of the flow direction of the steam at low volume flow conditions in the turbine.
[0011] In a preferred variant of the invention there are two grooves in diametrically opposing positions along essentially the same circumference. For ease of manufacture, it is best to design the one or more grooves such that they end at a joint line of the casing and bores for the extraction ports at the opposite side of the joint line. In this manner the bore can be implemented by drilling through the face of the joint.
[0012] The one or more grooves in conjunction with the extraction port are best adapted to remove working fluid from a volume in the vicinity of the tip of the blades for the purpose of cooling the tips of rotating blades, particularly blades of composite material, for which heating is a more severe problem than for metal blades. Hence the preferred position of the grooves is located between vanes and blades of the last stage of the turbine.
[0013] The above and further aspects of the invention will be apparent from the following detailed description and drawings as listed below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Exemplary embodiments of the invention will now be described, with reference to the accompanying drawings, in which:
[0015] FIG. 1 is a schematic axial cross-section of a turbine;
[0016] FIG. 2A shows an enlarged view of the last stage of the turbine of FIG. 1 ;
[0017] FIG. 2B is a circumferential cross-section along line A-A′ of FIG. 2A ;
[0018] FIGS. 2C and 2D are axial cross-sections along line B-B′ and C-C′ of FIG. 2B , respectively; and
[0019] FIGS. 3A and 3B illustrate the flow through the turbine at full volume flow and at low volume flow, respectively.
DETAILED DESCRIPTION
[0020] Aspects and details of examples of the present invention are described in further details in the following description. Exemplary embodiments of the present invention are described with references to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the invention. However, the present invention may be practiced without these specific details, and is not limited to the exemplary embodiments disclosed herein
[0021] FIG. 1 shows an exemplary multiple stage axial flow turbine 10 . The turbine 10 comprises a casing 11 enclosing stationary vanes 12 that are circumferentially mounted thereon and rotating blades 13 that are circumferentially mounted on a rotor 14 with the rotor resting in bearings (not shown). The casing 11 , vanes 12 and blades 13 define a flow path for a working fluid such as steam therein. Each blade 12 has an airfoil extending into the flow path from the rotor 14 to a tip region 131 wherein the tip region 131 is defined as the top one third of the airfoil part of the blade 13 . The blade 13 can be made of metal, including metal alloys, composites including layered composites that comprise layered carbon fibre bonded by resins or a mixture of both metal and composites. The multiple stages of the turbine 10 are defined as a pair of stationary vane and a moving blade rows wherein the last stage of the turbine 10 is located towards the downstream end of the turbine 10 as defined by the normal flow direction (as indicated by arrows) through the turbine 10 . The turbine 10 can be a steam turbine and in particularly a low pressure (LP) steam turbine. As LP turbine, it is followed typically by a condenser unit (not shown), in which the steam condensates.
[0022] The last stage of the turbine 10 with the last row of vanes 12 and blades 13 is shown enlarged in the following figures. The FIG. 2B shows a cross-section of part of the turbine along the line A-A′ of FIG. 2A . Before the last blades 14 a pair of shallow grooves 111 are machined into the inner face of the casing 11 (or of a vane carrier, if the vanes are not mounted directly onto the casing). The depth of each groove 111 increases gradually in direction of the rotation of the blades 13 from zero to a final depth d after approximately one half turn. At the final depth d the groove enters into an extraction hole or channel 112 .
[0023] The extraction hole 112 is tangentially to the groove 111 such that the opening of the channel is essentially perpendicular to groove. The extraction hole releases the steam into a water cooled mixing chamber or directly into a condenser.
[0024] The extraction hole or channel 112 can be shut using a valve 113 or other suitable means. In normal operations the extraction channels is closed and opened only when the extraction is required, i.e under low flow volumes or when the temperature of the blades is rising beyond their operational limits.
[0025] In FIG. 2C , which shows a cross-section along line B-B′ of FIG. 2B , the groove 111 has approached close to half its final depth d. In FIG. 2D , which shows a cross-section along line C-C′ of FIG. 2B , the groove 111 is shown at the point of entering the extraction hole or channel 112 .
[0026] The groove 111 and the extraction hole 112 are oriented such that hot steam having a circumferential velocity component due to the rotation of the turbine is diverted from a volume close to the tip of the last stage blades 13 and guide by the grooves into the tangential extraction hole.
[0027] The groove 111 and the extraction hole 112 are preferably located between the axial positions of the row of vanes 12 and blades 13 as volumes of hot steam are found to circulate in that volume. The width of the groove and the and the extraction hole 112 are design parameter and can in an extreme case take up most of the inner surface of the casing between the blades and vanes but are likely to be much smaller for typical turbines as in actual use today.
[0028] As shown by the comparison of FIGS. 3A and 3B the flow through the turbine can changes significantly as the mass flow volume drops from its operational level to a lower level such as less than 50 percent of the normal mass flow, or even less than 30 percent of the normal mass flow. It is found that under such low volume operations the flow through the turbine, which is usually optimized for the operation mass flow levels, changes to leave pockets where the flow has only a small axial component.
[0029] As shown in FIG. 3A the turbine has a smooth flow field as indicated by the stream lines under normal flow volumes. The flow has a predominant axial velocity component in direction to the exit of the turbine. When the flow volume through the turbine is reduced as is the case for example during start-up, run-out, load change or emergency situations the flow pattern changes to a more complex picture as illustrated in FIG. 3B .
[0030] Under reduced flow conditions, there are steam volumes with a small axial components. The volumes tend to have a much larger circumferential component as for example the volume 31 in FIG. 3B , which circulates predominantly into and out of the paper plane while have only a small circulation in axial direction. Thus wet film scraping bores which are used in turbines are rendered inefficient under low loads, as these devices typically depend on a axial flow velocity to catch the film.
[0031] By making use of the circumferential velocity hot steam can be extracted even with an adverse back pressure from the condenser unit of the turbine.
[0032] Estimates show that by extracting about 1% of the mass flow using a groove of 300 mm width and a maximum depth d of 20 mm the temperature of a last stage blade can be reduced from 178 degrees C. to 166 degrees C. This value can be further increased by extracting more albeit at the expense of reducing the overall efficiency of the turbine.
[0033] It is advantageous from a manufacturing point of view to have the bores for holes 112 start at the split between the upper and lower half of the turbine casing 11 . However the bores can be placed in principle at any point along the circumference of the casing or vane carrier. It is also possible to increase the number of grooves from 2 to 3, 4 or more along the same circumferential line. In such a variant of the invention, the gradient of the grooves is steeper to achieve the same target depth d after less than a half turn.
[0034] It can be further advantageous to place the extraction grooves and channels at locations other than between the last stage vanes and blades or to have extraction grooves and channels at more than just one location. It is further possible to place the two grooves and extraction channels as described above not along a single circumferential line but slightly staggered along the axial length of the turbine.
[0035] The present invention has been described above purely by way of example, and modifications can be made within the scope of the invention, particularly as relating to the shape, number and design of the extraction grooves and channels. The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or any combination of any such features or any generalization of any such features or combination, which extends to equivalents thereof. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
[0036] Each feature disclosed in the specification, including the drawings, may be replaced by alternative features serving the same, equivalent or similar purposes, unless expressly stated otherwise.
[0037] Unless explicitly stated herein, any discussion of the prior art throughout the specification is not an admission that such prior art is widely known or forms part of the common general knowledge in the field. | An axial flow turbine is described having a casing defining a flow path for a working fluid therein, a rotor co-axial to the casing, a plurality of stages, each including a stationary row of vanes circumferentially mounted on the casing a rotating row of blades, circumferentially mounted on the rotor, with an inner face of the casing exposed to the working fluid having one or more essentially circumferential grooves of increasing depth each ending in an extraction port with a bore. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Provisional U.S. patent application No. 60/370,779 filed Apr. 8, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] N/A
BACKGROUND OF THE INVENTION
[0003] This invention relates to electric fuel pumps used to supply fuel to internal combustion engines, and more particularly to a cartridge insertable in the inlet of a variety of such pumps to provide a relief valve assembly for the pumps. At low pressures (12 psi or less) such as occur in carbureted engine applications, the relief valve also acts as a pressure regulator. At higher pressure applications such as found in fuel injected engines, the valve acts to relieve excess pressure in the fuel rail between the fuel pump and engine should the pressure regulator in the rail fail, or if a fuel line becomes kinked or is otherwise blocked.
[0004] Electric fuel pumps are well-known in the art. The pump has an inlet side in which fuel is drawn into the pump at low pressure. The pump then has one or more pumping stages by which the fuel pressure is elevated to a significantly higher level. Finally, the pump has an outlet stage through which the pressurized fuel is delivered to an internal combustion engine, typically a fuel injected engine, requiring fuel at high pressure for proper operation. As noted, the fuel pumps are also usable in carbureted engine applications. The fuel pump can be mounted either inside or outside the fuel tank. Electric fuel pumps include a relief valve for directing fuel back to a fuel tank in which the pump is installed. In many pump constructions, the relief valve assembly is mounted in the inlet portion of the pump, and the fuel returned back to the inlet side of the pump through the relief valve is high pressure fuel from the outlet side of the pump.
[0005] It will be appreciated that there are wide variety of fuel pumps for different engine applications. The pumps are of different sizes and shapes and their outlet pressures vary over a wide range; i.e., from 100 psi or greater, to less than 10 psi. Because of this diversity, it is commonplace in manufacturing a line of fuel pumps for a manufacturer to have to stock a large number of different parts for use in their production. This makes inventory costs very high and can be particularly expensive because a few part numbers usually represent the vast portion of the sales volume; yet, many more part numbers must be made and stocked to complete the product line. The ability to utilize a single component throughout much of the product line would create significant cost savings. The impact would be not only in inventory costs, but also in production because fewer fixtures would be required, and less setup changes and machining operations would be involved in changing from one part number to another.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is directed to a relief valve assembly for electric fuel pumps. The assembly includes a molded plastic cartridge in which components of the relief valve are housed. The cartridge is readily inserted in the inlet porting plate of a wide variety of fuel pumps to direct high pressure fuel from the outlet side of the pump back to the inlet side of the pump. Using different springs within the cartridge allows the relief valve to be modified for use in pumps operating at different pressures. This can also be accomplished by changing the size of the inlet orifice of the cartridge. The combination of spring weights and orifice sizes enables a relief valve of a common design to be used in a variety of different pumps.
[0007] The housing of the cartridge is designed to readily fit into a porting plate so to simplify manufacture of a pump. Preferably, the cartridge is made of a light weight, slotted plastic material which is impervious to fuel varnish buildup which causes sticking of the relief valve. Slotting allows the cartridge to easily bypass fuel back to the inlet side of the pump when the relief valve is opened. The cartridge is color coded for ease of identification. Since the relief valve components are self-contained within the cartridge, they are readily tested prior to installation into a pump.
[0008] Other objects and features are in part apparent and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The objects of the invention are achieved as set forth in the illustrative embodiments shown in the drawings which form a part of the specification.
[0010] [0010]FIG. 1 is an elevation view, partly in section, of an electric fuel pump;
[0011] FIGS. 2 A- 2 D are an elevation view of a relief valve assembly of the present invention (FIG. 2A), respective end views of a cartridge housing relief valve components (FIGS. 2B and 2C), and a sectional view (FIG. 2D) of the cartridge taken along line 2 D- 2 D in FIG. 2C;
[0012] [0012]FIGS. 3A and 3B are perspective views of the cartridge from opposite ends of the cartridge;
[0013] FIGS. 4 A- 4 E are elevation views of a porting plate for a fuel pump in which the relief valve assembly is installed (FIG. 4A), respective end views of the porting plate (FIGS. 4B and 4C), a sectional view (FIG. 4D) of the porting plate taken along line 4 D- 4 D in FIG. 4B, and a sectional view (FIG. 4E) of the porting plate taken along line 4 E- 4 E in FIG. 4C; and,
[0014] [0014]FIG. 5 is a perspective of the cartridge with a different valve seating construction.
[0015] Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF INVENTION
[0016] The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode of carrying out the invention. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0017] Referring to FIG. 1, an electric fuel pump 10 pumps fuel from the fuel tank of a vehicle to an internal combustion engine (also not shown) powering the vehicle. The fuel pump can be either mounted in the tank, or externally of it. The pump has an inlet section 12 by which fuel is drawn into the pump by suction, a pumping section 14 in which the fuel pressure is increased from the nominal fuel pressure in the tank to a desired higher pressure level, and a fuel outlet 16 through which the pressurized fuel is pumped to the engine. In fuel injected engine applications, a pressure regulator (not shown) is installed in the fuel path between the pump and engine. An electric motor 18 operates the pump. The electric motor and other fuel pump components are enclosed in a housing 20 .
[0018] In accordance with the present invention, a universal valve is indicated generally 30 in FIG. 1. Valve 30 is a relief valve and utilizes a cartridge 32 sized to be received in the fuel inlet portion of the pump. Housed in the cartridge are relief valve components by which fuel flows from the high pressure, outlet side of the pump back to the inlet side of the pump. It is a feature of the invention that cartridge 32 , which is of a molded plastic material, fits in a wide range of fuel pumps. Accordingly, while certain elements housed in the cartridge vary depending upon the desired performance characteristics of the fuel pump, universal valve 30 significantly reduces the inventory of parts needed to manufacture a line of fuel pumps and substantially reduces manufacturing costs in assembling fuel pumps.
[0019] In FIG. 1, fuel inlet portion 12 of pump 10 includes a porting plate 22 . Plate 22 includes a recess 24 and cartridge 32 is sized to be received in this recess during pump assembly. The universal relief valve is installed in the porting plate during a sub-assembly operation, and the porting plate with the relief valve assembly are then installed in fuel pump housing 20 during a final assembly operation.
[0020] Cartridge 32 has a hollow core 34 extending the length of the cartridge. Core 34 is of a first diameter at the inlet end 36 of the cartridge. As shown in the drawings, the entrance end of the core curves inwardly from the inlet end of the cartridge. A valve seat 38 comprises a circumferential seat formed approximately midway along the length of the cartridge. The diameter of core 34 from the location of the seat to the other, outlet end 40 of the cartridge is greater than the core diameter at the inlet end of the relief valve assembly.
[0021] A relief valve 42 of the assembly is comprised of a disk 43 made of a plastic material which is resistant to fuel varnish buildup. This prevents relief valve sticking. A cover plate 44 is insertable into end 40 of the cartridge. A circular recess 45 is formed in the sidewall of core 34 inwardly of end 40 of the core. Cover plate 42 has a circumferentially extending shoulder 46 adjacent the inner end of the plate when the plate is inserted into end 40 of the core. The diameter of the cover plate at the location of shoulder 46 is greater than the diameter of the core at end 40 . However, the plastic material from which cartridge 32 is made is sufficiently flexible that the plate can be snap fit into place with shoulder 46 being received in recess 44 . Plate 42 has a central opening 48 extending completely through the plate. At the inner end of the installed plate is a circular recess 50 comprising a seat for a valve spring 52 .
[0022] Relief valve 42 has an associated backing plate 54 . Plate 54 comprises a circular disk 56 of the same diameter as disk 43 and abuts against the backside of disk 43 . Disk 43 has a central opening 58 through which a central hub 60 , formed in the center of disk 56 , protrudes. A stem 62 is formed on the backside of disk 56 , the lower portion of the stem extending into the opening 48 formed in cover plate 44 . Valve spring 52 extends about stem 62 , and the other end of the spring seats against the backside of disk 56 . Spring 52 urges backing plate 54 and relief valve 42 against valve seat 38 so to close off the relief valve.
[0023] Four slots 64 a - 64 d are formed in the side of cartridge 32 . It will be understood by those skilled in the art, that there may be more or fewer than four slots without departing from the scope of the invention. The slots extend longitudinally of the cartridge from end 40 of the cartridge to a location adjacent the outer end of relief valve disk 43 . Preferably, the slots are formed in the cartridge 90° apart. The slots provide fuel flow paths back from the outlet side of the fuel pump to the inlet side of the pump when relief valve 42 is opened. The material forming the sidewall of the cartridge, at the end of the cartridge adjacent the outer ends of the slots, is shown to be slightly curved. This curvature facilitates insertion of cover plate 44 when the relief valve is assembled.
[0024] A circular recess 66 is formed on the outer surface of cartridge 32 adjacent the inner end of the relief valve assembly when the cartridge is installed in recess 24 of inlet section 12 of the fuel pump. An O-ring seal 68 fits in the recess and provides a seal between the relief valve assembly and the sidewall of recess 24 .
[0025] In operation, relief valve 42 is normally closed by valve spring 52 . The amount of force holding the relief valve closed is a function of the spring 52 used in the assembly. When the fuel pressure in a fuel rail exceeds a predetermined level, the pressure regulator in the fuel line diverts fuel back to the inlet side of the pump. Now, fuel from the outlet side of pump 10 is directed into the relief valve assembly. The fuel pressure overcomes the force imposed on the relief valve by the spring, moving valve disk 43 away from seat 38 . Return fuel now flows through the inlet of the cartridge, about the valve disk, through the slots 62 a - 62 d formed in the side of the cartridge, and back to the inlet side of the pump. When the fuel pressure falls below the force exerted by spring 52 , disk 43 is again forced against seat 38 by the spring, closing the relief valve. In carbureted engines, where there is typically no pressure regulator, relief valve 30 functions as the pressure regulator. A portion of the fuel from the outlet side of the fuel pump is directed to the relief valve assembly. If the pressure of the fuel exceeds approximately 12 psi, the relief opens as above described to drain fuel back to the inlet side of the tank.
[0026] The advantages of relief valve assembly 30 , as above described, is that the cartridge fits into a large number of different fuel pumps. Preferably, the plastic material from which the cartridge is formed is of one or more desired colors. This color coding makes it easy to identify which cartridges fit into which fuel pumps during assembly. The interchangeability also reduces inventory costs. The difference between one relief valve assembly and another is the size of the spring 52 , since this determines the amount of pressure which must be overcome to open the relief valve.
[0027] In FIGS. 4 A- 4 E, porting plate 22 is shown to be a circular plate having a central opening 70 through which inlet fuel is drawn into pump 10 from the tank. The porting plate is bolted to the pump section of the fuel pump during assembly, prior to the pump components being fitted into pump housing 20 . If the fuel pump is mounted in the fuel pump, return fuel flowing through the relief valve flows directly into the tank. If the fuel pump is mounted outside the tank, the excess flow is diverted back to the inlet side of the pump.
[0028] Finally, as shown in FIG. 5, the cartridge, rather than having a curved inlet construction can employ a stepped valve seating construction. The advantage of this construction over that previously described is more consistent pressure regulation.
[0029] In view of the above, it will be seen that the several objects and advantages of the present invention have been achieved and other advantageous results have been obtained. | A universal relief valve assembly ( 30 ) installed in an electric fuel pump ( 10 ) for returning fuel from an outlet portion ( 16 ) of the fuel pump back to the inlet side of the pump. A cartridge ( 32 ) is mounted in the pump and has an opening ( 34 ) extending therethrough for fuel to flow from the outlet portion of the pump back to the inlet portion of the pump. A relief valve ( 42 ) installed in the cartridge is movable from a closed position to an open position by the pressure to which the relief valve is subjected. A valve spring ( 52 ) installed in the cartridge biases the relief valve closed. The cartridge is sized to fit into a variety of fuel pumps having a range of outlet pressures, so to reduce the number of relief valve assemblies required to manufacture a line of fuel pumps. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
The application claims the benefit of the earlier filing date of U.S. Provisional Patent Application No. 61/870,839, filed Aug. 28, 2013 entitled “Tunable Electrical Conductivity in Metal-Organic Framework Thin Film Devices”. The aforementioned application is hereby incorporated by reference, in its entirety, for all purposes.
STATEMENT OF GOVERNMENT RIGHTS
This invention was developed under Contract DE-AC04-94AL85000 between Sandia Corporation and the U.S. Department of Energy. The U.S. Government has certain rights in this invention.
FIELD
Metal-organic frameworks and organic semiconductor devices and uses.
BACKGROUND
Metal-organic frameworks (MOFs) are crystalline materials with a nanoporous supramolecular structure consisting of metal ions connected by organic ligands. Their tailorable porosity, ease of synthesis, and ultra-high surface areas, combined with a broad choice of suitable building blocks make them promising materials for gas storage, chemical separation, catalysis, chemical sensing, and drug delivery. Unfortunately, MOFs are usually poor electrical conductors because of the insulating character of the organic ligands and the poor overlap between their π orbitals and the d orbitals of the metal ions. Combining the crystalline order of MOFs with an ability to conduct electrical charge has the potential to create a new class of materials that would open a suite of unique applications. While strategies to engineer electrically conducting MOFs have been proposed (e.g., using second- or third-row transition metals, redox-active linkers, and heterobimetallic structures), few of these approaches have been realized. Until recently only one example of an intrinsically conducting framework with permanent porosity was known: a p-type semiconducting MOF in which conductivity occurs via a redox mechanism. Very recently, Gandara et al. described a series of metal triazolate MOFs, one of which exhibits Ohmic conductivity. Although the mechanism of conductivity in that case is not known, it appears to be highly specific to the presence of divalent iron in the structure, as MOFs in this series with the same structure but different divalent metals are not conducting. To date there is no report of a conducting MOF thin film device.
SUMMARY
In one embodiment, a composition including a porous metal organic framework (MOF) including an open metal site and a guest species capable of charge transfer that can coordinate with the open metal site, wherein the composition is electrically conductive is described. In another embodiment, a method including infiltrating a porous metal organic framework (MOF) including an open metal site with a guest species that is capable of charge transfer; and coordinating the guest species to the open metal site to form a composition including an electrical conductivity greater than an electrical conductivity of the MOF is described.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a top perspective view of a portion of a substrate including components of a thin film device including conductive pads.
FIG. 1B shows structure of FIG. 1A following the introduction of a porous MOF onto the conductive pads and the insulating layer therebetween.
FIG. 1C shows the structure of FIG. 1B following the infiltration of the Cu 3 (BTC) 2 MOF with a guest species of 7,7,8,8-tetracyanoquinododimethane (TCNQ) and the formation of a gate electrode on the device and contacts to MOF films and the gate electrode of the thin film device.
FIG. 2A shows current-voltage graphs of a thin film MOF of Cu 3 (BTC) 2 and a TCNQ infiltrated MOF thin film and a hydrated infiltrated MOF.
FIG. 2B shows a graph of electrical resistance versus channel length for the thin film device of FIG. 1C .
FIG. 2C shows a graph of a conductivity of a TCNQ-MOF thin film of FIG. 1C over time.
FIG. 2D shows a graph of a thin film TCNQ infiltrated MOF at different temperatures.
FIG. 2E shows a graph of conductivity as a function of temperature of a thin film TCNQ infiltrated MOF.
FIG. 2F shows a graph of conductivity as a function of exposure time for a TCNQ guest species.
FIG. 3 shows x-ray diffraction data for Cu 3 (BTC) 2 powder and thin film and each infiltrated with TCNQ.
FIG. 4A shows an absorption spectrum of films of a MOF of Cu 3 (BTC) 2 , a MOF of Cu 3 (BTC) 2 infiltrated with TCNQ and a hydrated infiltrated MOF as well as TCNQ in CH 2 CH 2 and hydrated TCNQ in CH 2 CH 2 .
FIG. 4B shows Raman spectra of a MOF of Cu 3 (BTC) 2 , a MOF of Cu 3 (BTC) 2 infiltrated with TCNQ and TCNQ.
FIG. 4C shows infrared absorption spectra of a MOF of Cu 3 (BTC) 2 .xH 2 O, Cu 3 (BTC) 2 , TCNQ@Cu 3 (BTC) 2 and TCNQ powder.
FIG. 4D shows room temperature continuous wave electron paramagnetic resonance spectra of activated Cu 3 (BTC) 2 , Cu 3 (BTC) 2 stirred in methanol, and Cu 3 (BTC) 2 stirred in methanol containing TCNQ (the asterisk (*) denotes an unidentified organic radical signal observed only in the activated Cu 3 (BTC) 2 sample.
FIG. 4E shows a representation of a minimum energy configuration for TCNQ@Cu 3 (BTC) 2 obtained from ab initio calculations.
FIG. 4F shows an illustration of a possible configuration for TCNQ@Cu 3 (BTC) 2 that would provide a conductive channel through the MOF unit cell.
FIG. 5A-5C shows a process for fabrication of conductive metal-organic framework thin film devices, and structural characterization data. (A) A thin film of metal-organic framework is grown on an insulating wafer pre-patterned with electrodes. Molecules are then infiltrated by exposing the thin film device to a solution containing the molecules. (B) A TCNQ molecule shown above a Cu 3 (BTC) 2 MOF with arrow pointing to the pore. (C) SEM image of MOF thin film device with optical images of devices before and after TCNQ infiltration.
DETAILED DESCRIPTION
In one embodiment, a composition is disclosed. The composition includes a porous MOF and a guest species that participates in charge transfer with the MOF. By combining a MOF and a guest species that participates in charge transfer with the MOF, the composition is electrically conductive. In another embodiment, a thin film device is disclosed. The device includes a thin film of a MOF infiltrated with a guest species that participates in charge transfer with the MOF. In another embodiment, the electrical transport properties of a MOF thin film device are tunable while preserving the MOF structure.
In one embodiment, a MOF is a compound including metal ions or clusters coordinated to organic ligands. Suitable metal ions or clusters include copper ions (e.g., Cu 2+ ), and ions of chromium (Cr), iron (Fe), nickel (Ni), molybdenum (Mo) and ruthenium (Ru). In one embodiment, a suitable MOF includes Cu 3 (BTC) 2 also known as HKUST-1.
In one embodiment, a guest species that participates in charge transfer with the MOF includes a delocalized π electron or π electrons. Representative guest species include one or more nitrile moieties, one or more thiol moieties, one or more carbonyl moieties, one or more thiolate moieties, one or more amine moieties, one or more imine moieties, one or more hydroxyl moieties, or a mixture thereof. A moiety is used generally to identify a portion of a molecule. In one embodiment, the guest species is 7,7,8,8-tetracyanoquinododimethane (TCNQ), a molecule having multiple nitrile moieties. In one embodiment, a composition includes a porous MOF of Cu 3 (BTC) 2 and a guest species of TCNQ. Without wishing to be bound by theory, it is believed the recited moieties of respective molecules participate in the charge transfer with the MOF and thus, are responsible for imparting electrical conductivity to the composition (MOF and guest species). In another embodiment, a representative guest species is a molecule that has a configuration that will interact with a MOF to impart electrical conductivity. Representative molecules include thiophenes, dithiophenes, tetrathiafulvalene, imidazole, triazole, tetrazole and derivatives and/or mixtures thereof. In a further embodiment, a representative guest species is a transition metal complex operable to undergo an outer sphere electron transfer. Examples include, but are not limited to, ruthenium hexamine, hexacyanoferrate and hexacyanocobaltrate. Such complexes can be assembled into bulk semiconducting coordination polymers operable to undergo a charge transfer reaction with an MOF resulting in conducting behavior.
FIGS. 1A-1C illustrate a method of forming an electrically conductive MOF thin film devices on a substrate. Referring to FIG. 1A , structure 100 includes substrate 105 that is, for example, a portion of a silicon wafer. In one embodiment, substrate 105 includes a device layer including a number of devices (e.g., transistor devices) and circuits (CMOS) established through metallization to the devices. Overlying a surface of substrate 105 (a top surface as viewed) is dielectric layer 107 of, for example, silicon dioxide that is grown on the substrate. In one embodiment, dielectric layer 107 has a thickness on the order of 100 nanometers (nm). As shown in FIG. 1A , also disposed on substrate 105 and on dielectric layer 107 are two conductive pads separated by a channel length, l. Representative lengths for channel length, l, include 100 microns (μm), 150 μm and 200 μm. In one embodiment, conductive pad 110 and conductive pad 120 , respectively, are each a metal material such as platinum (Pt). Representative dimensions of each of conductive pads 110 and 120 are 800 μm by 400 μm. A representative thickness of conductive pads 110 and 120 is 100 nm.
FIG. 1B shows structure 100 of FIG. 1A following the introduction of a porous MOF onto conductive pad 110 and conductive pad 120 , as well as over the dielectric layer 107 . In one embodiment, porous MOF is a film of Cu 3 (BTC) 2 conformally introduced on a surface of structure 100 including conductive pad 110 , conductive pad 120 , and dielectric layer 107 . A representative nominal thickness of a film of a porous MOF is 100 nm. Representatively, a Cu 3 (BTC) 2 film may be grown on dielectric layer 107 in a liquid cell reactor as described in the art. In one embodiment, a polycrystalline Cu 3 (BTC) 2 .xH 2 O film was grown with preferred orientation along the (111) direction. FIG. 1B shows MOF film portion 125 A and MOF film portion 125 B on conductive pad 110 and conductive pad 120 , respectively, and MOF film portion 125 C in a channel region or area of the structure. Current voltage (I-V) characteristics obtained for an as-grown thin film device in ambient are shown in FIG. 2A . A very small conductivity (˜10 −6 S/m) is observed, consistent with the expected insulating nature of Cu 3 (BTC) 2 .
FIG. 1C shows the structure of FIG. 1B following the infiltration of the Cu 3 (BTC) 2 MOF in areas corresponding to 125 A, 125 B, and 125 C with a guest species. In one embodiment, the MOF films were infiltrated with a guest species of 7,7,8,8-tetracyanoquinododimethane (TCNQ) by heating in vacuum at 180° C. for 30 minutes to remove the water molecules, and then immediately transferring to a saturated TCNQ/CH 2 CCl 2 solution for infiltration. FIG. 1C shows film 130 A on conductive pad 110 , film 130 B on conductive pad 120 , and film 130 C in a channel region each illustrative of an infiltrated MOF. I-V curves for four such devices after 72 hours of exposure to the TCNQ solution are shown in FIG. 2A . The infiltration leads to dramatic increase of the current, with a linear I-V curve with conductivity of 7 S/m, six orders of magnitude larger than the un-infiltrated devices. Measurements as a function of channel length ( FIG. 2B ) show a monotonic increase of resistance with increasing electrode separation (increasing l) thus indicating that contact resistance effects are not at the origin of the phenomenon. Further, the TCNQ-infiltrated devices are stable in ambient over a long period of time ( FIG. 2C ). The temperature dependence of the conductivity was also measured. The conductivity decreases with decreasing temperature ( FIG. 2D-2E ) and follows a thermally activated relation σ˜exp(−E a /T) with a low activation energy E a of 41±1 meV, similar to values reported for high mobility organic polymeric semiconductors such as poly-3-hexylthiophene (P3HT).
In one embodiment, as shown in FIG. 1C , a thin film device can also include an electrical gate structure to which a voltage is applied, which can be disposed on film 130 C either oriented above or below film 130 C. FIG. 1C shows an embodiment where gate structure is oriented above film 130 C as viewed (gate structure 150 shown in dashed lines). If the gate structure is oriented above film 130 C, an additional insulating layer may be present between the gate structure and film 130 C. The gate electrode serves to modulate the electrical current in the MOF device.
The above results show large conductance increases of a porous MOF through guest specie infiltration. It has also been found that the conductivity can be tuned. One technique for tuning the conductivity of a porous MOF involves modifying an exposure time of the MOF to the guest species. As shown for several devices in FIG. 2F , the conductivity can be controlled over several orders of magnitude by changing the exposure time. Furthermore, the time scale over which the conductivity varies is relatively long, implying that accurate control over the conductivity can be achieved.
EXAMPLE 1
A number of experiments to verify the TCNQ infiltration of a MOF were conducted. Powder XRD patterns of as-synthesized Cu 3 (BTC) 2 .xH 2 O, Cu 3 (BTC) 2 (activated) and Cu 3 (BTC) 2 (infiltrated) with TCNQ (hereinafter TCNQ@Cu 3 (BTC) 2 ) show that the MOF crystalline structure (face centered cubic, Fm 3 m) is unaffected by the infiltration process. The inset in FIG. 3D shows that the MOF lattice expands slightly upon TCNQ adsorption; Rietveld refinement yielded lattice parameters of 2.617 nm±0.001 nm and 2.635 nm±0.001 nm, for Cu 3 (BTC) 2 and TCNQ@Cu 3 (BTC) 2 powders, respectively. In addition, the surface area of the activated Cu 3 (BTC) 2 powder, obtained from N 2 adsorption isotherms using the Brunauer, Emmett, and Teller (BET) method is 1844 m 2 g −1 ±4 m 2 g −1 . This value is typical of high-quality Cu 3 (BTC) 2 material with little or no pore collapse or residual reactant. After drying in air, the TCNQ@Cu 3 (BTC) 2 material displays a BET surface area of 214 m 2 g −1 ±0.5 m 2 g −1 , suggesting high TCNQ loading. This result is confirmed by elemental analysis indicating a Cu 3 (BTC) 2 : TCNQ ratio of two based on carbon, nitrogen, and hydrogen content, corresponding to about eight TCNQ molecules per unit cell or one TCNQ molecule per MOF pore. Furthermore, visual examination of the powdered MOFs reveals an expected turquoise-blue color for the as-synthesized material and the violet-blue hue for the activated (dehydrated) MOF. Upon exposure to TCNQ, the color of the crystals changes to teal, clearly indicating a perturbation of the MOF. The color of TCNQ@Cu 3 (BTC) 2 does not change upon exposure to air indicating that TCNQ is not displaced by atmosphere water vapor. In contrast, the color of the activated MOF prior to TCNQ infiltration reverts almost instantly to that of the as-synthesized (hydrated) material when exposed to atmospheric moisture.
The TCNQ/MOF interaction was probed in several ways. UV-Vis spectra were collected on films of the uninfiltrated Cu 3 (BTC) 2 .(H 2 O) x , several ways. TCNQ@Cu 3 (BTC) 2 , H4-TCNQ@Cu 3 (BTC) 2 , as well as solutions of TCNQ and H4-TCNQ. The UV-visible absorption spectrum of a TCNQ@Cu 3 (BTC) 2 film ( FIG. 4A ) shows expected MOF peak at 340 nm, a peak at 410 nm associated with neutral TCNQ, as well as a broad absorption bands centered at ˜690 nm and ˜850 nm that is absent in both Cu 3 (BTC) 2 .(H 2 O) x and TCNQ in CH 2 Cl 2 . These additional bands are characteristic of TCNQ radical indicating charge transfer between the framework and TCNQ. In addition, Raman spectra of TCNQ@Cu 3 (BTC) 2 ( FIG. 4B ) are dominated by TCNQ peaks with frequencies shifted from those of neat TCNQ. The TCNQ C═C stretching frequency shifts from 1451 cm −1 to 1357 cm −1 and a new peak at 1296 cm −1 appears a strong indication that TCNQ interacts with the available coordination sites on the Cu 2+ ions in the framework.
The infrared absorption peaks of Cu 3 (BTC) 2 are also affected by infiltration with TCNQ ( FIG. 4C ). Peaks at 2223 cm −1 (C≡N stretching) and 1541 cm −1 (C═C stretching) shift to 2204 cm −1 and 1508 cm −1 , respectively. The frequency of the C≡N stretching is widely used to characterize the degree of charge transfer (z) in molecular TCNQ charge transfer complexes according to z=(v 0 −v)/44 cm −1 where v 0 is the frequency of neutral TCNQ (≈2223 cm −1 ) and v is the frequency observed in the molecular complex (2204 cm −1 for TCNQ@Cu 3 (BTC) 2 ). According to this interpretation, the extent of charge transfer estimated for TCNQ@Cu 3 (BTC) 2 is 0.43 electron charges. This is further supported by room temperature electron paramagnetic resonance spectroscopy of TCNQ@Cu 3 (BTC) 2 ( FIG. 4D ) that exhibit no evidence of isolated TCNQ radical anion, consistent with partial charge-transfer between Cu and TCNQ.
To test the importance of the guest/host interactions, experiments were carried out where TCNQ was replaced with its fully hydrogenated counterpart, H4-TCNQ (cyclohexane-1,4-diylidene)dimalononitrile), which lacks a delocalized π electron network. Elemental analysis indicates that the loading is similar to that of TCNQ, i.e., about one H4-TCNQ molecule per pore. The corresponding I-V curve ( FIG. 2A ) is essentially the same as the uninfiltrated MOF. This result suggests that the availability of guest molecule orbitals that can accept charge, as is the case in TCNQ but no H4-TCNQ, is crucial for achieving high conductivity.
Ab initio calculations of the TCNQ@Cu 3 (BTC) 2 hybrids were performed. As illustrated in FIG. 4E , favorable binding of the TCNQ (binding energy of 53.7 kJ/mol) was found when it bridges two nearby copper paddlewheels. This configuration suggests a possible mechanism for the appearance of conductance in this material: a path through a MOF unit cell can be created by using four TCNQ molecules to bridge copper sites ( FIG. 4F ).
This synthetic approach is generalizable to other MOFs and other guest molecules. For example, it is anticipated that MOFs containing paddlewheel-type structures, such as the NOTT, rht and nbo MOFs as well as MOF-74 (including the extended versions) and other MOFs containing open metal sites, will exhibit conducting behaviors. Examples of other guest molecules include thiols, thiophenes, diimides, molecules with conjugated pi systems, selenium and tellurium compounds and nitric oxides.
In conclusion, the incorporation of guest molecules into MOFs can lead to a sharp and tunable increase in the electrical conductivity while preserving the MOF porous, crystalline structure. The results suggest a novel strategy for creating families of electrically conducting MOFs, providing highly ordered, supramolecular electronic materials with applications including conformal electronic devices, reconfigurable electronics, sensors (e.g., electrochemical sensors, chemiresistors, piezoresistors, impedance sensors, and field-effect transistors), displays, low-cost electronics (logic, memory, etc.) and energy conversion and storage devices (such as photovoltaics, batteries, capacitors).
EXAMPLE 2
Our approach for realizing conductive MOF thin film devices is shown in FIG. 5A-5B . Si wafers with 100 nm of SiO 2 were pre-patterned with 100 nm-thick Pt pads (dimensions of 800 μm by 400 μm) and gaps of 100 μm, 150 μm, and 200 μm. Cu 3 (BTC) 2 films with 100 nm nominal thickness were grown on the wafers in a liquid cell reactor as described previously. Grazing incidence SEM imaging ( FIG. 5C ) and XRD measurements ( FIG. 3 ) indicate that a polycrystalline Cu 3 (BTC) 2 .xH 2 O film was grown with preferred orientation along the (111) direction.
In the description above, for the purposes of explanation, numerous specific details have been set forth in order to provide a thorough understanding of the embodiments. It will be apparent however, to one skilled in the art, that one or more other embodiments may be practiced without some of these specific details. The particular embodiments described are not provided to limit the invention but to illustrate it. The scope of the invention is not to be determined by the specific examples provided above but only by the claims below. In other instances, well-known structures, devices, and operations have been shown in block diagram form or without detail in order to avoid obscuring the understanding of the description. Where considered appropriate, reference numerals or terminal portions of reference numerals have been repeated among the figures to indicate corresponding or analogous elements, which may optionally have similar characteristics.
It should also be appreciated that reference throughout this specification to “one embodiment”, “an embodiment”, “one or more embodiments”, or “different embodiments”, for example, means that a particular feature may be included in the practice of the invention. Similarly, it should be appreciated that in the description various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects may lie in less than all features of a single disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of the invention. | A composition including a porous metal organic framework (MOF) including an open metal site and a guest species capable of charge transfer that can coordinate with the open metal site, wherein the composition is electrically conductive. A method including infiltrating a porous metal organic framework (MOF) including an open metal site with a guest species that is capable of charge transfer; and coordinating the guest species to the open metal site to form a composition including an electrical conductivity greater than an electrical conductivity of the MOF. | 2 |
[0001] This application claims priority from Korean Patent Application No. 2003-21114, filed on Apr. 3, 2003, the contents of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] This disclosure generally relates to nonvolatile flash memories and more specifically, to flash memories for reliable page copy operations with error correcting functions and their methods of operating therein.
BACKGROUND OF THE INVENTION
[0003] Flash memories are commonly applicable to mass storage subsystems for electronic devices employed in mobile communications, game sets, and so forth. Such subsystems are usually implemented as either removable memory cards that can be inserted into multiple host systems or as non-movable embedded storage within the host systems. In both implementations, the subsystem includes one or more flash devices and often a subsystem controller.
[0004] Flash memories are composed of one or more arrays of transistor cells, each cell capable of non-volatile storage of one or more bits of data. Therefore, flash memories do not require power to retain the data programmed therein. Once programmed however, a cell must be erased before it can be reprogrammed with a new data value. These arrays of cells are partitioned into groups to provide for efficient implementation of read, program and erase functions. The typical flash memory architecture for mass storage arranges large groups of cells into erasable blocks. Each block is further partitioned into one or more addressable sectors that are the basic unit for read and program functions.
[0005] Flash memories basically have their own functional operations of reading, writing (or programming), and erasing. Flash memories additionally extend their facilities to practice a page copy operation (or a copy-back operation). The page copy operation is to transcript data stored in a page assigned to a specific address to another page assigned to another address. During the page copy, data stored in a page of a specific address are transferred to a page buffer and then the data remaining in the page buffer are written into another page assigned to another address by way of a programming process without reading the data out of the flash memory. The page copy function eliminates a need of reading-out data to be written and of loading data to be written from the external source of the flash memory, which is advantageous to enhancing systemic data rates associated with the subsystem controller.
[0006] However, unfortunately, it may occur that the pages to be copied and to be written have their own error bits. As shown in FIG. 1, assuming that a page PG 4 is to be copied and a page PGn- 3 is to be written, both pages each having one error bit, the data stored in the page PG 4 is transferred to the page buffer 10 and then written into the page PGn- 3 from the page buffer 10 . As a result of the page copy operation, two error bits are included in the page PGn- 3 . Because most flash memory controllers used as subsystem controllers in a card-type memory are usually only designed to correct one-bit error for a page, such a two-bit error in a page may be incapable of being cured after completing the copy back operation.
[0007] Although a flash memory controller could be equipped with an error correcting function capable of coping even with the two-bit error per page, it would cause the circuit architecture to be much more complex and thereby deteriorate operational efficiencies in the memory control system.
[0008] Embodiments of the invention address these and other limitations of the prior art.
SUMMARY OF THE INVENTION
[0009] Embodiments of the present invention provide a nonvolatile memory capable of maintaining the integrity of data through a page copy operation, and a method thereof. Such a nonvolatile memory is capable of preventing a transcription of error bits during a page copy operation.
[0010] According to an aspect of the present invention, a nonvolatile memory includes a number of pages storing data; a page buffer temporarily storing data by the page; a circuit for correcting a bit error of source data of a specific one of the pages; circuitry configured to provide the source data to the circuit and to provide amended data to the page buffer from the circuit; and a copy circuit configured to copy the source data into the page buffer and to store the amended data into another page from the page buffer.
[0011] The circuit generates new parities from the source data and compares the new parities with the old parities. Additionally, the device includes a circuit for generating column parities for bits composing one byte of the source data; and a circuit for generating line parities for bytes of the source data.
[0012] In the embodiment, a nonvolatile memory includes: a data field composed of a number of pages for storing data; a first circuit configured to storing first parities in a predetermined region of the data field, the first parities being generated during a programming operation for the page; a page buffer for temporarily storing data by the page; a second circuit configured to copy source data stored in a specific one of the pages into the page buffer; a third circuit configured to generate second parities from the source data stored in the page buffer; and a fourth circuit configured to transfer amended data of the source data to the page buffer in response to a result of comparing the first parities with the second parities. A fifth circuit is further included to store the amended data held in the page buffer into another page of the pages.
[0013] In the embodiment, a method of transferring source data of a specific page, the source data containing old parities, to another page in a nonvolatile memory having a page buffer temporarily storing data by the page, includes the processes of: storing the source data into the page buffer; generating new parities from the source data stored in the page buffer; comparing the old parities with the new parities; creating modified data of the source data in response to a result of the comparing; and moving the modified data to the another page through the page buffer. From the embodiment, it is available to inform an error status by the comparing result of the outside of the memory.
[0014] In this embodiment, a nonvolatile memory includes: a data storage field composed of a number of pages storing data; a page buffer for storing data of a specific one of the pages, being connected to the data storage field; and error correction circuit connected to the page buffer and including: a bit error detector configured to detect an bit error of the data of the specific page; and a bit error corrector configured to amend the bit error. The bit error detector includes: a parity generator for creating new parities from the data stored in the page buffer; and a comparator for generating error address information by comparing the new parities with old parities of the data.
[0015] The error address information is referred by the bit error corrector to correct the data and to transfer amend data to the page buffer. The modified data are transcribed into the specific page and another page.
[0016] The present invention will be better understood from the following detailed description of the exemplary embodiment thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The forgoing and other features and advantages of the invention will be apparent from the more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention:
[0018] [0018]FIG. 1 is a block diagram illustrating a conventional page copy-back feature in a NAND flash memory device.
[0019] [0019]FIG. 2 is a block diagram illustrating a page copy-back feature with error correction according to embodiments of the present invention.
[0020] [0020]FIG. 3 is a block diagram illustrating an error correction circuit according to embodiments of the present invention.
[0021] [0021]FIG. 4 is a circuit diagram illustrating gating circuits for performing data transmission between page buffers and the error correction circuit of FIG. 3.
[0022] [0022]FIG. 5 is a timing diagram of data transmission between the page buffers and the error correction circuit of FIG. 3.
[0023] [0023]FIG. 6 is a table illustrating a procedure of generating column and line parities according to embodiments of the invention.
[0024] [0024]FIG. 7 is a circuit diagram illustrating a circuit for generating the column parities shown in FIG. 6.
[0025] [0025]FIG. 8 is a circuit diagram illustrating a circuit for generating the line parities shown in FIG. 6.
[0026] [0026]FIG. 9 is a timing diagram of signals used in data transmission between the page buffers and the error correction circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] It should be understood that the description of the preferred embodiment is merely illustrative and that it should not be taken in a limiting sense. In the following detailed description, several specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced without these specific details.
[0028] A flash memory applicable to the present invention is embodied on a NAND flash memory, adaptable to be embedded in portable electronic devices such as integrated circuit cards, in which a number of memory cells are arranged in the pattern of strings coupled to a plurality of wordlines and bitlines disposed in a matrix of rows and columns.
[0029] A NAND flash memory according to embodiments of the present invention has a memory cell array divided into a plurality of pages designated by addresses. Each page is formed of a number of memory cells coupled to a wordline and coupled to a plurality of bitlines each by each. The page is a unit of reading and writing.
[0030] A NAND flash memory according to embodiments of the present invention is designed to carry out functional operations such as erasing to remove data stored in memory cells, programming to write data in memory cells, reading data out of the memory (i.e. a read-out operation), verifying to check out the status of memory cells after completing the erasing and programming, and page-copying to transcript data of a page into another page without a read-out operation.
[0031] A NAND flash memory according to embodiments of the present invention includes a page buffer circuit for temporally storing data to be read from memory cells or loaded from outside the memory in the operations of programming, reading-out, or page-copying. Also including are buffers and decoders for selecting pages or memory cells with addresses supplied from the outside, sense amplifiers for detecting data values, gate circuitry for transferring data from/to the memory cell array to/from input/output channels, and control circuits for managing the operations therein.
[0032] Embodiments of to the present invention include an error correcting operation associated with the page copy function.
[0033] In this embodiment, the term “read-out” is used to identify an operation of reading data out of the memory, i.e. the state that data from memory cells go out of the memory. The term “copy” is used to identify an operation of transferring data of a specific page into the page buffer, and “transcription” is used to identify an operation of moving the data held in the page buffer into another page. Further, “source data” is used to identify data to be copied with an error bit, and “modified (or correct or amended) data” is used to identify data to be transcribed without any error bit.
[0034] Now, practical embodiments of the invention will be explained in conjunction with the drawings FIGS. 2 through 9.
[0035] [0035]FIG. 2 illustrates a schematic feature of correcting a bit error during a page copy operation mode according to embodiments of the present invention. First, data stored in, for example, the page PG 4 , i.e., the source data, are loaded into the page buffer 10 by way of a read operation (this reading is distinguishable from the read-out operation used elsewhere in the present specification), which is referred as the “copy” operation. The data stored in the page buffer 10 , i.e., the source data of the page PG 4 (hereinafter referred as “source page), are put into an error correction circuit 20 to cure an error bit embedded in the source data before they are written into another page (e.g., PGn- 3 ; hereinafter referred to “transcription page”). The data modified by the error correction circuit 20 are transferred back into the page buffer 10 and then written into the page PGn- 3 . As a result, the page PGn- 3 is rendered to be free from the error bit embedded in the source data, preventing from the transcription of an error bit by the source data.
[0036] Even if the page PGn- 4 to be transcribed has its own error bit, a known function of error correcting may cure the single bit error thereof. More details about the error correcting procedure during the page copy operation will be described hereinbelow.
[0037] [0037]FIG. 3 illustrates a functional structure for conducting the error correction during the page copy operation. Referring to FIG. 3, once the source data De temporally stored in the page buffer 10 are provided to the error correction circuit 20 , a comparator 50 compares old parities OP, which have been created during the former programming (or writing) cycle and stored in a predetermined field of the memory, with new parities NP that are generated by a parity generator 40 during the copy operation. The new parities NP are parity data to be used to correct a bit error, i.e., a progressive bit error generated during the page copy operation with the source data. The old and new parities, OP and NP, are generated by the same manner. After comparing the old parities OP with the new parities NP, an information signal Ae of the page address involved in the progressive bit error is generated from the comparator 50 . The erroneous address information signal Ae is applied to an error correction logic circuit 60 to cure the bit error. The amended data Dc from the error correction logic circuit 60 are transferred to the page buffer 10 together with control signals CNT therefrom. More details about the parity generation and comparison is described hereinbelow.
[0038] [0038]FIG. 4 is a circuit diagram of latching and column-decoding blocks LDB 0 ˜LDBm- 1 , being disposed between the page buffering and sensing logic block 12 (included in the page buffer 10 ) and input/output lines I/O 0 ˜I/On- 1 , for transferring the source and correct data. Referring to FIG. 4, the source data of the source page (e.g., PG 4 ) assigned to a specific address are transferred to the error correction circuit 20 from the page buffering and sensing block 12 through the latching and column-decoding blocks LDB 0 ˜LDBm- 1 each corresponding to the input/output lines I/ 0 ˜I/On- 1 . The latching and column-decoding blocks LDB 0 ˜LDBm- 1 also transfers the amended data Dc provided from the error correction circuit 20 to the transcript page (e.g., PGn- 1 ) through the page buffering and sensing block 12 .
[0039] The source data De of the source page PG 4 are read by the page buffering and sensing block 12 and stored in latches LCH 0 ˜LCHn- 1 each corresponding to the bitlines BL 0 ˜BLn- 1 . The source data staying at the latches LCH 0 ˜LCHn- 1 are transferred to the input/output lines I/O˜I/On- 1 through column gates (or Y-gates) AG 0 ˜AGn- 1 and BG 0 ˜BGk- 1 in response to column gating signals YA 0 ˜YAn- 1 (primary) and YB 0 ˜YBk- 1 (secondary) by a unit of bit sequentially, as shown in FIG. 5, which may be referred to as “error-data out” as an operational state. For instance, a source data bit corresponding to the bitline BL 0 is transferred to the error correction circuit 20 through the input/output line I/O 0 when both of the column gating signals YA 0 and YB 0 are active with high levels.
[0040] The amended data Dc are transferred through the input/output lines I/O 0 ˜I/On- 1 from the error correction circuit 20 to the latches LCH 0 ˜LCHn- 1 each coupled to the bitlines BL 0 ˜BLn- 1 , which may be referred to as “amended-data in” as an operational state.
[0041] For instance, an amended data bit corresponding to the bitline BL 0 is transferred to the page buffer 10 (i.e., the page buffering and sensing block 12 ) through the input/output line I/O 0 when both of the column gating signals YA 0 and YB 0 are active with high levels. The amended data Dc temporarily stored in the latches are written into the transcript page PGn- 1 by way of a programming process.
[0042] [0042]FIG. 6 shows a practical fashion of generating the new parities NP according to embodiments of the present invention. The old parities OP are previously stored in a predetermined field of the memory, which were made in a former programming operation.
[0043] Known techniques for generating parities are briefly divided into two ways: one is a serial way and the other is a parallel way. Embodiments of the present invention employs the serial way in order to save a topological circuit area, but either embodiment is acceptable.
[0044] Illustrating that the source data De from which the parities are established is composed of 8-bits by 512-bytes, the parities are classified into column parities and line parities. The column parities are obtained from the 8 bits of one byte, while the line parities from the 512 bytes.
[0045] The column and line parities can be made in the circuits shown in FIGS. 7 and 8 respectively, both circuits being included in the parity generator 40 shown in FIG. 4. The generation of the column and line parities is accomplished by conducting exclusive-OR (XOR) logic chains with binary combinations to obtain a bit error from the packages of bits or bytes.
[0046] Now will be described about creating the column parities from the eight bits b 0 ˜b 7 with reference to FIGS. 6 and 7 and Table 1 following.
TABLE 1 Arithmetic Combination Column Parity b7 b6 b5 b4 b3 b2 b1 b0 CP1 * * * * nCP1 * * * * CP2 * * * * nCP2 * * * * CP4 * * * * nCP4 * * * *
[0047] The letter “*” represents the XOR operator to obtain the comparison result from the relevant bit combination. Therefore, complete arithmetic equations of the XOR logic are summarized as follows each for the column parities of six bits.
CP 1 = b 7 * b 5 * b 3 * b 1
nCP 1 = b 6 * b 4 * b 2 * b 0
CP 2 = b 7 * b 6 * b 3 * b 2
nCP 2 = b 5 * b 4 * b 1 * b 0
CP 4 = b 7 * b 6 * b 5 * b 4
nCP 4 = b 3 * b 2 * b 1 * b 0
[0048] Referring to FIG. 7, implementing the arithmetic combinations to generate each column parity is associated with four XOR gates XR and one flipflop FF. Each input/output line corresponds to each data bit. The column parity nCP 4 is generated from a flipflop FF 6 receiving an output of an XOR gate XR 19 . The gate XR 19 receives an output of an XOR gate XR 13 and the column parity nCP 4 fed-back thereto from the flipflop FF 6 . The gate XR 13 receives outputs of XOR gates XR 1 and XR 2 . The input/output lines I/O 2 and I/O 3 are coupled to inputs of the gate XR 2 , while the input/output lines I/O 0 and I/O 1 to inputs of the gate XR 1 . The column parity CP 4 complementary to the nCP 4 is generated from a flipflop FF 5 receiving an output of an XOR gate XR 20 . The gate XR 20 receives an output of an XOR gate XR 14 and the column parity CP 4 fed-back thereto from the flipflop FF 5 . The gate XR 14 receives outputs of XOR gates XR 3 and XR 4 . The input/output lines I/O 4 and I/O 5 are coupled to inputs of the gate XR 3 , while the input/output lines I/O 6 and I/O 7 to inputs of the gate XR 4 .
[0049] The column parity nCP 2 is generated from a flipflop FF 4 receiving an output of an XOR gate XR 21 . The gate XR 21 receives an output of an XOR gate XR 15 and the column parity nCP 2 fed-back thereto from the flipflop FF 4 . The gate XR 15 receives outputs of XOR gates XR 5 and XR 6 . The input/output lines I/O 0 and I/O 1 are coupled to inputs of the gate XR 5 , while the input/output lines I/O 4 and I/O 5 to inputs of the gate XR 6 . The column parity CP 2 complementary to the nCP 2 is generated from a flipflop FF 3 receiving an output of an XOR gate XR 22 . The gate XR 22 receives an output of an XOR gate XR 16 and the column parity CP 2 fed-back thereto from the flipflop FF 3 . The gate XR 16 receives outputs of XOR gates XR 7 and XR 8 . The input/output lines I/O 2 and I/O 3 are coupled to an input of the gate XR 7 , while the input/output lines I/O 6 and I/O 7 to an input of the gate XR 8 .
[0050] The column parity nCP 1 is generated from a flipflop FF 2 receiving an output of an XOR gate XR 23 . The gate XR 23 receives an output of an XOR gate XR 17 and the column parity nCP 1 fed-back thereto from the flipflop FF 2 . The gate XR 17 receives outputs of XOR gates XR 9 and XR 10 . The input/output lines I/O 0 and I/O 2 are coupled to inputs of the gate XR 9 , while the input/output lines I/O 4 and I/O 6 to inputs of the gate XR 10 . The column parity CP 1 complementary to the nCP 2 is generated from a flipflop FF 1 receiving an output of an XOR gate XR 24 . The gate XR 24 receives an output of an XOR gate XR 18 and the column parity CP 1 fed-back thereto from the flipflop FF 1 . The gate XR 18 receives outputs of XOR gates XR 11 and XR 12 . The input/output lines I/O 0 and I/O 3 are coupled to an input of the gate XR 11 , while the input/output lines I/O 5 and I/O 7 to an input of the gate XR 12 .
[0051] A clock signal CLK and a reset signal RST are applied to the flipflops FF 1 ˜FF 6 in common. Thus, the flipflops FF 1 ˜FF 6 outputs the column parities in response to rising edges of every cycle of the clock signal CLK. The feedback input of each column parity to the XOR gate positioned before its corresponding flipflop (e.g., nCP 4 to XR 19 from FF 6 ) is directed to detect the variation between a current bit and the next bit in the source data (i.e., to detect a progressive bit error during the page copy operation) and then to manage it with the serial way of parity generation.
[0052] As a practical example in the column parity generation, the column parities CP 1 , CP 2 and nCP 4 will be set to “1”, provided the bit b 3 is an error bit.
[0053] The generation of the line parities from the 512 bytes will be described with reference to FIGS. 6 and 8 and the following Table 2. Table 2 arranges byte combinations for XOR arithmetic implements in order to obtain the line parities LP 1 , nLP 1 , LP 2 , nLP 2 , LP 4 , nLP 4 . . . , LP 512 , and nLP 512 (LP 1 ˜nLP 512 ; 18 bits) against the 512 bytes of the source data.
TABLE 2 Arithmetic Combination {circumflex over ( )}B511 Line {circumflex over ( )}B510 {circumflex over ( )}B255 {circumflex over ( )}B3 Parity {circumflex over ( )}B512 {circumflex over ( )}B509 . . . {circumflex over ( )}B256 {circumflex over ( )}B254 {circumflex over ( )}B253 . . . {circumflex over ( )}B4 {circumflex over ( )}B2 {circumflex over ( )}B1 LP1 * * . . . * * . . . * * nLP1 ** . . . * * . . . * * LP2 * * . . . * * . . . * * nLP2 ** . . . * * . . . * * LP4 * *** . . . * ** * . . . nLP4 . . . . . . * ** * . . . . . . LP512 * *** . . . . . . nLP512 . . . * ** * . . . * ** *
[0054] In Table 2, the letter “*” notes the XOR operator to obtain the comparison result from the relevant bit combination, and “{circumflex over ( )}B” represents a result of an XOR operation for eight bits of their corresponding byte (e.g., {circumflex over ( )}B 512 =b 7 *b 6 *b 5 *b 4 *b 3 *b 2 *b 1 *b 0 in the 512 th byte). The factor {circumflex over ( )}B will be referred to as “byte parity unit” hereinafter. Therefore, complete arithmetic equations of the XOR logic from Table 2 are summarized as follows each for the line parities of 18 bits.
LP1 = {circumflex over ( )}B512 * {circumflex over ( )}B510 * . . . *{circumflex over ( )}B 256 * {circumflex over ( )}B254 * . . . * {circumflex over ( )}B4 * {circumflex over ( )}B2 nLP2 = {circumflex over ( )}B511 * {circumflex over ( )}B509 * . . . *{circumflex over ( )}B 255 * {circumflex over ( )}B253 * . . . * {circumflex over ( )}B3 * {circumflex over ( )}B1 LP2 = {circumflex over ( )}B512 * {circumflex over ( )}B511 * . . . *{circumflex over ( )}B 256 * {circumflex over ( )}B255 * . . . * {circumflex over ( )}B4 * {circumflex over ( )}B3 nLP2 = {circumflex over ( )}B510 * {circumflex over ( )}B509 * . . . *{circumflex over ( )}B 254 * {circumflex over ( )}B253 * . . . * {circumflex over ( )}B2 * {circumflex over ( )}B1 LP4 = {circumflex over ( )}B512 * {circumflex over ( )}B511 * {circumflex over ( )}B510 * {circumflex over ( )}B509 * . . . * {circumflex over ( )}B256 * {circumflex over ( )}B255 * {circumflex over ( )}B254 * {circumflex over ( )}B253 * . . . * {circumflex over ( )}B8 * {circumflex over ( )}B7 *{circumflex over ( )}B6 * {circumflex over ( )}B5 nLP4 = {circumflex over ( )}B508 * {circumflex over ( )}B507 * {circumflex over ( )}B506 * {circumflex over ( )}B505 * . . . * {circumflex over ( )}B252 * {circumflex over ( )}B251 * {circumflex over ( )}B250 * {circumflex over ( )}B249 * . . . * {circumflex over ( )}B4 * {circumflex over ( )}B3 * {circumflex over ( )}B2 * {circumflex over ( )}B1 . . . LP512 = {circumflex over ( )}B512 * {circumflex over ( )}B511 *{circumflex over ( )}B510 * {circumflex over ( )}B509 * . . . * {circumflex over ( )}B260 * {circumflex over ( )}B259 * {circumflex over ( )}B258 * {circumflex over ( )}B257 nLP512 = {circumflex over ( )}B256 * {circumflex over ( )}B255 *{circumflex over ( )}B254 * {circumflex over ( )}B253 * . . . * {circumflex over ( )}B4 * {circumflex over ( )}B3 * {circumflex over ( )}B2 * {circumflex over ( )}B1
[0055] Referring to FIG. 8, the byte parity unit {circumflex over ( )}B for each byte is first obtained through XOR gates XR 31 ˜XR 37 . The byte parity unit {circumflex over ( )}B is generated from the gate XR 37 . The gate XR 37 receives outputs of the gates XR 35 and XR 36 . The gate XR 35 receives outputs of the gates XR 31 and XR 32 , and the gate XR 36 receives outputs of the gates XR 33 and XR 34 . Inputs of the gate XR 31 are coupled to the input/output lines I/O 0 and I/O 1 , and inputs of the gate XR 32 are coupled to the input/output lines I/O 2 and I/O 3 . Inputs of the gate XR 33 are coupled to the input/output lines I/O 4 and I/O 5 , and inputs of the gate XR 34 are coupled to the input/output lines I/O 6 and I/O 7 .
[0056] The output of the gate XR 37 , {circumflex over ( )}B, is branched into 18 ways to establish the 18 line parities LP 1 ˜nLP 512 , being applied to inputs of NAND gates ND 1 ˜ND 18 in common. If there is an error bit among the eight bits of their corresponding byte, the byte parity unit {circumflex over ( )}B is set to “1”. The NAND gates ND 1 ˜ND 18 respond each to clock control signals nCLK 1 , CLK 1 , nCLK 2 , CLK 2 , . . . , nCLK 512 , and CLK 512 (nCLK 1 ˜CLK 512 ; 18 ea) to control bit paths from the byte parity unit {circumflex over ( )}B to the line parities. Outputs of the NAND gates ND 1 ˜ND 18 are applied to inputs of XOR gates XR 1 ˜XR 18 respectively. The gates XR 1 ˜XR 18 also receive the line parities nLP 1 ˜LP 18 fed-back thereto from flipflops FF 1 ˜FF 18 receiving outputs of the gates XR 1 ˜XR 18 , respectively.
[0057] As the clock signal CLK and the reset signal RST are applied to the flipflops FF 1 ˜FF 18 in common, the flipflops FF 1 ˜FF 18 outputs the line parities in response to rising edges of every cycle of the clock signal CLK. The feedback input of each column parity to the XOR gate positioned before its corresponding flipflop (e.g., LP 512 to XR 1018 from FF 1018 ) is directed to detect the variation between a current bit and the next bit in the source data (i.e., to detect a progressive bit error during the page copy operation) and then to manage it with the serial way of line parity generation. As a practical example in the line parity generation, if the byte B 3 has an error bit, the line parities nLP 1 , LP 2 , nLP 4 , . . . , nLP 512 will be set to “1”.
[0058] The timing diagram of FIG. 9 shows pulsing states of the column gating signals and clock control signals for transferring the source data from the page buffer 10 to the error correction circuit 20 , associated with the operations in the circuits of FIGS. 4 through 8. The transmission procedure shown in FIG. 9 is exemplarily carried out by way of the latching and column-decoding block LDB 1 shown in FIG. 4.
[0059] Referring to FIG. 9, as the primary column gating signals YA 0 ˜YAn- 1 are successively active with high levels for the secondary column gating signal YB 0 is being enabled with a high level, data bits corresponding to the bitlines BL 0 ˜BLn- 1 are sequentially transferred to the error correction circuit 20 through their corresponding input/output lines I/O 0 ˜I/On- 1 . By the same manner, in accordance with the sequential activation of the primary column gating signals YA 0 ˜YAn- 1 for each active state of the secondary column gating signals YB 0 ˜YBk- 1 , all the 512 bytes of the source data are transferred to the error correction circuit 20 through the input/output lines I/O 0 ˜I/On- 1 .
[0060] In the error correction circuit 20 , responding to the periodic oscillation of the clock signal CLK, the flipflops FF 1 ˜FF 6 of the column parity generator shown in FIG. 7 output the column parities CP 1 ˜nCP 4 . At the same time, the clock control signals CLK 1 ˜nCLK 512 demultiplied from the clock signal CLK enable the bit paths to be conductive through the NAND gates ND 1 ˜ND 18 of the line parity generator shown in FIG. 8, and the flipflops FF 1 ˜FF 18 of the line parity generator outputs the line parities LP 1 ˜nLP 512 of 18 bits.
[0061] The bit number of the new parities NP is 24 that is composed of the eight column parities CP 1 ˜nCP 4 and the eighteen line parities LP 1 ˜nLP 512 , which is the same with the old parities OP that have been stored in a predetermined field of the flash memory. An overall sequence for carry out the page copy operation with the error correction is as follows.
[0062] First, the old parities OP are generated and stored in a predetermined field of the memory during a programming period. After then, the new parities NP are generated by the circuits and procedure aforementioned as shown in FIGS. 6 through 8. The old and new parities are compared from each other by 24 bits.
[0063] In comparing the old parities OP with the new parities NP by the parity comparator 50 , if all 24 bits of the old and new parities are identical (i.e., the XOR operations with the old and new parities result in “0”), it is regarded as no error bit. On the other hand, it is regarded as one-bit error when the comparison result is “1” for 12 bits (a half of the 24 bits) between the old and new parities. Such a one-bit error is cured by the correction logic circuit 60 . Otherwise, only a comparison result for one bit among the 24 bits becomes “1”, it is regarded as a single error that has been already contained in the source data of the page to be copied. Other case except the former cases of comparison results may be regarded as there are more than two error bits.
[0064] Such bit error conditions may be available to be identified by a user in response to a command. Further, it may be practicable to transcribe the amended data into the source page as well as the transcription page.
[0065] The error correction circuit may be embedded in the flash memory according to embodiments of the present invention.
[0066] As described above, since an error bit contained in the source data of a source page is detected and cured by the error correction circuit before being written into a transcription page, it prevents the error bit of the source data from being transcribed into the transcription page.
[0067] Moreover, the flash memory according to present invention efficiently eliminates a progressive bit error that could occur during a page copy operation.
[0068] And, according to the embodiment aforementioned, there is no need of buffering components for error correction during a page copy operation because the page buffer, which is basically employed in a normal flash memory, is efficiently usable to assist the operation without additional modifications.
[0069] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as described in the accompanying claims | The disclosure is a NAND flash memory with the function of error checking and correction during a page copy operation. The NAND flash memory is able to prohibit transcription of erroneous bits to a duplicate page from a source page. Embodiments of the inventive flash memory include a correction circuit for correcting bit errors of source data stored in a page buffer, a circuit configured to provide the source data to the correction circuit and to provide correction data to the page buffer, and a copy circuit configured to copy the source data to the page buffer, and to store the correction data in the other page from the page buffer. | 6 |
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY
[0001] This invention relates generally to a method and apparatus for insulating masonry walls that provides improved moisture control at the interface between the insulation material and the masonry wall. More particularly, this invention pertains to an insulating process and apparatus in which one or more vapor barrier, sorbent and wicking materials are used in an insulation product that is applied to a masonry wall to reduce or prevent the formation of liquid water on the masonry wall.
BACKGROUND OF THE INVENTION
[0002] The exterior walls of a building are typically insulated in order to reduce the heating and cooling demands resulting from variations between the exterior temperature from the desired interior temperature. A wide range of fibrous, solid and foam insulating materials have been used to achieve this insulation, with a common insulating material being faced or unfaced batts of mineral or glass fibers.
[0003] When using a faced insulating product in which a facing layer, such as asphalt-coated Kraft paper or a polymeric film, is adhered to the insulating layer, the insulation product is typically installed with the facing layer positioned toward the interior space. This orientation tends to reduce infiltration or diffusion of the moisture-laden interior air through the insulating layer to the interface between the insulating product and the exterior wall. Particularly in climates with long heating seasons and/or extremely cold temperatures, using faced insulation products limits the amount of moisture from the interior air that can reach the cooler exterior wall and condense to form liquid water on the surface of the exterior wall.
[0004] As used herein, masonry walls include constructions utilizing clay brick, concrete brick or block, calcium silicate brick, stone, reinforced concrete and combinations thereof. Water present at the interface between the insulating product and the inside surface of the exterior wall and/or the outer portion of the insulation product is associated with a host of problems including mold growth, efflorescence, reduced insulating efficiency and, if sufficiently cold, frost spalling resulting from water freezing and expanding within cracks and gaps in the masonry.
[0005] A major contributing factor to the accumulation of water at the interface and the resulting decreased performance of the associated masonry wall system is the leakage of warm humid air through the building envelope to surfaces that are at temperatures below the dew point of the adjacent air and the associated accumulation of condensation within the insulating layer and/or on the inside surface of the exterior wall.
[0006] A need thus exists for an improved method of insulating exterior walls, particularly masonry walls, that provides improved control of water, particularly that resulting from the condensation of water vapor, at the interface between an inside surface of the exterior wall and the outer surface of the insulation product applied to the wall.
SUMMARY OF THE INVENTION
[0007] To solve the problems outlined above, the present invention provides an insulation product and an insulation system incorporating such a product for insulating exterior walls, particularly masonry walls, that incorporates a wicking media to transport condensed water from the interface between the insulating product and the exterior wall to a more interior location where it can evaporate and/or a sorbent material for holding water. An active layer or layers comprising one or more of a wicking fabric, wicking media and sorbent material is provided on or near the exterior surface of the primarily insulating layer. When the insulating product is installed, the active layer will be closely adjacent and/or in contact with an inside surface of the exterior wall.
[0008] The insulation product is preferably installed with a corresponding support element to form an insulation system. The support element will typically be provided along the lower edge of the insulation product and define a space between the insulation product and the floor. The support element may comprise several cooperating elements or structures and may, for example, include a baseboard portion to create a more finished appearance for the interior surface of the insulation system.
[0009] This space defined by the insulation system may be used for routing an extension portion of the primary wicking material toward and/or into the interior space in order to increase the evaporation rate. Additional elements, such as vents, grills, fans, ducts, sorbent material, secondary wicking materials and heaters, may be included in or connected to the support element for further improving the performance of the insulation system.
[0010] Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0012] FIGS. 1-4 are cross-sectional views of exemplary embodiments of an insulation product and insulation system according to the invention; and
[0013] FIGS. 5-11 are cross-sectional views of portions of exemplary embodiments of an insulation system according to the invention.
[0014] These drawings have been provided to assist in the understanding of the exemplary embodiments of the invention as described in more detail below and should not be construed as unduly limiting the invention. In particular, the relative spacing, positioning, sizing and dimensions of the various elements illustrated in the drawings are not drawn to scale and may have been exaggerated, reduced or otherwise modified for the purpose of improved clarity. Those of ordinary skill in the art will also appreciate that a range of alternative configurations have been omitted simply to improve the clarity and reduce the number of drawings.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0015] As shown in FIG. 1 , the insulation system 100 will be installed adjacent an inside surface of an exterior wall 10 and above a floor 12 . The insulation system will include a primary insulating layer 14 , typically a mineral or glass fiber web and a wicking material layer 16 , provided on the outside surface of the insulating layer. As installed, the wicking material layer 16 will be adjacent to and will preferably have at least portions in contact with the inside surface of the exterior wall 10 . The wicking material layer 16 may be attached to the primary insulating layer 14 using any suitable method such as melt bonding or discontinuous adhesive layers.
[0016] Thus positioned, the wicking material layer 16 will preferentially collect water as it is formed by the condensation of water vapor 18 that has diffused through the primary insulating layer 14 from the interior space 24 , typically a heated room, to a point near or at the cool, inside surface of the exterior wall 10 where the temperature falls below the dew point of the moisture content of the air. Similarly, the wicking material layer 16 will collect water 20 that diffuses or seeps through the masonry wall 10 from its outside surface, particularly for subsurface portions of the exterior wall that are not completely sealed. In addition to seepage, it will be appreciated that in those regions subject to periods of hot, humid weather, water vapor diffusing from the environment outside the exterior wall may condense as it reaches the cooler inside surface resulting from the air conditioning of the interior space 24 .
[0017] The wicking material layer 16 is preferably a non-woven material that can be formed from a polymer or natural fiber. One suitable polymer for manufacturing the wicking material is rayon. Rayon fibers may be striated, or include channels, along the length of the fiber, which provide capillary channels within the individual fibers so the wicking action does not depend solely upon capillary action resulting from the channels formed between two adjacent fibers.
[0018] In addition to rayon fibers, other polymeric fibers including polyester, nylon, polypropylene (PP) and polyethylene terephthalate (PET), may be manufactured or processed in a manner that will produce fibers including striations or channels on their surface. A number of fiber configurations have been developed that provide a plurality of surface channels for capillary transport of water and have been widely incorporated in active wear for improved comfort. These types of materials can be collectively referred to as capillary surface materials (CSM) and include so-called deep-grooved fibers that have high surface area per unit volume as a result of their complex cross-sectional configuration. The capillary material layer can be provided in different configurations including, for example, a non-woven film or a fine mesh configuration.
[0019] As a result of gravity, the wicking material layer 16 will tend to transport any water 21 that condenses at the interface between the insulation product 100 and the exterior wall 10 downwardly along the interface and, near the lower edge of the insulation product, inwardly toward the interior space 24 . The portion of the wicking material layer 16 extending toward or into the interior space 24 will allow the water to evaporate as water vapor 26 into the interior space without dripping and without accumulating on the inside surface of the exterior wall 10 .
[0020] There are several methods to form the wicking material which may be configured as a non-woven film and/or as a relatively fine mesh. The fibers can be laid down dry with an acrylic emulsion being applied to the fibers and then cured by heating or UV radiation exposure. Standard fiber binding emulsions such as acrylic or EVA (ethylene vinyl acetate) can be utilized.
[0021] As illustrated in FIG. 2 , in another embodiment of the invention the basic insulating material of FIG. 1 may be modified to include a vapor retarding layer 30 . The presence of the vapor retarding layer 30 will tend to reduce the amount of moisture 18 from the moisture laden interior air diffusing through the primary insulating layer 14 by blocking a portion 18 a of the vapor. By limiting the amount of moisture that can reach the cool inside surface of the exterior wall and/or adjacent materials, the vapor retarding layer can reduce the amount of condensation 21 that will be formed and removed through the wicking material layer 16 .
[0022] As illustrated in FIG. 3 , in another embodiment of the invention the basic insulating material of FIG. 1 may be modified to include a layer of sorbent material 28 . The sorbent material layer 28 will tend to absorb water in excess of the volume that can be successfully transported through the wicking material layer 16 and reduce the likelihood of water being present at the inside surface of the exterior wall 10 even during periods of excessive condensation or seepage. The sorbent material layer 28 will cooperate with the wicking material layer 16 to provide a “damping” effect whereby periodic increases in the volume of water can be removed over a longer period of time and reduce the volume of the wicking layer required to remove the condensate from the interface region. The sorbent material layer 28 may be a separate premanufactured layer that is laminated to the primary insulating layer 14 along with the wicking material layer or may be applied to the primary insulating material as a liquid and then dried, cured and/or activated to form a sorbent surface region within the primary insulating layer.
[0023] As illustrated in FIG. 4 , depending on the volume of condensate and seepage that are anticipated for a particular installation, the wicking material layer 16 present in the insulation product illustrated in FIG. 1 may be replaced by a layer of sorbent material 28 . Such an embodiment may be of particular utility for installations in which brief periods of high humidity are separated by longer periods of relatively low humidity. In such an environment, the sorbent material layer 28 will collect and hold the condensate formed from diffusing moisture 18 during periods of high humidity and allow the water vapor 23 to evaporate and diffuse back through the primary insulating layer 14 during periods of low humidity, thereby reducing or preventing the formation of water on the inside surface of the exterior wall 10 . A variety of sorbent materials may be used to form the sorbent material layer 28 , but will generally be characterized by their ability to absorb and hold at least about five times, and preferably at least about ten times, their weight in water.
[0024] As illustrated in FIG. 5 , the basic insulating product of FIG. 1 may be incorporated with a support element to form an integrated insulating system. The support element may comprise one or more separate cooperating elements including a primary support element 32 , a fascia or trim element 32 a and one or more connecting or holding elements 32 b in order to simplify assembly, but will typically define a space into which an extending portion 16 a of the wicking material layer 16 will extend toward the interior space 24 . The primary support element 32 and/or the trim element 32 a may include openings such as vent holes 34 or a grill (not shown) to provide for evaporation of the water in the lower portion of the wicking material layer 16 into the interior space 24 .
[0025] As illustrated in FIG. 6 , the support element may incorporate a sorbent material 36 that is positioned in contact with the extending portion of the wicking material layer 16 a to provide extra water capacity in the case of periodic increases in the volume of water being removed from the interface between the insulating product and the exterior wall.
[0026] As illustrated in FIG. 7 , the support element may also incorporate other elements such as a heating element 38 to assist in the evaporation of water from the extending portion 16 a of the wicking material layer. As illustrated in FIG. 8 , the support element may configured to provide additional space for holding a second wicking and/or absorbent material element 40 for increasing the evaporative area and thereby increase the volume of water that can be removed from the interface between the insulating product and the interior surface of the exterior wall. The support element may also define one or more passages 42 through which air or another gas may be forced by a fan or blower to increase the rate of evaporation from the surfaces of the second wicking element 40 and/or the extending portion 16 a of the wicking material layer 16 .
[0027] As illustrated in FIGS. 8 and 9 , the primary support element 32 may be mounted on the inside surface of the exterior wall at a position above the floor, FIG. 8 , or on or closely adjacent the floor, FIG. 9 . The configuration illustrated in FIG. 9 also allows direct attachment to the floor (not shown) and/or the inside surface of the exterior wall 10 . In either configuration, the trim or fascia portion 32 a will typically be configured so that it can be attached, either permanently or removably, to the primary support element 32 , typically in a manner that will also engage at least the extending portion 16 a of the wicking material. The trim element, whether incorporated in a unitary support element or, more typically, provided as a separate complementary element 32 a that is subsequently attached to the primary support element 32 , will tend to be configured with a region that extends over a lower portion of the surface of the insulating product to provide a more finished and aesthetically pleasing appearance.
[0028] As illustrated in FIG. 10 , the support element may include a primary support element 32 that is fastened in some fashion to the inside surface of the wall 10 and/or the floor 12 (not shown). The primary support element may be configured to provide for some range of vertical adjustment during installation so as to provide a substantially level support surface onto which the lower surface of the insulating element may be placed during installation. As illustrated in FIG. 10 , the insulating element may include both a primary insulating layer 14 and a wicking material layer 16 . The wicking material layer will typically include an extending portion 16 a that will tend to drape over a forward portion of the primary support element 32 , or at least cover a portion of the top surface of the primary support element 32 , as the insulating element is set into place.
[0029] The insulating system may then be completed by attaching a trim element 32 a to the primary support element 32 . The trim element 32 a may include one or more projections 32 b or recesses (not shown) which will cooperate with complementary structures provided on the primary support element 32 for securing the trim element to the primary support element of the supporting element. As illustrated in FIG. 10 , the projection 32 b or other fastening structures provided on the trim element 32 a and primary support element 32 may also be configured to engage and hold the extending portion 16 a of the wicking material layer within the supporting element. As further illustrated in FIG. 10 , the primary support element 32 and or the trim element 32 a may be configured to define one or more raceways 44 in which cables, typically communication and networking cables 36 can be concealed and secured within the supporting element.
[0030] As illustrated in FIG. 11 , the primary support element 32 or the trim element 32 a (not shown) may be provided with one or more elements or structures as illustrated in FIGS. 5-8 for increasing the rate of evaporation of the water and/or condensate reaching the extending portion 16 a of the wicking material layer 16 . In the particular embodiment illustrated in FIG. 11 , the primary support element is provided with a secondary evaporative and/or wicking material 40 is configured with regions or structures 40 a that will increase the effective surface area 40 a or permeability (not shown). The secondary material 40 includes a contact region at which direct contact may be established between the primary portion (not shown) or, more typically, a region of the extending portion 16 a of the wicking material layer when the insulating system is assembled. As a result of this contact, a portion of the water and/or condensate reaching the extending portion 16 a of the wicking material layer will transfer to the secondary evaporative and/or wicking material 40 where it may be more readily evaporated as a result of the increased surface area provided by the fin structures 40 a . As will be appreciated, the secondary evaporative and/or wicking material 40 may assume a wide range of configurations within, and/or partially without, the support element housing. It will also be appreciated that the particular embodiments illustrated and discussed herein, while exemplary, are not to be considered limiting or exhaustive and that a wide variety of configurations may be utilized to achieve the desired functionality and/or adapt the insulating system for more and less challenging conditions.
[0031] As also shown in FIG. 11 , the trim element 32 a may incorporate other structures such as a raceway 44 for communication or power cables 46 . The raceway may be configured to maintain a separation between the cables and the moisture remediation elements of the wall insulating system. The raceway may also be configured in a manner that will allow it to be opened to the interior space 24 for insertion and removal of cables 44 without requiring detaching of the trim element 32 a from the primary support element (not shown).
[0032] The principle and mode of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from its scope. | Disclosed are an insulation product and an insulation system incorporating such a product for insulating exterior walls, particularly masonry walls, that incorporates a wicking media to transport condensate away from the interface between the insulating product and the exterior wall. The condensate will be removed to a more interior location where it can evaporate and/or be transferred to and held in a sorbent material until conditions allow permit evaporation. The insulation system includes an integrated support element that can be used to increase the rate of evaporation via various methods and/or improve the aesthetic appearance of the insulating product. The evaporation rate may be improved through the use of increased wicking material area, secondary evaporative surfaces, heating and/or forced or natural convection. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a bone grip, and particularly to a bone grip for use in the attachment of the greater trochanter in a total hip replacement operation.
The present inventors have previously developed a range of bone grips for use in hip replacement, and these are described in U.S. Pat. No. 4,269,180. FIG. 1 of the present application is a drawing from that earlier patent, showing a commercially successful embodiment. This is a grip 10 having two parallel side limbs 12 connected by two bridges 14. The limbs curve rearwardly, terminating in upper and lower teeth 16, 18. There are pairs of bores 20 extending completely through the grip, in the regions of the bridges 14.
In a hip replacement operation, part of the greater trochanter may be cut off and has subsequently to be firmly re-attached. For this purpose, it is engaged by a grip 10, which is held in place by cerclage cables which pass through the bores 20 and through holes in the main shaft of the femur. The illustrated grip is for use with two cables. The ends of each cable are passed in opposite directions through the two holes in one of the bridges 14 and tensioned, whereupon the bridge is crimped. The resulting assembly is quite stable, and generally lasts well. However, there are very considerable strains on such a grip, and it is very important that it should hold the trochanter immobile for a period of months. We have found that this design does have a certain tendency to shift in the "vertical" direction (perpendicular to the bridges 14), the motion often approximating to pivoting about one or other of the cables. This is the muscle pull direction, so the forces involved are considerable.
U.S. Pat. No. 4,269,180 discloses also some variants of this design, most of them being generally H-shaped, having a pair of side limbs bridged by a single bridge penetrated by bores. There is also brief mention of a design in the form of a letter A. This is essentially the same as the H-designs, having bores for the cable passing through the bridge (or "cross-bar") of the letter A.
SUMMARY OF THE INVENTION
Broadly, the present invention concerns a bone grip with provisions for at least one "vertical" cable in addition to the conventional "horizontal" cable or cables. Thus there may be formations for guiding and/or retaining a "vertical" cable. These may include one or more of guide groove(s) in the front face of the grip, a guide hole in the proximal end region, and a guide hole in a bridge.
According to the present invention there is provided a bone grip comprising a base structure having a rear face for overlying bone, said base structure comprising a pair of side limbs and at least one bridge extending between the side limbs. At least one hole for a first cerclage cable extends transversely through both side limbs, preferably extending through the at least one bridge (which is then preferably crimpable to lock a cable in the hole). The base structure further provides at least one guide structure to hold and align the second "vertically-acting" cable. For example in one embodiment at one end region the side limbs may curve rearwardly and be shaped to define at least one hook or tooth. At least one hole for a second cerclage cable, running transversely to the first cerclage cable, can be provided through a said hook or tooth e.g. at a proximal end.
Preferably said side limbs coalesce at said one end region. Thus the base structure may be substantially A-shaped. Said coalesced limbs thus curve rearwardly as a single hook or tooth, through which said at least one second cerclage cable extends. There may be a groove on the front face of the base structure for guiding the at least one second cerclage cable towards the hole. There may be a bridge between the side limbs with a transverse hole or holes for guiding and optionally locking the second cable or cables.
Alternatively, or preferably additionally, guide structure for the "vertical" cable can be arranged to hold and align a bight of that cable, e.g. extending away in the distal direction of a femur. This structure may include a bridge extending between the side limbs and defining an arcuate guide path with end holes through the side limbs which incline towards the direction of extension of the second cable, providing cable support without sharp bends.
The grip will be made of surgically acceptable material, e.g. stainless steel, chromium-cobalt or titanium alloy.
Some embodiments of the invention will now be described in more detail with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a prior art bone grip;
FIG. 2 is a perspective view of a bone grip which is a first embodiment of the invention;
FIG. 3 is a front elevation of the first embodiment;
FIG. 4 is a side elevation of the first embodiment;
FIG. 5 is a perspective view from below of a femur having been subject to a hip replacement operation using the first embodiment of bone grip;
FIG. 6 is a view of the femur of FIG. 5 seen from the right hand below;
FIG. 7 is a view of the femur of FIG. 5 seen from the left;
FIG. 8 is a view similar to FIG. 2 but showing a second embodiment of bone grip;
FIG. 9 is a detail of the top hook region of a bone grip showing another possible variant;
FIG. 10 is a schematic "flattened out" view of a third embodiment;
FIG. 11 is a side view of the third embodiment, showing its curvature;
FIG. 12 is a detail of the lower region of a further variant, and also shows a clip-on member, and FIG. 13 is a side view of the clip-on member shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2 to 4 show a bone grip 100 having a base structure approximating to a letter A, having a pair of side limbs 102, 104 and a single bridge 106. The rear face is curved to conform to the surface of a greater trochanter. Beneath the bridge 106, the side limbs curve rearwardly, ending in distal teeth 108, 110. The top portion also curves rearwardly, forming a proximal hook 112.
A pair of distal bores 114, 116 pass through the side limbs 102, 104 and the bridge 106.
The "A" has a major opening 118 above the bridge 106. Above this opening 118, there is a plate like portion 120 penetrated by a circular opening 122. A proximal cable hole 124 extends through the grip, in the region of the circular hole 122.
The proximal hook 112 is cannulated. That is to say, it is tubular, there being an exit hole 126 for a cable on the top face some way above the circular hole 122, and an entry opening 128 at the end of the hook. A cable groove 130 extends from the exit hole 126 to the circular hole 122 and beyond this, to the opening 118.
As can be seen in FIGS. 5, 6 and 7, the bone grip 100 is mounted to the greater trochanter, and secured to the rest of the femur by cerclage cables 140, 142 which pass through the distal and proximal cable holes 114, 116, 124, in a manner similar to the cerclage cables as used in the prior art discussed above. These cables are shown in FIG. 7 as passing through anchor holes 143 in the lesser trochanter. The distal cable 140 has its two ends passed through respective bores 114,116 which extend through the bridge, which is crimped to lock them in place by means of a crimping tool which grips the edge faces of the bridge (i.e. the face bordering the opening 118 and the oppositely directed face). The proximal cable is engaged in the upper anchor holes 124. It may be a pair of beaded cables, extending out in opposite directions from the circular opening 122.
Additionally, there is a "vertical" cable 144 extending through the vertical cable bore 126. From the entry hole at the tip of the hook 112, this cable passes through the medullary canal, reemerging beneath the bone grip 100. Thus the two ends of the vertical cable 144 can be passed through a conventional crimp sleeve 146, and locked in place.
FIG. 8 shows a substantially similar bone grip 200. Elements corresponding to those of the first embodiment have corresponding reference numbers, but raised by 100.
Thus there are side limbs 202, 204, and a distal bridge 206. However in this example, the bridge 206 is curved, projecting forwardly of the adjacent portions of the side limbs, and the bores 214, 216 are correspondingly curved. This facilitates smooth cable passage.
This second embodiment also has a second, minor bridge 250 with a "vertical" bore 252 (extending along the axis of the A), to provide an anchorage for the vertical cable, in this case at the distal end.
FIG. 9 shows a further variation, namely a proximal hook 312 which is doubly cannulated; that is, it has two bores 326 in place of the single bore 126 or 226 shown in FIGS. 2 and 8.
FIGS. 10 and 11 show a bone grip 300 which resembles that shown in FIG. 8 in that it approximates to an A-shape with an additional lower bridge 350. However this lower bridge does not have a "vertical" bore and is curved, being proximally convex. The side limbs 302, 304 have cable openings 360, 362 angled upwardly towards the interior, so as to guide a vertically-acting cable bight to follow the line of the bridge 350, which has a guide formation such as a groove 364 for locating and supporting such a cable bight without kinks: see broken line X in FIG. 10. Alternatively there may be an enclosed bore of proximally-convex path through the lower bridge. The other end of the cable bight can be secured at a relatively distal region of the femur.
As in the second embodiment the main bridge 306 curves out of the plane of FIG. 10, and has two arcuate cable bores 314, 316.
The upper region has a proximal cable hole 324. This may be curved like the lower bores 314,316. However a straight bore 324 permits the grip body to be thinner.
There is no upper central hole as in the previous embodiments (122 in FIG. 2). The cable groove 330 is relatively long, running from adjacent the main opening 318 to the exit hole 326 in the tubular end portion of the proximal hook 312.
FIG. 12 shows an alternative form of distal end region. This has a thin straight bar 450 for the distal (lower) minor bridge. A clip-on member 490 can be hooked onto the bar 450. This member has an upper hook portion 492 (FIG. 13) for the purpose, and a body portion 494 in which a transverse cable bore 496 is defined. As shown in FIG. 12 this may be arcuate (convex upwards). A cable may be passed through this. Its ends may extend downwards and be secured to a distal region of the femur.
The embodiments of FIGS. 10, 11 and 12 offer the user alternative ways of securing a vertically-acting cable. The proximal groove and hole will hold and align a vertically-running cerclage cable passing through the medullary canal, as in FIGS. 5 to 7. Or, the upwardly-convex guide path and hole(s) at the distal bridge will hold and align a vertically acting cable, particularly arranged as a bight, which can be secured at a relatively distal part of the femur by an additional anchorage without needing to pass a cable through the medullary canal.
Whereas the present invention has been described and illustrated with respect to some preferred embodiments, the skilled reader will appreciate that alternatives and modifications are possible. It is intended to include all such alternatives and modifications within the scope of the appended claims. | A bone grip (100; 200; 300) for use with cerclage cables (140, 142, 144) is typically A-shaped, with two side limbs (102, 104; 202, 204; 302, 304) joining to form a rearwardly curving proximal hook (112; 212; 312). There are "horizontal" holes (114, 116; 214, 216; 314, 316) for cerclage cables extending through the side limbs and through a bridge (106; 206; 306). A "vertical" cerclage cable (144) is guided through a tubular end portion of the hook (124; 224; 324). It may be further guided by a groove (130; 230; 330) on the front surface of the grip and/or by passage through a hole (252) in a bridge (250). | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus for scheduling data in a half-duplex transmission, which can be implemented e.g. in uplink and downlink burst data transmission for half-duplex terminals in burst-mode frequency division duplex (FDD) systems.
BACKGROUND OF THE INVENTION
[0002] Modern access systems support different higher layer protocols. Protocols define the format and order of messages exchanged between two or more communicating entities, as well as the actions taken on the transmission and/or receipt of a message or other event. The central purpose of the Medium Access Control (MAC) protocol is sharing of radio channel resources. The MAC protocol defines how and when an access point or subscriber unit may transmit on the channel. The MAC protocol includes the interface's procedures to provide guaranteed services to upper layers.
[0003] Wireless medium is a shared medium, which demands the MAC protocol to co-ordinate the transmission of multiple traffic flows over it. The basic distinction between different MAC protocols is the duplexing of the uplink and downlink channels. In Time Division Duplex (TDD), the downlink and uplink channels use the same carrier frequency. The data unit, i.e. MAC frame, is divided into an uplink portion and a downlink portion. The border between the uplink and downlink portion can be adaptive, which makes it suitable for asymmetric connections. In Frequency Division Duplex (FDD), different carrier frequencies are used in the downlink and uplink transmission. The terminals may thus simultaneously transmit and receive the signals. Finally, in Half-duplex Frequency Division Duplex (H-FDD), different carrier frequencies are used for the uplink and downlink transmission, but the terminals do not transmit and receive simultaneously. This poses a challenging problem to the uplink and downlink resource management. Furthermore, the type of physical channel has a significant influence on the radio access protocol and scheduling procedures. In a continuous transmission channel, the traffic flow is transmitted in the downlink direction and the whole traffic flow is received in the access point of the access network. The terminals have to decode the whole flow and pick up the packets addressed to them. In a Time Division Multiplexing (TDM) stream channel, the modulation type is changed within one MAC frame. The change has to be announced at the beginning of the MAC frame. The packets intended for various terminals have to be re-ordered according to the modulation type used by a particular terminal. In a Time Division Multiple Access (TDMA) burst channel, a standby mode is allowed when the data is not addressed to a particular terminal. The frame structure is announced at the beginning of the MAC frame.
[0004] An example of a wireless communication system, where FDD and a burst mode of transmission are adopted, and support of half-duplex terminal is required, is the air interface for the IEEE 802.16 fixed broadband wireless access system. In this burst-mode FDD system, the downlink channel is framed to allow adaptive modulation and forward error correction (FEC). To accommodate half-duplex terminals, the downlink channel uses TDMA or a mixture of TDM and TDMA, where TDM is utilized for bandwidth efficiency and TDMA is used for half-duplex terminal support. Furthermore, downlink and uplink burst transmissions are centrally scheduled on a frame-by-frame basis by a central controller or access point (AP), in order to meet specified quality of service (QoS) requirements. Scheduling deals with the manner in which queued data packets are selected for transmission on the respective link or channel. A downlink map message, transmitted at the beginning of each frame, broadcasts the frame layout to all other terminals in the system.
[0005] However, the QoS requirements can impose very tight constraints on the AP scheduler, which has to determine which packets to transmit next, and when, in order to meet system-defined QoS requirements. Similarly, half-duplex terminal transmission and reception scheduling imposes additional tight constraints which are independent of the QoS requirements. In particular, the burst data transmission order in each frame has to be arranged in such a manner that, for each of the half-duplex terminals, transmission and reception intervals do not overlap in time.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to provide a method and apparatus for scheduling data in a half-duplex transmission, by means of which both QoS and half-duplex constraints can be met.
[0007] This object is achieved by a method of scheduling data for transmission via at least two half-duplex time division multiple access connections, the method comprising the steps of:
allocating for each connection respective capacities of data portions of a transmission frame so that the total capacity of all data portions of the transmission frame does not exceed a predetermined capacity for each transmission direction, and that the sum of capacities of data portions of each connection of the transmission frame in both transmission directions does not exceed the predetermined capacity; and setting the transmission timing of the data portions within the transmission frame in such a manner that transmission and reception intervals of each connection do not overlap in time.
[0010] Furthermore, the above object is achieved by an apparatus for scheduling data for transmission via at least two half-duplex time division multiple access connections, said apparatus comprising:
allocation means for allocating for each connection respective capacities of data portions of a transmission frame so that the total capacity of all data portions of said transmission frame does not exceed a predetermined capacity for each transmission direction, and that the sum of capacities of data portions of each connection of said transmission frame in both transmission directions does not exceed said predetermined capacity; and setting means for setting the transmission timing of said data portions within said transmission frame in such a manner that transmission and reception intervals of each connection do not overlap in time.
[0013] Accordingly, scheduling can be optimised to meet both QoS and half-duplex requirements. The suggested scheduling procedure is optimal in the sense that it is always successful provided that the amount of capacity allocated in both transmission directions to a half-duplex terminal does not exceed the predetermined capacity, e.g. frame length. Furthermore, the number of data portions, e.g. bursts, transmitted in a frame can be minimized, thus minimizing the number of data portions for each transmission direction in a frame. Thereby, the number of entries in a transmission map provided for each transmission direction, e.g. uplink and downlink, can be minimized, while allowing to schedule transmissions according to whatever QoS model.
[0014] The predetermined capacity may correspond to the maximum amount of capacity, e.g. frame length, available in the transmission frame for both transmission directions.
[0015] It ist to be noted that in the light of the present invention, the term “connection” should be interpreted in such a manner that each connection connects to a different terminal. Thus, an allocation for a connection also refers to a specific terminal. The connections may be wireless connections of a wireless communication system, wherein the transmission directions may be uplink and downlink directions.
[0016] The setting step comprises the steps of:
i) defining said set of capacity allocations for the one transmission direction of the transmission frame; ii) setting an allocation start time for the other transmission direction of a subsequent connection, whose transmission timing directly follows a transmission timing of a selected reference connection, according to an allocation start time for the one transmission direction of the reference connection; iii) setting an allocation start time for the other transmission direction of a non-subsequent connection, whose transmission timing does not directly follow the transmission timing of the selected reference connection, according to an allocation end time for the other transmission direction of a preceding connection, whose transmission timing directly precedes the transmission timing of the non-subsequent connection, and iv) setting an allocation end time for said other transmission direction according to the sum of the set allocation start time and a value corresponding to the allocated capacity.
[0021] The steps ii) to iv) may be successively performed for each connection.
[0022] A connection whose transmission timing is the first timing within said transmission frame is initially selected as said reference connection, and wherein a connection with a subsequent transmission timing is selected if said scheduling does not lead to a feasible allocation. The feasibility may be checked by determining for each connection whether the sum of the total value of allocated capacities for that connection for both transmission directions and a capacity value corresponding to the difference between the set allocation start time for said one transmission direction and the set allocation end time for said other transmission direction is less then or equal to said predetermined capacity.
[0023] Furthermore, the capacities of said data portions may be determined based on respective quality requirements of said connections. The transmission frame may be a MAC frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following, the present invention will be described in greater detail based on a preferred embodiment with reference to the accompanying drawings, in which:
[0025] FIG. 1 shows a schematic diagram of a wireless communication system in which the present invention can be implemented;
[0026] FIG. 2 shows a schematic diagram of an FDD based MAC protocol;
[0027] FIG. 3 shows a schematic diagram indicating notation of an uplink and downlink capacity allocation within a frame;
[0028] FIG. 4 shows a schematic diagram of specific allocation cases;
[0029] FIG. 5 shows a flow diagram of a scheduling procedure according to a preferred embodiment of the present invention;
[0030] FIG. 6 shows a schematic diagram indicating a feasible allocation; and
[0031] FIG. 7 shows a pseudo-code implementation example of the scheduling procedure according to the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] The preferred embodiment will now be described in greater detail based on an H-FDD scheduling scheme for scheduling uplink and downlink burst data transmission for half-duplex terminals or connections at an air interface of a fixed broadband wireless access (FBWA) system, e.g. according to the IEEE 802.16 specification.
[0033] FIG. 1 shows such an FBWA system, which comprises an access point AP, usually called base station (BS), and subscriber-stations (SS) S 1 to S 4 . An SS can either be an individual end user terminal or a group terminal with several end user terminals connected to it. All data traffic goes through the access point AP, so that the access point AP can control the allocation of capacity (bandwidth) on the radio channel. The capacity is scheduled and allocated by the access point AP according to agreed traffic and/or QoS parameters.
[0034] FIG. 2 shows an example of an FDD based MAC protocol. The downlink and uplink MAC frames F 1 to F 3 are of constant length. The downlink structure transmitted on a downlink carrier begins with a broadcast phase BP where information about uplink and downlink structure is announced. The broadcast phase BP is followed by a downlink phase DP for transmitting data bursts in the downlink direction. The uplink structure transmitted on an uplink carrier begins with an uplink phase UP for transmitting data bursts in the uplink direction, and is followed by a random access phase RAP primarily used for initial access but also for the signalling when a terminal has no resources allocated within the uplink phase UP.
[0035] In the following, a scheduling procedure according to the preferred embodiment for optimising uplink and downlink scheduling for half-duplex terminals or connections is described. The proposed procedure can be implemented in the access point AP or any other central controller of the communication system. Downlink and uplink bursts are simply characterized by their transmission duration, independently of the presence or absence of preambles and switching time gaps. The solution is sufficiently general to be adapted to many different systems, where TDM is also used for bandwidth efficiency, and the TDM portion needs to be ordered by burst robustness.
[0036] FIG. 3 shows a frame scheme indicating respective notations of a generic uplink and downlink capacity allocation for a terminal i, used in the following description of the scheduling procedure.
[0037] According to FIG. 3 , u i is the amount of uplink capacity allocated to terminal i, d i is the amount of downlink capacity allocated to terminal i, T is the total amount of capacity, available in the frame, both for uplink and downlink, s i u is the time offset at which the uplink capacity allocation for terminal i starts, s i d is the time offset at which the downlink capacity allocation for terminal i starts, and f i u is the time offset at which the uplink capacity allocation for terminal i ends. The following relationship must hold for uplink capacity allocations:
F i u =|s i u +u i | T , i.e., s i u =|f i u −u i | T (1)
[0038] Furthermore, the following relationship must hold for downlink capacity allocations:
f i d =|s i d +d i | T , i.e., s i d =|f i d −d i | T (2)
wherein f i d is the time offset at which the downlink capacity allocation for terminal i ends.
[0039] In the following, the term (s i u ,u i ) denotes the uplink capacity allocation for terminal i, and the term (s i d ,d i ) denotes the downlink capacity allocation for terminal i. The operator “| | T ” denotes a modulo operation with respect to the total amount T of capacity.
[0040] The conditions to be met for a feasible capacity allocation are as follows. A set U={(s i u ,u i )} (D={(s i d ,d i )}) of uplink (downlink) capacity allocations is considered feasible if and only if, for any time instant t ε[0,T], there exists only one capacity allocation (s j u ,u j ) ⊂ U (s j d ,d j ) ⊂ D), if any, such that:
| t−s j u | T <u j (| t−s j d | T |<d j ). (3)
[0041] Inequation (3) states that a time instant is included between the start and the end of the capacity allocation for terminal j. The uniqueness of j implies that capacity allocations for different terminals do not overlap in time.
[0042] A set U={(s i u ,u i )} of uplink capacity allocations is feasible if and only if
| s i u −f j u | T +u i +u j ≦T, ∀i,j, (4)
wherein:
1. |s i u −f j u | T is the time interval between the end of one allocation and the beginning of the other; 2. u i is the capacity allocated starting from s i u onward, u j is the capacity allocated starting from f j u backward; 3. in order that the two capacity allocations are not overlapping, the sum of the three must be not greater than T.
[0046] FIG. 4 shows a schematic diagram of specific cases for the above inequation (4). In the upper case, inequation (4) is true, while in the lower case inequation (4) is not true due to the overlapping uplink and downlink bursts.
[0047] A similar result can be stated for downlink allocations. A set D={(s i d ,d i )} of downlink capacity allocations is feasible if and only if
| s i d −f j d | T +d i +d j ≦T, ∀i,j. (5)
[0048] As an additional feasibility condition, a pair of uplink U={(s i u ,u i )} and downlink D={(s i d ,d i )} capacity allocation sets is considered feasible if and only if, for any terminal i and time instant t ε[0,T], such that |t−s i u | T <u i , it applies:
| t−s i d | T ≧d i . (6)
[0049] Thus, uplink and downlink sets of capacity allocations are feasible if and only if uplink and downlink allocations for the same terminal do not overlap in time. A pair of uplink U={(s i u ,u i )} and downlink D={(s i d ,d i )} feasible capacity allocation sets is feasible if and only if
| s i d −f i u | T +u i +d i ≦T, ∀i. (7)
[0050] In summary, the proposed scheduling procedure has to solve the following problem. Given a pair of uplink U={(s i u ,u i )} and downlink D={(s i d ,d i )} capacity allocation sets, the pair (U,D) is feasible if the inequations (4), (5) and (7) are all true.
[0051] Necessary conditions for the above inequations (4), (5), and (7) to be met can be immediately derived and are as follows:
1. Σu i ≦T;
2. Σd i ≦T;
3. u i +d i ≦T, ∀i. (8)
[0052] These conditions are also sufficient for a feasible pair of capacity allocation sets to exist.
[0053] It is assumed that U={(s i u ,u i )} is a feasible uplink capacity allocation set. Without losing generality, it is further assumed that indexes are assigned to terminals such that i<j s i u <s j u , i.e., terminals are indexed by increasing uplink capacity allocation start time. Now, for a specific feasible downlink capacity allocation set D={(s i d ,d i )} the following must apply:
s i d = { s j u + ∑ k = j + 1 i - 1 d k T i > j s j u + ∑ k = j + 1 n d k + ∑ k = 1 i - 1 d k T i ≤ j ( 9 )
where j is a terminal index between 1 and n. For any feasible uplink capacity allocation set U={(s i u ,u i )}, and for any set of {d i } satisfying conditions 2 and 3 of the condition set (8), there exists at least one j, such that the downlink capacity allocation set D={(s i d ,d i )}, obtained by assigning offsets according to equation (9), is feasible when combined with U, i.e., (U,D) is a feasible pair of capacity allocation sets.
[0054] FIG. 5 shows a flow diagram of a scheduling procedure based on the above allocation scheme defined in equation (9).
[0055] In the scheduling procedure, the following pre-conditions are considered to be met:
1. A set U={(s i u ,u i )} of uplink capacity allocations is defined. The set is feasible, i.e., capacity allocations for different terminals do not overlap in time. Any suitable scheduling algorithm, tailored to the system specific uplink QoS requirements, can be used. 2. Access terminals are identified by an index number ranging from 1 to n, such that i<j s i u <s j u , i.e., by increasing uplink capacity allocation start time. 3. The amount of downlink capacity allocated for each terminal has been determined, i.e., the set of capacities {d i } is defined. The procedure by which the set has been determined can be any suitable scheduling algorithm, tailored to the system specific downlink QoS requirements. 4. The set of capacities {d i } is such that Σd i ≦T, and u i +d i ≦T, ∀i.
[0060] The proposed procedure is aimed at defining or setting the time offsets {s i d }, at which the downlink capacity allocations must start, so that the resulting downlink capacity allocation set D={(s i d ,d i )} is feasible when combined with u, i.e., (U,D) is a feasible pair of capacity allocation sets.
[0061] The scheduling operation can be detailed step-by-step according to the sequence of steps indicated in FIG. 5 .
[0062] In step S 100 , the next terminal or connection j is set as a reference from which to start setting the capacity allocation starting offsets or times. The first time step S 100 is performed, j=1 is set, i.e. the terminal or connection with the first or earliest allocation start time is set as the reference terminal, while the next times j=1+|j| n is set.
[0063] Based on the choice of the reference terminal made in step S 100 , it is verified if the corresponding downlink allocation is feasible. This is accomplished as follows. A subsequent start terminal i=|j| n +1 to be considered first is determined in step S 101 , and going on considering one terminal at a time by increasing index (modulus n, i.e., the index after n is 1), the following operations are performed. In step S 102 , it is checked whether the considered terminal is the start terminal, i.e. i=|j| n +1. The downlink allocation starting offset of terminal i is then set as follows. If i=|j| n +1, i.e. the answer in step S 102 is “yes”, then the downlink allocation start time or offset is set according to the uplink allocation start time or offset of the reference terminal, e.g. s i d =s j u . Otherwise, if the answer in step S 102 is “no”, then the downlink allocation start time or offset is set according to the uplink allocation end time or offset of the preceding terminal, e.g. s i d =f i-1 d .
[0064] Then, in step S 105 , the downlink capacity end time of the considered terminal i is set according to the sum of the downlink allocation start time and the respective downlink capacity allocated to the considered terminal, e.g. f i d =|s i d +d i | T . It is noted that, by determining the allocation according to this formula, it could happen that the allocation wraps around the end of the frame and, in this case, two different allocations to the same terminal are actually defined, one at the end and the other at the beginning of the frame, respectively. However, this can happen for at most one terminal per frame.
[0065] In step S 106 , it is checked whether the obtained allocation for the considered terminal or connection is feasible. As an example, the overall current allocation can be tested or checked according to the following calculation based on (7). If |s i u −f i d | T +u i +d i >T, the terminal j selected in step S 100 is not suitable. Then, the answer in step S 106 is “no” and the current allocation procedure is stopped and reset in step S 107 , wherein the allocated downlink capacity starting times or offsets are deleted. Furthermore, the procedure returns to step S 100 so as to select the next reference terminal.
[0066] Otherwise, if the answer in step S 106 is “yes”, i.e. the allocation defined for terminal i is fine. Then, it is checked in step S 108 whether all terminals have been considered, i.e. i=j. If so, all of the downlink capacity allocation starting times or offsets have been set successfully. The scheduling procedure has finished and the resulting set D={(s i d ,d i )} gives the optimized downlink capacity allocation.
[0067] Otherwise, if there are still terminals to be considered, the next terminal must be considered. To achieve this, the next terminal is set in step S 109 , i=1+|i| n , and the procedure returns to step S 102 .
[0068] By referring to the procedure illustrated above, it can be stated that the procedure for optimal downlink allocation consists of searching for a downlink capacity allocation set where allocation start times are determined as a function of the set of downlink capacities and the set of uplink capacity allocations, according to equation (9). The suggested procedure implements a linear search by increasing the index of the reference terminal, i.e. the value of j, starting from j=1, and verifying whether the corresponding downlink allocation set resulting from equation (9), combined with the uplink allocation set U, is feasible or not.
[0069] FIG. 6 shows an example of a feasible pair, where the downlink allocation set D was obtained according to equation (9) with j=4. As can be gathered from FIG. 6 , the allocation start times or offsets of the downlink data bursts 1 to 4 are arranged in such a manner that no downlink data burst overlaps with a corresponding uplink data burst of the same terminal or connection. The downlink data burst 2 has been split up at the end and the start of the frame due to the modulo operation with respect to the maximum capacity value of the frame.
[0070] FIG. 7 shows a pseudo-code example for a software routine for controlling a scheduling function at the access point AP or another central controller of the communication system. This pseudo-code routine corresponds to a specific implementation example of the procedure indicated in FIG. 5 when using equation (9).
[0071] It is noted that the present invention is not restricted to the preferred embodiment described above, but can be used in any scheduling function for scheduling data portions to be allocated to transmission frames of half-duplex connections. In particular, the present invention is not restricted to the specific use of an initial preset uplink allocation. As an alternative, a downlink allocation may be preset, based on which uplink allocation start times and end times are determined. In general, one transmission direction can be scheduled based on the other transmission direction. Thus, the preferred embodiments may vary within the scope of the attached claims. | The present invention relates to a method and apparatus for scheduling data for transmission via at least two half-duplex time division multiple access connections, wherein for each connection respective capacities of data portions to a transmission frame are allocated so that the total capacity of all data portions of the transmission frame does not exceed a predetermined capacity for each transmission direction, and that the sum of capacities of data portions of each connection of the transmission frame in both transmission directions does not exceed the predetermined capacity. Then, the transmission timing of the data portions within the transmission frame is set in such a manner that transmission and reception intervals of each connection do not overlap. Accordingly, scheduling can be optimised to meet both QoS and half-duplex requirements. | 7 |
BACKGROUND OF THE INVENTION
[0001] Presently, there exists no system for integrating and automating the various communication, record keeping, vehicle maintenance, and route management needs of commercial vehicle fleet operators. For example, DOT log book records may be stored on a portable or on-board computer. Haendel et al., in U.S. Pat. No. 5,359,528, hereby incorporated by reference in its entirety, discloses a vehicle monitoring system using a satellite positioning system for recording the number of miles driven in a given state for purposes of apportioning road use taxes. Also, cellular telephone communication and other wireless mobile communication systems have improved the communication between a vehicle operator and a central dispatcher. However, there still exists a need for a single, comprehensive vehicle management system that can integrate all aspects of commercial fleet operators.
SUMMARY OF THE INVENTION
[0002] It is, therefore, an object of the present invention to provide a commercial vehicle fleet management system which integrates a vehicle on-board computer, a precise positioning system, and communication system to provide automated calculating and reporting of jurisdictional fuel taxes, road use taxes, vehicle registration fees, and the like.
[0003] It is another object of the present invention to provide a system which allows for driver and vehicle performance and evaluation.
[0004] It is another object of the present invention to provide a system that allows a commercial fleet operator, and the customers thereof, to monitor the position of a given shipment.
[0005] It is another object of the present invention to provide a system for aiding in accident reconstruction or accident investigation.
[0006] It is yet another object of the present invention to provide a system which automates all other aspects of a commercial fleet operation, such as scheduling of routine maintenance, vehicle operator payroll, hours on service or mileage limitation compliance, DOT log books, inventory control, speed, engine RPM, braking, and other vehicle parameters, route analysis, pick up and delivery scheduling, fuel consumption and efficiency, border crossings, driver error, data transfer, safety, security, etc.
[0007] A first aspect of the present invention employs position information and geographical database information to calculate and automate reporting of fuel tax and vehicle registration fees.
[0008] A second aspect of the present invention employs position information, geographical database information and vehicle operational parameters to calculate and automate vehicle operator logs, operator and vehicle performance and efficiency, route analysis, vehicle operator payroll, hours on service (HOS) compliance, etc.
[0009] A third aspect of the present invention employs vehicle position information and a communication system for increasing the efficiency of a commercial vehicle operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The detailed description of the invention may be best understood when read in reference to the accompanying drawings wherein:
[0011] [0011]FIG. 1 shows a preferred embodiment of the present invention wherein a satellite based positioning system is employed to monitor vehicle position.
[0012] [0012]FIG. 2 shows a diagrammatic embodiment of an exemplary system according to the present invention.
[0013] [0013]FIG. 3 shows a diagrammatic representation of truck employing the vehicle management system according to the present invention.
[0014] [0014]FIG. 4 shows an embodiment of the present invention wherein route analysis may be employed to direct a driver to an appropriate service center for refilling, servicing, and the like.
[0015] [0015]FIG. 5 shows the interior of a vehicle equipped with the system according to the present invention.
[0016] [0016]FIGS. 6A, 6B, and 6 C show various embodiments of the hand-held terminals employable with the system according to the present invention.
[0017] [0017]FIG. 7 shows an exemplary removable data storage media according to the present invention.
[0018] [0018]FIG. 8 shows an infra red (IR) data port mounted on the exterior of a vehicle at a data extraction station.
[0019] [0019]FIGS. 9A and 9B depict an exemplary embodiment of the on-board computer wherein vehicle parameters such as speed, RPM, fuel use, and the like may be monitored and stored in memory for later downloading.
[0020] [0020]FIG. 10 depicts exemplary vehicle parameters which may be monitored and stored in memory.
[0021] FIGS. 11 A- 11 C show a flow diagram of a preferred means for communicating data stored on-board to a central dispatcher.
[0022] [0022]FIG. 12 show a flow diagram wherein radio frequency communication is used to for data transfer and route analysis.
[0023] [0023]FIG. 13 shows a flow diagram for recording a jurisdiction change event and associated data.
[0024] [0024]FIGS. 14 and 15 shows a somewhat more elaborate flow diagram for monitoring jurisdictional line crossings.
[0025] [0025]FIG. 16 shows a flow diagram for the monitoring and recording of engine RPM events.
[0026] [0026]FIG. 17 shows a flow diagram for the monitoring and recording of vehicle speed events.
[0027] [0027]FIG. 18 shows a flow diagram for the monitoring and recording of hard braking events.
[0028] [0028]FIG. 19 shows a flow diagram depicting the ability of the present system to anticipate a temperature change and adjust the temperature of the freight hold accordingly.
[0029] [0029]FIG. 20 shows a flow diagram depicting a security feature of the present invention.
[0030] [0030]FIG. 21 shows a flow diagram depicting yet another security feature of the present invention.
[0031] [0031]FIG. 22 shows a flow diagram depicting HOS compliance monitoring according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Although the invention is primarily described with respect to the commercial trucking industry it is understood that the system according to the present invention may likewise be advantageously employed in other air, water, or land based vehicle operations. Also, the system can likewise advantageously be employed in non-commercial vehicles for calculating, reporting, and paying road tolls and the like.
[0033] Referring now to FIG. 1, there is shown a diagrammatic representation of a commercial vehicle 104 employing a precise positioning means on board (not shown). Although the depicted embodiment in FIG. 1 depicts the use of a satellite 108 based positioning service such as GPS and the like, it will be understood by those skilled in the art that the present invention is not limited to any particular positioning means, and other positioning devices may also be used as an alternative to, or in addition to, satellite based positioning, such as LORAN, OMEGA, and the like. By continuously determining position at periodic intervals, a vehicle path 112 can be calculated and stored in memory.
[0034] The present invention allows position data to be used in conjunction with miles traveled (e.g., based on odometer readings), gas mileage, and a database stored in memory which contains information such as jurisdictional boundaries to correlate vehicle path 112 with border crossing events as vehicle 104 crosses jurisdictional borders 116 , thereby automating the calculation and reporting of fuel tax apportionment among various jurisdictions (e.g., under the International Fuel Tax Agreement (IFTA)), vehicle registration fee apportionment (e.g., under the International Registration Plan (IRP)). Additionally, any other jurisdiction-specific road use taxes, vehicle entrance fees, e.g., tolls, based on vehicle weight, number of axles, etc., may likewise be computed and reported. Since border crossing is monitored, payment or reporting requirements can be handled automatically, e.g., via a wireless data transmission or storage in a memory-device on-board for later batch downloading, thus eliminating the need for toll booths.
[0035] The present invention employs a database containing information corresponding to geographical location. Such location information is based on certain defined areas hereinafter termed “geo-cells.” A geo-cell may be based on jurisdictional boundaries, such as country borders, state borders, or even county or city lines, etc. However, the boundaries of a given geo-cell may alternatively correspond to a division of a geographical area without regard to jurisdictional boundaries, although the jurisdictional information for any such boundaries within a given geo-cell will be stored in the database. A geo-cell may contain additional information, such as climactic conditions, landmarks, services areas, and the like.
[0036] In this manner, the use of the geo-cells allows only the database information that will be needed for a given route to be downloaded to a on-board vehicle memory device, minimizing the memory storage requirements. For example, the selection of geo-cells can be performed by route analysis software at the start of a trip. If a vehicle is rerouted while in transit, or if position tracking data indicates that a driver is about to enter a geographic area corresponding to a geo-cell for which the geo-cell data has not been downloaded, route analysis software may be used to anticipate such an event and request the appropriate data via a wireless communication link with a central dispatch office.
[0037] [0037]FIG. 2 shows a somewhat graphical representation of an exemplary communication system according to the present invention. A transceiver (not shown) on-board a vehicle 104 allows two-way communication with a central office or dispatcher 120 . Although in FIG. 2 satellite communication via satellite 109 and centrally located base station 124 is contemplated, the present invention is not limited to satellite communication links, and other forms of wireless two-way data and voice communication are likewise advantageously employed within the context of the present invention, e.g., cellular voice or data links, PCS links, radio communications, and the like.
[0038] In a preferred embodiment, a vehicle will have the capability to communicate via satellite as well as via land based towers as depicted in FIG. 3., showing vehicle 104 , tower 116 , and satellite 110 . In this manner, the less expensive land-based communication can be used whenever available with the more expensive satellite communication being used when necessary to maintain continuous two-way contact.
[0039] [0039]FIG. 4 depicts a vehicle 104 at a service center 128 in relation to map 132 . FIG. 4 illustrates the manner in which position information may be employed to direct the vehicle operator to a given site for fuel, servicing, and the like. In this manner, an operator of a vehicle fleet, or another purchasing therefore, may purchase fuel at a discounted rate, e.g., a bulk rate or when prices are advantageous, and the vehicle operators may accordingly be instructed as to which outlets the fuel may thereafter be purchased from. Similarly, by monitoring vehicle mileage, scheduled or routine maintenance may be scheduled by the system according to the present invention and the vehicle operator informed when such servicing is due, thereby avoiding costly breakdowns.
[0040] [0040]FIG. 5 shows a vehicle operator 136 and vehicle interior 140 and an exemplary embodiment of an on-board data terminal 144 useable with the system according to the present invention. In the embodiment depicted in FIG. 5, data terminal 144 comprises a display screen 148 , keypad 152 , and removable data storage media 156 . Removable media 156 allows vehicle to vehicle transfer of trip event data for a given operator, allowing the system to prepare operator payroll, e.g., as where a driver is paid per mile driven, and can monitor compliance with HOS requirements, though the driver may operate multiple vehicles in a given time period.
[0041] [0041]FIGS. 6A, 6B, and 6 C depict alternative embodiments of vehicle mounted data terminals. FIG. 6A shows a data terminal 160 and a data terminal vehicle dock 164 . Terminal 160 and docking unit 164 preferably comprise mating data and power connectors. FIG. 6B depicts a data terminal 168 and data cable 172 . Each of data terminals 160 may preferably be removed and transferred from vehicle. Similarly, they may be removed from a vehicle for batch downloading at a central location. FIG. 6C depicts a data terminal 144 having removable memory card 156 .
[0042] [0042]FIG. 7 shows the operation of dash mounted data terminal 176 wherein driver 136 is inserting memory card 156 . The card 156 may contain the trip start and end locations, driver 136 data, route information, and the like, and may be used for storage of events, locations and associated data.
[0043] [0043]FIG. 8 shows the operation of a vehicle exterior data transfer pod 180 having infra red (IR) port 184 and the mating data station receptacle 188 of interface 192 of a main computer system or network (not shown). Interface 192 preferable comprises data transfer indicator lights 196 to indicate when data transfer is complete. Although an IR data port is depicted, other forms of data transfer may likewise be employed, such as radio frequency (RF) transmission, cable connection, optical, e.g., fiber optics coupling, ultra sound, and the like.
[0044] [0044]FIGS. 9A and 9B show a vehicle 104 having an on-board computer 200 with data terminal 204 whereby engine RPM, vehicle speed, and fuel consumption may be monitored and correlated with position tracking data. Vehicle 104 may also have sensors 202 , which may be, for example, drive train transducers, weight sensors, and the like.
[0045] [0045]FIG. 10 depicts an engine 208 , on-board computer 200 and data bus 212 whereby various engine and vehicle parameters may be processed, recorded, and correlated with position tracking data.
[0046] [0046]FIG. 11A depicts a flowchart depicting a method for communication between a vehicle in transit and a dispatch office. In step 300 a trip event is recorded in memory. Step 304 determines whether an emergency or urgent status is warranted. Emergency status may be assigned to any predetermined event, such as accident or vehicle breakdown, and the like. Also, emergency status may be manually assigned by a vehicle operator. For example, the on-board computer system may provide a panic button or emergency button which would alert the central dispatching office. Thus, if the driver is involved in an accident, or of the driver suffers a medical emergency while driving such as a heart attack, the system according to the present invention would not only alert the dispatcher, but would also provide precise position information to allow emergency or rescue workers to reach the scene immediately.
[0047] If such an emergency or urgent status exists, then the data is sent immediately (step 320 ). If the event recorded in step 300 is not urgent, then it will be stored in memory for batch downloading at a later time in step 308 . In this way, the number of transmissions may be reduced, and costs associated with wireless communication may thereby be reduced. Step 312 determines if the time elapsed since the last download of data reaches a certain threshold value. If a predetermined time interval since the last download have not elapsed, the system will return to step 312 , which will continue until the predetermined time period has elapsed. When the time period has elapsed, recorded events stored since the last download are sent in step 320 . After downloading, the program will return to step 300 and repeat.
[0048] [0048]FIGS. 11B and 11C depict a preferred method for communication between a vehicle in transit and a dispatch office. In an especially preferred embodiment, the processes of FIGS. 11A and 11B are run as parallel or concurrent processes. Referring now to FIG. 11B, in step 301 trip events are monitored continuously In step 305 , the monitored event is compared to preselected or predetermined criteria for data monitoring. Examples of such criteria may include, for example, state line crossing, vehicle engine parameters outside of a given range such as excessive engine RPM, excessive speed, hard braking events, delivery drop off and pick up, driving time, on-duty time, mileage events, driver errors, route changes, freight temperature, weather conditions, road closings, cost or efficiency parameters, and the like. In step 309 , it is determined whether the event monitored warrants recordation. The criteria are predetermined. Some events may, for example, warrant recordation each time they occur. Examples of such events would be, for example, border crossings, loading and unloading events, change of geo-cell, accident events, emergency communications from driver, e.g., driver in trouble or vehicle breakdown events, and the like. For these events, the criteria for recording the event may be said to be the occurrence of the event itself. Other events monitored may occur continuously or too frequently for recording, i.e., dynamic events, and thus, the system may accordingly be programed to record such events upon the meeting certain criteria. For example, events such as engine RPM may be required to meet a certain range or level, e.g., in an engine idle or excessive RPM range. Other examples of such parameters include, for example, vehicle speed, mileage, driving or driver on duty time, only if they exceed a given value an emergency or urgent status is warranted. In addition to range limitations as criterial for event recording, such continuously or frequently occurring events may also be sampled at given time interval. In such cases, the criteria for recordation becomes the passage of a certain period of time since the last recordation.
[0049] If the event does not meet the predetermined criteria, it is not recorded and the program returns to step 301 . If the monitored event does meet the established criteria, the event is stored in memory in step 313 . The program then returns to step 301 and continues monitoring events.
[0050] Referring now to FIG. 11C, in a process that runs parallel to that depicted in FIG. 11B, the importance of the event recorded in step 313 (FIG. 11B) is established in step 317 . Importance is established according to preset or preloaded fixed criteria. Event criteria importance will depend on, for example, time, distance, date, cost, resources, location, geo-cell, state line crossing, state line missed, and the like. Depending on the importance of the event recorded as determined in step 317 , action to be taken is evaluated in step 321 . If immediate action is required, as determined by the event importance, e.g., emergency, accident, and the like, or upon the expiration of a predetermined period of time, appropriate action will be taken in step 333 . Appropriate action may be, for example, driver notification (e.g., of route change, route change, delivery of pick-up time or location change, etc.) or alerting a central dispatch office (e.g., in case of accident, breakdown, or other urgent or emergency situation), or batch wireless download of recorded data (e.g., upon expiration of a predetermined time period or other event such as the amount of data storage resources used). If immediate action is not required , the event status is updated and the program returns to step 317 . Updating event status comprises logging the fact that the event was processed and establish a time or other criteria for next review. The event status may also optionally be updated at other steps in the process, including, for example, step 317 , step 321 , and/or step 333 .
[0051] [0051]FIG. 12 shows a flow diagram of the use of data sent over radio frequencies, such as public access data and the like, in conjunction with vehicle location information. In step 324 , vehicle location is determined. In step 328 , the geo-cell database is checked for available frequencies in the vehicle's location. The frequencies are tried in step 332 and in step 336 , the best frequency is determined based on factors such as reception, cost, and the like. After handshake step 340 or the like, information is then requested in step 344 . Vehicle and recorded event information may likewise be transmitted in step 348 . The computer then determines whether a change of course is warranted in step 352 , depending on the information received in step 344 and/or step 348 such as weather, accident, construction, or other information pertaining to traffic delays or other travel advisory information, availability of an additional load to pick up, change in delivery time or destination, etc. The determination can be made based on the availability of an alternative route or routes and a comparison of estimated arrival times based on analysis of the various alternatives. If no change is warranted, i.e., the current route is still the best option, then the program will return to step 324 and repeat. If a change of course is warranted, the dispatch office is contacted in step 356 via a wireless link, new data such as time of arrival are calculated and forwarded in step 360 , and the driver is instructed as to the new route in step 364 . The program then returns to step 324 and repeats.
[0052] [0052]FIG. 13 shows a flow diagram of a general method for determining when a border crossing event has occurred. In step 364 , the position of the vehicle is determined. In step 368 , the determined position is compared with a database containing jurisdictional boundary information and the jurisdiction, e.g., state, country, etc., is determined in step 372 . In step 376 , it is determined whether the vehicle is in the same jurisdiction as it was during the last calculation and comparison. If the vehicle is in the same jurisdiction, a crossing must have occurred and the border crossing event is recorded in step 380 , along with associated data such as date, time, new state, mileage, fuel consumption, fuel taxes paid and/or owed, and the like. The process is then performed again from step 364 . At certain intervals, the recorded events are downloaded to a central dispatch office via wireless link in step 384 .
[0053] [0053]FIG. 14 shows a flow diagram for a preferred method of detecting a jurisdiction crossing event and is discussed in conjunction with FIG. 15. Although the jurisdictional border crossings will hereinafter be referred to as state line crossings for the sake of brevity, it will be understood by that the invention is equally applicable outside of the United States and will find utility in detecting any positional event, including local jurisdictional crossings, country borders, and even boundaries based on climate, elevation or other geographical or physical features. Similarly, the general approach, as depicted in FIG. 13, is to determine in which state the current position exists and determine if the current state is different from the last known state. If the states are different then a crossing must have occurred.
[0054] There are a series of calculations performed in the preferred embodiment of FIG. 15 to determine the current state, as well as ensure that the location of the detected crossing is accurate. Such issues as the magnitude of error associated with the GPS signal and other possible errors are considered when calculating the location of the crossing. Details of these calculations are provided in the FIG. 15.
[0055] Once a state line crossing has been detected, the state line crossing algorithm (SLCA) updates a global data structure that contains the current and old states, as well as other important data. The SLCA then notifies the host application that a crossing has been detected via returning True (>1=). The host application then reads the data in the global structure and record the necessary data. If a state line crossing is not detected, the SLCA returns a False (>0=).
[0056] The SLCA operates in two modes, initialization and detection. These modes are entered via a host application calling one of the two public routines that exist in the SLCA. Currently the SLCA is operated at 0.5 Hz.
[0057] Initialization mode is entered via the host application calling the “Init Crossing Detection” routine. This routine requires the address of the SLCA Boundary Database. The routine then initializes the various internal pointers used to extract data from the database. The database is currently compiled into the host application as a pre-initialized array.
[0058] Detection mode is entered via the host application calling the second public routine inside the SLCA, “State Crossing.” This routine requires the current position and time data (i.e., the raw GPS data) converted to an appropriate format or data structures.
[0059] Once the SLCA receives the data structure it checks the GPS quality field to determine if the quality is acceptable (FOM<= 6). If the quality is unacceptable (FOM> 6), the SLCA returns a>0= to the host indicating no crossing. If the GPS quality is acceptable, the SLCA then checks the elapsed time since the last good set of data was received. If the elapsed time is more than 200 seconds the SLCA triggers a cold start internally. If the elapsed time is less than 200 seconds the SLCA executes the normal detection sequence.
[0060] After checking the quality of the GPS and the elapsed time, the SLCA then checks to see if the current location is in an area of ambiguity. If the current location is not in the area of ambiguity the SLCA then checks to see if the current state is the same as the last state, if they are not the SLCA returns TRUE to indicate a crossing has occurred.
[0061] The area of ambiguity is calculated using three different measurements of uncertainty.
[0062] This uncertainty is associated with the type of boundary points that are used to create the current boundary line in questions. This error is illustrated in FIG. 15 as distance d 22 . There are three different types of points used to create the boundaries.
[0063] Political Point—A Political Point is a point along a known border that is non-meandering. The associated error of a Political Point is 0 meters.
[0064] Crossing Point—A Crossing Point is a known crossing. The associated error of a Crossing Point is 100 meters.
[0065] Supplemental Point—A Supplemental Point is located along a meandering border and is not located at a known crossing. The associated error of a supplemental point is 250 meters.
[0066] This uncertainty is obtained from the quality of the GPS, and is illustrated as d 21 in FIG. 15.
[0067] This uncertainty is the product of the elapsed time between valid GPS data and a default velocity value. Currently the default velocity value is 50 m/s.
[0068] The total distance of uncertainty is the sum of the uncertainties listed above. If the calculated distance from the current location to the boundary line is less than the distance of uncertainty the vehicle is said to be in the area of ambiguity.
[0069] During initialization the SLCA must be provided the address of the SLCA Boundary database, in order to initialize the SLCA=s internal variables prior to running in detection mode.
[0070] While running in detection mode, the SLCA is supplied with the current status data via an instance of a “Status Record” that is globally defined data structure. This data structure is then passed from the host application to the SLCA. The data that is contained in a “Status Record” data structure comprises, for example, Current Longitude/Latitude, Quality of the GPS signal, Odometer, Month/Day/Year/Hour/Minute/Second, Old State, New State.
[0071] The SLCA returns a Boolean value after each execution that indicates either a state line crossing has been detected or that one has not been detected. Prior to returning the boolean value, the SLCA modifies the appropriate date fields in the “Crossing Record” data structure.
[0072] [0072]FIG. 16 shows a flow diagram of a method for recording engine RPM events. Recording engine RPM events is useful in determining, for example, the amount of engine idle time, or alternatively, in determining drivers who subject a vehicle to excessive RPM. This parameter can be useful in driver evaluation and training and reducing engine and vehicle wear. In step 600 , engine RPM is determined by a sensor interfaced with an on-board processor. The RPM value is compared RPM values stored in memory to determine if the RPM value is within a normal range, or whether the RPM is in a range of excessively high values, or within a range of low values indicating engine idle in step 604 . In step 608 , it is determined whether the engine is idling. If the engine is idling, an engine idle event is recorded in step 612 and the percentage of engine idle time is recorded in step 620 and the program returns to step 600 and repeats.
[0073] In step 624 , if the engine is determine not to be idling in step 608 , it is determined whether the RPM value is excessive. If not, the program returns to step 600 and repeats. If the RPM is in the excessive range, an excessive RPM event is recorded along with associated data in step 628 . The percentage of total driving time during which the RPM value is in the excessive range is calculated, along with the total number of excessive RPM events, in step 632 and the driver is informed of the values in step 620 and the program returns to step 600 and repeats.
[0074] [0074]FIG. 17 shows a flow diagram of a method for monitoring vehicle speed. Vehicle speed is important in evaluating driver safety or fitness and compliance with posted speed limits, and is an important factor in fuel efficiency. In step 640 , vehicle speed is determined via a sensor interfaced with an on-board processor, and position is determined by a positioning service such as a satellite positioning system or the like. In step 644 , speed is compared with information stored in a database containing speed limits, e.g., the speed can be compared with the maximum allowable speed in the geo-cell in which a vehicle is located, or, alternatively, more detailed position specific speed limit data may be stored. In step 644 , it is determined whether the driver is exceeding the maximum speed. If the driver is not exceeding the speed limit, the program returns to step 640 and repeats. If the driver is exceeding the maximum speed in step 648 , a speeding event and associated data are recorded in step 652 . The percentage of driving time during which the driver is speeding is calculated in step 656 . In step 660 , it is determined whether the percentage of time speeding exceeds a predetermined value. If the percentage of time speeding is below the preselected threshold, the program returns to step 640 and repeats. When the value in step 660 reaches the selected threshold, the driver is warned. Also, speed data is also downloaded to a central dispatch office periodically.
[0075] [0075]FIG. 18 depicts a flow diagram for monitoring hard braking. This parameter is useful in evaluating drivers for safety or fitness for duty. For example, if a driver is makes an excessive number of hard brake applications, it may be an indication that the driver is operating the vehicle in an unsafe manner which may cause the driver to lose control of the vehicle of become involved in an accident. It may indicate, for example, that a driver follows other vehicles too closely or drives too fast. In step 672 , the braking pressure being applied is determined, e.g., via a sensor interfaced with an on-board processor, e.g., brake fluid pressure, an accelerometer, brake pedal depression sensor, and the like. In step 676 , it is determined whether the braking pressure being applied is greater than a predetermined threshold value. If the braking pressure in step 676 does not exceed the threshold, the program loops to step 672 and repeats. If the braking event exceeds the excessive value, an excessively hard braking event is recorded along with associated data and the program returns to step 672 and repeats.
[0076] [0076]FIG. 20 depicts a flow diagram of the temperature monitoring function according to the present invention. It is possible for a vehicle to traverse regions with vastly different climates, and the system according to the present invention allows anticipation of such changes along a given route. In step 700 , it is determined whether the shipment is temperature sensitive. This may be determined, e.g., by user input, data download from the dispatch office, etc. If it is determined that the shipment is not temperature sensitive, the program ends at step 704 and no further inquiry is made until a new shipment is picked up. If the shipment is temperature sensitive, the temperature of the cargo bay or freight hold of the vehicle is determined via a sensor interfaced with an on-board computer in step 708 . The determined temperature is compared to a predetermined acceptable temperature range in step 712 . If the temperature is not within the prescribed value, the temperature is adjusted accordingly, e.g., via a thermostat device, in step 720 . In a preferred embodiment, if the temperature is within the prescribed range, the route is analyzed in step 724 for geographical areas where a temperature extreme or drastically different temperature from the current temperature is likely, using geo-cell information stored in a database, e.g., climactic, seasonal, and positional data. In step 728 , it is determined through route analysis whether the current route will pass through any areas of expected or likely large temperature differences. The data employed may be derived from geographical and optionally seasonal temperature gradients stored in memory, or actual reported temperatures may be downloaded and used. If the shipment is not likely to pass through an area of temperature extreme, then the program loops back to step 708 . If the shipment is determined to be likely to pass through a region of extreme temperature in step 728 , the distance or time until such an area is reached is calculated in step 732 . If the distance or time until arrival in the region temperature extreme is not within a certain threshold value, the program loops ack to step 708 . When the mileage or time until arrival to such a region is within a threshold value as determined in step 736 , the temperature change is anticipated in step 740 and the temperature is increased or decreased accordingly (step 720 ).
[0077] [0077]FIG. 20 shows a flow diagram illustrating a security feature of the system according to the present invention whereby the cargo hold of a vehicle may be locked until the position data indicates that the vehicle is at the appropriate delivery destination. In step 760 , the vehicle cargo bay is locked, e.g., at the start of a trip or immediately after loading. In step 764 , the vehicle position is determined. In step 768 , the vehicle position is compared with the delivery destination stored in memory. In step 772 , it is determined whether the vehicle's current position is the same as the delivery destination. If the vehicle has not arrived that the delivery destination, the vehicle remains locked and the program returns to step 764 . If the vehicle is at the delivery destination, the cargo bay is then unlocked for unloading. The delivery event is recorded in step 780 and stored for downloading in step 784 .
[0078] [0078]FIG. 21 depicts a flow diagram showing a method for recording vehicle unloading events in accordance with a preferred embodiment according to the present invention. In step 800 , the weight on wheels is calculated, e.g., via acoustic or laser measurement of spring compression. In step 804 , the weight is compared with the previously determined weight. If the current weight is not less than the pervious weight (step 808 ), the program returns to step 800 and repeats. If the current weight is less than the previous weight, a vehicle unloading event and associated data such as time, date, position, is recorded in step 812 . In step 816 , it is determined whether the unloading event occurred at the correct delivery destination. If not, the dispatch office is alerted as to a potential misdelivery or security breach in step 820 . If the delivery destination is correct in step 816 , the remaining carrying capacity resulting from the unloading event is determined in step 824 . If there is not enough room for an additional load in step 828 , the driver is instructed to continue of prescheduled route in step 832 . If there is room for an additional load in step 828 , it is determined in step 836 whether there is a suitable additional load available. If not, the driver is instructed to continue of prescheduled route in step 832 . if there is a suitable additional load available for pick up, the driver and dispatch operator are notified of a change of course in step 840 . Upon loading of the new shipment, the program then starts again at step 800 and continues.
[0079] [0079]FIG. 22 shows a flow diagram demonstrating how the system according to the present invention can monitor and ensure compliance with HOS requirements. Typically drivers of commercial vehicles are subject to certain maximum hours of continuous driving time, continuous on-duty time (which included not only driving, but loading and unloading, waiting, performing administrative duties and the like). Such limits apply to both to a 24 hour period and to a period of consecutive days, such as the previous seven and/or eight days. Also, such periods usually depend on a sufficient preceding rest period. The diagram present is intended for illustrative purposes and may incorporate other factors such as exceptions based on vehicle weight, the particular industry and the like, and may be adapted to various regulatory changes as they are promulgated.
[0080] In step 900 , it is determined whether the driver is on duty. If the driver is not on duty, the rest period duration is calculated in step 904 . In step 908 , it is determined whether the statutory resp period has been satisfied. If not, the estimated remaining time is calculated and the driver is informed in step 912 . Upon expiration of an adequate rest period or off-duty time in step 908 , the driver is informed in step 916 . If the driver then decides to go on-duty in step 920 , the program returns to step 900 .
[0081] If the driver is on-duty (step 900 ), it is determined whether the driver is driving in step 924 . If the driver is driving, the period of continuous driving time is calculated in step 928 . If the continuous driving time has not exceeded the maximum allowable driving time, it is estimated in step 936 when the limit will be reached and the driver is informed. If the driver does exceed the maximum allowable time in step 932 , the driver is told to stop and the violation is recorded in step 940 .
[0082] If it is determined in step 924 that the driver is on-duty, but not driving, the continuous on-duty time is calculated. If the continuous on-duty time is determined to be within the allowable period in step 948 , the time until the maximum on-duty time will be exceeded is estimated and the driver is informed in step 952 . If the maximum continuous on-duty time is exceeded, the driver is informed and the violation is recorded in step 940 .
[0083] In step 956 , the total on-duty time in the past week (or alternatively, in the past eight days), is calculated. In step 960 , it is determined if the total weekly on-duty time has been exceeded. If not, the estimated time remaining until a violation will occur is estimated and the driver informed in step 964 . If the maximum has been exceeded, the driver is informed to stop and the violation is recorded in step 940 .
[0084] It is apparent that the method of monitoring HOS compliance can readily be adapted to additional requirements such as mileage requirements and to accommodate the various regulatory exceptions.
[0085] The description above should not be construed as limiting the scope of the invention, but as merely providing illustrations to some of the presently preferred embodiments of this invention. In light of the above description, various other modifications and variations will now become apparent to those skilled in the art without departing from the spirit and scope of the present invention as defined by the appended claims. Accordingly, scope of the invention should be determined solely by the appended claims and their legal equivalents. | A commercial vehicle fleet management system which integrates a vehicle on-board computer, a precise positioning system, and communication system to provide automated calculating and reporting of jurisdictional fuel taxes, road use taxes, vehicle registration fees, and the like. Also disclosed is an online mobile communication system and a system for monitoring carrier vehicle efficiency and vehicle and driver performance. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
Reference is made to commonly-assigned, copending U.S. patent application Ser. No. 09/626,752, filed Jul. 27, 2000, pending of Landry-Coltrain et al. entitled “Ink Jet Recording Element”.
FIELD OF THE INVENTION
This invention relates to an inkjet printing method, more particularly to a method using a porous ink jet recording element.
BACKGROUND OF THE INVENTION
In a typical ink jet recording or printing system, ink droplets are ejected from a nozzle at high speed towards a recording element or medium to produce an image on the medium. The ink droplets, or recording liquid, generally comprise a recording agent, such as a dye or pigment, and a large amount of solvent. The solvent, or carrier liquid, typically is made up of water, an organic material such as a monohydric alcohol, a polyhydric alcohol or mixtures thereof.
An ink-jet recording element typically comprises a support having on at least one surface thereof an ink-receiving or image-forming layer. The ink-receiving layer may be a porous layer which imbibes the ink via capillary action or a polymer layer which swells to absorb the ink.
Inkjet prints, prepared by printing onto ink jet recording elements, are subject to environmental degradation. They are especially vulnerable to water smearing and light fade. For example, since ink-jet dyes are water-soluble, they can migrate from their location in the image layer when water comes in contact with the receiver after imaging. Highly swellable hydrophilic layers can take an undesirably long time to dry, slowing printing speed, and will dissolve when left in contact with water, destroying printed images. Porous layers speed the absorption of the ink vehicle, but often suffer from insufficient gloss and severe light fade. Porous layers are also difficult to coat without cracking.
U.S. Pat. No. 4,849,457 discloses a porous membrane for use as a recording medium for ink jet printing comprising a mixture of two water-insoluble polymers and about 9% of polyvinylpyrrolidone. However, there is a problem with this element in that the density obtained with an element having less than about 25% by weight of a water-absorbent polymer is too low, as will be shown hereafter. Further, this membrane is made by coating the two materials from a solvent, and then passing the coated element through a nonsolvent bath. The porous membrane employed in this invention is formed solely upon drying of the coated solution without the need for a nonsolvent bath.
JP95040647A discloses a porous membrane for use as a recording medium for ink jet printing comprising a mixture of a hydrophobic binder containing cationic conductive macromolecules. However, there is a problem with this element in that the density and dye lightfastness obtained with an element having less than about 25% by weight of a water-absorbent polymer is too low, as will be shown hereafter.
U.S. Pat. No. 5,374,475 discloses a porous layer for ink jet printing comprising a thermoplastic polymer free of filler. However, there is a problem with this element in that the density obtained with an element without a water-absorbent absorbent polymer is too low, as will be shown hereafter.
U.S. Pat. No. 5,759,639 discloses a printing medium for ink jet printing which uses a polymeric dope solution. A porous layer is formed using a phase inversion technique. Although a second polymer is used in the process, most of it is washed out in a coagulation step. There is a problem with this element in that the density obtained with an element having less than about 25% by weight of a water-absorbent polymer is too low, as will be shown hereafter.
EP 940,427 discloses a method for making a microporous film for an ink jet recording element in which a hydrophobic polymer and a second hydrophilic polymer or copolymer of N-vinylpyrrolidone is dissolved in a certain solvent system, partially dried, and then washed to extract at least 50% by weight of the second polymer. There is a problem with the elements formed by this process in that a separate washing step is employed which adds to the complexity of the coating process.
It is an object of this invention to provide an ink jet printing method using a recording element which will provide improved ink uptake speed. Another objective of the invention is to provide an ink jet printing method using a recording element having a receiving layer that when printed upon has an excellent image quality.
SUMMARY OF THE INVENTION
These and other objects are provided by the present invention comprising an ink jet printing method, comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with an ink jet recording element comprising a support having thereon an image-receptive layer capable of accepting an ink jet image comprising an open-pore membrane of a mixture of a water-insoluble polymer and a water-absorbent polymer, the mixture containing at least about 25% by weight of the water-absorbent polymer, the image-receiving layer being made by dissolving the mixture of polymers in a solvent mixture, the solvent mixture comprising at least one solvent which is a good solvent for the water-insoluble polymer and at least one poor solvent for the water-insoluble polymer, the poor solvent having a higher boiling point than the good solvent, coating the dissolved mixture on the support, and then drying to remove approximately all of the solvents to obtain the open-pore membrane;
C) loading the printer with an ink jet ink composition; and
D) printing on the ink jet recording element using the ink jet ink in response to the digital data signals.
Using the method of the invention, a recording element is obtained which will provide improved ink uptake speed and when printed upon has an excellent image quality.
DETAILED DESCRIPTION OF THE INVENTION
In order for the image-receptive layer to be sufficiently porous, the water-insoluble polymer must be coated from a solvent mixture combination such that an open-pore membrane structure will be formed when the solution is coated and dried, in accordance with the known technique of dry phase inversion. The formation of an open-pore membrane is accomplished by using a mixture of a good and poor solvent for the water-insoluble polymer. As noted above, the poor solvent has a boiling point that is higher than that of the good solvent. When the solution is coated or cast onto a support and dried, the good solvent evaporates faster than the poor solvent, forming the membrane structure of the layer when the polymer phase separates from the solvent mixture. The open-pore structure results when the good solvent and poor solvent are removed by drying.
The water-insoluble polymer that can be used in the invention may be, for example, a cellulose ester such as cellulose diacetate, cellulose triacetate, cellulose acetate propionate or cellulose acetate butyrate, cellulose nitrate, polyacrylates such as poly(methyl methacrylate), poly(phenyl methacrylate) and copolymers with acrylic or methacrylic acid, or sulfonates, polyesters, polyurethanes, polysulfones, urea resins, melamine resins, urea-formaldehyde resins, polyacetals, polybutyrals, epoxies and epoxy acrylates, phenoxy resins, polycarbonates, vinyl acetate polymers and copolymers, vinyl chloride-vinyl acetate copolymers, vinyl chloride-vinyl acetate-vinyl-alcohol copolymers, vinyl chloride-vinyl acetate-maleic acid polymers, vinyl chloride-vinylidene chloride copolymers, vinyl chloride-acrylonitrile copolymers, acrylic ester-acrylonitrile copolymers, acrylic ester-vinylidene chloride copolymers, methacrylic ester-styrene styrene copolymers, butadiene-acrylonitrile copolymers, acrylonitrile-butadiene-acrylic or methacrylic acid copolymers, or styrene-butadiene copolymers. Cellulose ester derivatives, such as cellulose diacetates and triacetates, cellulose acetate propionate, cellulose acetate butyrate, cellulose nitrate, and mixtures thereof are preferred.
The water-absorbent polymer that is used in the invention may be, for example, polyvinylpyrrolidone and vinylpyrrolidone-containing copolymers, polyethyloxazoline and oxazoline-containing copolymers, imidazole-containing polymers, polyacrylamides and acrylamide-containing copolymers, poly(vinyl alcohol) and vinyl-alcohol-containing copolymers, poly(vinyl methyl ether), poly(vinyl ethyl ether), poly(ethylene oxide), hydroxyethylcellulose, hydroxpropylcellulose, hydroxypropylmethylcellulose, methylcellulose, and mixtures thereof.
The choice of a good and poor solvent for the water-insoluble polymer will be effectively determined by the specific choice of polymer. The good solvent that can be used in the invention includes alcohols such as methanol, ethanol, n-propyl alcohol, isopropyl alcohol, isobutyl alcohol, Dowanol® solvents, glycols, ketones such as acetone, 2-butanone, 3-pentanone, cyclopentanone, and cyclohexanone, ethyl acetate, methylacetoacetate, diethylether, tetrahydrofuran, acetonitrile, dimethylformamide, dimethylsulfoxide, pyridine, chlorinated solvents such as methylene chloride, chloroform, carbon tetrachloride, and dichloroethane, hexane, heptane, cyclopentane, cyclohexane, toluene, xylenes, nitrobenzene, and mixtures thereof.
The poor solvent that can be used in the invention may be, for example, alcohols such as ethanol, n-propyl alcohol, isopropyl alcohol, isobutyl alcohol, 2-methyl-2,4-pentanediol, and Dowanol® solvents, glycols, ketones such as 2-butanone, 3-pentanone, cyclopentanone, and cyclohexanone, ethyl acetate, methylacetoacetate, diethylether, tetrahydrofuran, acetonitrile, dimethyl-formamide dimethylsulfoxide, pyridine, chlorinated solvents such as carbon tetrachloride, and dichloroethane, hexane, heptane, cyclopentane, cyclohexane, toluene, xylenes, nitrobenzene, water, and mixtures thereof.
After printing on the ink jet recording element, heat and/or pressure can be applied to the element to improve surface gloss, image density and durability. Various methods can be used such as hot presses, hot rolls, hot air, IR-radiation, high frequency heating, and a fusing belt or roller apparatus. For example, the printed element can be passed through a fuser consisting of rollers or a belt and a roller. Temperatures can range from slightly above ambient temperature to an upper temperature limited only by the thermal stability of the support and the membrane components. Temperatures should not be so high as to cause delamination of layers within the support, or any bubbles or defects to form in the support or the open-pore membrane. The heating time is mot limited.
The fusing temperature need not be so high as to be above the glass transition temperature of all of the individual components in the open-pore membrane. Fusing may result in clarification (becoming transparent) or in only partial clarification of the membrane. The degree of clarification need not be identical in printed and non-printed areas of the image or in printed areas of differing density.
The open-pore membrane layer may include low molecular weight or polymeric plasticizers to aid in the fusing step. These plasticizers are compounds that typically have low glass transition temperatures. Plasticizers useful in the open-pore membrane layer include, but are not limited to, poly(ethylene glycol), poly(propylene glycol), chlorinated paraffins such as those sold under the tradenames of Chlorowax® (Occidental Chemical Corp.) and Paroil® (Dover Chemical, Inc.), aliphatic polyesters, such as polyester sebacate available commercially as Paraplex® G-25 from C.P. Hall Co., poly(butylene glycol adipates) available commercially as Drapex® polymeric plasticizers from Witco Corporation, poly(ethylene succinate), poly(hexamethylene sebacate), or poly(butylene adipate), polycaprolactone, diphenyl phthalate and di(2-ethylhexyl phthalate).
Also, the high boiling components of the inks may remain in the open-pore membrane and aid in the fusing step. Compounds commonly found in ink compositions can also be used to plasticize the open-pore membrane ink receiving layer and facilitate fusing. Examples of such compounds include, but are not limited to, glycols and glycol ethers such as diethylene glycol, diethylene glycol monobutylether, triethylene glycol, dipropylene glycol monomethylether, tripropylene glycol monomethylether, glycerol, Dowanol® compounds, and poly(ethylene glycol) monobutyl ether; triethanolamine; methyldiethanolamine; 2-pyrrolidone, and N-methyl-2-pyrrolidone.
The plasticizers can be incorporated directly into the coating solution of the membrane, or can be incorporated into the formed open-pore membrane through the printing of the ink which contains these plasticizing compounds or in a printing step prior to printing the inks.
Since the image recording element may come in contact with other image recording articles or the drive or transport mechanisms of image recording devices, additives such as filler particles, surfactants, lubricants, crosslinking agents, matte particles and the like may be added to the element to the extent that they do not degrade the properties of interest.
Filler particles may be used in the open-pore membrane such as silicon oxide, fumed silica, silicon oxide dispersions such as those available from Nissan Chemical Industries and DuPont Corp., aluminum oxide, fumed alumina, calcium carbonate, barium sulfate, barium sulfate mixtures with zinc sulfide, inorganic powders such as y-aluminum oxide, chromium oxide, iron oxide, tin oxide, doped tin oxide, alumino-silicate, titanium dioxide, silicon carbide, titanium carbide, and diamond in fine powder, as described in U.S. Pat. No. 5,432,050.
A dispersing agent, or wetting agent can be present to facilitate the dispersion of the filler particles. This helps to minimize the agglomeration of the particles. Useful dispersing agents include, but are not limited to, fatty acid amines and commercially available wetting agents such as Solsperse® sold by Zeneca, Inc. (ICI). Preferred filler particles are silicon oxide, aluminum oxide, calcium carbonate, and barium sulfate. Preferably, these filler particles have a median diameter less than 1.0 μm. The filler particles can be present in the amount from about 0 to 80 percent of the total solids in the dried open-pore membrane layer, most preferably in the amount from about 0 to 40 percent.
The open-pore membrane layer may include lubricating agents. Lubricants and waxes useful either in the open-pore membrane layer or on the side of the element that is opposite the open-pore membrane layer include, but are not limited to, polyethylenes, silicone waxes, natural waxes such as camauba, polytetrafluoroethylene, fluorinated ethylene propylene, silicone oils such as polydimethylsiloxane, fluorinated silicones, functionalized silicones, stearates, polyvinylstearate, fatty acid salts, and perfluoroethers. Aqueous or non-aqueous dispersions of submicron size wax particles such as those offered commercially as dispersions of polyolefins, polypropylene, polyethylene, high density polyethylene, microcrystalline wax, paraffin, natural waxes such as carnauba wax, and synthetic waxes from such companies as, but not limited to, Chemical Corporation of America (Chemcor), Inc., Michelman Inc., Shamrock Technologies Inc., and Daniel Products Company, are useful.
The open-pore membrane layer may include coating aids and surfactants such as nonionic fluorinated alkyl esters such as FC-430®, FC-431®, FC-10®, FC-171® sold by Minnesota Mining and Manufacturing Co., Zonyl® fluorochemicals such as Zonyl-FSN®, Zonyl-FTS®, Zonyl-TBS®, Zonyl-BA® sold by DuPont Corp.; other fluorinated polymer or copolymers such as Modiper F600® sold by NOF Corporation, polysiloxanes such as Dow Corning DC 1248®, DC200®, DC510®, DC 190®and BYK 320®, BYK322®, sold by BYK Chemie and SF 1079®, SF1023®, SF1054®, and SF 1080®sold by General Electric, and the Silwet® polymers sold by Union Carbide; polyoxyethylene-lauryl ether surfactants; sorbitan laurate, palmitate and stearates such as Span® surfactants sold by Aldrich; poly(oxyethylene-co-oxypropylene) surfactants such as the Pluronic® family sold by BASF; and other polyoxyethylene-containing surfactants such as the Triton X® family sold by Union Carbide, ionic surfactants, such as the Alkanol® series sold by DuPont Corp., and the Dowfax® family sold by Dow Chemical.
The open-pore membrane layer may include crosslinking agents, such as organic isocyanates such as tetramethylene diisocyanate, hexamethylene diisocyanate, diisocyanato dimethylcyclohexane, dicyclohexylmethane diisocyanate, isophorone diisocyanate, dimethylbenzene diisocyanate, methylcyclohexylene diisocyanate, lysine diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate; aziridines such as taught in U.S. Pat. No. 4,225,665; ethyleneimines such as Xama-7® sold by EIT Industries; blocked isocyanates such as CA BI-12 sold by Cytec Industries; melamines such as methoxymethylmelamine as taught in U.S. Pat. No. 5,198,499; alkoxysilane coupling agents including those with epoxy, amine, hydroxyl, isocyanate, or vinyl functionality; Cymel® crosslinking agents such as Cymel 300®, Cymel 303®, Cymel 1170®, Cymel 1171® sold by Cytec Industries; and bis-epoxides such as the Epon® family sold by Shell. Other crosslinking agents include compounds such as aryloylureas, aldehydes, dialdehydes and blocked dialdehydes, chlorotriazines, carbamoyl pyridiniums, pyridinium ethers, formamidinium ethers, and vinyl sulfones. Such crosslinking agents can be low molecular weight compounds or polymers, as discussed in U.S. Pat. No. 4,161,407 and references cited.
The useful thickness range of the open-pore membrane layer used in the invention is from about 1 μm to about 100 μm, preferably from about 2 μm to about 50 μm.
In the present invention, the base support for the open-pore membrane layer of the recording element can be opaque resin coated paper, plain paper, coated paper, synthetic paper, or a transparent material, such as cellulose derivatives, e.g., a cellulose ester, cellulose triacetate, cellulose diacetate, cellulose acetate propionate, cellulose acetate butyrate; polyesters, such as polyethylene terephthalate, polyethylene naphthalate, poly-1,4-cyclohexanedi-methylene terephthalate, polybutylene terephthalate, and copolymers thereof; polyimides; polyamides; polycarbonates; polystyrene; polyolefins, such as polyethylene or polypropylene; polysulfones; polyarylates; polyether imides; and mixtures thereof The papers listed above include a broad range of papers, from high end papers, such as photographic paper to low end papers, such as newsprint.
The support used in the invention may employ an undercoat or an adhesive layer such as, for example, a vinylidene chloride-methyl acrylate-itaconic acid terpolymer or a vinylidene chloride-acrylonitrile-acrylic acid terpolymer. Other chemical adhesives, such as polymers, copolymers, reactive polymers or copolymers, that exhibit good bonding between the open-pore membrane layer and the support can be used. Other methods to improve the adhesion of the layer to the support include surface treatment such as by corona-discharge, plasma-treatment in a variety of atmospheres, UV treatment, etc, which is performed prior to applying the layer to the support.
The recording element used in the invention can contain one or more conducting layers such as an antistatic layer to prevent undesirable static discharges during manufacture and printing of the image. This may be added to either side of the element. Antistatic layers conventionally used for color films have been found to be satisfactory, such as those in U.S. Pat. No. 5,147,768, the disclosure of which is hereby incorporated by reference. Preferred antistatic agents include metal oxides, e.g., tin oxide, antimony doped tin oxide and vanadium pentoxide. These antistatic agents are preferably dispersed in a film-forming binder.
The layers described above may be coated by conventional coating means onto a support material commonly used in this art. Coating methods may include, but are not limited to, wound wire rod coating, knife coating, slot coating, slide hopper coating, gravure coating, spin coating, dip coating, skim-pan-air-knife coating, multilayer slide bead, blade coating, curtain coating, multilayer curtain coating and the like. Some of these methods allow for simultaneous coatings of more than one layer, which is preferred from a manufacturing economic perspective if more than one layer or type of layer needs to be applied. The support may be stationary, or may be moving so that the coated layer is immediately drawn into drying chambers.
Ink jet inks used to image the recording elements employed in the present invention are well known in the art. The ink compositions used in ink jet printing typically are liquid compositions comprising a solvent or carrier liquid, dyes or pigments, humectants, organic solvents, detergents, thickeners, preservatives, and the like. The solvent or carrier liquid can be solely water or can be water mixed with other water-miscible solvents such as polyhydric alcohols. Inks in which organic materials such as polyhydric alcohols are the predominant carrier or solvent liquid may also be used. Particularly useful are mixed solvents of water and polyhydric alcohols. The dyes used in such compositions are typically water-soluble direct or acid type dyes. Such liquid compositions have been described extensively in the prior art including, for example, U.S. Pat. Nos. 4,381,946; 4,239,543 and 4,781,758, the disclosures of which are hereby incorporated by reference.
The following examples further illustrate the invention.
EXAMPLES
Example 1
Shows Need for Water-absorbent Polymer
Preparation of Element 1
A homogeneous solution was prepared from 8 wt. % cellulose diacetate, CDA, (CA398-30, Eastman Chemical Company), 4 wt. % polyvinylpyrrolidone, PVP, (K25 from Aldrich Chemical Co.), 52.8 wt. % acetone (good solvent), and 35.2 wt. % 2-methyl-2,4,-pentanediol (poor solvent). The solution was metered to a slot-die coating apparatus and coated onto a plain paper support moving at a speed of about 15 m/min. The coated support immediately entered the drying section of the coating machine to remove substantially all solvent components and form an image receiving element comprised of a microporous membrane. The thickness of the dry microporous membrane layer was measured to be about 9 μm.
Preparation of Element 2
This element was prepared and coated the same as Element 1 except that the CDA was 6 wt. %, the PVP was PVP-360 (Sigina-Aldrich Company) at 2 wt. %, the acetone was 55.2 wt. % and the 2-methyl-2,4,-pentanediol was at 36.8 wt. %.
Preparation of Element 3
This element was prepared and coated the same as Element 1 except that the CDA was 6 wt. %, polyethyloxazoline, PEOx (Polysciences Inc.) was employed instead of PVP at 2 wt. %, the acetone was 59.8 wt. % and the 2-methyl-2,4,-pentanediol was at 32.2 wt. %.
Preparation of Control Element C-1 (No Water-absorbent Polymer)
A homogeneous solution was prepared from 9 wt. % cellulose diacetate, CDA, (CA398-30, Eastman Chemical Company), 52.3 wt. % acetone (good solvent), and 38.7 wt. % 2-methyl-2,4,-pentanediol (poor solvent). This element was coated and dried as in Element 1.
Preparation of Control Element C-2 (No Water-absorbent Polymer)
A homogeneous solution was prepared from 9 wt. % CDA (CA398-30), 3 wt. % poly(methyl methacrylate), PMMA, (Scientific Polymer Products, Inc), 50.6 wt. % acetone, and 37.4 wt. % 2-methyl-2,4,-pentanediol. The solution was coated onto a plain paper support using a calibrated coating knife, and dried to remove substantially all solvent components to form a microporous membrane.
Preparation of Control Element C-3 (No Water-absorbent Polymer)
This element was prepared and coated the same as Control Element C-2 except that poly(vinyl acetate), PVAc, (Scientific Polymer Products, Inc.) was used instead of PMMA.
Printing
A cyan ink jet ink was prepared using a standard formulation with Direct Blue 199 as the dye. Using an Epson 200® ink jet printer, a series of square patches of varying dye density were printed onto the above elements. The density of each patch was read using an X-Rite 820® densitometer. The red channel density of the cyan patch at D-max (the highest density setting) is reported in the following Table 1:
TABLE 1
Element
Polymers (Wt. Ratios)
D-max
1
CDA/PVP (67/33)
1.5
2
CDA/PVP (75/25)
1.3
3
CDA/PEOx (75/25)
1.3
Control C-1
CDA (100)
1.0
Control C-2
CDA/PMMA (75/25)
0.6
Control C-3
CDA/PVAc (75/25)
0.5
The above results show that the elements employed in the invention all had higher densities as compared to the control elements.
Example 2
Shows Need for at Least 25 wt. % Water-absorbent Polymer
Preparation of Element 4
This element was prepared the same as Element 1 except that the acetone was 50.6 wt. % and the 2-methyl-2,4,-pentanediol was at 37.4 wt %. The solution was coated the same as Control C-2.
Preparation of Element 5
This element was prepared and coated the same as Element 4 except that the CDA was 5 wt. %, the PVP was at 3 wt. %, the acetone was 52.9 wt. % and the 2-methyl-2,4,-pentanediol was at 39.1 wt. %.
Preparation of Element 6
This element was prepared the same as Element 4 except that the CDA was 6 wt. %, the PVP was at 2 wt. %, the acetone was 59.8 wt. % and the 2- methyl-2,4,-pentanediol was at 32.2 wt. %. The element was coated the same as Element 1.
Preparation of Element 7
This element was prepared and coated the same as Element 6 except that Polymer M-1 (see below) was added at 4 wt. %, the acetone was 52.8 wt. % and the 2-methyl-2,4,-pentanediol was at 35.2 wt. %.
Preparation of Element 8
This element was prepared and coated the same as Element 4 except that the CDA was 6 wt. %, polymer M-2 (see below) was employed instead of PVP at 2 wt. %, the acetone was 55.2 wt. % and the 2-methyl-2,4,-pentanediol was at 36.8 wt. %.
Preparation of Element 9
This element was prepared and coated the same as Element 8 except that the polymer M-2 (see below) was at 4 wt. %, the acetone was 54.0 wt. % and the 2-methyl-2,4,-pentanediol was at 36.0 wt. %.
Preparation of Element 10
This element was prepared and coated the same as Element 1 except that the CDA was 6 wt. %, polymer M-1 (see below) was employed instead of PVP at 3 wt. %, the acetone was 52.3 wt. % and the 2-methyl-2,4,-pentanediol was at 38.7 wt. %.
Preparation of Control Element C-4 (Water-absorbent Polymer Less Than 25 wt. %)
This element was prepared and coated the same as Element 4 except that the CDA was 9 wt. %, the PVP was at 2 wt. %, the acetone was 51.2 wt. % and the 2-methyl-2,4,-pentanediol was at 37.8 wt. %.
Preparation of Control Element C-5 (Water-absorbent Polymer Less Than 25 wt. %)
This element was prepared and coated the same as Control Element C-4 except that the PVP was at 1 wt. %, the acetone was 51.8 wt. % and the 2-methyl-2,4,-pentanediol was at 38.2 wt. %.
Preparation of Control Element C-6 (Water-absorbent Polymer Less Than 25 wt. %)
This element was prepared and coated the same as Element 10 except that the polymer M-1 (see below) was at 1.2 wt. %, the acetone was 53.4 wt. % and the 2-methyl-2,4,-pentanediol was at 39.4 wt. %.
Printing
The above elements of Example 2 were printed the same as in Example 1, except that Elements 8-10 and Control Element 6 were printed on a Lexmark Z-51 Printer and an additional ink was used: a magenta ink containing Dye 6 from U.S. Pat. No. 6,001,161. The following results were obtained:
TABLE 2
Total wt.
% water-
Ma-
Polymers
absorbent
Cyan
genta
Element
(Wt. Ratios)
polymer
D-max
D-max
4
CDA/PVP (67/33)
33.3
1.5
5
CDA/PVP (62.5/37.5)
37.5
1.3
6
CDA/PVP (75/25)
25.0
1.3
3
CDA/PEOx (75/25)
25.0
1.3
7
CDA/PVP/M-1 (50/17/33)
50.0
1.4
8
CDA/M-2 (75/25)
25
1.5
1.5
9
CDA/M-2 (60/40)
40
1.5
1.6
10
CDA/M-1 (67/33)
33
1.4
1.4
Control C-4
CDA/PVP (81.8/18.2)
18.2
0.8
Control C-5
CDA/PVP (90/10)
10.0
0.8
Control C-6
CDA/M-1 (83/17)
17
1.2
1.2
The above results show that the elements employed in the all had a higher D-max than the control elements with less than 25 wt. % water-absorbent polymer.
Preparation of M-1
Compound M-1 is a water-absorbent polymer and is a random copolymer of 1-vinylimidazole and ethyl acrylate and was synthesized as follows. A 3-L three-necked, round-bottomed flask fitted with a mechanical stirrer, reflux condenser and nitrogen inlet, was charged with 1200 g of N,N-dimethyl-formamide, 193.8 g of 1-vinylimidazole, and 206.2 g of ethyl acrylate. The as sparged with dry nitrogen for 30 min, and then 2.0 g of 2,2′-azobis(isobutyronitrile) was added and the flask was immersed in a 60° C. constant temperature bath under a slight positive pressure of nitrogen and stirred for 24 hr. The polymer was precipitated into diethyl ether, filtered, and dried in vacuo for several days, resulting in an off-white solid.
Preparation of M-2
Compound M-2 is a water-absorbent polymer and is a random copolymer of 1-vinylimidazole and 1-vinylpyrrolidone and was synthesized as follows. A 1-L three-necked, round-bottomed flask fitted with a mechanical stirrer, reflux condenser and nitrogen inlet adapter, was charged with 320 mL of pH 7 buffer, 45 mL of isopropyl alcohol, 8.7 g of 1-vinylimidazole, and 82.5 g of 1-vinylpyrrolidone. This solution was sparged with dry nitrogen for 30 min, and then 0.67 g of 4,4′-azobis(4-cyanovaleric acid) was added. The flask was immersed in a 60° C. constant temperature bath under a slight positive pressure of nitrogen and stirring begun. A solution of 40 mL of pH 7 buffer, 6 mL of isopropyl alcohol, 8.7 g of 1-vinylimidazole, and 0.67 g of 4,4′-azobis(4-cyanovaleric acid) was prepared in a similar way and pumped into the reaction flask over 210 min. The polymerization was allowed to proceed for a total of 7 hours. The polymer was then dialyzed in Membra Cel® tubing with a 12,000-16,000 molecular weight cutoff for 16 hours, and then freeze-dried, giving an off-white solid.
Example 3
Shows Need for at Least 25 wt. % Water-absorbent Polymer
Preparation of Element 11
This element was prepared the same as Element 1 except that the CDA was 6 wt. %, the PVP was at 2 wt. %, the acetone was 53.0 wt. % and the 2-methyl-2,4,-pentanediol was at 39.0 wt. %. The element was coated the same as Control Element C-2.
Preparation of Element 12
This element was prepared the same as Element 3 except that the acetone was 53.0 wt. % and the 2-methyl-2,4,-pentanediol was at 39.0 wt. %. The element was coated the same as Control Element C-2.
Printing and Dye Light Stability Testing
The above elements of Example 3 and Element 10 and Control Elements C-1 and C-6 were printed the same as in Example 1, except that a Lexmark Z5 1 ink jet printer was used, with a magenta ink jet ink prepared using a standard formulation with Dye 6 from U.S. Pat. No. 6,001,161, and a yellow ink jet ink prepared using a standard formulation with Direct yellow 132 dye. The density of each patch was read using an X-Rite® 820 densitometer.
The printed elements were then subjected to 2 weeks exposure to 50 Klux high intensity daylight. The density of each patch was read after the light exposure test using an X-Rite® 820 densitometer. The % dye retention was calculated as the ratio of the density after the light exposure test to the density before the light exposure test. The results for magenta D-max and yellow D-max were as follows:
TABLE 3
Polymers
% dye retention
% dye retention
Element
(Wt. Ratios)
magenta D-max
yellow D-max
11
CDA/PVP (75/25)
87.8
84.1
12
CDA/PBOx (75/25)
90.2
89.5
10
CDA/M-1 (67/33)
91.6
88.3
Control C-1
CDA (100)
33.6
38.7
Control C-6
CDA/M-1 (83/17)
91.6
53.6
The above results show that the elements employed in the invention all had greater dye lightfastness of the printed image for both magenta and yellow dyes than the control elements with less than 25 wt. % water-absorbent polymer.
Example 4
Shows Varying Proportions of Good and Poor Solvent and Proportion of Water-absorbent to Water-insoluble Polymer
Preparation of Element 13
This element was prepared and coated the same as Element 1 except that the CDA was 6 wt. %, the PVP was at 2 wt. %, the acetone was 55.2 wt. % and the 2-methyl-2,4,-pentanediol, MPD, was at 36.8 wt. %.
Preparation of Element 14
This element was prepared and coated the same as Element 13 except that acetone was 62.1 wt. % and the 2-methyl-2,4,-pentanediol was at 29.9 wt. %.
Preparation of Element 15
This element was prepared and coated the same as Element 13 except that the CDA was 7.33 wt. %, the PVP was K30 (Aldrich Chemical Co.) at 3.67 wt. %, the acetone was 62.3 wt. % and the 2-methyl-2,4,-pentanediol was at 26.7 wt. %.
Printing and Evaluation
The above elements of Example 4 were printed the same as in Example 3, except that a cyan ink jet ink, prepared using a standard formulation with Direct Blue 199 as the dye, was also used. The red channel density (cyan), green channel density (magenta), and blue channel density (yellow) patches at D-max (the highest density setting) are reported in Table 4. The gloss of the top surface of the unprinted image receiving layer was measured using a BYK Gardner gloss meter at an angle of illumination/reflection of 60°. The results are related to a highly polished black glass with a refractive index of 1.567 that has a specular gloss value of 100. The following results were obtained:
TABLE 4
Polymers
Acetone/
60°
Cyan
Magenta
Yellow
Element
(Wt. Ratios)
MPD
gloss
D-max
D-max
D-max
13
CDA/PVP
60/40
38
1.4
1.3
1.3
(75/25)
14
CDA/PVP
67.5/32.5
47
1.5
1.4
1.3
(75/25)
15
CDA/PVP
70/30
65
1.7
1.6
1.5
(67/33)
The above results show that the surface gloss and printed image density of the elements employed in the invention can be controlled by varying the relative proportions of good and poor solvent for the water-insoluble polymer, as well as the proportion of water-absorbent to water-insoluble polymer within the confines of the invention.
Example 5
Shows the Effect of Fusing a Printed Image
Preparation of Element 16
This element was prepared and coated the same as Element 7 except that the PVP was K30 (Aldrich Chemical Co.) at 3 wt. %, the polymer M-1 was at 2 wt. %, the acetone was at 62.3 wt. % and the 2-methyl-2,4,-pentanediol, was at 26.7 wt. %.
Preparation of Element 17
This element was prepared and coated the same as Element 16 except that barium sulfate (Sachtoperse® HU-D from Sachtleben Chemie) was added at 2 wt. %, the acetone was at 60.9 wt. % and the 2-methyl-2,4,-pentanediol, was at 26.1 wt. %.
Printing, Fusing, and Evaluation
Elements 15-17 were printed and evaluated for density and surface gloss the same as in Example 4. After the image element was printed, it was fused between rollers, at least one of which was heated, at a setting temperature of 171° C. (where the sample actually feels a temperature of about 140° C.) and a speed of 1.1 cm/s. The gloss of the top surface of the fused image receiving layer in an unprinted area was measured using a BYK Gardner gloss meter at an angle of illumination/reflection of 60°, and the density of the printed and fused patches was read using an X-Rite® 820 densitometer. The red channel density (cyan), green channel density (magenta), and blue channel density (yellow) of the patches at D-max (the highest density setting) before and after fusing were as follows:
TABLE 5
Polymers
60°
Cyan
Magenta
Yellow
Element
(Wt. Ratios)
gloss
D-max
D-max
D-max
15 before
CDA/PVP (67/33)
65
1.7
1.6
1.5
fusing
15 after
CDA/PVP (67/33)
84
2.2
2.3
1.8
fusing
16 before
CDA/PVP/M-1
49
1.7
1.6
1.5
fusing
(54.5/27.3/18.2)
16 after
CDA/PVP/M-1
87
2.1
2.3
1.7
fusing
(54.5/27.3/18.2)
17 before
CDA/PVP/M-1/BaSO 4
23
1.7
1.6
1.5
fusing
(46.2/23.1/15.4/15.3)
17 after
CDA/PVP/M-l/BaSO 4
81
2.2
2.4
1.8
fusing
(46.2/23.1/15.4/15.3)
The above results show that the surface gloss and printed image density of the elements employed in the invention can be increased by fusing the printed image.
This invention has been described with particular reference to preferred embodiments thereof but it will be understood that modifications can be made within the spirit and scope of the invention. | An ink jet printing method, comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with an ink jet recording element comprising a support having thereon an image-receptive layer capable of accepting an ink jet image comprising an open-pore membrane of a mixture of a water-insoluble polymer and a water-absorbent polymer, the mixture containing at least about 25% by weight of the water-absorbent polymer, the image-receiving layer being made by dissolving the mixture of polymers in a solvent mixture, the solvent mixture comprising at least one solvent which is a good solvent for the water-insoluble polymer and at least one poor solvent for the water-insoluble polymer, the poor solvent having a higher boiling point than the good solvent, coating the dissolved mixture on the support, and then drying to remove approximately all of the solvents to obtain the open-pore membrane;
C) loading the printer with an ink jet ink composition; and
D) printing on the ink jet recording element using the ink jet ink in response to the digital data signals. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a method of manufacturing sulfur-modified polyacrylonitrile used for a cathode active material of a lithium secondary battery (so called lithium rechargeable battery), sulfur-modified polyacrylonitrile manufactured by the method, and a lithium secondary battery comprising the sulfur-modified polyacrylonitrile as a cathode active material.
BACKGROUND ART
[0002] A lithium secondary battery is a secondary battery which has high charge-discharge capacity and can exhibit high power. Currently, a lithium secondary battery is mainly being used as a power source for portable electronic appliances, and is expected to be used as a power source for electric automobiles predicted to be used more in the future. However, when a lithium secondary battery is used as a power source for portable electronic appliances, particularly, a power source for automobiles, it is required to reduce costs and space. Further, a lithium secondary battery currently and mainly being used as the power source for portable electronic appliances is also being required to become short, small, light and thin.
[0003] Among currently-used lithium secondary batteries, lithium secondary batteries, which are manufactured using rare resources, called rare metals such as cobalt, nickel and the like, as cathode materials, are being chiefly used. Therefore, battery materials advantageous in terms of resources are desired.
[0004] Sulfur is a resourceful and inexpensive material. Moreover, when sulfur is used as a cathode active material for a lithium secondary battery, it is theoretically expected that the cathode active material is a material having a maximum capacity among well-known cathode materials and that the cathode active material has an electric capacitance about six times larger than that of a lithium cobalt oxide cathode material which is the most frequently used among currently commercially-available cathode materials. Therefore, it is required to put sulfur to practical use as a cathode material.
[0005] However, a compound of sulfur with lithium is soluble in a nonaqueous solvent, such as ethylene carbonate, dimethyl carbonate or the like, which is used as a nonaqueous electrolyte for a lithium secondary battery. Therefore, when this compound is used as a cathode material, there is a problem in that this compound is gradually deteriorated by the elution of the composition to an electrolyte, thus decreasing the capacity of a battery. For this reason, methods of preventing the elution of the compound to an electrolyte using a polymer electrolyte or a solid electrolyte have been reported. However, these methods are also problematic in that the electric resistance of a battery becomes high, so that it is difficult to operate the battery at room temperature or a low temperature, with the result that the battery must be operated at high temperature, and the power of the battery becomes low.
[0006] Therefore, if the elution of sulfur to a nonaqueous solvent can be prevented and a sulfur-containing material can be practically used as a cathode material of a lithium secondary battery, it is possible to increase the capacity of a lithium secondary battery, decrease the weight thereof and reduce the space thereof. Further, if an electrolyte composed of a nonaqueous solvent, not a polymer electrolyte or a solid electrolyte, is used, it is possible to operate the battery even at room temperature or a low temperature.
[0007] As an attempt to prevent the elution of sulfur to a nonaqueous solvent, a sulfur-containing polymer having a —CS—CS— bond or a —S—S— bond has been proposed (refer to non-patent document 1 below). However, when this sulfur-containing polymer is used as a cathode material, lithium (Li) bonds with sulfur (S), so that the polymer is cut, thereby losing reaction reversibility. Therefore, there is a problem in that the cycle life characteristics of a battery deteriorate.
[0008] Further, a polymer lithium battery including carbon polysulfide essentially consisting of carbon and sulfur is disclosed in patent document 1 below. Such a polymer lithium battery including the carbon polysulfide is considered to have good stability and excellent charge-discharge cycle life characteristics. However, in the case of Example 9 in which aluminum foil is used as a collector, it cannot be expected that the cycle life characteristics of the polymer lithium battery were sufficiently improved, considering that the discharge capacity of the polymer lithium battery was 610 mAh/g per active material at the 10th charge-discharge cycle, whereas the discharge capacity thereof was decreased to 146 mAh/g at the 50th charge-discharge cycle. The reason for this may be that the carbon polysulfide has a structure in which sulfur is added to a straight-chain unsaturated polymer, so that the —CS—CS— bond and/or —S—S— bond of the carbon polysulfide is easily cut, with the result that the carbon polysulfide is converted into a low-molecular-weight polymer, thereby causing the low-molecular-weight polymer to be dissolved in an electrolyte, during the charge-discharge cycles.
[0009] Further, there is a problem in that it requires a multi-step process and a lot of time to synthesize the carbon polysulfide because the synthesis method of the carbon polysulfide is very complicated. Moreover, the carbon polysulfide does not have sufficient conductivity. Therefore, when the carbon polysulfide is used as a cathode active material, there are problems in that it is required to add a large amount of an auxiliary conductivity agent and in that the capacity of the polymer lithium battery per electrode weight becomes low.
CITED REFERENCE
Patent Document
[0000]
Patent document 1: Japanese Unexamined Patent Application Publication No. 2002-154815
Non-Patent Document
[0000]
Non-patent document 1: Polymer lithium battery, written by Yoshio UETANI, published by CMC Inc.
SUMMARY OF INVENTION
Technical Problem
[0012] Accordingly, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to put inexpensive and high-capacity expectable sulfur to practical use as a cathode material for a lithium secondary battery, and, particularly, to provide a sulfur-containing cathode material which can exhibit high power, has excellent cycle life characteristics and other characteristics and can use a general nonaqueous electrolyte. Further, another object of the present invention is to provide a method of realizing a high-capacity cathode using the sulfur-containing cathode material having such excellent properties.
Solution to Problem
[0013] In order to accomplish the above objects, the present inventors have done research eagerly. As a result, they found that, according to a method of mixing sulfur powder with polyacrylonitrile powder and then heating this mixture under a nonoxidative atmosphere while preventing the effluence of sulfur, sulfur vapor reacts with polyacrylonitrile simultaneously with the ring-closing reaction of polyacrylonitrile, thus obtaining sulfur-modified polyacrylonitrile. Further, they found that the sulfur-modified polyacrylonitrile obtained in this way maintains sulfur's own high capacity and has excellent cycle life characteristics because the elution of sulfur to a nonaqueous solvent is inhibited. Further, they found that, when sulfur powder is mixed with polyacrylonitrile powder, and then the mixture is charged in a collector for a cathode and then heated, the sulfur-modified polyacrylonitrile is obtained, and simultaneously the obtained sulfur-modified polyacrylonitrile can be integrated with a collector without using a binder, and thus the reduction in capacity of a battery per electrode weight attributable to the use of a binder can be prevented, thereby obtaining a cathode for a lithium secondary battery having excellent performance. Based on these findings, the present invention was completed.
[0014] That is, the present invention provides a method of manufacturing sulfur-modified polyacrylonitrile, sulfur-modified polyacrylonitrile manufactured by the method, a cathode for a lithium secondary battery comprising the sulfur-modified polyacrylonitrile as a cathode active material, and a lithium secondary battery comprising the cathode.
[0015] 1. A method for manufacturing sulfur-modified polyacrylonitrile, comprising: mixing a base powder comprising sulfur powder and polyacrylonitrile powder; and heating the base powder under a nonoxidative atmosphere while preventing the effluence of sulfur vapor.
[0016] 2. The method according to claim 1 , wherein the base powder is heated in a closed atmosphere.
[0017] 3. The method according to claim 1 , wherein the base powder is heated while refluxing sulfur vapor in a reaction container having an opening for discharging hydrogen sulfide produced by a reaction.
[0018] 4. The method according to any one of claims 1 to 3 , wherein the base powder further includes an auxiliary conductivity agent made of a high-crystallinity carbon material.
[0019] 5. The method according to any one of claims 1 to 4 , wherein the base powder is heated to a temperature of 250˜500 degree Celsius.
[0020] 6. The method according to anyone of claims 1 to 5 , further comprising: heating the Sulfur-modified polyacrylonitrile heated by the method of any one of claims 1 to 5 to a temperature of 150-400 degree Celsius under a nonoxidative atmosphere.
[0021] 7. Sulfur-modified polyacrylonitrile, manufactured by the method of any one of claims 1 to 6 , wherein the Raman spectrum has a major peak in the vicinity of 1331 cm −1 of Raman shift, and has other peaks in the vicinity of 1548 cm −1 , 939 cm −1 , 479 cm −1 , 381 cm −1 , 317 cm −1 in a Raman shift range of 200 cm −1 ˜1800 cm −1 .
[0022] 8. A cathode for a lithium secondary battery, comprising the sulfur-modified polyacrylonitrile according to claim 7 as an active material.
[0023] 9. A method of manufacturing a cathode for a lithium secondary battery, comprising: charging a base powder comprising sulfur powder and polyacrylonitrile powder in a collector made of a porous material; and heating the base powder under a nonoxidative atmosphere while preventing the effluence of sulfur vapor.
[0024] 10. The method according to claim 9 , wherein the collector made of a porous material is a nonwoven or woven fabric made of a carbon material having high degree of graphitization.
[0025] 11. The method according to claim 9 or 10 , wherein the base powder further includes an auxiliary conductivity agent made of a high-crystallinity carbon material.
[0026] 12. A cathode fora lithium secondary battery, manufactured by the method according to any one of claims 9 to 11 .
[0027] 13. The method of manufacturing a cathode for a lithium secondary battery, comprising: heating the cathode according to claim 8 or 12 to a temperature of 150˜400 degree Celsius under a nonoxidative atmosphere.
[0028] 14. A lithium secondary battery, comprising the cathode according to claim 8 or 12 .
[0029] 15. A lithium secondary battery, comprising: the cathode according to claim 8 or 12 ; and an anode including an anode material containing no lithium as an active material, wherein one or both of the cathode and the anode is pre-doped with lithium.
BEST MODE
[0030] Hereinafter, a method of manufacturing sulfur-modified polyacrylonitrile used for a cathode active material for a lithium secondary battery, sulfur-modified polyacrylonitrile manufactured by the method, a cathode for a lithium secondary battery comprising the sulfur-modified polyacrylonitrile as a cathode active material, and a lithium secondary battery comprising the cathode will be described in detail. Here, it is preferred that a carbon material having a high degree of graphitization and a carbon material having high crystallinity do not contain hydrogen or contain a small amount of hydrogen.
[0031] Method of Manufacturing Sulfur-Modified Polyacrylonitrile
[0032] (1) Raw Material
[0033] In the method of present invention, sulfur powder and polyacrylonitrile powder is used as a raw material.
[0034] The particle size of sulfur powder may be, but is not particularly limited to, the range of 150 μm ˜40 μm, preferably, 100 μm ˜40 μm, when it is classified using a sieve.
[0035] Polyacrylonitrile powder may have a weight average molecular weight of 10,000˜300,000. Further, polyacrylonitrile powder may have a particle size of 0.5˜50 μm, preferably, 1˜10 μm, when it is observed using an electron microscope.
[0036] The mixing ratio of sulfur powder to polyacrylonitrile powder may be determined such that the amount of sulfur powder is 50˜1000 parts by weight, preferably, 50˜500 parts by weight, and more preferably, 150˜350 parts by weight, based on 100 parts by weight of polyacrylonitrile powder. However, the present invention is not particularly limited thereto.
[0037] (2) Method of Manufacturing Sulfur-Modified Polyacrylonitrile
[0038] In the method of the present invention, a base powder including sulfur powder and polyacrylonitrile powder as a raw material is heated under a nonoxidative atmosphere while preventing the effluence of sulfur. As a result, the ring-closing reaction of polyacrylonitrile occurs, and simultaneously sulfur vapor reacts with polyacrylonitrile, thus obtaining sulfur-modified polyacrylonitrile.
[0039] As an example of the methods of heating the base powder while preventing the effluence of sulfur, a method of heating the base powder under a closed atmosphere may employed. In this case, the closed atmosphere must be maintained such that sulfur vapor generated by heating does not dissipate.
[0040] Further, the nonoxidative atmosphere, which is a depressurized state in which the concentration of oxygen is reduced to such a degree that an oxidation reaction is not conducted, may be an inert gas (nitrogen, argon or the like) atmosphere or a sulfur gas atmosphere.
[0041] The detailed method for making the closed nonoxidative atmosphere is not particularly limited. For example, a raw material is put into a container in which airtightness is maintained to such a degree that sulfur vapor does not dissipate, and is than heated in the container in a decompressed state or inert gas atmosphere. In addition, a mixture of sulfur powder and polyacrylonitrile powder may be heated in a state in which it is wrapped with a material which does not react with sulfur vapor, such as an aluminum laminate film or the like. In this case, in order that the wrapping material may not be damaged by sulfur vapor, for instance, it is preferred that a raw material is put into a pressure-resistant container, such as an autoclave or the like, charged with water and is then heated to produce water vapor, and then the wrapping material is externally pressured by the produced water vapor. According to this method, since the wrapping material is externally pressured by water vapor, it is possible to prevent the wrapping material from being inflated and damaged by sulfur vapor.
[0042] Sulfur powder and polyacrylonitrile powder may be only mixed, but may also be formed into pellets.
[0043] Heating temperature may be 250˜500 degree Celsius, preferably 250˜400 degree Celsius, and more preferably 250˜300 degree Celsius.
[0044] Heating time may be 10 minutes ˜10 hours, preferably, 30 minutes ˜6 hours at the above heating temperature although it is not particularly limited and is changed depending on the actual heating temperature. In the method of present invention, it is possible to form sulfur-modified polyacrylonitrile in a short period of time.
[0045] Further, as another method of heating the base powder while preventing the effluence of sulfur, a method of heating a base powder including sulfur powder and polyacrylonitrile powder while refluxing sulfur vapor in a reaction container having an opening for discharging hydrogen sulfide produced by a reaction may be employed. In this case, the opening for discharging hydrogen sulfide may be disposed at the position at which sulfur vapor is completely liquefied and refluxed to prevent sulfur vapor from being discharged through the opening. For example, when the opening is disposed at the position at which the temperature of the reaction container may be 100 degree Celsius or lower, hydrogen sulfide produced by a reaction is discharged to the outside through the opening, but sulfur vapor condenses around the opening and then returns to the reaction container without being discharged to the outside.
[0046] FIG. 1 is a schematic view showing a reactor which can be used in this method. In the reactor shown in FIG. 1 , a reaction container filled with a base powder is disposed in an electric furnace, and the upper portion of the reaction container protrudes out of the electric furnace. In this reactor, the temperature of the upper portion of the reaction container is lower than that of the reaction container disposed in the electric furnace. In this case, the temperature of the upper portion of the reaction container may be a temperature at which sulfur vapor is liquefied. As shown in FIG. 1 , the reaction container is provided at the top thereof with a silicon rubber plug, and this silicon rubber plug is provided with an opening for discharging hydrogen sulfide and an opening for introducing inert gas. Further, the silicon rubber plug is provided with a thermocouple for measuring the temperature of a raw material. The silicon rubber plug is convex downward, and sulfur vapor condenses and liquefies at this convex portion of the silicon rubber plug and then drops onto the bottom of the reaction container. The reaction container may be made of an alumina Tammann tube, a heat resistant glass tube or the like which is resistant to the heat and/or corrosion caused by sulfur. The silicon rubber plug is treated with fluorine resin tape in order to prevent corrosion.
[0047] In order to create a nonoxidative atmosphere in the reaction container, for instance, in the early stage of heating, inert gas, such as nitrogen, argon, helium or the like, is introduced into the reaction container through an inert gas feed pipe to create an inert gas atmosphere. Subsequently, since sulfur vapor is slowly generated as the temperature of a raw material increases, in order to prevent the inert gas feed pipe from being blocked by precipitated sulfur, the inert gas feed pipe may be closed when the temperature of the raw material becomes 100 degree Celsius or higher. Thereafter, inert gas is discharged to the outside together with hydrogen sulfide produced by heating the raw material. As a result, atmosphere in the reaction container becomes sulfur vapor atmosphere, mainly.
[0048] In this case, heating temperature, the same as in the above method of heating a raw material in a closed atmosphere, may be 250˜500 degree Celsius, preferably 250˜400 degree Celsius, and more preferably 250˜300 degree Celsius. Reaction time, the same as in the above method, may be 10 minutes˜10 hours at a temperature of 250˜500 degree Celsius. Generally, when the temperature in the reaction container reaches the above temperature and then heating stops, the temperature in the reaction container is maintained for a time necessary for the above temperature range to be maintained, because the reaction go with an exothermic reaction. Further, it is required to control heating conditions such that the maximum temperature including the above mentioned temperature-up caused by exothermic reaction reaches the above heating temperature. Further, since an exothermic reaction occurs, it is preferred that the rate of temperature increase be 10 degree Celsius/min or less.
[0049] In this method, since excess hydrogen sulfide produced by the reaction is removed, the reaction container is filled with liquid sulfur and sulfur vapor, and thus the reaction of sulfur powder with polyacrylonitrile powder can be accelerated compared to when the reaction is performed in the closed reaction container.
[0050] The hydrogen sulfide discharged from the reaction container can be passed through hydrogen peroxide water or an aqueous alkali solution to precipitate sulfur, and this sulfur precipitate may be treated.
[0051] After the temperature in the reaction container reaches a predetermined reaction temperature, heating can be stopped and natural cooling can be conducted to obtain a mixture of sulfur-modified polyacrylonitrile and sulfur, and sulfur-modified polyacrylonitrile is extracted from the mixture.
[0052] According to the method of the present invention, sulfur-modified polyacrylonitrile having high electric capacitance can be easily obtained.
[0053] (3) Sulfur-Modified Polyacrylonitrile
[0054] According to the above method, the ring-closing reaction of polyacrylonitrile and the reaction of sulfur with polyacrylonitrile occur simultaneously to obtain sulfur-modified polyacrylonitrile.
[0055] As a result of elemental analysis, the obtained sulfur-modified polyacrylonitrile includes carbon, nitrogen and sulfur, and may further include a small amount of oxygen and hydrogen.
[0056] Among the above methods of manufacturing sulfur-modified polyacrylonitrile, according to the method of manufacturing sulfur-modified polyacrylonitrile by heating a raw material in a closed atmosphere, the obtained sulfur-modified polyacrylonitrile includes 40˜60 wt % of carbon, 15˜30 wt % of sulfur, 10˜25 wt % of nitrogen, and 1˜5 wt % of hydrogen, as a result of elemental analysis.
[0057] Further, among the above methods of manufacturing sulfur-modified polyacrylonitrile, in the method of manufacturing sulfur-modified polyacrylonitrile by heating a raw material while discharging hydrogen sulfide gas, the manufactured sulfur-modified polyacrylonitrile include larger amount of sulfur than another method. From the results of elemental analysis and the results of calculating a peak area ratio by XPS measurement, the obtained sulfur-modified polyacrylonitrile was shown to include 25˜50 wt % of carbon, 25˜55 wt % of sulfur, 10˜20 wt % of nitrogen, 0˜5 wt % of oxygen, and 0˜5 wt % of hydrogen. When the sulfur-modified polyacrylonitrile including a large amount of sulfur, obtained in this way, is used as a cathode active material, electric capacitance increases.
[0058] Further, in the sulfur-modified polyacrylonitrile obtained by the method of the present invention, according to the result of thermogravimetric analysis when it is heated from room temperature to 900 degree Celsius at a temperature increase rate of 20 degree Celsius/min, the reduction of the weight thereof is 10% or less at 400 degree Celsius. Meanwhile, when a mixture of sulfur powder and polyacrylonitrile powder is heated under the same condition as the sulfur-modified polyacrylonitrile, the weight of the mixture starts to decrease at about 120 degree Celsius, and rapidly decreases at 200 degree Celsius or higher due to the loss of sulfur.
[0059] Further, as a result of the X-ray diffraction analysis of the sulfur-modified polyacrylonitrile using CuKα ray, only a broad peak is observed at a diffraction angle (2θ) near 20° ˜30° because a peak based on sulfur is lost.
[0060] From these points of view, it is considered that, in the obtained sulfur-modified polyacrylonitrile, sulfur does not exist as a single body, but exists in a state in which it is bonded with the ring-closed polyacrylonitrile.
[0061] FIG. 2 shows an example of a Raman spectrum of the sulfur-modified polyacrylonitrile obtained by using 200 parts by weight of sulfur atoms based on 100 parts by weight of polyacrylonitrile. In the Raman spectrum of the sulfur-modified polyacrylonitrile, there is a major peak in the vicinity of 1331 cm −1 of the Raman shift, and there are other peaks in the vicinity of 1548 cm −1 , 939 cm −1 , 479 cm −1 , 381 cm −1 , 317 cm −1 in a Raman shift range of 200 cm −1 ˜1800 cm −1 . The peaks in the Raman shift are observed at the same peak positions even when the ratio of sulfur atoms to polyacrylonitrile is changed, and represent the characteristics of the sulfur-modified polyacrylonitrile obtained by the method of the present invention. These peaks may exist in a range of about ±8 cm −1 from the center of their respective peak positions. Further, the Raman shift is measured using RMP-320 (exciting wavelength λ=532 nm, grating: 1800 gr/mm, resolution: 3 cm −1 ) manufactured by JASCO Corporation. Further, in the Raman spectrum, the number of peaks may be changed or the position of the top of a peak may be out of alignment because of a difference in the wavelength or resolution of the incident light.
[0062] The sulfur-modified polyacrylonitrile exhibits high capacity as a cathode active material for a lithium secondary battery because of the content of sulfur included therein. That is, the sulfur-modified polyacrylonitrile exhibits an electric capacitance of about 740 mAh/g, which is about five times or more that of a conventional cathode material using LiCoO 2 .
[0063] In the sulfur-modified polyacrylonitrile obtained by the above method, when polyacrylonitrile, which is a raw material of this sulfur-modified polyacrylonitrile, is heated, the ring-closing reaction of polyacrylonitrile occurs. In this case, this ring-closing reaction proceeds while forming a three-dimensional condensed ring. Therefore, polyacrylonitrile is mixed with sulfur, and then the mixture is heated to form a sulfur-modified polyacrylonitrile structure in which polyacrylonitrile is three-dimensionally cross linked, thus preventing the elution of sulfur active material to an electrolyte in a charge-discharge cycle.
[0064] Accordingly, the elution of the sulfur-modified polyacrylonitrile to a nonaqueous electrolyte is prevented, so that the cycle life can be improved, and a battery can be fabricated using a conventional nonaqueous electrolyte for a lithium secondary battery, thereby greatly improving a practical value.
[0065] (4) Heat Treatment Process
[0066] When the sulfur-modified polyacrylonitrile obtained by the above method is further heated in a nonoxidative atmosphere, unreacted sulfur remaining therein can be removed. Thus, high-purity sulfur-modified polyacrylonitrile can be obtained. Further, the charge-discharge cycle life characteristics of the sulfur-modified polyacrylonitrile are more improved after heat treatment.
[0067] For example, the nonoxidative atmosphere may be a depressurized state in which oxygen concentration is reduced to such a degree that an oxidation reaction does not proceed, or may be an inert gas (nitrogen, argon or the like) atmosphere.
[0068] The heating temperature may be 150˜400 degree Celsius, preferably 150˜300 degree Celsius, and more preferably 200˜300 degree Celsius. When heating time excessively increases, the sulfur-modified polyacrylonitrile can be decomposed. Therefore, careful attention is required.
[0069] The heat treatment time, but not particularly limited, may be 1˜6 hours.
[0070] Cathode for Lithium Secondary Battery
[0071] The above sulfur-modified polyacrylonitrile can be usefully used as a cathode active material for a lithium secondary battery. A cathode manufactured using the sulfur-modified polyacrylonitrile may have the same structure as a cathode for a general lithium secondary battery.
[0072] For example, the cathode may be fabricated by mixing the sulfur-modified polyacrylonitrile obtained by the above method with an auxiliary conductivity agent such as acetylene black (AB), Ketjen black (KB), vapor grown carbon fiber (VGCF) or the like, a binder such as polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), styrene-butadiene rubber (SBR) or the like, and a solvent such as N-methyl-2-pyrrolidone (NMP) or the like to form paste, and then applying the paste onto a collector. The amount of the auxiliary conductivity agent used may be, but is not limited to, 20˜100 parts by weight based on 100 parts by weight of the sulfur-modified polyacrylonitrile. The amount of the binder used may be, but is not limited to, 10˜20 parts by weight based on 100 parts by weight of the sulfur-modified polyacrylonitrile. In addition to this method, the cathode may also be fabricated by mixing the sulfur-modified polyacrylonitrile with the auxiliary conductivity agent and the binder, kneading the mixture using mortar and/or a press to form a film, and then pressing the film onto a collector using the press.
[0073] Examples of the collector may include, but are not limited to, aluminum foil, aluminum mesh, stainless steel mesh and the like, which are materials generally used as a cathode for a lithium secondary battery. Further, since the sulfur-modified polyacrylonitrile is used at a relatively low voltage range of 1˜3 V, nickel-based collectors, for example, nickel foam, nickel nonwoven fabric and the like, which could not be used because they can become dissolved due to the high potential range when lithium cobalt oxide is used as an active material. Particularly, nonwoven fabric, woven fabric or the like, which is made of a carbon material having a high degree of graphitization, is suitable for the collector because its reactivity to sulfur is low. The carbon material having a high degree of graphitization may not include hydrogen having high reactivity to sulfur, and can be obtained by heat-treating pitch (a by-product of petroleum, coal, coal tar or the like) or polyacrylonitrile (PAN) fiber, which is a raw material of carbon fiber, using the same method as in the treatment of carbon fiber, that is, under a nonoxidative atmosphere at a temperature of 2000 degree Celsius ˜3200 degree Celsius and then removing hydrogen to increase the graphitization degree. The heat treatment time may be, but is not limited to, 10 minutes˜10 hours. In this case, the nonoxidative atmosphere may be the same as that of the above heat treatment process. Further, the heat treatment temperature may become low, and the heat treatment time may become short, as long as hydrogen can be completely removed.
[0074] Further, in the auxiliary conductivity agent, since a carbon material having high crystallinity, such as vapor grown carbon fiber (VGCF), carbon nanotubes, graphite or the like, does not inhibit the production reaction of sulfur-modified polyacrylonitrile accompanying the ring-closing reaction of polyacrylonitrile, it is preferred that, when manufacturing the sulfur-modified polyacrylonitrile, the carbon material be heated together with sulfur powder and polyacrylonitrile powder in order to improve conductivity. In particular, it is preferred that the vapor grown carbon fiber (VGCF) have a diameter of 100 nm ˜500 nm and a length of 5 μm ˜20 μm. FIG. 3 is a schematic view showing the structure of the sulfur-modified polyacrylonitrile obtained by heat treatment together with an auxiliary conductivity agent. As shown in FIG. 3 , in this method, a nano-level conductivity network can be established on the surface and/or in the space between the particles of sulfur-modified polyacrylonitrile having a particle diameter of several 100 nm, and a cathode active material having more excellent conductivity can be formed. In this case, the amount of the auxiliary conductivity agent may be, but is not limited to, 1˜50 parts by weight, preferably, 5˜20 parts by weight based on 100 parts by weight of the sum of sulfur powder and polyacrylonitrile powder. Since sulfur-modified polyacrylonitrile powder combined with the carbon material obtained in this way has good conductivity, when a cathode is formed by applying and attaching this sulfur-modified polyacrylonitrile powder to a collector, the amount of an auxiliary conductivity agent and/or a binder can be greatly reduced, and electrode capacitance density and/or electrode power density can be greatly improved.
[0075] When a porous material, such as carbon nonwoven fabric (carbon paper), carbon woven fabric, nickel foam, nickel nonwoven fabric or the like, is used as a collector, sulfur powder and polyacrylonitrile powder are charged in a collector and then heated under the above conditions to form sulfur-modified polyacrylonitrile in the collector. In this case, the sulfur-modified polyacrylonitrile can be integrated with the collector without using a binder. As a result, the cathode material obtained in this way has excellent cycle life characteristics, and a binder is not used, thus further improving electrode capacitance density and electrode power density. Further, sulfur powder and polyacrylonitrile powder are charged in a collector together with the above carbon material having high crystallinity and then heated to form a cathode material having excellent conductivity. In this case, the ratio of respective components may be such that sulfur powder is 50˜500 parts by weight, preferably, 150˜350 parts by weight, and the high-crystallinity carbon material as auxiliary conductivity agent is 1˜50 parts by weight, based on 100 parts by weight of polyacrylonitrile powder.
[0076] As a method of charging the base powder in a porous collector, there is a method of mixing sulfur powder, polyacrylonitrile powder and, if necessary, a carbon material, putting the mixed powder onto the collector and then vibrating the collector or a method of charging the base powder in the pores of a collector by pressing the base powder using a spatula. In addition, there is a method of mixing sulfur powder, polyacrylonitrile powder and, if necessary, a carbon material, dispersing the mixed powder in a solvent such as N-methyl-2-pyrrolidone (NMP), alcohol or the like to form slurry, applying the slurry onto a collector and then vibrating the collector or a method of impregnating a collector with the base powder in a vacuum. Further, if necessary, the slurry may be repeatedly applied onto the collector. Thereafter, this collector is heated under the above conditions, that is, under a closed nonoxidative condition to form a cathode including sulfur-modified polyacrylonitrile integrated with a collector.
[0077] FIG. 4 is a schematic view showing the cathode obtained by the above method. As shown in FIG. 4 , this cathode is an electrode in which sulfur-modified polyacrylonitrile is charged in the pores an electrode to be integrated with the electrode, in which the adhesion between an active material and a collector is excellent and which has excellent conductivity. For example, when carbon nonwoven fabric is used as a collector, sulfur-modified polyacrylonitrile can be charged in the fiber gap thereof.
[0078] Further, when nickel foam is used as a collector, nickel sulfide is formed on the interface between sulfur-modified polyacrylonitrile and nickel foam, thus more strongly maintaining an active material as a collector. Here, since nickel sulfide is a material which can also be used as a cathode active material for a lithium secondary battery, when a battery is fabricated using nickel sulfide, there is an advantage in that nickel sulfide contributes to the improvement of charge-discharge capacity of the battery.
[0079] Further, when carbon nonwoven fabric (carbon paper), carbon woven fabric or the like is used as a collector, particularly, the above-mentioned carbon nonwoven fabric (carbon paper) or carbon woven fabric made of a carbon material having high graphitization has low reactivity to sulfur. Therefore, when this nonwoven fabric (carbon paper) or carbon woven fabric is used as a collector, the synthesis of sulfur-modified polyacrylonitrile is not inhibited, thus obtaining an electrode having high conductivity.
[0080] Meanwhile, a porous collector made of aluminum, copper, iron or chromium is problematic in that, when the porous collector is charged with a raw material and reacted, the conductivity of an electrode is easily deteriorated by the formation of a surface film, and in that, when sulfur-modified polyacrylonitrile is synthesized by the reaction of sulfur with polyacrylonitrile, the porous collector inhibits this reaction. Therefore, this porous collector is not preferable for the above purpose.
[0081] Further, when the cathode obtained by attaching sulfur-modified polyacrylonitrile to a collector or by charging a collector with sulfur powder and polyacrylonitrile powder and then heating the collector is also heated under a nonoxidative atmosphere in the same manner as in the above heat treatment process, unreacted sulfur remaining in the cathode can be easily removed. Owing to this heat treatment, the elution of sulfur to an electrolyte can be prevented, thus preventing the deterioration of an electrode or a battery and improving the cycle life characteristics thereof.
[0082] The cathode for a lithium secondary battery according to the present invention, the shape and thickness thereof being not limited, may be charged with an active material and then compressed such that it has a thickness of 10˜200 μm, preferably, 20˜100 μm. Therefore, according to the kind, structure and the like of the collector used, the amount of an active material in the collector must be suitably adjusted such that the thickness of the compressed cathode is the same as the above thickness.
[0083] Lithium Secondary Battery
[0084] A lithium secondary battery using the above cathode may be manufactured using commonly-known methods. That is, the lithium secondary battery is manufactured by assembling known battery components while using the above mentioned material as a cathode material, using well known lithium metal, a carbon material such as graphite or the like, a silicon material such as silicon thin film or the like, or an alloy material such as copper-tin alloy, cobalt-tin alloy or the like as an anode material, and using a solution in which a lithium salt, such as lithium perchlorate, LiPF 6 , LiBF 4 , LiCF 3 SO 3 or the like, is dissolved in a nonaqueous solvent, such as ethylene carbonate, dimethyl carbonate, propylene carbonate or the like, to a concentration of 0.5 mol/L˜1.7 mol/L.
[0085] Further, when a material containing no lithium, for example, a carbon material, a silicon material or an alloy material, is used as an anode material, there is an advantage in that it is difficult for the formation of dendrite to cause a short between a cathode and an anode. However, in the case where this anode material containing no lithium is used, since both cathode and anode do not contain lithium when this anode material is used in combination with the cathode of the present invention, a lithium pre-doping treatment for previously charging lithium in one or both of the cathode and anode is required. The lithium pre-doping treatment may be conducted by a commonly-known method. For example, when an anode is pre-doped with lithium, lithium is used as a counter electrode to constitute a half cell, and then lithium is charged in the anode by an electrolytic doping method of electrochemically doping lithium or by an attaching pre-doping method of attaching lithium foil to an electrode and then leaving the electrode in an electrolyte to allow lithium to diffuse into the electrode, and then the half cell is combined with the counter electrode, thereby constituting a battery. Further, even when a cathode is pre-doped with lithium, the above electrolytic doping method may be used.
[0086] As the anode material without containing lithium, a silicon material, which is a high-capacity anode material, may be used, and, more preferably, silicon thin film may be used because it is advantageous in capacity per volume.
Advantageous Effects of Invention
[0087] The sulfur-modified polyacrylonitrile of the present invention is manufactured by using sulfur, which is a plentiful resource and an inexpensive material, as a raw material. When this sulfur-modified polyacrylonitrile is used a cathode active material of a lithium secondary battery, the cathode active material has high capacity and excellent cycle life characteristics because the elution of sulfur to a nonaqueous solvent is inhibited.
[0088] Further, in the method of manufacturing sulfur-modified polyacrylonitrile of the present invention, scaling up in the heat treatment in a closed reactor is easy, and industrial practicality is high.
[0089] Further, when a method of manufacturing sulfur-modified polyacrylonitrile by charging a raw material in a collector and then heating the raw material under a closed nonoxidative atmosphere is employed, the obtained sulfur-modified polyacrylonitrile can be integrated with a collector without using a binder, thus easily obtaining a cathode material having high capacitive density.
DESCRIPTION OF DRAWINGS
[0090] FIG. 1 is a schematic view showing a reactor used in Example 2;
[0091] FIG. 2 is a graph showing a Raman spectrum of a product of Example 1;
[0092] FIG. 3 is a view showing sulfur-modified polyacrylonitrile obtained by heat treatment together with an auxiliary conductivity agent;
[0093] FIG. 4 is a view showing an electrode obtained by charging sulfur powder and polyacrylonitrile powder in a collector and then heating them;
[0094] FIG. 5 is a graph showing an X-ray diffraction pattern of a product of Example 1;
[0095] FIG. 6 is a graph showing the results of thermogravimetric analysis of a product of Example 1 and a sulfur single body;
[0096] FIG. 7 is a graph showing a Raman spectrum of a product of Example 2;
[0097] FIG. 8 is a graph showing an X-ray diffraction pattern of a product of Example 3;
[0098] FIG. 9 is a graph showing a Raman spectrum of a product of Example 4;
[0099] FIG. 10 is a graph showing an infrared (IR) spectrum of a product of Example 4;
[0100] FIG. 11 is a graph showing an X-ray diffraction pattern of a product of Example 4;
[0101] FIG. 12 is a graph showing an XPS spectrum of a product of Example 4;
[0102] FIG. 13 is a graph showing a 13 C CP/MAS NMR spectrum of a product of Example 4;
[0103] FIG. 14 is a graph showing an X-ray diffraction pattern of a product of Example 5;
[0104] FIG. 15 is a graph showing the results of a charge-discharge test in Example 6 when a product of Example 1 is used as an active material;
[0105] FIG. 16 is a graph showing the results of a charge-discharge test in Example 6 when a product of Example 3 is used as an active material;
[0106] FIG. 17 is a graph showing the results of a charge-discharge test in Example 6 when a product of Example 5 is used as an active material;
[0107] FIG. 18 is a graph showing the results of cycle life characteristics in Example 6 when a product of Example 1 is used as an active material;
[0108] FIG. 19 is a graph showing the results of cycle life characteristics in Example 6 when a product of Example 3 is used as an active material;
[0109] FIG. 20 is a graph showing the results of a charge-discharge test of a battery using a sulfur single body as a cathode;
[0110] FIG. 21 is a graph showing the results of a charge-discharge test in Example 7;
[0111] FIG. 22 is a graph showing the results of measuring cycle life characteristics in Example 7;
[0112] FIG. 23 is a graph showing the results of a charge-discharge test in Example 8;
[0113] FIG. 24 is a graph showing the results of a charge-discharge test in Example 10;
[0114] FIG. 25 is a graph showing the results of a charge-discharge test in Example 11;
[0115] FIG. 26 is a graph showing the results of a charge-discharge test in Example 12;
[0116] FIG. 27 is a graph showing the results of measuring cycle life characteristics in Example 12;
[0117] FIG. 28 is a graph showing the results of a charge-discharge test in Example 13; and
[0118] FIG. 29 is a graph showing the results of measuring cycle life characteristics in Example 13.
DESCRIPTION OF EMBODIMENTS
[0119] Hereinafter, the present invention will be described in detail with reference to the following Examples.
Example 1
[0120] 1.0 g of sulfur powder having an average particle size of 50 μm and 0.50 g of polyacrylonitrile powder having an average particle size of 1 μm, which are starting materials, were mixed to form pellets having a diameter of 10 mm and a thickness of 5 mm. Subsequently, the pellets were wrapped with aluminum foil, and then additionally wrapped with aluminum laminate film. Then, the aluminum laminate film was fusion-bonded to obtain a sample in which raw material is enclosed.
[0121] The sample where raw material is enclosed and 80 mL of water were put into a 200 cc autoclave, and were then heated to 270 degree Celsius for 6 hours after the autoclave was tightly closed. At this time, the pressure in the autoclave was about 3.7 MPa. Subsequently, the sample was cooled to obtain a pellet-type black product.
[0122] The X-ray diffraction measurement of this product was conducted using CuKα ray emitted from an powder X-ray diffractometer (manufactured by MAC Science Corp., model number: M06XCE). This X-ray diffraction measurement of this product was conducted under the conditions of a voltage of 40 kV, an electric current of 100 mA, a scan rate of 4°/min, a sampling of 0.02°, an integration number of 1 and a diffraction angle (2θ) of 10°˜60°.
[0123] FIG. 5 shows the obtained diffraction pattern. Only a broad diffraction peak was observed at about 25° in a diffraction angle (2θ) of 20°˜30°.
[0124] Subsequently, Raman analysis of the product was conducted using RMP-320 (exciting wavelength λ=532 nm, grating: 1800 gr/mm, resolution: 3 cm −1 ) manufactured by JASCO Corporation. FIG. 2 shows the Raman spectrum obtained in this way. In FIG. 2 , the horizontal axis represents Raman shift (cm −1 ), and the longitudinal axis represents relative intensity. As shown in FIG. 2 , according to the results of Raman analysis of this sample, there is a major peak in the vicinity of 1331 cm −1 of Raman shift, and there are other peaks in the vicinity of 1548 cm −1 , 939 cm −1 ,479 cm −1 , 381 cm −1 , 317 cm −1 in a Raman shift range of 200 cm −1 ˜1800 cm −1 . This sample did not have C—S, N—S, S—S bonds observed generally in a range of 500˜750 cm −1 . However, this fact is presumed that the position of peak is shifted under the influence of the unsaturated bonds of carbon and nitrogen (C═C, C═N bonds) derived from polyacrylonitrile.
[0125] Further, the thermogravimetric-differential thermal analysis of the product was conducted by heating the product at a temperature increase rate of 20 degree Celsius/min while blowing high-purity nitrogen gas at a flow rate of 0.15 L/min and then measuring the relation between temperature change and weight change using a thermogravimetric analyzer (model number: Thermo Plus TG 8120) manufactured by RIGAKU CORPORATION. The results thereof are shown in FIG. 6 . Further, for comparison, the results of the thermogravimetric-differential thermal analysis of a sulfur single body are also shown in FIG. 6 . From these results, it can be seen that the weight of the sulfur single body starts to decrease at about 120 degree Celsius and rapidly decreases at 200 degree Celsius or higher, whereas the weight of the obtained product slowly decreases to about 400 degree Celsius (the rate of the weight reduction thereof to 400 degree Celsius: about 10%) and the rate of the weight reduction thereof to 600 degree Celsius is about 20%. Therefore, it can be seen that this product is a stable compound.
Example 2
[0126] 5.061 g of polyacrylonitrile powder and 25.008 g of sulfur powder were mixed with mortar to make a starting material. This raw material was put into an alumina Tammann tube (outer diameter: 60 mm, inner diameter: 50 mm, length: 180 mm, alumina SSA-S, manufactured by NIKKATO CORPORATION), which is used as a reaction container.
[0127] The opening of the alumina Tammann tube was capped with a silicon rubber plug (No. 15) fixed on a rubber adapter, and a portion of the silicon rubber plug, coming into contact with the atmosphere in the alumina Tammann tube was wound with fluorine resin tape such that the silicon rubber plug does not directly come into contact with the atmosphere in the alumina Tammann tube.
[0128] Three holes was made in the silicon rubber plug, and was provided with an alumina protection tube (outer diameter: 4 mm, inner diameter: 2 mm, length: 250 mm, alumina SSA-S, manufactured by NIKKATO CORPORATION) including a thermocouple therein and two alumina tubes (outer diameter: 6 mm, inner diameter: 4 mm, length: 150 mm, alumina SSA-S, manufactured by NIKKATO CORPORATION). The tip end of the thermocouple disposed in the alumina protection tube was brought into contact with a sample to measure the temperature of the sample. The two alumina tubes are used as an inert gas feed pipe and a gas discharge pipe, respectively, and are disposed such that they protrude out of the bottom of a cap to 3 mm. The inert gas feed pipe is connected with an argon gas pipe, and the gas discharge pipe is connected with a pipe which go through under the hydrogen peroxide water to serve as a hydrogen sulfide gas trap.
[0129] Referring to the reactor shown in FIG. 1 , the alumina Tammann tube was put into an electric furnace (crucible furnace, opening: 80 mm, heating head of alumina Tammann tube: 100 mm), and argon gas was blown into the alumina Tammann tube at a flow rate of 100 cc/min for 10 minutes. The sample disposed in the alumina Tammann tube was heated to 100 degree Celsius at a temperature increase rate of 5 degree Celsius/min, and the supply of argon gas was stopped at 100 degree Celsius. Exhaust gas was generated in the alumina Tammann tube from about 200 degree Celsius, and the heating of the sample was stopped at 360 degree Celsius. The temperature of the sample increased to 400 degree Celsius and then decreased thereafter. The sample was cooled to about room temperature and a product was extracted therefrom.
[0130] The unreacted sulfur remaining in the product was removed by the following procedures, that is, pulverizing the product using a mortar, putting 2 g of the pulverized product into a glass tube oven and then heating the product to 250 degree Celsius for 3 hours while keeping the glass tube oven under a vacuum condition. In this way, the unreacted sulfur was vaporized, thus obtaining sulfur-modified polyacrylonitrile.
[0131] As the result of the X-ray diffraction measurement of the obtained product, the same as in Example 1, only a broad diffraction peak was observed at about 25° in a diffraction angle (2θ) of 20°˜30°.
[0132] Further, the Raman analysis of this product was conducted using RMP-320 (exciting wavelength λ=532 nm, grating: 1800 gr/mm, resolution: 3 cm −1 ) manufactured by JASCO Corporation. FIG. 7 shows the Raman spectrum obtained in this way. In FIG. 7 , the horizontal axis represents Raman shift (cm −1 ), and the longitudinal axis represents relative intensity. As shown in FIG. 7 , according to the results of Raman analysis of this sample, there is a major peak in the vicinity of 1328 cm −1 of Raman shift, and there are other peaks in the vicinity of 1558 cm −1 , 946 cm −1 , 479 cm −1 , 379 cm −1 , 317 cm −1 in a Raman shift range of 200 cm −1 ˜1800 cm −1 .
Example 3
[0133] The reaction product of sulfur powder and polyacrylonitrile powder was obtained in the same manner as in Example 1, except that the weight ratio of sulfur powder to polyacrylonitrile powder (S:PAN) was 2.5:1.
[0134] FIG. 8 shows the diffraction pattern obtained by the X-ray diffraction measurement of this product. As shown in FIG. 8 , abroad diffraction peak was observed at about 25° in a diffraction angle (2θ) range of 20°˜30°, and a sharp peak showing the existence of a sulfur single body was observed at a diffraction angle (2θ) of 23.2°, 24.2°, 24.6°, 25.2°, 25.9°, 26.8°, 27.8°, 31.5°.
[0135] Subsequently, the X-ray diffraction measurement of this product was conducted after pulverizing this product into powder, putting the powdered product into a glass tube oven and then heating the powdered product to 250 degree Celsius for 6 hours while vacuuming the glass tube oven. The diffraction pattern of a sample after heat treatment is also shown in FIG. 8 . In this sample, since only a broad diffraction peak was observed at about 25° in a diffraction angle (2θ) of 20°˜30°, it was found that superfluous sulfur was lost. Further, even in Raman analysis and thermogravimetric analysis, the same spectrum pattern and thermogravimetric-differential thermal analysis results as in Example 1 were obtained.
Example 4
[0136] The reaction products of sulfur powder and polyacrylonitrile powder were obtained in the same manner as in Example 1, except that 300, 400, 600 or 800 parts by weight of sulfur powder was used based on 100 parts by weight of polyacrylonitrile powder.
[0137] Subsequently, each of the products was pulverized into powder, and then the powdered product was put into a glass tube oven and then heated to 250 degree Celsius for 6 hours while vacuuming the glass tube oven.
[0138] As the result of the X-ray diffraction measurement of each of the obtained products, the same as in Example 1, only a broad diffraction peak was observed at about 25° in a diffraction angle (2θ) of 20°˜30°.
[0139] The Raman analysis of the product, which is a product obtained using 400 parts by weight of sulfur powder based on 100 parts by weight of polyacrylonitrile powder and from which a sulfur single body was removed, was conducted using RMP-320 (exciting wavelength λ=532 nm, grating: 1800 gr/mm, resolution: 3 cm −1 ) manufactured by JASCO Corporation. FIG. 9 shows the Raman spectrum obtained in this way. In FIG. 9 , the horizontal axis represents Raman shift (cm −1 ), and the longitudinal axis represents relative intensity. As shown in FIG. 9 , according to the results of Raman analysis of this sample, there is a major peak in the vicinity of 1327 cm −1 of Raman shift, and there are other peaks in the vicinity of 1556 cm −1 , 945 cm −1 , 482 cm −1 , 381 cm −1 , 320 cm −1 in a Raman shift range of 200 cm −1 ˜1800 cm −1 .
[0140] Further, FIG. 10 shows the results of the infrared absorption measurement of this product using an infrared absorption spectrometer (model number: IRAffinity-1, manufactured by SHIMADZU CORPORATION). In FIG. 10 , the horizontal axis represents wave number (cm −1 ), and the longitudinal axis represents absorbance. In the IR spectrum of this obtained product, there are peaks in the vicinity of 474 (S—S), 516, 586, 628, 678 (C—S), 748, 806, 949 (S—S), 999, 1033, 1107 (C—C), 1176, 1257 (C═N), 1319, 1365 (C—C, C═C), 1435 (C═N), 1512, 1550 (C═C), 1705 (C═O), 2580, 2916, 3147, 3236, 3348, 3630, 3745 cm −1 . The infrared absorption measurement of this product was conducted using a diffuse reflectance method under the conditions of resolution: 4 cm −1 , integration number: 100, measuring range: 400 cm −1 ˜4000 cm −1 .
[0141] Further, the X-ray diffraction measurement of this product was conducted using an X-ray diffractometer with CuKα ray (manufactured by MAC Science Corp., model number: M06XCE), and the results thereof are shown in FIG. 11 . In FIG. 11 , a broad scattered peak was observed at substantially about 25° in a diffraction angle (2θ) of 20°˜30°. This X-ray diffraction measurement of this product was conducted under the conditions of a voltage of 40 kV, an electric current of 100 mA, a scan rate of 4°/min, a sampling of 0.02°, and an integration number of 1.
[0142] Further, the X-ray photoelectron spectroscopy analysis of the product was conducted using an X-ray photoelectron spectrometer (AXIS-ULTRA, manufactured by SHIMADZU CORPORATION). This X-ray photoelectron spectroscopy analysis thereof was conducted using a monochromic AlX radiation source under the conditions of an electric current of 10 mA, a voltage of 15 kV, and a sampling step of 0.50 eV. FIG. 12 shows the obtained XPS spectrum. In this XPS spectrum, peaks were observed in the vicinity of 530 eV, 398 eV, 285 eV, 227 eV, and these peaks correspond to oxygen (O 1s), nitrogen (N 1s), carbon (C 1s), and sulfur (S 2p), respectively. Calculating the molar ratio of elements using the area of the peaks revealed that the molar ration of oxygen (O 1s): nitrogen (N 1s): carbon (C 1s): sulfur (S 2p) was 0.52:2.00:8.40:2.17.
[0143] Further, the 13 C CP/MAS NMR measurement of the product was conducted using a solid nuclear magnetic resonator (NMR) (model number: FNM-ECA 500, manufactured by JEOL LTD.). This 13 C CP/MAS NMR measurement thereof was conducted under the conditions of a 13 C resonance frequency of 125.77 MHz, a contact time of 2 ms, a MAS rate of 10 kHz and a repetition time of +5s and under the condition that the integration number is counted until the desired spectrum is obtained.
[0144] FIG. 13 shows the obtained 13 C CP/MAS NMR spectrum. In this NMR spectrum, signals having peak tops at 29, 116, 123, 149, 160, 174 ppm were observed. Further, for comparison, FIG. 13 shows the 13 C CP/MAS NMR spectrum of the polyacrylonitrile powder, containing no sulfur, treated under the same conditions as above.
Example 5
[0145] The reaction product of sulfur powder and polyacrylonitrile powder was obtained in the same manner as in Example 1, except that 0.4 g of vapor grown carbon fiber having a diameter of 150 nm and a length of 10 μm was added to a raw material including 1.0 g of sulfur powder having an average particle size of 50 μm and 0.5 g of polyacrylonitrile having an average particle size of 1 μm.
[0146] Subsequently, the product was pulverized into powder, and then the powdered product was put into a glass tube oven and then heated to 250 degree Celsius for 6 hours while the glass tube oven was kept under a vacuum.
[0147] FIG. 14 shows the X-ray diffraction pattern of the obtained product. As shown in FIG. 14 , the same as in Example 1, a broad diffraction peak was observed at 25° in a diffraction angle (2θ) of 20°˜30°. In addition, a peak of carbon, such as graphite having high crystallinity, was observed at 26.4°. Further, considering that the peak based on a sulfur single body was not observed, it was found that sulfur-modified polyacrylonitrile was produced.
Example 6
[0148] A lithium secondary battery using each of the products obtained Examples 1, 3 and 5 as a cathode active material was fabricated, and the characteristics thereof were evaluated.
[0149] First, 2.7 mg of acetylene black and 0.3 mg of polytetrafluoroethylene (PTFE) were mixed with 3 mg of each of the products obtained in Examples 1, 3 and 5, and then the mixture was kneaded into a film using an agate mortar while adding a suitable amount of ethanol thereto.
[0150] The obtained film including a cathode active material was pressed onto a circularly-punched aluminum mesh having a diameter of 14 mm using a press, and was then dried at 140 degree Celsius for 3 hours to obtain a cathode.
[0151] An anode was fabricated by punching metal lithium foil having a thickness of 500 μm to a diameter of 14 mm.
[0152] A solution in which LiPF 6 is dissolved in a mixed solvent of ethylene carbonate and diethyl carbonate of a weight ratio of 1:1 to a concentration of 1.0 mol/L was used as an electrolyte.
[0153] A member for a CR2032 type coin battery (manufactured by HOSEN CORPORATION) made of a stainless steel container was used, and the cathode and anode were arranged in a dry room in a state in which a separator (Celgard 2400) having a thickness of 25 μm and made of a polypropylene microporous film and a glass nonwoven fabric filter having a thickness of 500 μm are disposed between them. Subsequently, the container was charged with an electrolyte and then sealed by a sealing machine to fabricate a lithium secondary battery.
[0154] The charge-discharge test of the lithium secondary battery was conducted at an electric current of 50 mA per 1 g of a cathode active material. In this case, the final voltage of charge was set to 1.0 V, and the final voltage of discharge was set to 3.0 V. The charge-discharge curves of the lithium secondary battery using the cathode active material of Example 1 are shown in FIG. 15 , the charge-discharge curves of the lithium secondary battery using the cathode active material of Example 3 are shown in FIG. 16 , and the charge-discharge curves of the lithium secondary battery using the cathode active material of Example 5 are shown in FIG. 17 . Further, the cycle life characteristics of the lithium secondary battery using the product obtained in Example 1 as a cathode active material are shown in FIG. 18 , and the cycle life characteristics of the lithium secondary battery using the product obtained in Example 3 as a cathode active material are shown in FIG. 19 .
[0155] As a Comparative Example in which a sulfur single body is used as a cathode active material, a lithium secondary battery was fabricated in the same manner as the above, except that a film containing the cathode active material obtained from a mixture of sulfur, acetylene black and PTFE of a mixing ratio of 6:3:1 by weight was used as a cathode, and a solution in which lithium bistrifluoromethanesulfonylimide (LiTFSI), as a lithium salt, is dissolved in tetraethyleneglycol dimethyl ether (TEGDME), as an ether-based solvent from which sulfur is not easily eluted, to a concentration of 1 mol/L was used as an electrolyte. The charge-discharge test of this lithium secondary battery was conducted under the condition that the final voltage of discharge was set to 1.5 V, and the final voltage of charge was set to 3.0 V. The charge-discharge curve of this lithium secondary battery is shown in FIG. 20 .
[0156] From the comparison of FIG. 15 with FIG. 20 , the following points can be clearly understood. The lithium secondary battery using sulfur as a cathode active material exhibits a capacity of about 900 mAh/g during the first cycle, but the capacity thereof decreases after this. Therefore, the cycle life characteristics of this lithium secondary battery very deteriorate. In contrast, in the lithium secondary battery using the product (sulfur-modified polyacrylonitrile) obtained in the above Example as a cathode active material, the capacity thereof at a charge-discharge cycle slightly decreases. Therefore, it can be seen that the stability of this lithium secondary battery to an electrolyte is excellent.
Example 7
[0157] A coin battery was fabricated using the product obtained in Example 2 as a cathode active material in the same manner as in Example 6, and the characteristics of a battery were evaluated in the same manner as in Example 6. The charge-discharge curve of a lithium secondary battery is shown in FIG. 21 , and the cycle life characteristics thereof are shown in FIG. 22 . Referring to FIGS. 21 and 22 , in the lithium secondary battery of Example 7, the capacity thereof at a charge-discharge cycle slightly decreases. Therefore, it can be seen that the stability of this lithium secondary battery to an electrolyte is excellent. In particular, since this lithium secondary battery exhibits a high discharge capacity of about 760 mAh/g or more during the second cycle, it was found that an electrode material having excellent characteristics was obtained by the method of Example 2.
Example 8
[0158] A mixture of 300 parts by weight of sulfur powder and 100 parts by weight of polyacrylonitrile powder was charged in nickel foam, which has a thickness of 1.4 mm and a size of 1 cm×1 cm, by strongly pressing the nickel foam using a spatula, and then the nickel foam charged with the mixture was wrapped with aluminum foil, further wrapped with aluminum laminate film and then fusion-bonded to form a sample where the raw material is enclosed. The sample where raw material is enclosed and 80 mL of water were put into a 200 cc autoclave, and were then heated to 270 degree Celsius for 6 hours after the autoclave was tightly closed.
[0159] A lithium secondary battery was fabricated in the same manner as in Example 6, except that an electrode formed by integrating the sulfur-modified polyacrylonitrile and a nickel foam collector obtained in this way with each other was used as a cathode, and the charge-discharge test of this lithium secondary battery was conducted. FIG. 23 shows the charge-discharge curve of this lithium secondary battery. From FIG. 23 , it can be seen that this lithium second battery is slightly polarized and has low internal resistance. In this case, it is considered that nickel sulfide produced on the interface between an active material and a collector contributes to the increase in capacity of a battery, whereas the voltage of a battery becomes low under the influence of this nickel sulfide.
Example 9
[0160] Polyacrylonitrile powder and sulfur powder were charged in a carbon nonwoven fabric and then heat-treated in an autoclave in the same manner as in Example 8, except that a carbon nonwoven fabric (carbon paper TGP-H-030, manufactured by TORAY INDUSTRIES, INC.), which has a thickness of 120 μm and a size of 1 cm×1 cm, was used as a collector instead of nickel foam.
[0161] A lithium secondary battery was fabricated in the same manner as in Example 6, except that an electrode formed by integrating the sulfur-modified polyacrylonitrile and a carbon nonwoven fabric collector obtained in this way with each other was used as a cathode, and the charge-discharge test of this lithium secondary battery was conducted. As a result, the same as the charge-discharge results of the lithium secondary battery of Example 6 fabricated by using the product obtained in Example 3 as a cathode active material and using aluminum mesh as a collector, in the lithium secondary battery obtained by the method of Example 9, the capacity thereof at a charge-discharge cycle slightly decreases. Therefore, according to the method of Example 9, the lithium secondary battery having excellent stability to an electrolyte was obtained. Particularly, in this case, since a binder and an auxiliary conductivity agent may not be used, this lithium secondary battery is advantageous in terms of electrode capacity density.
Example 10
[0162] A lithium secondary battery was fabricated in the same manner as in Example 6, except that a coin battery was fabricated using the product of Example 1 in the same manner as in Example 6, and the final voltage of charge was set to 3.8 V. The characteristics of this lithium secondary battery were evaluated in the same manner as in Example 6, and the results thereof are shown in FIG. 24 . From FIG. 24 , it can be seen that, even when the lithium secondary battery is repetitively overcharged, the cycle life characteristics of this lithium secondary battery do not deteriorate, and this lithium secondary battery exhibits stable performance.
Example 11
[0163] The characteristics of a lithium secondary battery were evaluated in the same manner as in Example 6, except that output characteristics were evaluated by changing the current value per 1 g of a cathode active material to 0.1 C, 0.2 C, 0.5 C, 1.0 C, 2.0 C, 5.0 C by C rate. The results thereof are shown in FIG. 25 . From FIG. 25 , it can be seen that output characteristics are very high because the capacity in 2.0 C is about 85% the capacity in 0.1 C.
Example 12
[0164] A lithium secondary battery was fabricated using the product obtained in Example 1 as a cathode material by the following method, and the characteristics thereof were evaluated.
[0165] First, 40.5 mg of acetylene black and 4.5 mg of polytetrafluoroethylene (PTFE) were mixed with 45 mg of the product obtained in Example 1, and then the mixture was kneaded into a film using an agate mortar while adding a suitable amount of ethanol thereto.
[0166] The obtained film including a cathode active material was extended to a size of 25 mm×30 mm, pressed onto an aluminum mesh cut to a size of 30 mm×30 mm using a press, and was then dried at 140 degree Celsius for 3 hours. Then, the portion of the aluminum mesh having a width of 5 mm, on which the cathode active material was not applied, was spot-welded with aluminum foil having a width of 4 mm and a thickness of 120 μm to form a conductive tab.
[0167] An anode (called a carbon electrode in the description of pre-doping below) was fabricated by a general method of fabricating a carbon-based anode as follows. First, 85 parts by weight of OMAC2 (manufactured by OSAKA GAS CHEMICALS CO., LTD.), which is an anode material formed by surface-coating spheroidized natural graphite and having a particle diameter of about 20 μm, as an anode active material, 3 parts by weight of Ketjen black (KB) as an auxiliary conductivity agent, 12 parts by weight of polyvinylidene fluoride (PVdF) as a binder, and 200 parts by weight of N-methyl-2-pyrrolidone (NMP) as a solvent were put into a mixing container and then stirred 20 times for 8 minutes to form uniform paste. This paste was uniformly applied onto copper foil having a thickness of 23 μm using a doctor blade, and was then dried in vacuum at 140 degree Celsius for 3 hours to form an electrode layer having a thickness of 80 μm. This electrode layer was cut to a size of 25 mm×30 mm, and was then spot-welded with nickel foil having a width of 4 mm and a thickness of 120 μm as a conductive tab to fabricate an anode.
[0168] The active materials, which were used to fabricate the cathode and anode, are lithium-deficient materials, and lithium does not exist in neither of the cathode and anode. Therefore, when these cathode and anode are assembled into a lithium secondary battery, lithium cannot be exchanged between the cathode and the anode, and thus the lithium secondary battery cannot be charged and discharged. Therefore, lithium was previously charged in the anode containing a carbon-based active material using an electrolytic pre-doping technology of lithium. In the electrolytic pre-doping technology of lithium, a metal lithium electrode cut to a size of 25 mm×30 mm and having a thickness of 0.5 mm was used as a counter electrode. Nickel foil having a width of 4 mm and a thickness of 120 μm was used as a conductive tab of the metal lithium electrode, and this nickel foil is pressed to the metal lithium electrode to impart conductivity to the metal lithium electrode. This metal lithium electrode was combined with the carbon-based electrode, and then an aluminum laminate battery for electrolytic pre-doping was fabricated according to the following method. Aluminum laminate film (model number: D-EL40H, manufactured by HOSEN CORPORATION) cut to a size of 6 cm×7 cm was used in the exterior of a battery, the carbon-based electrode and the lithium counter electrode were arranged in a dry room in a state in which a separator (Celgard 2400) made of a polypropylene microporous film having a thickness of 25 μm is disposed between them, and then the laminate of the carbon-based electrode, the separator and the lithium counter electrode were charged with 0.1 cc of the same electrolyte as that of Example 6, and then four sides of the aluminum laminate film were fusion-bonded to fabricate an aluminum laminate battery for electrolytic pre-doping. In this case, the tabs of both electrodes protrude out of an aluminum laminate sack such that the charge-discharge of a battery can be performed by a conductive tab.
[0169] Subsequently, the charge-discharge of the aluminum laminate battery for electrolytic pre-doping at 2.5 cycles was conducted by allowing electric current of 15 mA per 1 g of an active material of a carbon-based electrode to flow. Here, the reason why the charge-discharge test thereof was conducted at 2.5 cycles is that the first 2 cycles are set in order to remove and the confirm the effect of the irreversible capacity which occurring at the initial stage of cycle, when a carbon-based active material is used, and the final 0.5 cycles are set in order to charge lithium in the carbon-based electrode. For the purpose of performing only the electrolytic pre-doping, the aluminum laminated battery may be discharged using a lithium metal electrode as a counter electrode, and lithium may be charged into an electrode to be doped.
[0170] Subsequently, after 2.5 cycles, the aluminum laminate battery for electrolytic pre-doping was disassembled to obtain a carbon-based electrode pre-doped with lithium. A lithium secondary battery was fabricated in the same manner as was the aluminum laminate battery for electrolytic pre-doping, except that the carbon-based electrode pre-doped with lithium was used as an anode, and the electrode including sulfur-modified polyacrylonitrile was used as a cathode. The charge-discharge of this lithium secondary battery was conducted by allowing electric current of 50 mA per 1 g of a cathode active material to flow. In this case, the final voltage of charge was set to 0.85 V, and the final voltage of discharge was set to 2.9 V. FIG. 26 shows the charge-discharge curve of this lithium secondary battery, and FIG. 27 shows the cycle life characteristics thereof. From FIGS. 26 and 27 , it was found that this lithium secondary battery is a high-performance lithium secondary battery having excellent cycle life characteristics because it exhibits high capacity of 410 mAh/g based on the reduction of an active material in the cathode at the 20th charge-discharge cycle.
[0171] From the above results, it is obvious that a high-capacity lithium secondary battery can be fabricated when the electrode including sulfur-modified polyacrylonitrile was used as a cathode and the carbon-based electrode pre-doped with lithium was used as an anode.
Example 13
[0172] A lithium secondary battery was fabricated by combining the sulfur-modified polyacrylonitrile cathode with the anode of Example 12 in the same manner as in Example 12, except that silicon thin film was used as the anode instead of a carbon-based electrode used in Example 12, and the final voltage of discharge was set to 0.45 V and the final voltage of charge was set to 2.80 V during the charge-discharge test. The characteristics of this lithium secondary battery were evaluated.
[0173] Further, the silicon thin film used as the anode of this lithium secondary battery may be formed by forming a silicon layer having a thickness of 5 μm on apiece of copper foil used as a collector by sputtering, cutting the complex of the silicon layer and copper film to create an electrode area of 25 mm×30 mm, welding the complex with a nickel conductive tab and then pre-doping the welded complex of anode with lithium in the same manner as in Example 12.
[0174] FIG. 28 shows the charge-discharge curve of this lithium secondary battery, and FIG. 29 shows the cycle life characteristics thereof. From FIGS. 28 and 29 , it was found that this lithium secondary battery is a high-performance lithium secondary battery having excellent cycle life characteristics because it exhibits high capacity of 440 mAh/g based on the reduction of an active material in the cathode at the 20th charge-discharge cycle.
[0175] Further, when silicon having a theoretical capacity (3500 mAh/g) higher than the theoretical capacity (370 mAh/g) of carbon is used as an anode, the thickness of the anode can be reduced, which is advantageous to fabricate a large-capacity lithium secondary battery in volume. | Provided is a sulfur-modified polyacrylonitrile manufacturing method that is characterized in that a starting base powder that comprises sulfur powder and polyacrylonitrile powder is mixed and the mixture is heated in a non-oxidizing environment while outflow of sulfur vapor is prevented. Also provided are a cathode for lithium batteries that uses, as the active substance, the sulfur-modified polyacrylonitrile manufactured with the method, and a lithium secondary battery that includes the cathode as a component element. This enables the practical use of an inexpensive sulfur-based material as the cathode material for lithium secondary batteries, and in particular, a sulfur-based cathode material that enables higher output and has excellent cycle life characteristics, as well as other characteristics, and secondary lithium batteries using the same can be obtained. | 2 |
OBJECT OF THE INVENTION
[0001] The invention relates to rotary filters, such as disc and drum filters where a precoat layer is used in assisting the filtration. Especially the invention is suited for precoat removal in filtering lime sludge of the chemical pulping industry.
PRIOR ART
[0002] A precoat layer is commonly used in filtering processes and it is especially advantageous in filtering white and green liquor of the chemical pulping industry, whereby the material to be filtered itself acts as the precoat. One and the same layer cannot be used continuously, since it gets clogged by fines. The layer has to be periodically removed and be replaced by a new layer. The normally used technique is to automatically move the scrapers according to a certain program closer to the filtering surface for at least one rotation and to return them back, whereby a clogged surface layer can be removed, but only partially. When a scraper has this way several times approached the filtering surface, the precoat layer is totally removed and a new precoat layer is created. The replacement of the precoat is typically performed 3-8 times per day. The more efficient the precoat removal is the less is disturbs the operation of the filter and the downstream subprocesses.
[0003] The precoat is removed from the filtering surfaces usually by blowing pressurized gas backwards through the filtering surface or by subjecting the precoat to powerful liquid sprays. In both cases the precoat is removed above the scraper. The precoat removal can also be performed by slurrying it in the filter basin by means of liquid sprays below the scraper, as in the method presented in U.S. Pat. No. 5,897,788 or after the filtering surface has risen from the basin, as in the method presented in U.S. Pat. No. 5,149,448.
PROBLEMS RELATING TO PRIOR ART
[0004] When the precoat is removed by blowing, the filtering cloth and other device surfaces inside the filter are to be occasionally washed by means of high pressure liquid sprays in order to prevent their fouling from hampering the operation of the filter. The blowing method requires complex channeling structures for controlled removal of the precoat and washing means of the filtering surface and the interior areas and therefore the apparatus will be expensive.
[0005] Precoat containing lime sludge sticks onto surfaces extremely well. It easily forms hard deposits that are hard to remove and they can clog channels or otherwise hamper the operation of the filter, especially the moving parts thereof.
[0006] When the precoat is removed by directing liquid sprays above the scraper, a large portion of the used liquid leaks from between the scraper and the filtering surface into the basin, where it dilutes the lime milk. This dilution is desirably avoided in order to assist in reusing the liquor as a filtrate.
[0007] When the liquid sprays are directed into the rotational direction of the filter or perpendicularly to the filtering surface, the sprays continuously has to pass through the layer before the layer is removed from where the spray hits. Simultaneously a powerful spray presses the precoat against the wire and inside it. Splashes from the precoat also hamper the hitting of the spray onto the uncovered filtering surface, and thus the washing thereof. A very large amount of water and/or high spraying pressure or several nozzles or more than one filter revolution are required in order to remove the precoat from the filtering surface and on ensure proper washing of the wire surface at the same time. The amount of water that is used and that gets into the basin is thus very high.
[0008] When the liquid sprays are located below the scraper or after the filtering surface has risen from the basin, the sprayed liquid dilutes the slurry in the basin and thus the filtrate to be recovered.
[0009] The precoat can be removed in narrower strips instead of the whole width of the filtering surface, as presented in U.S. Pat. No. 5,897,788 or U.S. Pat. No. 5,149,448. However, this has no influence especially on the dilution problem, which is only intensified, if the precoat removal is continuous. When the operation is uninterrupted, lime mud layers are not regularly removed from the interior of the apparatus, while that is easy to do when removing the whole width of the precoat layer.
[0010] Filters are expensive and essential apparatuses and methods and devices intensifying their operation should be such that they can be performed also to existing apparatuses with the least possible changes, in order to keep the costs and production breaks small. Further, the downstream processes after the filtration may be disturbed by production breaks.
THE PURPOSE AND SOLUTION OF THE INVENTION
[0011] The present invention provides a solution for the above problems. An efficient solution has been developed that is easily and even without major changes performed in conjunction with present apparatuses.
[0012] The invention relates to a method and an apparatus, where removal of precoat can be performed efficiently by means of water sprays above the scraper so that the filtering surfaces of the filter are rotated to a direction opposite to the filtering process. More precisely, the solution according to the present invention is characterized in what is presented in the independent claims.
[0013] When the liquid sprays located above the scraper are directed sloping downwards against the normal rotational direction of the filter, the liquid efficiently penetrates between the precoat and the filtering surface and scrapes off the precoat, most preferably during one rotation of the filter. Also the filtering surface below the precoat is efficiently cleaned, when the spray removing the precoat can hit directly onto its surface, and the pressure of the removal spray does not push the precoat against the wire and inside it.
[0014] The releasing precoat drops into the lime sludge chutes without splashes disturbing the washing of the uncovered filtering surface. The precoat moving aside during the washing closes the space between the scraper and the filtering surface so that leaking of the liquid into basin is prevented before the layer has been totally removed. Further, the upwards rising filtering surface hampers the flow downwards, which also decreases leakage between the scraper and the filtering surface.
[0015] Because the method is quick, and the use thereof does not have any major effect on the concentration of the solution in the basin, there is no need to always stop the filter feed. Even when the feed is stopped, the stoppage remains short. When the precoat is delivered to a drop chute instead of a basin, two main capacity-related advantages will be realized. Firstly, when the precoat needs to be replaced, it is blocked by the finest particles. If they are returned back to the basin they will cause blocking again. By removing them from the process, the periods of time between the precoat removals are substantially longer and the filtering capacity is increased. Secondly, the removed precoat will be part of the production flow of the filter and does not need to be filtered twice.
[0016] The blades of the scraper may not need to be moved to a different position during the precoat removal. When the precoat has already been removed, e.g. in connection with the washing of the wire, bringing the blades close is advantageous when there is a desire to minimize bypassing of liquid into the basin.
[0017] To avoid damages to the filter because of increased thickness of the cake, scraping the precoat thinner is advantageous to perform just before the removal of the precoat. To prevent the increase of thickness, reducing the pressure difference or emptying the basin may also be performed e.g. a half of a rotation before the removal of the precoat.
[0018] After the precoat is removed, there is a short time for some liquid to be sprayed into the basin from between the scraper and the filtering surface, despite the countercurrently moving filtering surface. However, the amount is much smaller than when operating in conventional ways. This is partly an advantageous phenomenon, because the passing liquid spray simultaneously can remove lime sludge layers accumulated onto the lower side surfaces of the scraper. Due to this cleaning effect, the liquid spray can be used extra time after the precoat is removed, if needed.
[0019] Advantages of the method and apparatus according to the invention include e.g.:
Changes in the apparatus are minimal, production break is shortened and periods of time between them are longer, the solution in the basin is not unnecessarily diluted, the precoat is released in an easier, more reliably and more efficiently when the liquid spray is directed against the rotational direction between the precoat and the surface of the filter, the precoat removal can be performed efficiently, with minimal liquid amounts and spraying pressures and with almost no disturbance for the apparatus and the filtering surface as well as the area below the scraper can be washed with the same nozzles in the same event.
LIST OF DRAWINGS
[0026] In the following, the invention is disclosed in more detail with reference to the appended drawings, of which
[0027] FIG. 1 illustrates general features of a disc filter apparatus,
[0028] FIG. 2 illustrates a disc filter arrangement of prior art used in precoat removal, seen from the side of the scraper,
[0029] FIG. 3 illustrates an arrangement according to an embodiment of the invention used in precoat removal, seen from the side of the scraper, and
[0030] FIG. 4 illustrates the washing of the lower surfaces of the scraper according to an embodiment of the invention, seen from the side of the scraper.
DETAILED DESCRIPTION OF THE INVENTION
[0031] FIG. 1 illustrates general features of a filter disc used in lime sludge filtration. A drum filter may be used as an alternative type of filter as it operates according to the same principle. The filtering surfaces 56 of a drum filter are on the cylinder surface of the drum, and in a disc filter they are on both sides of the discs.
[0032] The disc filter comprises a rotary shaft 10 that is hollow or otherwise provided with filtrate flow channels 16 . The shaft 10 is supported at its ends and connected via bearings to the frame of the apparatus, in which the drive devices are arranged. The shaft 10 is connected to drive devices (not shown), such as a motor, a reduction gear etc. A number of filter discs 12 are arranged on the shaft, which discs comprise sectors 14 having wire coated filtering surfaces 56 on both sides. Filtrate coming from sectors 14 is led out of the filter via flow channels 16 , which may be combined to discharge into a hollow shaft 10 .
[0033] In order to ensure functional operation of the filter, a pressure difference is created between the inner and outer sides of the filtering surfaces 56 . Therefore the interior of the filter is pressurized e.g. by means of an air compressor to produce the pressure difference. Alternatively or in addition, pressure difference can be created or increased by means of a vacuum source connected to the flow channels 16 of the shaft 10 . The pressure difference can be adjustable and it can be switched off e.g. by means of a valve.
[0034] The lower part of the filter discs 12 are submerged in lime sludge slurry fed into as basin 40 . The surface L 1 of the slurry in the basin 40 extends to a level where it completely covers the sector 14 that is at the bottom dead center. As the filter disc 12 rotates in the basin 40 , lime sludge is accumulated on the filtering surface 56 forming a cake, and the liquid filtrate passes through the filtering surface. At first, a precoat 57 (in FIG. 2 ) layer is usually formed on the filtering surfaces 56 for assisting the filtration. After being filtered, the cake may be washed, whereby the cake is flushed with washing liquid sprays as displacement wash. Then the cake is dried, usually to be as dry as possible.
[0035] A scraper 20 is arranged on a declined level slightly above the slurry level L 1 in the basin 40 on both sides of the filter disc 12 . The distance between the scraper 20 and the filtering surface 56 is usually adjustable. The scraper 20 is located in the vicinity of the slurry level L 1 in order to maximize the drying period of the cake. The scraper 20 scrapes off filtered lime sludge layer being on the filtering surface 56 or on the precoat layer 57 on the filtering surface. On the scraper 20 the lime sludge layer flows from between the discs 12 into a drop chute 38 that is separated from the basin 40 . Lime sludge is accumulated in the drop chute 38 approximately to the height of level L 2 . The drop chute 38 may be provided with a mixer 22 , which mixes the dried lime sludge with the liquid being fed into the drop chute, so that the lime sludge can flow in slurried form out of the apparatus via channel 24 .
[0036] FIG. 2 illustrates a conventional arrangement in connection with the removal of the precoat 57 performed on a two-sided filter disc 12 . The disc 12 of the disc filter rotates to the same direction used in a normal filtering process. Liquid sprays 54 exiting from downwards sloping nozzles 52 remove the precoat 57 from the surface of the disc 12 and the exiting lime sludge flows into the chute 38 . The liquid being sprayed is usually mainly water.
[0037] The scraper 20 may be moved closer to the filtering surfaces 56 before removal of precoat 57 , whereby it assists in the removal by reducing the thickness thereof. The scraper 20 cannot be moved to touch the filtering surface 56 , because that would lead to breakage of the filtering surface. Therefore, a portion of the sprayed liquid always gets from between the scraper 20 and the filtering surface 56 into the basin 40 . The rotational motion towards to basin 40 intensifies this leakage flow. Because the liquid sprays 54 do not directly penetrate under the precoat 57 , but the precoat is partly removed by slurrying, the method is relatively slow. Intensifying the removal by increasing the amount of liquid being sprayed or the spraying pressure leads to stronger dilution of the slurry in the basin 40 , and possibly to damages of the wire.
[0038] FIG. 3 illustrates an arrangement according to the invention. The rotational direction is changed to the opposite, i.e. the precoat 57 to be removed rises from below the scraper 20 . It is efficiently and reliable removed by means of liquid spray 54 penetrating directly between the precoat 57 and the filtering surface 56 . The precoat 57 is removed, partially in pieces and flows into the basin 38 . The precoat 57 moving upwards on the disc 12 and acts as a barrier preventing the liquid being sprayed from getting into the basin via a gap between the scraper 2 and the precoat 57 .
[0039] The spray nozzles 52 are mounted to direct the liquid spray 54 sloping downwards. A smaller hitting angle onto the filtering surface 56 assist in removing the precoat 57 and a wider angle intensifies the washing of the filtering surface 56 . Most preferably the set angle between the nozzle 52 of the liquid spray 54 and the filtering surface 56 moving to the opposing direction is in the vertical direction 25-70 degrees.
[0040] Most preferably the change of the rotational direction is performed by means of an inverter adjusting the rotational speed of the electric motor that moves the filter disc. The inverter has a special advantage in that during the removal of the precoat 57 it allows an easier way to use optimized and preferably greater rotational speeds and not the same as during the filtering.
[0041] If an inverter is not available, a three-phase motor can change its direction by connecting two phases instead of to each other e.g. by means of relays or mechanical switches. Also other commonly known methods or mechanical transmissions can be used for changing the rotational direction of the filter's motor or the drum, and if needed, also its rotational speed.
[0042] While the filter is in operation, the lime sludge layer accumulated onto the filtering surface 56 is at its thinnest after the scraper 20 and get continuously thicker as it passes forward at the basin 40 . If the filtering is not stopped by partially or totally releasing the pressure difference e.g. half of a rotation before changing the rotational direction, the lime sludge layer would grow also when traveling a second time in the basin into a different direction and when stopping during the change of direction. The filtered layer may be substantially thicker when it returns to the gap between the scraper 20 and the filtering surface 56 . This may cause damages to the structure of the filter and the filtering surfaces 56 particularly can easily get broken or eroded.
[0043] The alteration of the thickness of the cake can be taken into account in the distance between the scraper 20 and the filtering surface 56 , so that the cake does not have to be packed between the scraper and the filtering surface. The distance to the filtering surface 56 may be increased to correspond to the thickest point before removing the precoat 57 , but then for a portion of the precoat removal cycle, a larger gap will remain between the cake and the scraper 20 .
[0044] Although the precoat 57 being removed acts as an efficient barrier for the liquid passing into the basin, the slot between it and the scraper 20 can be minimized if needed either based on experience based knowledge or on knowledge based on observations of measurements by changing the position of the scraper 20 in accordance with the thickness alteration. The metering information can be obtained e.g. by measuring the lime sludge layer's thickness or the slot between the scraper 20 and the pulp layer e.g. by means of measuring devices operating mechanically, capacitively or optically.
[0045] The precoat 57 can be scraped thin just before it is removed to avoid damages. If in the same connection the filtering is stopped by decreasing the pressure difference and/or emptying the basin e.g. back into the causticizing tank or lime sludge tank, the precoat 57 remains thin and of uniform thickness. Then it is more efficiently removed by using less liquid and lower spraying pressures and the position of the scraper 20 need not be changed during the removal. When the precoat 57 is of uniform thickness, the conditions for its removal, such as rotating speed and spraying pressure can best be optimized and too high a spraying pressure can be avoided, and the use of liquid can be limited.
[0046] It may not be necessary for removing the precoat 57 to move the scrapers 20 closer to the filtering surface 56 . If after the removal there is e.g. a desire, for instance for washing of the filtering surface, to decrease the amount of water passing into the basin 40 , the scrapers 20 can be brought closer to better guide the liquid into the drop chute 38 instead of the basin 40 .
[0047] The nozzles 52 in disc filter are located at different distances from the shaft 10 , i.e. the moving speed of the filtering surface increases towards the outer circumference, so that the nozzles 52 , the spraying pressure and the positioning angle may at different distances from the shaft 10 be adapted to be different for optimizing the spraying conditions.
[0048] The washing of the filtering surface 56 taking place in connection with the removal of the precoat 57 can be intensified by using, in addition to the liquid sprays 54 removing the precoat 57 , washing sprays (not shown), which are directed to the point where the filtering surface 56 has been completely uncovered. In these washing sprays, the most suitable spraying pressures and nozzles and the directing angle for especially washing the filtering surface 56 can be used. The washing conditions can be optimized also depending on the distance of the nozzle from the central shaft 10 . These washing nozzles can be connected to a flow duct 50 , which is either the same as or a different from that of the nozzles 52 . This or these flow duct(s) 50 can be arranged rotatable around its longitudinal axis, so that the directing of the sprays can be best optimized in every situation. E.g. after removing the precoat 57 , it may be advantageous to change the directing for more efficient washing of the filtering surface 56 or the components of the apparatus.
[0049] In connection with the removal of the precoat 57 , also blowing of air or liquid in a known way to the inner side of the filtering surface 56 may be directed at least to the zone where removal of the precoat 57 is taking place.
[0050] FIG. 4 illustrates how after the removing of the precoat 57 , lime sludge accumulated onto the lower surfaces of scraper 20 can be flushed away, if needed, by means of liquid passing to the lower slide of the scraper via the gap between the scraper 20 and the filtering surface 56 . By appropriate directing of the removal sprays 54 or the washing sprays, an adequately cleaning effect is obtained by means of a small liquid amount.
[0051] The liquid spray could remove the precoat 57 using the normal rotating direction as well and diluting the solution in the basin still less, if it was inclined upwardly against the rotating direction of the filtering surface 56 . This is not easy to perform in practice, since then the spray would be directed upwards and it would splash around the liquid and the layer being removed and would foul the whole apparatus, which inevitably would lead to repeated extra maintenance operations. However, this might possibly be performed adequately by covering the spraying point, if there is space for that in the apparatus. Further, efficient cleaning of the lime sludge layers off the surfaces of these covers and surfaces that get fouled would need to be arranged.
[0052] Although the above description relates to embodiments of the invention that in the light of present knowledge are considered the most preferable, it is obvious to a person skilled in the art that the invention can be modified in many different ways within the broadest possible scope defined by the appended claims alone. | A method associated for treating a precoat on a rotating filtering surface of lime sludge filter including: accumulating a precoat of lime sludge on the filtering surface by rotating the filtering surface in a first direction through a lime sludge slurry; after accumulating the precoat, rotating the filtering surface in an opposite direction to the first direction; while rotating the filtering surface in the opposite direction, spraying a liquid onto the precoat on the filtering surface wherein the spraying is applied to the precoat above a scraper adjacent the filtering surface and the spraying removes at least a portion of the precoat from the filtering surface, and flowing the removed precoat over the scraper and into a basin. | 1 |
This application is a continuation, of application Ser. No. 08/418,334 filed Apr. 7, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel absorbent materials, a process for preparing these materials and absorbent articles containing the absorbent. More specifically, the absorbent materials comprise polysaccharides which have been synthesized to have a particle size of greater than 200 mesh as measured using a Tyler screen and have a desirable combination of absorbency and gel strength properties.
2. Technology Description
Many attempts have been described in the patent literature to prepare absorbent materials, i.e. materials which are capable of absorbing many times their weight of water or various body fluids.
The following list is representative of United States patents which have issued in this area: U.S. Pat. No. 3,528,421 (disposable absorbent underpad for hospital patients or similar product, hydrous calcium silicate chemical absorbent); U.S. Pat. No. 3,563,243 (absorbent pads such as diapers, underpads and the like-hydrophilic polymer absorbent); U.S. Pat. No. 3,669,103 (absorbent products containing a hydrocolloidal polymeric absorbent lightly cross-linked polymer such as poly-N-vinyl-pyrrolidone, polyvinyltoluenesulfonate, poly-sulfoethyl acrylate, and others); U.S. Pat. No. 3,686,024 (water absorbent articles coated with a water-swollen gel such as cross-linked partially hydrolyzed polyacrylamide); U.S. Pat. No. 3,670,731 (absorbent dressing using water soluble hydrocolloidal composition); U.S. Pat. No. 3,783,872 (absorbent articles such as diapers, and the like using insoluble hydrogels as the absorbing media); U.S. Pat. No. 3,898,143 (disposable absorbent articles using poly(ethylene oxide) and at least one other water soluble polymer co-crosslinked by high energy irradiation); U.S. Pat. No. 4,055,184 (absorbent pads for disposable diapers, sanitary napkins, bandages or the like using solid, finely-divided mixture of a hydrolyzed starch polyacrylonitrile graft copolymer in acidic form and a non-irritating and non-toxic water-soluble basic material); U.S. Pat. No. 4,069,177 (water absorbing and urine stable step-wise grafted starch-polyacrylonitrile copolymers); U.S. Pat. No. 4,076,663 (water absorbing starch resins); U.S. Pat. No. 4,084,591 (absorber for blood made from filaments of a lower alkyl or a lower hydroxyalkyl substituted cellulose ether).
In U.S. Pat. No. 3,903,889 the patentee describes as an absorbent composition for use in absorbent products a guar gum which is modified with borate anion in an amount sufficient to complex the gel formed from the hydration of guar gum alone. Specifically, the patentee teaches introducing borate ion into the absorbent product in the form of an essentially water insoluble borate-release agent in which the free borate ion is released slowly to the absorbent system and only after the aqueous liquid sought to be absorbed by the product has entered the product itself. It is suggested that the modified guar gum can absorb up to at least 20 times its weight of water to produce a relatively dry non-sticky and inert gel.
U.S. Pat. Nos. 4,333,461 and 4,624,868 are directed to absorbent materials which comprise borate cross-linked polysaccharides. The enabled polysaccharides are guar gum and its derivatives.
U.S. Pat. No. 4,952,550 is directed to particulate absorbent materials which are carboxylated cellulosic materials. More specifically, the materials are cellulosic base materials which are reacted with a cross-linking agent and a hydrophobicity agent. Preferred cross-linking agents include metals such as aluminum, iron or chromium. Similarly, Research Disclosure 349,296 suggests the use of aluminum cross-linked cellulose gums as absorbent materials.
Other patent documents discuss the use of finely divided polygalactomannan powder materials in absorbent articles of manufacture. They include EP 0 260 135; U.S. Pat. No. 3,070,095; U.S. Pat. No. 3,347,236; U.S. Pat. No. 3,645,836; and U.K. Patent No. 1,331,964. A primary limitation in the use of such materials, which have a particle size of less than 200 mesh as measured by using a Tyler screen (i.e., mesh number is 200 or greater) is that they do not possess the requisite gel strength necessary for certain absorbent applications and that they migrate during manufacture, shipment storage or use, limiting their utility. To overcome the migration problem, U.K. Patent No. 1,331,964 suggests adhering the powder to other fibrous materials. U.S. Pat. No. 3,347,236 suggests forming fibrous materials by adding guar flour to an organic liquid to form a slurry, adding water to the slurry to precipitate a hydrate of the guar, and extruding the resulting hydrate. U.S. Pat. No. 3,645,836 suggests adding water to guar gum to form a hydrate, adding an organic liquid to form a fibrous precipitate and drying the fibrous material.
Other known absorbent materials include those derived from acrylic polymers and those derived from amino acids.
Except for the polyacrylates and starch grafted acrylates, with respect to their application for absorbing or holding fluids such as in diapers, sanitary napkins, bandages, gloves, sporting goods, pet litter and the like the absorbent materials and absorbent products described in these references have not been commercially acceptable. Such problems as insufficient absorbing capacity, insufficient rigidity of the swollen gel, breakdown of the gel structure upon contact with saline fluids, incompatibility with absorbent articles, still exist.
U.S. Pat. Nos. 4,605,736 and 4,677,201 are directed to cross-linking polygalactomannans with a titanium based cross-linking agent. The in situ cross-linking reaction is performed in an aqueous environment and the polygalactomannan is not recovered. These aqueous systems are suggested for use in oil recovery.
U.S. Pat. No. 4,959,464 is directed to the production of aluminum cross-linked derivatized polygalactomannans. The resulting products are suggested for use as thickening agents which readily hydrate under alkaline pH conditions.
Despite the above teachings, there still exists a need in the art for novel compositions which have functionality as absorbent materials.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention novel solid compositions are provided which have functionality as absorbent materials. More specifically, the solid compositions comprise one or more polysaccharides having a mean particle size of greater than about 200 mesh, a gel strength of greater than about 2000 dynes per square centimeter and an absorbency of greater than about 15 grams of saline solution per gram of polysaccharide when immersed in a 0.9% saline solution for a time period of one hour.
Particularly preferred polysaccharides include cellulose materials, and polygalactomannans such as guar gum and locust bean gum. Particularly preferred are the use of guar polymers. The polysaccharide materials may be used alone as absorbent materials or may be combined with other known materials such as carbohydrates, natural or synthetic hydrophilic polymers, hydroxylated compounds, carboxylic acids, hydroxyacids, amino acids, peptides and proteins. The absorbent materials may also be combined with conventional materials commonly used for their absorbent properties.
An additional embodiment of the present invention comprises an absorbent article of manufacture including an absorbent solid composition comprising one or more polysaccharides having a mean particle size of greater than about 200 mesh, a gel strength of greater than about 2000 dynes per square centimeter and an absorbency of greater than about 15 grams of saline solution per gram of polysaccharide.
Particularly preferred article of manufactures include diapers, diaper pads, feminine hygiene articles, wound dressings, pet litter, cosmetics, personal care products, pharmaceuticals, textiles, agricultural chemicals, paper materials, construction materials, energy materials, communications materials, food packaging products and the like.
Still another embodiment of the present invention comprises a process for producing a polysaccharide having utility as an absorbent. The process comprises
(a) hydrating guar gum splits to a hydration level of between about 20 and about 100
(b) grinding the hydrated guar gum splits to a mean particle size of greater than about 200 mesh; and
(C) drying said splits.
In a particularly preferred embodiment, the splits may be extruded after hydration.
An object of the present invention is to provide novel absorbent compositions.
Still another object of present invention is to provide novel absorbent articles of manufacture.
A further object of the present invention is to provide a process for producing compositions which have excellent utility as absorbent materials.
These, and other objects, will readily be apparent to those skilled in the art as reference is made to the detailed description of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing the preferred embodiment, certain terminology will be utilized for the sake of clarity. Such terminology is intended to encompass the recited embodiment, as well as all technical equivalents which operate in a similar manner for a similar purpose to achieve a similar result.
The present invention provides absorbent solid compositions comprising one or more polysaccharides having a mean particle size of greater than about 200 mesh, a gel strength of greater than about 2000 dynes per square centimeter and an absorbency of greater than about 15 grams of saline solution per gram of polysaccharide when immersed in a 0.9 percent saline solution for one hour. The polysaccharides are either water insoluble or slightly soluble (less than 50 percent, preferably less than 30 percent, and even more preferably less than 20 percent of the polysaccharide dissolves in water).
The compositions are polysaccharides, preferably polygalactomannans. The polygalactomannans may be derivatized, having a degree of substitution and/or a molar substitution of between about 0 and about 3.0.
The polygalactomannans are naturally occurring polysaccharides composed principally of galactose and mannose units and are usually found in the endosperm of leguminous seeds, such as guar, locust bean, honey locust, flame tree, and the like. Guar flour, for example, is composed mostly of a galactomannan which is essentially a straight chain mannan with single membered galactose branches. The mannose units are linked in a 1-4-β-glycosidic linkage and the galactose branching takes place by means of a 1-6 linkage on mannose units in an irregular manner. The ratio of galactose to mannose in the guar polymer is about one to two.
Locust bean gum is also a polygalactomannan gum of similar molecular structure in which the ratio of galactose to mannose is one to four. Guar and locust bean gum are the preferred sources of the polygalactomannans, principally because of the commercial availability thereof.
In use the polygalactomannan may be either in its natural state (i.e., pure guar gum or locust bean gum) or may be derivatized. Derivatized polygalactomannans include one or more non-ionic and/or ionic groups. Examples of the types of functional groups involved in producing the derivatives include hydroxyalkyl groups, carboxyl group, carboxyalkyl groups, quaternary ammonium groups, sulfonate groups, cyanoalkyl groups, phosphate groups, siloxane groups and the like having varying degrees of substitution and molecular substitution. Specific examples of such polygalactomannans include hydroxypropyl guar, hydroxyethyl guar, carboxymethyl guar, carboxymethyl hydroxypropyl guar, guar hydroxypropyltrimonium chloride and the like having varying degrees of substitution and molar substitution. Such derivatized polygalactomannans are sold by Rhone-Poulenc Inc. under the trade names Jaguar 8000, Jaguar 8710 and Jaguar 8600. Many commercially available starting guar materials may contain small amounts of additives such as borax, glyoxal and the like. These starting materials are expressly intended to constitute part of the present invention.
The term "degree of substitution" as employed herein is the average substitution of functional groups per anhydro sugar unit in the polygalactomannan gums. In guar gum, the basic unit of the polymer consists of two mannose units with a glycosidic linkage and a galactose unit attached to a hydroxyl group of one of the mannose units. On the average, each of the anhydro sugar units contains three available hydroxyl sites. A degree of substitution of three would mean that all of the available hydroxyl sites have been esterified with functional groups. A particularly preferred functional group is the carboxymethyl group, with good results obtained with starting materials having a degree of substitution of between about 0.0 and about 3.0, specifically including materials having a degree of substitution ranging from about 0.05 to about 1.00.
Similarly, the term "molar substitution" as employed herein is the average number of moles of functional groups per anhydro sugar unit in the polygalactomannan gum. A particularly preferred functional group is the hydroxypropyl group, with good results obtained with starting materials having a molar substitution of between about 0.0 and about 3.0. In a preferred embodiment the resulting polysaccharide is carboxymethyl hydroxypropyl guar having a molar substitution of hydroxypropyl groups of between about 0.25 and about 0.35 and a degree of substitution of carboxymethyl groups of between about 0.10 and about 0.15.
Alternative polysaccharide materials which may be selected as the starting material include starches, celluloses and xanthan gum. Examples of starches include both natural and modified starches, such as dextrinated, hydrolyzed, oxidized, cross-linked, alkylated, hydroxyalkylated, acetylated, or fractionated (e.g., amylose and amylopectin). The starch may be of any origin, for example, corn starch, wheat starch, potato starch, tapioca starch, sago starch, rice starch, waxy corn starch or high-amylose corn starch.
Examples of celluloses include hydroxyethyl cellulose, hydroxypropyl cellulose, cellulose gum, carboxymethyl cellulose and alkyl celluloses. Similar to the polygalactomannans, these derivatized materials may have a degree of substitution and/or molar substitution ranging from about 0.0 to about 3.0.
Still other polysaccharides which may be selected as a starting material include polydextrose, chitin/chitosan and derivatives thereof, alginate compositions, carageenan gum, pectin, gum karaya and gum arabic.
Critical to the success of the claimed invention is that the polysaccharide selected have a mean particle size of greater than 200 mesh, as measured by using the Tyler Screen Standard. The applicants have discovered that the use of polysaccharides having such a mean particle size provide an optimal balance between gel strength and absorbency so that the materials are ideal commercial candidates for absorbent compositions. Particularly preferred are the use of polysaccharides having a mean particle size of greater than 100 mesh, with a mean particle size of between about 20 to about 100 mesh being even more preferred.
Such polysaccharides are capable of producing compositions which have excellent gel strength and absorbency properties. With respect to gel strength, the inventive compositions have a gel strength of greater than 2000 dynes/square centimeter, and more preferably compositions have a gel strength of greater than 5000 dynes/square centimeter.
The absorbency properties are defined as the amount of a 0.9% saline solution that can be absorbed by one gram of the inventive material. In practice, the inventive compositions have an absorbency of greater than 15 grams of saline absorbed per gram of composition, with an absorbency of greater than 30 grams of saline absorbed per gram of composition.
The large particle size compositions may be obtained by using any of a number of methods. In one embodiment, the compositions can be prepared by simply agglomerating more fine material such as guar flour so that the final particle size exceeds the minimum 200 mesh. In yet another method, a fine material, such as guar gum flour can be extruded to yield a material having a particle size of greater than 200 mesh.
In still another method, particularly when using polygalactomannans, the use of a coarse grinding technique has demonstrated outstanding results. When using such a method, the first step of the method involves hydrating polygalactomannan splits, preferably guar gum splits by adding water to the splits such that the moisture content of the splits is between about 20 and about 100 percent, more preferably between about 30 and about 80 percent, and most preferably between about 40 and about 60 percent.
While still in a hydrated state, the polygalactomannan splits are then grinded using any grinding technique known in the art. Grinding is accomplished at a level sufficient to produce a composition having a mean particle size in the above described profile. Particularly preferred is grinding to yield particulates having a mean particle size of between about 20 and about 100 mesh.
Thereafter, the ground particulates are dried so that the final moisture content of the composition is less than 20 percent, more preferably less than 15 percent and most preferably less than 10 percent by weight. Drying is accomplished by using means known in the art such as air drying, oven drying, drum drying, filtering, evaporative drying, fluid bed drying, centrifuging, flash grinding, addition of solvents, freeze drying and the like.
In an alternative embodiment, the ground splits may be modified by extruding, flake forming and the like prior to drying. Forms such as flakes, films, sheets, spherical shapes and irregular shapes are all considered to be within the scope of the present invention. The key selection criteria for the final shape of the particulates is primarily dictated by the intended final use for the absorbent material.
As will be shown in the examples, when starting with a fine polysaccharide material having a mean particle size of less than 200 mesh, forming a film of this material followed by coarse grinding does not yield a suitable material as the gel strength and absorbency properties are not sufficient for practical use.
While not necessary to yield efficacious results, it is also possible to crosslink the polysaccharide. Either chemical or physical means may be used to crosslink the polysaccharide. The crosslinking of the inventive materials is considered purely optional.
The agents may be inorganic, organic or organometallic compounds. They may be charge neutral species or ionically charged. Particularly preferred are salts of boron, aluminum, titanium or zirconium. The aluminum, titanium or zirconium metals may form the nonionic, cationic and/or anionic portion of the compound. Other metals which may be selected in accordance with the present invention include hafnium, scandium, yttrium, vanadium, lanthanum, chromium, cerium, zinc, manganese, iron, cobalt, nickel, copper, calcium, magnesium, sodium or potassium or any other metal, including transition metals, which possesses crosslinking properties.
Examples of suitable salts include the acetates, alkoxides such as isopropoxides and hydroxides, halides, lactates, carbonates, nitrates, sulfates and the like. Also useful within the scope of the present invention are the alkali metal and ammonium salts of the respective aluminum, titanium or zirconium cross-linking materials, such as the sodium, potassium or ammonium salts.
Examples of specifically useful cross-linking agents include aluminum acetate, aluminum sulfate, aluminum isopropoxide, aluminum hydroxide, sodium zirconium lactate, zirconium lactate, zirconium acetate, potassium zirconium carbonate, ammoniacal zirconium carbonate, aluminum chloride, titanium acetate and mixtures thereof.
Other crosslinking agents include di, tri and multifunctional organic materials such as dichloroacetic acid, diglycidyl ether and dichlorosuccinic acid. As is the case with the inorganic or organometallic cross-linking agents, the key criteria is not the agent used per se, but rather, the ability of the agent to form a cross-linked polysaccharide which possesses absorbent properties.
Also contemplated within the scope of the present invention is the use of physical means to cross-link the polysaccharide. Such means include the use of heat, vacuum, pressure, surface treatment, mixing and the like.
When crosslinking the compositions of the present invention, a solution or dispersion of the polysaccharide is prepared by adding the polysaccharide to a solvent. Alternatively, the reaction may be performed in a "dry" state where the cross-linking agent is added to a dry polysaccharide and the other optional components. When using a solution reaction, water is the preferred solvent in the polysaccharide solution although other solvents such as alcohols, ethers, glycols, hydrocarbons and mixtures thereof may be used. Addition of the polysaccharide typically takes place at temperatures ranging from about 20° C. to about 90° C., with temperatures between about 40° C. to about 50° C. being most preferred.
The amount of polysaccharide added to the solvent is not critical, the primary consideration being that the polysaccharide be fully wetted (hydrated when the solvent is water). The amount of solvent generally will range from about 1 part to about 200 parts water per part of polysaccharide, preferably from about 30 parts to about 120 parts water per part of polysaccharide. The polysaccharide-solvent solution is allowed to mix for a time sufficient until the polysaccharide is at least substantially completely wetted, preferably completely wetted. To enhance the wetting procedure the mixture may be stirred. Generally from about 5 minutes to about 2 hours will be sufficient for the polysaccharide to be completely wetted. Thereafter, the solution is crosslinked by chemical and/or physical means.
In yet another embodiment, crosslinking may be accomplished by adding a crosslinking agent to the splits. The splits may be hydrated to various levels of hydration and may optionally be derivatized. The crosslinking agent may be added before, during or after derivatization or any combination thereof.
In a preferred embodiment chemical agents, and more preferably aluminum, titanium or zirconium cross-linking agents, including optional auxiliary cross-linking agent are added to the solution in amounts ranging from about 0.01 parts to about 50 parts, more preferably about 0.10 to about 10 parts per 100 parts of polysaccharide. The agent may be added to the solution in neat form, or, more preferably, in a carrier liquid which is preferably the same as the solvent of the solution. This will typically be water. Cross-linking occurs by thoroughly stirring the solution and is demonstrated by the formation of a thixotropic mass. The time required for cross-linking the polysaccharide typically takes between about 5 seconds and about 2 hours, with times ranging from about 1 minute and about 30 minutes being especially preferred. Another preferred embodiment is set forth in Example 4 (i.e., the crosslinking reaction takes place directly on the guar split, which may or may not be derivatized).
Other methods can be used to cross-link the solution such as by adjusting pH, heating and other methods known by those skilled in the art. The rate of cross-linking depends upon such factors as the temperature, pH, amount, rate and degree of mixing, concentration of the cross-linking agent and the like. The cross-linking reaction is completed when the viscosity of the resulting thickened gel-like mass no longer changes or becomes very high. Accordingly, the cross-linked polysaccharide gum may have a consistency ranging from a coherent slowly pourable gel through first stage gelling or gelation in which the thickened mass is no longer pourable but does not have dimensional stability and will spread if unconfined or second stage gelling in which the gel will have some dimensional stability and will temporarily hold a shape but will spread if unconfined for a short period of time.
In practice the novel compositions may be either used alone as absorbents or combined with other chemicals or physical materials to provide potential synergistic absorbency properties. For example, the compositions of the present invention can be combined either prior to or after their synthesis with one or more of the following classes of chemicals: carbohydrates; synthetic hydrophilic polymers; hydroxylated organic compounds; carboxylic acids, their salts and anhydrides; hydroxyacids and their salts; amino acids; proteins and peptides and mixtures thereof. In the case where acid materials are used in combination with the novel polysaccharides of the present invention, their acid salts may alternatively be used.
Specific examples of the above added combined chemicals include sucrose, glucose, lactose, fructose, mannitol, maltose, isomaltulose, gluconic acid, glucoronic acid, glucono-δ-lactone, xylose, sorbose, xylitiol, galactose, mannose, sorbitol, polyvinyl alcohol, polyethylene glycol, polypropylene glycol, polyacrylic acid and its salts, hydrophilic polyacrylates, polyacrylamide, methanol, ethanol, ethylene glycol, propylene glycol, glycerol, formic acid, acetic acid, oxalic acid, succinic acid, maleic acid, fumaric acid, benzoic acid, phthalic acid, 1,2,4,5-benzene tetracarboxylic acid, glycolic acid, lactic acid, citric acid, tartaric acid, aspartic acid, polyaspartic acid, glutamic acid, polyglutamic acid, gelatin, soy protein, beef hydrolysate and mixtures thereof.
Also contemplated for use in association with the present invention is the combination of the novel absorbent composition with commercially viable absorbent compositions. Such materials include crosslinked poyacrylic acid and starch grafted polyacrylic acid. Salts of the above materials may also be combined with the polysaccharide compositions of the present invention.
Also considered for combination with the inventive absorbent polysaccharides of the present invention are the following materials: cellulose fiber, cellulose fluff, peat moss, paper, wood fluffs, cellulose acetate, polyester, polylactide, polyglycolide, polyhydroxybutyrate, polyhydroxyvalerate, polyethylene, polypropylene, polystyrene, polyamide, starch based grafted polymers, cellulose grafted polymers, polyacrylates, polyacetals and mixtures thereof.
In any of the above combinations, the inventive polysaccharides of the present invention should constitute at least 0.01% of the absorbent blend composition.
In addition, for ultimate use as an absorbent material the inventive polysaccharides of the present invention may be combined with one or more of the following additives materials to provide a preferred commercial product: surfactant(s), silicone(s), defoamer(s), silica, diatomaceous earth, alumina, clay and mixtures thereof. Such additives may not function to improve absorbency but rather to complement the absorbent properties of the inventive compositions.
When liquids are added to these inventive compositions and/or blends, the compositions demonstrate an excellent balance of absorbency and gel strength. As such, they are considered good candidates for absorbent materials having a wide variety of use. Generic examples of such uses include diapers, adult incontinence articles, feminine hygiene articles, wound dressings, pet litter, agricultural uses such as hydromulching and soil amendment, automotive filters, underground cables, deodorants, cosmetics, pharmaceuticals, textiles, papers, engineering materials, energy materials, communication material, food materials, waste disposal, sporting goods, gloves such as work gloves, cosmetic gloves, batteries and the like.
Specific uses of the inventive compositions in baby diapers include the following: baby diaper, baby diaper pad, disposable baby diaper, disposable baby diaper pad, flushable baby diaper, flushable baby diaper pad, compostable baby diaper, compostable baby diaper pad, biodegradable baby diaper and biodegradable baby diaper pad.
Specific uses of the inventive compositions in adult diapers include the following: adult diaper, adult diaper pad, disposable adult diaper, disposable adult diaper pad, flushable adult diaper, flushable adult diaper pad, compostable adult diaper, compostable adult diaper pad, biodegradable adult diaper, biodegradable adult diaper pad, adult incontinence pad, adult incontinence diaper, biodegradable adult incontinence diaper and biodegradable adult incontinence pad.
Specific uses of the inventive compositions in feminine hygiene products include the following: feminine napkin, feminine pad, sanitary napkin, disposable feminine napkin, disposable feminine pad, disposable sanitary napkin, compostable feminine napkin, compostable feminine pad, compostable sanitary napkin, flushable feminine napkin, flushable feminine pad, flushable sanitary napkin, biodegradable feminine napkin, biodegradable feminine pad, biodegradable sanitary napkin, tampons, disposable tampons, flushable tampons, compostable tampons, biodegradable tampons, panty shield, panty liner, disposable panty shield, disposable panty liner, compostable panty shield, compostable panty liner, flushable panty shield, flushable panty liner, biodegradable panty shield and biodegradable panty liner.
Specific uses of the inventive compositions in cosmetics products include the following: moisture retention agents, moist towel, towel for make-up application, towel for make-up removal, rheology modifier, thickener, cosmetic emulsifier, hair styling agent, skin conditioner and hair conditioner, fragrance retention agent, fragrance releasing gel, gel deodorant and gel deodorant/antiperspirant.
Specific uses of the inventive compositions in pharmaceutical and medical products include the following: poultice, bandage, wound healing, burn healing, wound dressing, blocking agent for sexually transmitted diseases, burn dressing, blood absorbent, body fluid absorbent, patient bedsheet, absorbing material during and after surgery, transportation and disposal of medical waste, packaging material for the transfer of medical samples, drug delivery system, tablet disintegrant, pharmaceutical formulation and slow release matrix.
Specific uses of the inventive compositions in agriculture and horticulture include the following: water retention agents, plant growth accelerator, coating seedling and plant roots, water retention in flower pots, plant culturing bed, transportation of seedlings and plants, storage of seedlings and plants, growing of seedlings and plants, mushroom farming, fluid sowing, soil improving agent, planting on roads, artificial culture soil, artificial soil for hydroponics, seed coating, seed germination, seeding, slow releasing agent for fertilizer and other agrochemicals, matrix for application of fertilizer and other agrochemicals to prevent runoff, afforestation of desert, hydromulching, transplanting, prevention of soil erosion, interior house plant, food for humans and/or animals, and the like.
Specific uses of the inventive compositions in textile and/or paper products include the following: absorbent sheet, absorbent towel, water absorbent and water proof sheet, dyeing and printing paste and recording material for ink jet recording.
Specific uses of the inventive compositions in construction and/or engineering products include the following: water stop material, sealing materials, slurry shield tunneling, prevention of moisture condensation, desiccant, dehydrating agent, environmental trenching and cement & mortar mixers.
Specific uses of the inventive compositions in energy products include the following: battery paste, water tight electric cable, removal of water from fuel and fuel filter.
Specific uses of the inventive compositions in communication, machinery and instrument products include the following: water tight communication cable, water tight optical fiber cable and joint, desiccant for sensitive instruments and water tight packaging of sensitive instruments.
Specific uses of the inventive compositions in food products include the following: packaging to retain moisture to preserve freshness, water and odor absorbent for food container and drip prevention in trays.
Other miscellaneous uses of the inventive compositions include the following: fire extinguishing, separation of oil and water, dehydrating material, dehydrating waste, dehydrating sludge, transportation and disposal of liquid waste, cold storage agent, chemical pocket heater, cooling agent, dust control, water stop coating material, adhesive, cat litter, toy, controlled release matrix, slow release matrix, media for microbiology, slow release gel for household deodorizing agent, slow release agent for household pesticide and/or insecticide killer, oil field fracturing and/or drilling fluids and fluid loss agent.
In the preferred mode, the above absorbent articles may be designed for throw-away single use applications and they are used in contact with body fluids such as urine, catamenial discharge, perspiration and the like. In its broadest sense, therefore, the present invention provides absorbent articles in which absorbent particles of the cross-linked polysaccharide are contained in, on, or carried by a substrate material, the articles being capable of being held in contact with the body of the user such that the absorbent particles are in contact with body fluids exuded by the body either directly or after passing through a body-contacting cover sheet.
In comparison to the known polyacrylate based materials, the inventive compositions offer advantages because they are more environmentally friendly as they are derived from naturally occurring materials, are biodegradable and less sensitive to salts. Further, as compared to polygalactomannans which have been cross-linked by borate materials as suggested in U.S. Pat. No. 4,333,461 and 4,624,868, and as shown in the Examples to follow, the inventive compositions demonstrate superior performance in terms of absorbency and gel strength.
The invention is described in greater detail by the following non-limiting examples.
EXPERIMENTAL TEST PROCEDURE
The following procedure is used to qualitatively and quantitatively test the properties of the experimental compounds. Saline solution is a 0.9% solution of sodium chloride in distilled water. Sheep blood is citrated.
Absorbency: A nylon bag is prepared using 150 micron (100 mesh) or 20 micron (635 mesh) nylon cloth. The material (approximately 200 mg) is weighed and poured in the bag. The open side of the bag is closed. The bag containing the material is immersed in saline solution (or sheep blood for blood absorbency). After one hour, the bag is taken out from the solution (or sheep blood). The bag is hanged for 30 minutes and weighed to determine the amount of saline solution (or sheep blood) absorbed by the material. The amount of saline solution (or sheep blood) absorbed by one gram of material is defined as the absorbency.
Centrifuge Retention Capacity: The nylon bag containing the saline (or sheep blood) absorbed material from the above experiment is placed over some paper towels inside the basket of a centrifuge (Beckman TJ-6). The centrifuge is operated at 1600 rpm for 3 minutes. The absorbed material in the bag is weighed after centrifugation to determine the amount of saline solution (or sheep blood) retained. The amount of saline solution (or sheep blood) retained by one gram of material is the Centrifuge Retention Capacity (CRC).
Absorbency Under Load: One side of a small cylinder is closed by a stainless steel screen of 100 mesh. Four small pins are attached to the cylinder in such a way that the cylinder could stand on the pins allowing liquid to come through the screen. A small amount (100 mg) of material is evenly distributed on the screen inside the cylinder. The top of the material is covered with a Plexiglas disk and a weight of 100 g is placed on the disk to provide a load of 20 g/cm 2 on the material. The cylinder is placed in a container containing the saline solution. After one hour, the cylinder is removed and weighed to determine the amount of saline solution absorbed under the load. The amount of saline solution absorbed under the load by one gram of material is defined as the Absorbency Under Load (AUL).
Gel Strength: The saline solution absorbed material is prepared in the same way as mentioned under absorbency before. The absorbed material is placed between the parallel plates of a Rheometrics Dynamic Spectrometer II. The dynamic shear modulus G * at 1 H z is reported as the Gel Strength and expressed in Dynes/cm 2
EXAMPLE--1
Distilled water (500 ml) is heated to 180° F. The hot water is added to guar split (weighing 250 g). The mixture is maintained at 180° F. for 15 minutes. The hydrated split has a total moisture content of 63%. The split is grinded in a laboratory blender. The grounded split is dried in a fluid bed drier. The final moisture content is 2.8%. The dried material is separated into various particle sizes by screens of different sieves using the Tyler Screen Standard. The saline absorbency, CRC and gel strength of materials of different particle sizes are determined using a 20 micron (635 mesh) nylon bag and are in Table-1.
TABLE 1______________________________________Particle Size Absorbency CRC Gel StrengthMesh Size g/g g/g Dynes/cm.sup.2______________________________________+20* 18 12 11790020 to 50 33 19 3278050 to 100 61 24 8081100 to 200 10 32 6494-200** 72 35 1508______________________________________ *particles that will not pass through a 20 mesh screen **particles that will pass through a 200 mesh screen
EXAMPLE--2
A guar split (3 kg) is hydrated with water (6 l) under nitrogen atmosphere at 180° F. for 15 minutes to a final moisture content of 64.2%. The hydrated split is grinded in a laboratory blender and dried in a fluid bed drier. The dried material is separated into various particle sizes. The absorbency properties are determined using a 150 micron (100 mesh) nylon bag and are tabulated in Table-2.
TABLE 2______________________________________Saline Sheep BloodParticle Size Absorbency CRC AUL Absorbency CRCMesh g/g g/g g/g g/g g/g______________________________________+20 30 18 13 ND ND20 to 35 32 19 11 ND ND35 to 50 51 23 9 33 1720 to 50 35 17 10 ND ND50 to 100 54 24 9 ND ND______________________________________ ND = Not Determined
EXAMPLE--3
The hydrated guar split is passed through a flaker and dried in an oven. The dried product is grinded in a laboratory blender. The materials of different particle sizes were separated. The absorbency properties are determined using 150 micron (100 mesh) nylon bag and are in table-3.
TABLE 3______________________________________Saline Sheep BloodParticle Size Absorbency CRC AUL Absorbency CRCMesh g/g g/g g/g g/g g/g______________________________________+20 31 20 10 ND ND20 to 50 40 21 10 31 1550 to 100 84 28 9 55 21______________________________________ ND = Not Determined
EXAMPLE--4
Guar split (3 kg) is hydrated with water (4 l) at 180° F. for 15 minutes under nitrogen atmosphere. The final moisture content is 55%. To a portion of the hydrated split (2500 g) a solution (28 ml) of sodium zirconium lactate (zirconium content is 5.4%) in water (2 l) is added under nitrogen atmosphere. The product is grinded in a laboratory grinder and dried in a fluid bed drier. The materials of different particle sizes are separated. The absorbency properties are determined using 150 micron (100 mesh) nylon bag and are in table4 below.
TABLE 4______________________________________Saline Sheep BloodParticle Size Absorbency CRC AUL Absorbency CRCMesh g/g g/g g/g g/g g/g______________________________________20 to 50 38 21 11 25 1150 to 100 69 27 9 35 20______________________________________
EXAMPLE--5
Guar split is converted to carboxymethyl hydroxypropyl guar in the conventional manner by reaction with sodium monochloroacetate and propylene oxide. The carboxymethyl hydroxypropyl guar still in the split form is grinded in a laboratory blender and dried in a fluid bed drier. The dried material is separated into various particle sizes. The absorbency properties are determined using a 150 micron (100 mesh) nylon bag and are tabulated in Table-5.
TABLE 5______________________________________Saline Sheep BloodParticle Size Absorbency CRC AUL Absorbency CRCMesh g/g g/g g/g g/g g/g______________________________________+20 25 15 9 ND ND20 to 50 54 21 10 32 1750 to 100 82 25 ND ND ND______________________________________ ND = Not Determined
EXAMPLE--6
The 20 to 50 mesh carboxymethyl hydroxypropyl guar obtained above is heated in an oven at 300° F. for 30 minutes. The saline absorbency properties are determined using a 150 micron (100 mesh) nylon bag. The results are in table-6.
TABLE 6______________________________________Saline______________________________________ Absorbency: 50 g/g CRC: 30 g/g AUL: 12 g/g______________________________________
COMPARATIVE EXAMPLE--7
Commercially available guar powder, (Jaguar 6003-VT from Rhone-Poulenc, 20 g) is added to water (2 l) under rapid mixing. After hydrating at 115° F. in nitrogen atmosphere for 1 hour, the solution is poured in a stainless steel tray. The material is allowed to air dry. The film obtained after drying is grinded in laboratory blender and separated according to particle size. The absorbency properties of the particle size 35 to 50 mesh is determined using 150 micron (100 mesh) nylon bag. The results are in Table-7.
TABLE 7______________________________________SalineAbsorbency: 11 g/gCRC: 2 g/gAUL: 6 g/gGel Strength: 308 Dynes/cm.sup.2Sheep BloodAbsorbency: 20 g/gCRC: 3 g/g______________________________________
EXAMPLE --8
Guar powder (100 g) is taken in a food mixer (Hobart mixer). Water is sprayed over while mixing at a moderate speed. This results in agglomeration of the powder. The mixture is dried in an oven kept at 150° F. for 5 hours. The moisture content of the dried material is 3%.
The product is separated into various particle sizes, their saline absorbency properties are determined and reported in Table-8.
TABLE 8______________________________________Particle Size Absorbency CRC AUL Gel StrengthMesh g/g g/g g/g Dynes/cm.sup.2______________________________________20-50 80 25 9 1883050-100 94 30 9 2456______________________________________
EXAMPLE--9
A dough is made by mixing guar powder (150 g) and water (300 ml). The mixture is placed in a household handheld pasta maker. On compression the long spaghetti type material is obtained. This material is dried in an oven maintained at 120° F. for 16 hours. The dried product has moisture content of 1.5%. The product is grinded in a laboratory grinder and particles of different sizes are separated. The saline absorbency properties are determined and are shown in Table-9.
TABLE 9______________________________________Particle Size Absorbency CRC AUL Gel StrengthMesh g/g g/g g/g Dynes/cm.sup.2______________________________________20-50 36 15 9 1543050-100 75 16 9 256______________________________________
COMPARATIVE EXAMPLE--10
Commercially available guar powder (Jaguar 6003-VT) is separated into particles of various sizes. The relative proportions of various particle sizes are determined. Particles larger than 100 mesh constitutes a negligible fraction (0.5% or less) of the commercial guar powder. The saline absorbency properties of different particle sizes are determined using a 20 micron (635 mesh) bag. The results are in table-10.
TABLE 10______________________________________Particle Size Proportion Absorbency CRC Gel StrengthMesh % of total g/g g/g Dynes/cm.sup.2______________________________________100-200 19.5 90 35 232-200 80 95 35 132______________________________________
Having described the invention in detail and by reference to the preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the appended claims. | A solid composition of matter comprising one or more polysaccharides which has a coarse particle size is provided. The composition demonstrates absorbent properties and is useful in absorbent articles of manufacture. Also provided is a method for preparing the compositions. | 2 |
This application is a continuation, of co-pending application Ser. No. 593,380, filed Mar. 26, 1984 now abandoned.
BACKGROUND OF THE INVENTION
The conventional cylinder or round shaped door knob can be extremely difficult to operate when a good grip of the knob is interfered with for any reason. For example, a wet or oily door knob may be quite difficult to turn. In addition, when a person does not have a free hand as in the case of carrying packages or the like, it is sometimes difficult to open a door.
Further, in the case of handicapped persons, the person may lack the gripping power required to operate the door knob or lack the wrist mobility necessary to turn the knob. Further, in the case of a handicapped person, particularly amputees, the artificial limb fitted to the handicapped may not be compatible with turning of door knobs.
For these and other reasons, lever operated door knobs are finding increased popularity and are specified in many cases for use by handicapped persons in places where handicapped persons are employed or are present.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a simple, more reliable, economical, decorative and easy to use and install means for operating the conventional door knob. The object of the invention is to provide a retrofit lever assembly for use with a conventional door knob that is easy to install and does not require special tools for installation.
A further object of the invention is to provide a retrofit lever assembly which will not detract from the decorative appearance of the door knob and will allow the use of existing hardware trim.
A further object of the invention is to provide a retrofit lever assembly which has no sharp ends and which does not protrude so as to create a hazard on the door.
A further object of the invention is to provide a retrofit lever assembly which does not appreciably interfere with the normal mode of operation, that is, by hand wrapped around the door knob. The retrofit lever assembly of this invention is easily operated by the handicapped or under other adverse conditions such as emergency exits.
Further, an object of the invention is to provide a means for installing the lever without need for hardware. Thus, the invention is particularly adapted for its retrofit to existing door knobs.
It is especially an object of this invention to set forth a retrofit lever assembly comprising a lever; said lever having (a) a body portion with a substantially planar surface, and (b) an arm portion extending outwardly, from said body portion, generally parallel with said surface; said body portion having (a) an aperture formed substantially centrally therethrough, in which to accommodate a door knob shank, and (b) a relief formed therein, opening onto, and at one side of, said aperture; and retaining means for removable fastening thereof to said body portion at a side of said aperture which is opposite said one side.
Further objects of this invention, as well as the novel features thereof, will become more apparent by reference to the following description taken in conjunction with the accompanying figures which are described herebelow.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front side isometric view of an assembled door lock having a a retrofit lever assembly according to present invention installed thereon.
FIG. 2 shows an exploded assembly view of the back side of a door knob, having the lever assembly according to the present invention.
FIG. 3 is a detail view of the underside of a door knob lever assembly according to the present invention showing the retaining plate.
FIG. 4 is a sectional elevation view of taken about section line 4--4 of FIG. 3.
FIG. 5 is a plan view of the retaining plate according to the present invention.
FIG. 6 is an end elevation of the retaining plate which is partially sectioned along section line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a conventional lock assembly is generally shown by reference numeral 1. The lock assembly includes a body 10 having trim plates 11, door knobs 12, a latch bolt housing 13, latch 14, face plate 15, key cylinder 16 and a retrofit lever 20 assembly according to the present invention.
The lock as shown is normally installed on a door and provides a means for securing the door in its closed position. The construction of the lock is conventional.
FIG. 2 shows an exploded assembly view of the retrofit lever assembly 20 having a spacer 22 for use with a tulip or truncated cone design door knob 12. The spacer is unnecessary for round door knobs and merely fills the void to securely seat the lever assembly against the door knob 12 in the case of the tulip design. The door knob 12 is shown having a shank 17 which connects through a spindle (not shown) to the lock body and provides the means for retracting the latch bolt upon rotation of the door knob. A knob catch slot 18 is shown on both sides of the knob shank 17 and permits reversal for different hands of rotation. A projection (not shown) on the door lock spindle coacts with the door knob catch slot to retain the knob in its position relative to the lock body and trim plates.
As can be seen in FIG. 2 the retrofit lever assembly 20 is mounted to the underside of the. The lever assembly 20 comprises a lever 20a which is attached to the door knob at its shank 17 by means of a retaining plate 25 which is secured to the lever 20a by means of screws 30. An alignment slot 36 provides access to the door knob catch slot and further provides a means for alignment relative to the slots 18 so that the retaining plate may be properly aligned and coact with its knob catch slot 18.
FIG. 3 shows the detail of the underside of the lever assembly 20. The lever 20a comprises two portions, a generally cylindrical body 21 which mounts the lever to the door knob and surrounds the shank 17, and an arm 23. The lever arm 23 extends from the body portion 21 for a sufficient length to provide adequate hand grip. As can be seen in FIGS. 1 and 2, the tip of the lever arm is bent back (i.e., towards where the face of an associated door would be) to minimize the possibility of a pinch point or of the lever accidentally tangling a piece of clothing or the like and thereby accidentally opening the door or tearing the clothing.
In general, the lever 20a may be manufactured from a plastic material such as acetal copolymer, nylon or reinforced fiberglass although any similar material which may be readily formed to the shape of the lever may be utilized effectively.
As can be seen in FIG. 3, the retaining plate 25 is provided with a cog 35 which coacts with the knob catch slot to retain the lever 20a in position relative to the knob. This novel attachment means provides several benefits.
First, the plastic material of the lever 20a is securely attached to the knob shank 17 by means of the metal cog thus providing greater strength in the localized small area of the knob catch slot. The forces generated in turning the door knob are transmitted through the cog 35 to the retaining plate 25 where the load is substantially spread through the plastic material. The mounting screws 30 merely retain the plate in a depressed slot in the lever 20a. The depressed slot 40 is best seen in FIG. 2.
FIG. 4 shows the retrofit lever 20a of the present invention installed on a round type door knob. Again, the retaining plate 25 is shown mounted to the body 21 by means of the retaining screws 30. Cog 35 is shown actively engaged in the door knob catch slot 18. Bearing surfaces 41 are provided in the lever 20a to align the latter with the shank of the door knob. In this manner, the retrofit lever assembly 20 is retained in a secure and stable manner on the door knob.
FIG. 5 shows the detail of the unique retaining plate of the present invention. The plate is made of a metallic material for greater structural strength. The plate is counter sunk in the depressed slot 40 in the lever 20a and is retained there by screws 30 which pass through the retaining plate in slots 32. The slots 32 are provided with a screw seat 31 which securely holds the screws and plate in position.
FIG. 6 shows an elevation view of the retaining plate and further details of the screw retaining slot 32 and screw seat 31.
As can be appreciated by one skilled in the art, the present invention provides a means for securely fastening the retrofit lever assembly 20 to the door knob without the need for perforating the door knob and placing screws therein.
In addition, the unique design permits the torque applied to the door knob through the assembly 20 to be applied through metallic interface by means of the cog interacting with the door knob retaining slot 18. The forces transmitted from the lever 20a are transmitted to the retaining plate by means of its depressed position in the slot depression 40. The means of construction prevents the need for the torque to be transmitted through the relatively fragile screws which are holding the plate in the plastic material. The unique retaining plate design therefore permits easy installation without the need of special tools other than a screwdriver. The resulting connection is secure and durable and provides a distinct improvement over previous connecting means for such levers.
The embodiment of the retrofit lever assembly 20 depicted and described represents the best mode contemplated by the inventor for carrying out his invention. As can be seen, the body portion 21 of the lever 20a has a central aperture 42 formed therein. The bearing surface 41 is defined by a tubular wall 44, within which the shank 17 of the door knob 12 is received, and which bounds the aperture 42. Body portion 21 also has a circumferential wall 46 which extends substantially normal to a planar surface 48 of portion 21. Wall 46 has a terminal, annular edge 50, and arm 23 is integral with, and extends from, a sector of edge 50. It should be appreciated by one skilled in the art that the intimate contact provided by annular edge 50 with the door knob will stabilize and provide rigidity to the retrofit lever structure. To assure this contact, spacer 22 is provided in application to other door knob configurations. The added stability is an important aspect of the present invention for use with plastic material. Aperture 42 has a given radius "r", and the retaining plate 25 has an arcuate edge 52 defined of the same, given radius "r". The cog 35 projects from the edge 52.
Having described my invention in terms of a preferred embodiment, I do not wish to be limited in the scope of my invention except as claimed. | The lever assembly is of two principal parts: a lever with a circular aperture to engage the shank of a door knob, and a retaining plate, for fastening thereof to the lever, having a projecting cog. The cog engages a knob catch slot in the door knob shank. Accordingly, as the lever is rotated/manipulated, it turns the door knob through the engagement of the cog with the slot, and the fastening of the plate to the lever. The assembly accommodates retrofitting thereof to doors having round door knobs. | 8 |
FIELD OF THE INVENTION
This invention relates to the field of cooling apparatus for such things as foods and beverages.
BACKGROUND OF THE INVENTION
Commercial coolers for foodstuffs and beverages are well known. However, it may be that it would be desirable to have a cooling apparatus that may be placed next to the cash register in a grocery or convenience store. Further, rather than having a door that may slide or swing open and closed, it may be desirable to have a cooler that, during the hours in which the store is open, may have an open face.
While this may be desirable, it poses a number of technical challenges. First, the space available on the counter near the cash register may be quite constricted. Second, the cooling apparatus may need to be relatively quiet. These desiderata may tend to suggest that it would be helpful to have a unit that is self-contained, and that may be operated from a standard 120 V, 60 Hz single phase electrical outlet (or, in Europe or other places, 220 V, 50 Hz, single phase), and that a relatively low power unit be employed, both to keep the noise level down, and to reduce the heat rejection to the interior of the store. The combined desired features of an open faced cooler with a low power requirement may tend to be a difficult challenge to meet, since open faced coolers, by their nature, may tend to spill cooled air outside the cooler envelope, and may, conversely, tend to gain warm (and frequently humid) air that may spill in from the surrounding environment. Finally, for a unit of this nature, it may be desirable that the unit be relatively portable, such that it may be carried and installed by one, or at most two, persons of average size and strength.
SUMMARY OF THE INVENTION
In an aspect of the invention, there is a cooling apparatus having a plenum. The plenum has an inlet and an outlet. The outlet is located higher than the inlet, and is offset in a lateral direction therefrom. A heat exchanger is mounted in the plenum between the inlet and the outlet. At least one air moving device is mounted in the plenum in series with the heat exchanger. The air moving device is operable to draw air in at the inlet, and to compel air to pass through the heat exchanger and to exit the plenum at the outlet. An open faced bed is mounted between the outlet of the plenum and the inlet of the plenum. The bed has a pooling zone to which relatively cooler air may drain. The inlet of the plenum is mounted to draw from the pooling zone. The bed has an air drain manifold mounted therein. The drain manifold is located in the bed in a position to facilitate movement of air to the pooling zone.
In a feature of that aspect of the invention, the cooling apparatus is a self-contained cooling apparatus further including a housing, the open bed being defined within the housing. The housing has an upper portion and a lower portion, and at least one intermediate mounting fitting. The upper portion stands upwardly of the mounting fitting, and the lower portion extends downwardly of the mounting fitting. In another feature, the mounting fitting is a peripheral mounting array. In still another feature, the peripheral mounting array includes at least one shoulder. In an alternate feature, the upper portion has a first peripheral footprint, the lower portion has a second peripheral footprint, at least a portion of the first peripheral footprint extending proud of the first peripheral footprint, and the mounting fitting including at least one shoulder between the upper and lower portions of the housing. In another feature, the cooling apparatus is a self-contained cooling apparatus further including a housing, the open bed being defined within the housing, and the plenum being contained within the housing. A vapour cycle cooling system is mounted within the housing, the heat exchanger being an evaporator of the vapour cycle cooling system; and the cooling apparatus is contained in a volumetric envelope of less than 15,000 cubic inches.
In another feature, the cooling apparatus is a self-contained cooling apparatus having an upper portion, a lower portion, and a mounting fitting, the mounting fitting being placed between the upper portion and the lower portion, the upper portion having a first height, the lower portion having a second height, and a ratio of the first height to the second height being in the range of 1:5 to 1:3. In another feature of that aspect of the invention, the apparatus has a width and the plenum extends across at least half of the width. In still another feature, the plenum extends across more than 80% of the width. In yet another feature, a portion of the plenum downstream of the heat exchanger has a width, W, and a depth, D, and an aspect ratio of the width to the depth of greater than 8:1. In a more narrow range the aspect ratio is greater than 12:1. In still yet another feature, the plenum has a narrowed region downstream of the heat exchanger, and a wider, deceleration region downstream of the narrowed region adjacent the outlet.
In another feature of that aspect of the invention, the cooling apparatus includes a resistance array mounted athwart the outlet. In still another feature, the bed has a base wall, and the base wall of the bed also forms a wall of the plenum downstream of the heat exchanger.
In another feature, the open bed has raised sidewalls extending between the outlet of the plenum and the inlet of the plenum. In a further feature, the bed included an inclined base wall. In a still further feature, the cooling apparatus has a removable cover for enclosing the open bed.
In another feature of that aspect of the invention, the cooling apparatus has a molded plastic housing, the housing bounding the bed, and defining a lodgement for a vapour cycle cooling system, the heat exchanger being an evaporator of the vapour cycle cooling system, the moulded plastic housing including an insulated wall between the lodgement and the plenum. In still a further feature, the cooling apparatus has a weight of less than 80 lbs., and falling within an envelope less than 30 inches wide, 30 inches high, and 36 inches deep. In still another feature, the apparatus causes a cooling flow to pass through the bed, and the cooling flow has a nominal Reynolds number in the range of 2500 to 10,000. In yet another feature, the plenum and the bed are separated by a bed plate, the bed plate forming a wall of the plenum, and, in operation, downstream of the heat exchanger, the bed plate flow interacting with the bed plate within the plenum has a nominal Nusselt number in the range of 10 to 25.
These and other aspects and features of the invention may be understood with reference to the detailed descriptions of the invention and the accompanying illustrations as set forth below.
BRIEF DESCRIPTION OF THE FIGURES
The principles of the invention may better be understood with reference to the accompanying figures provided by way of illustration of an exemplary embodiment, or embodiments, incorporating principles and aspects of the present invention, and in which:
FIG. 1 shows a front view of an example of cooling apparatus embodying an aspects of the present invention;
FIG. 2 shows a left hand side view of the cooling apparatus of FIG. 1 ;
FIG. 3 shows a right hand side view of the cooling apparatus of FIG. 1 ;
FIG. 4 shows a rear view of the cooling apparatus of FIG. 1 ;
FIG. 5 shows a top view of the cooling apparatus of FIG. 1 ;
FIG. 6 shows a bottom view of the cooling apparatus of FIG. 1 ;
FIG. 7 shows a perspective view from above, in front, and to the right of the apparatus of FIG. 1 ;
FIG. 8 shows a cross-sectional view of the cooling apparatus of FIG. 1 taken on the central plane of the apparatus;
FIG. 9 is a side view of the apparatus of FIG. 1 with a cover in place;
FIG. 10 is a top view of the apparatus of FIG. 1 with a cover in place;
FIG. 11 shows the apparatus of FIG. 1 from above and to one side with internal panels removed;
FIG. 12 shows a bed panel of the apparatus of FIG. 1 ;
FIG. 13 shows internal deck panels of the apparatus of FIG. 1 ;
FIG. 14 shows rear view of the apparatus of FIG. 1 with closing panel released;
FIG. 15 a shows a manifold panel of the apparatus of FIG. 1 ; and
FIG. 15 b shows an enlarged detail of the manifold panel of FIG. 15 a.
DETAILED DESCRIPTION OF THE INVENTION
The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings are not necessarily to scale and in some instances proportions may have been exaggerated in order more clearly to depict certain features of the invention.
In terms of general orientation and directional nomenclature, for the cooling apparatus 20 described herein, the height, in most common use, is measured vertically, and may be measured either from the base of the unit, or from a datum defined by the upper surface of a counter 18 , such as a check-out counter in a grocery or convenience store, or fast food outlet. The width of the unit is a dimension measured generally horizontally across the unit as a person facing the unit might see it. The depth of the unit, or portion thereof, may be the front-to-back distance through the unit. The term “depth” is used in several contexts in this disclosure. In the context of a display bed, the depth may be the normal distance from the base of the display array or bed which, itself, may be angled relative to the horizontal. In the context of a flow plenum, the depth may be the through thickness of the plenum, as contrasted with the length (distance along the plenum) or width or breadth (across the plenum, cross-wise to the flow direction).
By way of general overview, a cooling apparatus according to an aspect of the present invention is shown in the various Figures as 20 . At a global level, apparatus 20 includes a housing, such as may be termed a housing structure or assembly, 22 , to which a bed plate 24 is mounted to define a heat exchange plenum 26 (below bed plate 24 ), and a bed for objects to be cooled, indicated generally as 28 , and in which a lodgement 30 is defined for various elements of a heat extraction system, such as a vapour cycle cooling system 32 . In operation, cooled goods such as beverages or sandwiches are placed in bed 28 . Cooling system 32 is operated to cool air in plenum 26 running under bed 28 , and to urge that air out through an outlet, or outlet manifold 34 to drift down over the objects to be cooled in the bed. At the lower end of bed 28 there is an air intake 36 for plenum 26 . Inasmuch as bed 28 may have a shape generally resembling a box that has been tilted on an incline, there may tend to be a pooling region 38 next to air intake 36 such that the cooler air may tend to be re-circulated back into the plenum.
Looking at cooling apparatus 20 in greater detail, the framework structure of the self-contained cooling apparatus 20 is the housing, or housing assembly 22 . Housing assembly 22 may have a two piece moulded construction that may include a first moulded part 40 and a second moulded part 42 , bonded or fastened together after moulding. The two moulded parts, 40 , 42 may have continuous double walls filled with a foam insulation. Housing assembly 22 may be made of a moulded plastic such as Polyethylene which may be rotationally moulded. The first moulded part 40 , such as may be referred to as the base, may include a front wall portion 44 , a generally upwardly and rearwardly extending wall 46 which may be of irregular form, and left and right hand side wall portions 48 and 50 .
Front wall portion 44 may have a first, or main portion 52 that is generally rectangular, and that slopes generally upwardly and forwardly of the meeting with wall 46 . The outwardly facing surface of portion 44 may have a decorative pattern formed therein, such as corrugations, or flutes 54 . At the upward end, front wall portion 44 may terminate in a bulbous portion 56 that may have a generally upwardly facing stepped sill 58 for interlocking mating engagement with second molded part 42 . The inner facing portion of front wall portion 44 may have a standoff member 60 , or members, such as may be in the nature of lateral lands 62 and 64 , such as may have the form of an abutment, or shoulder, standing proud of the main inwardly facing surface 66 , and which may be referred to as plenum intake manifold abutments.
Wall portion 46 may have a first, downwardly facing region 68 that in use may sit in a substantially horizontal orientation, and, in some instances, may provide a base surface 70 upon which the unit (i.e. apparatus 20 generally) may sit. Wall portion 46 may also have a generally upwardly facing surface 72 that may be sloped, and that may run into surface on a smoothly radiused corner. Surface 72 may have a first, or lower, portion 74 , a second, or upper portion 76 , with a convergent transition portion 78 between portions 74 and 76 . Wall portion 44 may also have formed in it, possibly centrally, a relief or port 80 by which an evaporator return line may be installed. Bed plate standoff members, such as may be in the nature of ledges, or shoulders identified as lateral abutments 82 and 84 stand proud of surface 72 , and may provide side rails or seats on which to support laterally extending bed plate 24 .
Inclined wall portion 46 may also include a downwardly opening relief portion 86 such as may tend to define the inner and upper walls 88 , 30 of a lodgement, indicated generally as 30 , for accommodating elements of the heat extraction apparatus such as a compressor 92 , condensor 94 , an expansion device, such as may be an adiabatic nozzle 96 , and exhaust fans 98 , 100 . The upward and rearward edge 102 of inclined wall portion 46 may be formed to mate with a corresponding edge of portion of second molded part 42 . The inner and upper surfaces of lodgement 30 may have a thermally conductive metal liner plate.
The side wall portions 48 and 50 may include a first portion 106 forming a generally triangular web between front wall portion 44 and inclined wall 46 . First portion 106 may have a generally horizontal upper margin 108 . Sidewall portions 48 and 50 may also include rearward side wall portions 110 , 112 that bound lodgement 30 laterally. That region of side wall portion 110 , 112 lying above the height of upper margin 108 may be outwardly relieved to accommodate the mating, downwardly extending sidewall, or skirt, portions 114 , 116 of second molded part 42 .
Second molded part 42 may include left and right hand sidewalls, 118 , 120 , a front framing member 122 , and a rear cowling 124 . Each of side walls 118 , 120 has a notched region 126 for accommodating a clear plastic side shield 128 , whose upper margin may be roughly tangent to front framing member 122 and rear cowling 124 . Front framing member 122 has a stepped lower surface 130 for mating engagement with the stepped (or keyed, or indexed) upper sill 58 of the bulbous portion 56 of front wall portion 44 ; and a may have a radiused upper surface generally matching the radius of bulbous portion 56 . Sidewalls 118 and 120 are molded to fit outside then wing or skirt portions 114 , 116 of the sidewalls of lower molded part 40 , such that the externally visible separation line 132 runs horizontally from the front to the back of the unit.
Rear cowling 124 may include a substantially vertically extending rear wall portion 134 , and a substantially horizontal top wall portion 136 , the two meeting at a smoothly radiused corner, and extending laterally from side-to side between side walls 118 , 120 . Rear wall portion 134 also has a depending lip 138 . The lower edge of vertical wall portion 134 may be angled inwardly of lip 138 to form a mating notch to seat on with the chamfered nose of the upper edge of inclined wall portion 46 of first molded part 40 . The overlapping interface of molded parts 40 and 42 at back and front, and in large portion along the sides, may tend to yield an assembly that is easily fit together, particularly if the upper molded part 42 is molded for a slight interference fit. It may be noted that the side portions of second molded part 42 may include upper wing extensions 140 having a slot 142 formed therein to receive a roll bar 144 of a removable cover 146 . Cover 146 may be extended to cover bed 28 , at times, for example when the store is closed, cover 146 then discouraging the spilling of cooling air from bed 28 . The bottom edge 148 of cover 146 may have a cross bar 150 whose ends extend to seat in notches 152 in the upper margin of the clear plastic side shields 128 .
The two plastic moulded parts 40 , 42 may tend to provide an assembly that may be quickly joined together, with a small number of fasteners and without undue effort. The moulded hard foam plastic may tend to yield an insulated layer (namely the sloped sheet region) between the cooling air plenum, and the lodgement or chamber for the vapour cycle system such as the compressor and condenser, that may reject a significant amount of heat. Lodgement 30 may itself tend to form a hot air heat rejection plenum.
As assembled, it may be noted that the sidewall portions 48 , 50 of lower molded part 40 , have laterally extending flanges 160 , 162 , that may underlie the downwardly depending lower margins of the skirts 114 , 116 of upper molded part 42 . The underside of flanges 160 , 162 may form downwardly facing peripheral supports, or mounting fittings, or seats, 164 , 166 , through which interfaces the weight of the unit may be carried into surrounding structure, as in the case where unit 20 is mounted to sit in a partially sunken manner in an aperture or accommodation made in a store counter. It may also be that the juncture of the radiused bulbous portion 56 of front wall portion 44 may be roughly flush with seats 164 , 166 , thereby providing a third edge along which underlying structure may support the loaded unit. This may yield a three-sided, generally U-shaped mounting fitting support interface.
It may be noted that many possible configurations of mounting fitting may be constructed. In the embodiment illustrated, the footprint of the base is smaller than the footprint of the shoulder, such that at least a portion of the footprint of the shoulder extends beyond the footprint of the base, with the result that while the footprint of the base may be lowered through an opening made therefore in a counted, those portions of the footprint of the mounting fitting that protrude beyond the footprint of the base may tend to seat upon, or mate with, the land about the opening formed to admit the base. Although additional fittings, such as brackets, may be mounted to the housing for this purpose, provision of the shoulder in the molded form of the housing itself may tend to eliminate the need for additional separate parts to be made and attached.
The mounting fitting support interface may be located to permit apparatus 20 to be mounted either on the planar base, generally, or for a substantial portion of apparatus 20 to be mounted in a sunken, or recessed, manner, which may be less obtrusive, and which may require less above counterspace. Taking the height of the base of the unit as h 1 as measured from the substantially planar, horizontal bottom surface to the substantially parallel planar underside of the mounting fitting, and taking the height of the superior portion of the unit as h 2 , with the total oval height of the unit, h total being the sum of h 1 and h 2 . In one embodiment, the ratio of h 1 to h 2 may be in the range of 1:4 to 1:2, and may be about 2:5.
The lower portion 168 , 170 of the outwardly facing surfaces of side wall 118 , 120 , lying below flanges 164 , 166 may have a decorative wavy, or fluted, or corrugated pattern 172 formed in relief, and such pattern may be inclined at an angle. The angle may be roughly the same as the angle of inclination of front wall portion 44 more generally.
Once the upper and lower parts 40 , 42 of the moulded housing assembly 22 have been fit together and secured, either by mechanical fasteners such as threaded fasteners or by bonding, the remaining fittings may be installed.
A heat exchanger 174 may be mounted to lower portion 74 of surface 72 . Heat exchanger 174 may extend the full width between shoulder abutments 62 and 64 , and may have a through thickness depth that is, within tolerance, substantially the same as the height of the shoulder abutments 62 , 64 such that the upper surface of the heat exchanger is roughly flush with the upper surface of the shoulders. The upper-surface of the heat exchanger may have a seal member 176 , such as may be an elastomer, to take up any mismatch in height, and to discourage air flow past the heat exchanger, rather than through it. When overlying plate 24 of the cooler bed 28 is in place, heat exchanger 174 may tend to lie across the entire flow path of the resulting plenum, such that air forced along plenum 26 may tend to be compelled to flow through heat exchanger 174 rather than around it. The upslope bottom corner of heat exchanger 174 may seat in a relatively sharp corner formed at the juncture of transition portion 78 with lower portion 74 of surface 72 .
Upstream of heat exchanger 174 is a baffle plate 178 that also extends across, and blocks, the flow path of air plenum 26 . Baffle plate 178 has two openings 180 , 182 formed therein, and location fittings 184 , in the nature of appropriate fastener hole patterns, to which a pair of air moving devices 186 , such as may be blowers or fans 188 , 190 may be mounted. It may be understood that a single fan could be used, or more than two fans could be used, and that the illustration of two such fans is intended to be representative of any number of such units. It may be that two such units, mounted to work in parallel, may be employed.
A thermally conductive sheet or plate member, such as plate 24 may seat over shoulders, thus closing, the hollow rectangular passageway to define air cooling plenum 26 . It may be noted that plate member 24 has a first portion 192 for seating on the shoulders namely abutments 82 , 84 which portion may be planar; and a second, lower or foot portion 194 , that may be bent at a right angle, and that may seat on the shoulders defined by lateral lands 82 , 84 of front portion 44 of housing assembly 22 . Foot portion 194 may have intake porting, such as may be in the nature of an array of vents or apertures or slots, indicated generically as 196 . The placement of plate 24 in this position may tend to enclose internal air cooling plenum 26 . Plenum 26 may then have an inlet, indicated generally as air intake 36 at array 196 , and an outlet indicated generally as 200 at the upper, laterally offset end of the enclosure. An outlet array 202 may be mounted across outlet 200 between a retaining guide, or channel 204 mounted in the roof portion, and an angle retainer 206 installed along the lower edge of array 202 and secured at either end to shoulders 82 , 84 . Outlet array 202 may be in the nature of a flow resistance element 208 that may be porous. In one embodiment array 202 may include a large number of tubes, or a honeycomb, or honeycomb-like structure (See enlarged detail of FIG. 15 b ) that may tend to yield a measure of flow resistance, and that may tend also to cause the flow leaving the plenum to have a relatively flat velocity profile. That is, the velocity of cooled air leaving the plenum may tend to be generally uniform across the outlet array, or more uniform than it might otherwise be.
The resulting plenum structure may be thought of as having several regions. There is an inlet manifold region, indicated generally as 210 , that may lie between sidewalls 48 , 50 , the inclined front wall portion 44 , and foot portion 194 ; a high pressure region 212 located between the air movers 186 and heat exchanger 174 , a convergent region 214 immediately downstream of heat exchanger 174 ; a generally rectangular, relatively high aspect ratio region 216 downstream of the convergent section, and an outlet manifold region 218 where the narrowed rectangular region 216 deepens (and in which the flow may tend to decelerate and be impeded by the outlet manifold flow resistance element 208 of an outlet manifold region 218 . As may be appreciated, in operation, the inflow at foot portion 194 may tend to be diffuse. Operation of air movers 186 , may tend to create a low pressure in intake manifold region 210 as compared to external ambient (indicated as P ∞ ) outside the cooling apparatus. This difference in static pressure may tend to cause air to enter, in a relatively even manner through the intake manifold array 196 into the intake manifold region 210 . Air movers 186 may draw in that air, and may urge it, at a raised static pressure, into pressurized region 212 . The resistance of heat exchanger 174 may tend to have at least a modest flow-evening effect. The mean flow velocity through the heat exchanger may not be excessive, given the large cross-sectional area of the heat exchanger element (the full width of the plenum W P , at a depth δ 1 as great as the size of the fan housings). Downstream of heat exchanger 174 , the flow velocity may tend to increase as the plenum section decreases. In one embodiment, the depth of the air flow passage may be reduced by half, and may be reduced by as much as 60% (+/−). The length, L 2 of the narrowed portion may be more than five times the through-thickness depth δ 2 , which may also tend to encourage the flow to settle into a sheet-like profile that is relatively even across the width of the unit. In width, the width of the plenum, W P , which is substantially constant between the inlet manifold and the outlet manifold, extends across more than half the width of the unit, and may, other than for the width of the shoulders, extend across substantially the entire width of housing assembly 22 . In the narrowed, or shallowed, region of the plenum, in one embodiment the Nusselt number based on hydraulic diameter, Nu d may nominally be in the range of 10 to 25, and may be about 14, without adjustment for non-fully developed flow. In one embodiment, the flow Reynolds number based on hydraulic diameter may be in the range of 3000 to 10 0000. Similarly, in one embodiment the nominal convection heat transfer coefficient, h d , 3 to 15 W/mK, and may be about 5½ to 6 W/mK. In one embodiment, the aspect ratio of width, W P , to depth, δ 2 , of the plenum in the narrowed region 216 may be 8 or greater. In another embodiment, it may be 12 or greater, and in another embodiment it may be about 15 where the depth of the narrowed section may be about 1¼ inches, and the width may be about 19 inches. This may tend to yield a duct having an hydraulic diameter greater than 160% of the through thickness of the passage, with a consequent relatively higher convective heat transfer co-efficient on the underside of the overlying inclined portion 192 of the bed plate 24 . Like the relatively high flow resistance of the heat exchanger, the high aspect ratio of the duct may tend to cause the velocity profile of the flow in the duct to be relatively flat from side to side across the duct. As the flow leaves shallow, or narrowed region 216 , the section of the plenum widens (or deepens, actually, while the width remains constant), which may tend to encourage the flow to decelerate. The momentum of the flow, as it may be, may tend to encourage the flow to attach (i.e., work preferentially along) the curved rear wall 220 . A flow interrupter 222 , such as may be in the nature of an angle 224 , may be mounted to the rear wall 220 of the outlet manifold region 218 . Flow interrupter 222 may tend to force the flow outward from wall 220 into the main body of outlet manifold region 216 . The flow resistance in the outlet manifold, like the resistance of the heat exchanger and the high aspect ratio of the duct, may tend to urge the velocity profile of the exiting flow field to be generally uniform. It may also be noted that the outlet array 202 has roughly the same width as the flow plenum 26 , more generally, but a depth of roughly four to six times the depth of narrow portion of the flow plenum. It may be that the outlet flow field may have a mean flow velocity of the order of 6–18 inches/second. Considering the bed to be a three sided open channel, the overall Reynolds number based on hydraulic diameter may be of the order of 2,500 to 10,000, and may in one embodiment be about 5000.
Bed 28 may have additional panel member 230 , 232 , such as may be in the nature of formed channels 234 , 236 . Channels 234 , 236 may have legs 238 , 240 and a web 242 . Panel members 230 and 232 may be mounted with their toes facing downward, such that legs 238 , 240 may function as stand-off members to hold webs 242 in spaced relationship away from upper portion 192 of the bed plate 24 . This may tend to yield a drain plenum, or plenums 246 , 248 . The webs 242 of panel members 230 and 232 may have porting in the nature of an array of apertures 250 . The length of panel members 230 and 232 may be slightly shorter in length that the space between foot panel 134 and retainer angle 206 . Moreover the radius between portion 194 and 192 may tend to prevent the open bottom end of channel members 234 , 236 from being tightly closed. As may be noted, bed plate 24 may be made of a thermally conductive material, such as may be aluminum or stainless steel, and may tend to be cooled by the output of heat exchanger 174 . Consequently, air tending to drain between channels 234 , 236 and plate 24 may tend also to be cooled. Further, that air, being relatively cooler and denser than other air, may tend to have a negative buoyancy, and may tend to drain downward toward foot panel 194 . Further still, as that cooled air drains away, it may tend to draw in replacement air, and, as such, may tend to urge the air immediately above to be drawn toward the base plate through apertures 254 , rather then to be forced out into the ambient surroundings. Channels 234 , 236 may be considered to be air drain manifolds. It may also be noted that apertures 250 may be of a shape, such as square, and a size, to co-operate with the locating feet of zone dividers, 244 , such as may be used in either cross-wise or length-wise orientations to divide rows of bottles, or to space sandwiches or fruits to keep them from impinging on adjacent items.
As may be noted, bed 28 may have something of the shape of a tilted open front box, in which the desired flow direction is between the outlet manifold 218 of cooling plenum 26 and the inlet manifold 210 of cooling manifold 26 , The maintenance of a relatively stable, predominantly uni-directional flow field between outlet manifold 218 and the inlet manifold 210 may tend to be enhanced by a number of factors.
First, the proportions and overall size of the apparatus may tend to discourage flow perturbations, and to encourage the flow to remain within a relatively small envelope. The sides of the open flow channel of bed 28 may include superior portions that may include see-through baffles or partitions, such as side shields 128 , such as may be mounted in the upper margins of the side walls of upper moulded part 42 . These baffles, and the sidewalls generally, may tend to channel the flow to run linearly between the outlet manifold and the inlet manifold of plenum 26 . They may also tend to discourage external perturbations from interfering with the desired cooling flow. In addition, the overall depth of the sidewall, indicated as h 3 , may be greater than the depth of the outlet manifold, indicated as h 4 . The ratio of h 3 to h 4 may lie in the range of 6:5 to 5:3, and may be about 9:7 to 4:3. Further, the overall width of the open flow channel is not excessive as compared to its length. That is, the mean length of the flow path from the center of the outlet manifold of plenum 26 to the center of the inlet manifold of plenum 26 is indicated as L 1 . The width is indicated as W. The ratio of depth h 3 to width W may be more than ¼., may be in the range of 1:2 to 1:2, and may be about 2:5. The ratio of the width W to length L may be less than 3:2, may lie in the range of 4:3 to 4:5, and may be about ⅚ to ⅞, (+/−10%). The length of the flow path between the outlet manifold and the inlet manifold may also be relatively short as compared to the depth. The ratio of h 3 to L may be greater than ¼, may lie in the range of than 3/10 to ½, and may, in one embodiment be between ⅓ and ⅜. In one embodiment, W may be about 22 inches, L may be 18½ to 19 inches, h 1 may be about 6½ inches, h 2 may be about 15½ inches, h 3 may be about 6½ to 7 inches and h 4 may be about 8½ to 9 inches, all dimensions being +/−10%. The unit may fall within an overall envelope that is less than 30 inches wide, less than 36 inches deep from back to front, and less than 30 inches tall. The volumetric envelope of the entire apparatus 20 may be less than 15,000 cu. in., and in one embodiment may be less than 11,000 cu. in., and of that, if a sunken installation is used, the exposed volume occupied may fit within an envelope that is less than 30 inches wide, less than 36 inches deep, and less than 24 inches high; and that envelope may have a volume of less than 11,000 cu. in, and in one embodiment, less than 8,500 cu. in. In one embodiment, the unit may weigh less than 80 lbs.
Second, the use in flow resistance element 208 of parallel capillaries or small diameter tubes, such as may have a length more than 5 times their diameter, may tend to straighten, and calm, the output of cooling plenum 26 . Further, the resistance of those tubes may tend to cause the output across the array to be more even. Third, the lower end of the box may tend to form a pooling zone having a triangular bottom between parallel sidewalls in which the relatively cooler air, being less buoyant, may tend to collect. The upper lip of the pooling region may be the top of front framing member 122 . Fourth, the use of an intake manifold array of porting or apertures, such as slots 212 in foot panel 64 may tend to permit the pooling zone to be drained, and may permit the draining to be distributed across the face of the pooling zone. Fifth, the low, or very low, Reynolds number may point to a flow that is substantially laminar if undisturbed, or that may have a tendency away from being strongly turbulent. Sixth, the use of a perforated return drain along the floor of the bed (namely channels 234 , 236 ) may tend to draw the cooled air down, toward bed plate 24 , rather than encouraging it to spill outside the box. These features are thought advantageously to increase the proportion of air returned to the intake manifold that may tend to be recirculated cooled air that has already been cooled below the more generally prevailing ambient temperature T ∞ , and may tend to improve the overall efficiency of the unit and tending to reduce the cooling load and so too the power required and the heat rejection to ambient.
In cooling apparatus 20 , the cooling system may be a vapour cycle system 32 , and heat exchanger 174 may be the evaporator of such a system. The other elements of such a system may include compressor 92 whose intake is from a low pressure return line 256 in fluid connection with the output fitting of heat exchanger 28 . Low pressure return line 256 may by installed through molded port 258 made in inclined wall portion 46 . Insulating putty or sealant may be used to further discourage heat loss or flow migration through port 208 . Compressor 92 may be mounted on a base plate 260 , itself mounted to lower part 40 of moulded housing 22 . The compressed working fluid output from compressor 92 may be led through a high pressure gas line 262 to condensor 94 . Condensor 94 may be mounted to a rear closure panel 264 that forms the closed back panel of the vapour cycle equipment lodgement 30 . Condensor 94 may take the form of a heat exchanger mounted to seat against the peripheral seals 266 of a corresponding opening 268 in back panel 264 . Air moving equipment, such as may be in the nature of a pair of rejected heat exhaust blowers, or fans, 98 , 100 are mounted to another portion of panel 264 , and, given the otherwise generally sealed nature of lodgement 30 , conservation of mass requires that air drawn in through the heat exchanger fin array of condensor 94 must be purged through fans 98 , 100 , thus cooling compressor 92 as well. An exhaust shroud, or doghouse, or standoff housing 274 may be mounted about the outlet of fans 98 , 100 to prevent the unit from being forced too tightly against a rear surface, such as might otherwise prevent fans 98 , 100 from providing the airflow desired to cool the unit. A cooled high pressure line 274 leads from condenser 94 to a substantially adiabatic expansion device, such as may be in the nature of a nozzle 276 . The cooled, low pressure output of this element is fed through a coolant feed line 278 through insulated inclined panel portion 46 to the downstream side of heat exchanger 174 , bringing the cycle back to its starting point. The unit may be controlled by conventional thermostatic settings on the rear of the unit.
An optional cover 280 may be employed when the unit is in a passive mode, such as when the store is closed, if the unit is used in a store. The unit is provided with a thermometer 282 . To reduce the height profile of the unit, much of the base can be sunk into a counter top, such that the unit is supported about its periphery on the shoulder 284 , the front portion of the shoulder being defined by the underside of the bulbous portion of the front of the unit.
Thus, the apparatus described is a mechanically cooled, insulated container that may be used to permit manual dispensing of bottled or canned goods, sandwiches and other fast food items. The container is so configured that a cold air curtain, which tends to isolate the merchandise from the outside temperature, drops at a relatively acute angle such as may tend to allow the merchandise to be displayed in an advantageous, highly visible, and conveniently reachable angle.
Various embodiments of the invention have been described in detail. Since changes in and or additions to the above-described best mode may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details but only by the appended claims. | A cooling apparatus for such things as convenience foods and beverages has a tilted, open faced bed from which persons may select objects. The apparatus is self-contained, and may run from a standard, single phase electrical outlet. It may be carried by two people, and is suitable for mounting either on its own base in a recess in a checkout counter or other similar installation. The open faced be may have a channel depth of section that is relatively deep as compared with to its width, the flow path length, or the depth of the flow released to run along the channel, thereby tending to discourage mixing of the cooled flow with the surrounding ambient environment. The apparatus may include a two piece molded housing that defines the structural skeleton for both the cooling bed and a lodgement for various elements of the cooling system. The bed may include a porous deck, or drain panels, that may tend to encourgare cooled air to drain toward a cooling plenum intake panel. The bed may include a pooling region adjacent to the air intake plenum in which cooler, less buoyant air may collect. | 0 |
[0001] This application is a continuation of parent application Ser. No. 10/699,194 filed Oct. 30, 2003
FIELD OF THE INVENTION
[0002] The present invention relates generally to doors and cabinetry but more particularly to a method of assembly for extruded profile panels for multipurpose usage such as doors or cabinetry doors.
BACKGROUND OF THE INVENTION
[0003] Extruded frames have been known and used for years, especially in the making of window frames as several patents attest to. Extruded profiles have also been used for creating various structures but many of these frames are meant to be permanent once they are assembled. Those that are meant to be dissassemblable usually require visible exposed screws or similar mechanical fastening means. These visible mechanical fastening means can mar an otherwise esthetically pleasing surface. There is therefore a need for an assembly process and method to make easily assemblable and disassemblable panels having invisible fastening means.
SUMMARY OF THE INVENTION
[0004] In view of the foregoing disadvantages inherent in the known devices now present in the prior art, the present invention, which will be described subsequently in greater detail, is to provide objects and advantages which are:
[0005] To provide for a set of simple parts used for assembling a variety of panel types in a simple, efficient and secure manner.
[0006] To provide for a panel that, once assembled, does not show any visible screws or mechanical fasteners of any kind.
[0007] To provide for a panel that allows for easy replacement of defective or broken parts and which can be assembled as a kit.
[0008] To provide for a panel that is easy to manufacture without no need for bending or folding tools and does not require any welding of parts at all.
[0009] To provide for a panel that can accept most of the standard accessories used in cabinetry such as hinges and handles.
[0010] To attain these ends, the present invention generally comprises a rigid peripheral frame of extruded material which serves as a base structure comprised of base elements. Thed base elements are used in combination to create profiles. The profiles have slits and slots which are used in combination with threaded mechanical fasteners. The base elements are comprised of a first, second, third, and fourth element wherein the first element has a flat surface and a pair of hooks, the second element has an edge, channels, and a profile fin, the third element has a hookable groove, channels and clips, and the fourth element has a hook, and a trim face. The profiles combine to create a panel by having four profiles intersecting in order to form a frame having four sides.
[0011] An intersection creating a corner wherein two intersecting profiles are being partially assembled by being loosely connected by way of the threaded mechanical fasteners moving within a range allowed by the slots and a spacing block used for setting a relative distance between the profiles.
[0012] A first fascia is inserted and then the profiles are moved so as to completely encase the first fascia within the slits. The threaded mechanical fasteners are then tightened so as to secure the frame. A second fascia is inserted by bending it convexedly and then relaxing it so that the edges along its length can slide into the slits of the second element and the second fascia is slid along its length so that its first wide side can be fitted into one of the slits. A wide side has a gap filled in by the fourth element that engages the third element by way of the fourth element's hook which engages a complementary notch of the third element.
[0013] The panel thus assembled is versatile (flush panel, glazed panel, door panel, single or double panel, etc.). It can be used indoors as well as outdoors, and its use includes kitchen cabinets, garage or basement storage cupboards but also for use in commercial applications such as laboratories, offices, workshops and so on.
[0014] Because there are no visible mechanical fasteners, the finished surface can be made very smooth. Moreover, it can be made entirely of aseptic materials such as stainless steel and/or aluminum so it can produce cabinet frames and doors that will not harbor germs, which is ideal for hospitals and laboratories.
[0015] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
[0016] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0017] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0018] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
[0019] These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter which contains illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIGS. 1 abcd cross sectional views of the base elements of the profiles.
[0021] FIGS. 2 ab cross sectional views of sample profiles.
[0022] FIGS. 3 abc front elevation of a frame being assembled in its open configuration with partial profiles in top elevations.
[0023] FIGS. 3 de continuing with the frame being assembled in semi closed, and closed configuration respectively.
[0024] FIG. 4 Perspective view of frames prior to assembly with block spacer.
[0025] FIGS. 5 abc front face of a panel, top side of a panel, and side cross section of a panel, respectively.
[0026] FIGS. 6 ab Front elevation of a panel with hinges and and front elevation of a panel with a handle, respectively.
[0027] FIGS. 7 abcd Show various front elevations of combinations of profiles to make a variety of panels.
[0028] FIGS. 8 ab front elevation of a glazed panel and top elevation of the profile, respectively.
[0029] FIGS. 9 abc side, front and back views of a panel, respectively.
DETAILED DESCRIPTION
[0030] FIGS. 1 a - d show the 4 base elements from which all profiles are built. Element 1 a ( 100 ) has a flat surface ( 12 ) and a pair of hooks ( 14 ).Element 1 b ( 200 ) has an edge ( 16 ), channels ( 56 ), and a profile fin ( 18 ). Element 1 c ( 300 ) has a hookable groove ( 20 ), channels ( 56 ), and clips ( 46 ). Element 1 d ( 400 ) has a little hook ( 22 ) and a trim face ( 24 ). Element 1 d ( 400 ) has a little hook ( 22 ) and a trim face ( 24 ).
[0031] Using these elements in combination produces profiles ( 500 , 600 ) such as in FIGS. 2 ab where elements 1 b , 1 c , and 1 d ( 200 , 300 , 400 ) are co-joined to create profile 2 a ( 500 ). Using elements 1 a , 1 b , and 1 c ( 100 , 200 , 300 ) produces profile 2 b ( 600 ). Element 1 c ( 300 ) has legs ( 46 ) which snap into receiving protrusions ( 48 ) which are part of element 1 b ( 200 ).
[0032] Profiles 2 a ( 500 ) and 2 b ( 600 ) show other components not part of the profiles per se such as a locking trim ( 26 ) which has both a decorative and a useful purpose which will be explained later.
[0033] Once a profile ( 500 or 600 ) is partially assembled, finishing surfaces known as fascia ( 28 ) are inserted, but more on that later. With these two profiles ( 500 and 600 ), a frame ( 30 ) can be assembled.
[0034] Looking at FIG. 3 a , the first step in assembling the frame ( 30 ) is in having corner threaded mechanical fasteners ( 32 ), that is one pair per each corner of the frame ( 30 ) in position AA as determined by the position of threaded mechanical fasteners ( 32 ) in relation to their slots ( 34 ).
[0035] The vertical section of the frame ( 30 ′) has two vertical slots while the horizontal section of the frame ( 30 ″) has two horizontal slots and all of the slots are designed to afford a certain range of motion to each section of the frame ( 30 ′, 30 ″).
[0036] At any rate, the orientation of the slots ( 34 ) is always so that their long side is running parallel to the length of that particular section of frame ( 30 ′or 30 ″), whether these sections are from profiles 2 a or 2 b ( 500 , 600 ).
[0037] At the intersection of both frames ( 30 ′, 30 ″) Only elements 1 b ( 200 ) as per FIGS. 3 bc but beyond the intersection, element c ( 300 ) can be added. In position AA the frame ( 30 ) is expanded and can receive a first fascia ( 28 ) (shown in FIG. 5 a ), the size of the fascia ( 28 ) is such that it is slightly larger than what the inner perimeter of the frame ( 30 ) will be once closed, that way, when moving from position AA to position BA as per FIG. 3 d , where the vertical section of the frame ( 30 ′) is closed in, the edges of the fascia are inserted into slits ( 42 ) as seen in FIG. 5 bc.
[0038] The threaded mechanical fasteners ( 32 ) are still accessible and remain accessible even when moving to position BB as per FIG. 3 e where both the horizontal and vertical sections of the frame ( 30 ′, 30 ″) are closed in. Once closed in, the mechanical fasteners can be tighten to secure the assembled frame. Of course, the order in which the frame is closed in whether the horizontal side of the frame or the vertical side is of no importance.
[0039] FIG. 4 shows a block spacer ( 70 ) which lies between frame ( 30 ′) and frame ( 30 ″), the thickness of the block spacer ( 70 ) depends upon the thickness of the edge ( 16 ).
[0040] An assembled panel ( 38 ) can be seen in FIG. 5 a where the frame ( 30 ) holds in the fascia ( 28 ). After the first fascia ( 28 ) is put in, a solid core ( 36 ) can be fitted inside the frame ( 30 ) to add strength to the panel ( 38 ). In the configuration shown in FIGS. 5 abc , the frame ( 30 ) is made up of element 1 b ( 200 ) for the top and bottom horizontal frame ( 30 ) and profile 2 b ( 600 ) is used for the left and right sides.
[0041] Of course permutations are possible and element 1 b ( 200 ) could be placed vertically and profile 2 b ( 600 ) horizontally, it all depends on the orientation of the panel ( 38 ) as a whole and the terms horizontal and vertical are strictly to facilitate description in the context of FIGS. 5 abc.
[0042] Also, FIG. 9 abc shows both the front and back of a panel with the difference when the front side FIG. 9 b has element 1 d ( 400 ) at the top and FIG. 9 c which shows the back of the panel without element 1 d ( 400 ). The apparent frame is the edge ( 16 ) of element 1 b ( 200 ).
[0043] As can be best appreciated from FIG. 4 b , fascia ( 28 ) is inserted into slits ( 42 ) of element 1 b ( 200 ) while the solid core ( 36 ) is encased within elements 1 a ( 100 ) on at least two sides, possibly all four.
[0044] This is but one of many possible panel ( 38 ) configurations. Inserting a second fascia ( 28 ′) as in FIG. 2 a for the second face of the panel ( 38 ) is different than inserting the first fascia ( 28 ). As explained earlier, after inserting the first fascia ( 28 ) the frame ( 30 ) is closed in so that the second fascia ( 28 ′) can hardly be inserted in a way where its perimeter is inserted into the slits ( 42 ).
[0045] In order to achieve insertion of the second fascia ( 28 ′), it is first bent convexedly and then relaxed so that the edges along its length can slide into slits ( 42 ) of element 1 b ( 200 ) and then it is slid along its length so that its first wide side can be fitted into yet another slit ( 42 ).
[0046] At this point, 3 out of 4 sides are properly inserted into slits ( 42 ), now for the second wide side, the final side, the second fascia ( 28 ′) having been cut slightly shorter in length than the first fascia ( 28 ), has a gap left between it and the fourth slit ( 42 ), this gap is filled in by element 1 d ( 400 ) as per FIG. 2 a which is fitted so that its little hook ( 22 ) engages a 20 complementary notch ( 44 ), part of element 1 c ( 300 ).
[0047] Inserting element 1 d ( 400 ) thusly still leaves a little gap which is filled by the spacer trim ( 26 ) inserted between element 1 d ( 400 ) and the edge ( 16 ).
[0048] This method of installation, with minor variations, is applied to the various panel ( 38 ) configurations. Looking back at FIG. 5 a , one side shows a configuration as per FIG. 7 a while the other side, because it is framed using element 1 a ( 100 ) would look more like FIG. 7 b or FIG. 7 d.
[0049] For a panel with glass as per FIG. 8 a , profile 2 a ( 600 ) is used with a pane of glass ( 50 ) along with element 1 a ( 100 ) on either side acting as a framing device. A seal ( 52 ) can be readily accepted by element 1 c ( 300 ). Sealing gaskets ( 54 ) can also be inserted in available channels ( 56 ) made into element 1 b ( 200 ) and element 1 c ( 300 ).
[0050] Element 1 b ( 200 ) can have different thicknesses while keeping the rest of its profile identical, this allows for various thicknesses in panels.
[0051] Doors such as for cupboards can be made by adding hinges ( 58 ) and a handle ( 60 ) as in FIGS. 6 ab.
[0052] As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
[0053] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0054] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | Extruded profiles for use in assembling panels comprises a rigid peripheral frame of extruded material which serves as a base structure onto which are put flat surfacing materials such as glass, metal, wood or any of a variety of composite materials normally used for making cabinetry. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 06/569,526, filed Jan. 9, 1984, now U.S. Pat. No. 4,531,845.
BACKGROUND OF THE INVENTION
Oil rings are extensively used as conduit means for carrying oil or other lubricant from a reservoir to moving members, such as journal bearings, shafts, and the like. In operation, the oil ring is normally loosely disposed around the shaft and rotates as the shaft rotates, through contact with the shaft. Lubricant is carried from a sump or reservoir to the shaft, in the contours or grooves of the oil ring and by frictional attraction as the ring moves through the reservoir. The lubricant is deposited on the shaft or other member through the gravitational, frictional, and centrifugal forces inherent in the operation. Under conditions of slow rotation, the gravitational and frictional forces generally deliver a sufficient supply of lubricant; however, at higher velocities, which can be as high as 3000 to 4000 ft./min., the oil ring is either moving too fast for gravity to effect dispersion of the oil, or the centrifugal force on the ring and the oil is too great to overcome, and the oil either remains on the ring or is thrown outside of the rotational field. Thus, the lubricant does not reach the desired area, resulting in early wear and possible failure of the shaft, bearing, oil ring, or other associated members.
Rotation of the oil ring depends on a propulsive force developed between the rotating shaft and the ring. As speeds increase, a fluid film is developed, and the driving force is transmitted to the ring by this lubricant film. The situation is analogous in many ways to that in a floating ring bearing and, without a direct drive mechanism, a slippage occurs. Prior attempts to develop a higher frictional coefficient and, thus, a more positive drive mechanism, have focused on modification of the cross-sectional geometry of the ring, including both inside and outside surfaces of the ring. Such prior ring structures have included T-shaped rings where the cross of the T serves as the inside surface, rings having a generally trapezoidal cross-section where the inner ring surface is planar, and rings having a generally trapezoidal cross-section where the inner ring surface contains a single wide groove thereacross.
Factors opposing rotation of the ring are the drag on the lower portion of the ring which is submerged in the lubricant reservoir, the force required to lift the lubricant from the reservoir toward the top of the journal, and the frictional drag on the ring applied by close-running stationary surfaces, such as the sides of the ring slot in the bearing. Other factors affecting lubricant delivery include the composition of the ring and the viscosity of the lubricant used in the bearing. In addition, since a conventional oil ring rests on the upper surface of the shaft during operation and during periods of non-use, much wear results from the contact alone. When at rest, most of the lubricant drains back into the reservoir and very little lubricant protection is available for the start-up operation. Thus, until the lubricant film is re-established, early wear of the shaft, ring, bearings, and other associated members is likely to occur. This, in turn, leads to repair and replacement expenses, and the concomitant loss of operating time.
SUMMARY OF THE INVENTION
It is, therefore, one of the principal objects of the present invention to enhance the lubricating ability of oil rings, thereby increasing the capability and the capacity of thrust and journal bearings, by providing a bearing lubrication device having an oil ring configured to afford a greater oil delivery to the shaft and bearings, even at high rotational speeds.
A still further object of the present invention is to provide an oil ring which is usable with most or all devices currently employing conventional oil rings, and which is economical to produce and to use.
Yet another object of the present invention is to provide an improved oil ring that is stable at high operating speeds with superior oil delivery.
These and other objects are attained by the present invention which generally relates to a bearing lubrication device for use in ring-oiled bearings and the like, which has a rotatable shaft, a bearing surface, a lubricant reservoir, and a generally circular ring member eccentrically rotatably received about said shaft for carrying lubricant from the reservoir for deposition on the shaft and the bearing surface. The ring member, preferably metal rotates with the shaft, and is constructed for stable operation at high rotational speeds with superior lubricant delivery than was possible with the conventional oil rings.
More specifically, the improved oil rings according to the present invention comprise an outer surface, right and left sides that angle from said outer surface at a predetermined angle, for a predetermined distance and then angle radially inwardly, generally perpendicular to said outer surface, and an inner surface that has at least one, though preferably a plurality of grooves therein.
Preferred oil rings according to the present invention, have a particular size and weight with a plurality of grooves being provided in the inside ring surface. Optimum unit weight for present oil rings from a standpoint of oil delivery and ring stability ranges from about 0.131 to about 0.142 pounds per inch of circumferential length. Relative inner diameter of the ring to outer diameter of the journal should be from about 1.5 to about 2.0, and preferably about 1.7. Further, the right and left angled side walls preferably define an angle from the upper surface in a range of from approximately 25 degrees to approximately 35 degrees and most preferably approximately 30 degrees. Moreover, the perpendicular side wall portions preferably should have at least a predetermined length.
Various other objects and advantages of the present invention will become apparent from the below description, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, shown partially in cross-section, of a pillow block-type journal bearing assembly with an oil ring according to the present invention disposed around the shaft of the bearing assembly;
FIG. 2 is a partial perspective view of the bearing lubrication device embodying the present invention, shown here installed in a pillow block-type bearing, with a portion of the bearing structure broken away, revealing the cross-section and orientation of the oil ring with respect to the shaft;
FIG. 3 is an enlarged cross-sectional view of a preferred oil ring embodiment according to the present invention;
FIGS. 4, 5 and 6 are enlarged cross-sectional views of further preferred oil ring embodiments according to the present invention;
FIGS. 6a and 5a are partial plan views of the grooved inner surfaces of oil rings as illustrated in FIGS. 6 and 5, respectively;
FIG. 7 is a graph of the relationship of shaft speed and oil delivery for the oil rings depicted in FIGS. 3 through 6 compared to prior art oil rings; and
FIG. 8 is a general graphical representation of oil ring behavior as a function of journal speed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more specifically to the drawings, and to FIGS. 1 and 2 in particular, numeral 10 designates generally the bearing lubrication device embodying the present invention. The device is shown here disposed in a journal bearing 12, although its application is not limited in any way thereto. The assembly can normally be used wherever conventional oil rings are used for lubrication purposes, and in a variety of different devices. In normal operations with bearings of the type shown, an oil ring 19 is loosely, eccentrically disposed around a rotatable shaft 14, and rotates therewith in a manner to be explained below. Oil ring 19 rotates in a ring slot 16 located in a bearing member or liner 40, through a lubricant reservoir 18 and, as rotation occurs, carries lubricant from reservoir 18 upwardly for deposition on the shaft and the bearing surfaces.
A most preferred oil ring embodiment according to the present invention is illustrated in FIGS. 2 and 3. As thus illustrated, ring 19 has an outer surface 20, right and left side portions 21, 22, that taper outwardly from outer surface 20 an angle α, and right and left vertical side portions 23, 24, that are of a predetermined length and are generally perpendicular to outer surface 20. Ring 19 further has an inner surface 25 that defines a plurality of circumferentially extending side-by-side grooves 26 therein.
A second oil ring embodiment 119 according to the present invention is illustrated in FIG. 4. Ring 119 has an outer surface 120, right and left side portions 121, 122 at an angle α as shown in FIG. 3, generally vertical side portions 123, 124 and an inner surface 125. Inner surface 125 of ring 119 is shown to have a plurality of circumferential grooves therein, including a central groove 127 with outer, narrower grooves 126 along opposite sides of same.
FIGS. 5 and 5a illustrate yet another embodiment of the oil ring of the present invention. Ring 219 has an outer surface 220, side portions 221, 222 at a predetermined angle α, perpendicular side portions 223, 224 and an inner surface 225. Inner surface 225 has a plurality of grooves 226 therein and located therearound which, as shown in FIG. 5a, are transverse to the circumference of ring 219.
FIGS. 6 and 6a likewise illustrate an oil ring 319 having generally transverse grooves 326 around an inner surface 325. Grooves 326 are, however, V-shaped with the legs of the V being at an angle β of approximately 135 degrees.
With oil rings of the present invention, the relative angle α of angular sides 21, 22 in conjunction with the length of vertical sides 23, 24 have the greatest impact on oil delivery, particularly, as angle α of sides 21, 22 approaches zero degrees (0°), side drag of ring 19 in ring slot 16 approaches maximum. Such causes the ring to operate erratically due to the greater side drag, and oil delivery is reduced due to insufficient ring speed. Conversely, as angle α of sides 21, 22 is increased, consequently shortening the length of vertical sides 23, 24, oil delivery increases accordingly and the lubricant is thrown off the ring by the rotational forces in the form of a splash or spray. Through experimentation, angle α for angular sides 21, 22 has been determined to preferably range from about 25 degrees to about 35 degrees and most preferably is approximately 30 degrees, regardless of the diameter of the ring or the depth of the inside grooves 26.
Through experimentation it has also been determined that the length of vertical sides 23, 24 relative to angle α may be controlled for improved oil delivery dependant upon journal speed ranges. Shorter vertical side dimensions are preferred for low journal speeds, while longer vertical sides are preferred for the higher journal speed ranges. Also it has been determined that vertical side lengths less than one millimeter produced wear and unstable operation at low journal speeds.
FIG. 8 generally represents a curve of oil ring behavior over a range of journal speeds and depicts relative oil delivery by the ring through four regimes, I, II, III and IV. Curve N R represents ring rotational frequency, Q R oil delivery, and R O , ring oscillation. In regime I, at low journal speeds, oil ring 19 follows the journal at approximately the same peripheral speed. As the speed of shaft 14 increases, a transition point is reached at the end of regime I where, a hydrodynamic lubricant film begins to form. Ring speed at this transition point is considered to be the primary speed of the ring with respect to the journal speed. Primary speed of the oil ring is a combined function of the ring weight, shape, projected areas of contact, journal speed, lubricant viscosity, and localized temperature.
As journal speed increases into regime II, thus increasing the speed of the ring above the primary speed, formation of the hydrodynamic lubricant film causes ring slippage accompanied by a corresponding decrease in oil delivery. Upon establishment of a full hydrodynamic film between the journal and ring, further increase in journal speed is followed by increased ring speed and oil delivery to a maximum oil delivery for the ring. Maximum oil delivery occurs at the end of regime II where the actual rotating speed of the ring is a balance between the propulsive force at the region of contact between the ring and the journal and the resistive force of the lubricant drag on the ring, and is designated as the secondary speed. The secondary speed is also a function of many parameters, including journal speed, oil viscosity, ring submersion level, and ring shape. For example, the greater the length of vertical sides 23, 24 the lower the secondary speed.
Moving into regime III, a significant decrease in ring speed and oil delivery are observed. Coincidentally in regime III, it is noted that significant ring oscillation (curve R O ) is present. Ring oscillation in the plane of ring rotation actually begins to appear during the trailing portion of regime II, and though ring speed drops only slightly, oil delivery drops drastically in regime III, asymptotically approaching zero. Ring speed in regime III is referred to as tertiary speed and is believed to be the first rigid-body, critical speed of the ring.
In regime IV oscillating vibrations abate while conical vibrations (angular with respect to the shaft) and translatory vibrations (lateral with respect to shaft) begin, (curve R CT ) with frequency of both being that of ring rotational frequency or speed. Throughout regime IV, oil delivery remains essentially zero, resulting from oil splash and throw-off from the surface of the ring and partly also from the journal or shaft. Hence, above the tertiary speed regardless of journal speed, the rotational speed of the ring either remains constant or falls. Several specific factors influence this tertiary speed, including the ring shape, the ring-bore configuration which strongly controls the hydrodynamic stiffness of the ring, the weight or mass of the ring, and the ring diameter; for example, a larger ring has a lower tertiary speed. The effects of changes in lubricant viscosity on ring speed and lubricant delivery were also studied using lubricants of SAE 10, 20 and 30 weight, and it was found that though viscosity affected the primary and secondary speeds of the ring, tertiary speed was found to be independent of viscosity.
Various materials may be used in the fabrication of oil rings according to the present invention, including brass, Muntz (60% Cu, 40% Zn), and bronze (SAE-660). Tests conducted on these materials using lubricant SAE 10 at 120° F. and a ring submersion level at 15% of the ring diameter, indicated that bronze attained an oil delivery approximately 10% higher than the others tested. Tests of the wear properties, consisting of 30,000 start-stop cycles and 7,200 hours of continuous running at 1800 rpm, with lubricant SAE 10, indicated less wear with the brass ring, but differences were slight.
Referring back to FIG. 2, oil ring 19 is shown disposed eccentrically around shaft 14 with contact made at the top of shaft 14. Shaft 14 is rotatable in bearing member or liner 40, which may be of any suitable type and, in the embodiment shown, rotation is in the direction of the arrow. Ring 19 assumes approximately the position shown in FIG. 2 when the apparatus is at rest, thereby allowing the outer edges of ring 19 to contact shaft 14. As rotation of the shaft and ring occurs, lubricant is carried upwardly from reservoir 18 by inside grooves 26 where it is deposited on shaft 14.
In copending application Ser. No. 06/569,526, the oil ring of FIGS. 1 and 4 is described in conjunction with a cantilevered leaf scraper, along with certain information demonstrating improved oil delivery over the use of such an oil ring per se. While such is true, the improved oil rings of the present invention achieve improved results without a stabilizer over prior oil rings. Such results are graphically demonstrated in FIG. 7. Particularly, in FIG. 7, graph 1 represents a commercial oil ring having a trapezoidal cross-section with a single wide groove along an inner surface of same, referred to as a Wulfel ring. Graph 2 represents a commercial oil ring having a T cross-section where the cross of the T provides an inner ring surface. Graphs 3, 4, 5 and 6 are representative of the oil rings of the present invention as illustrated in FIGS. 3, 4, 5 and 5a, and 6 and 6a, respectively. As can be seen, all of the instant oil rings performed significantly better than the prior art rings across the shaft speed range shown. Further, rings of the present invention not only exhibit superior lubricant delivery, but also, maintained stable operation beyond 2000 rpm.
The effects of varying the depth of groove on lubricant delivery for various shaft speeds was determined as set forth in copending application Ser. No. 06/569,526 and is incorporated herein by reference. Three rings of the embodiment shown in FIG. 4 were tested and were identical, except for the variance in inside groove depth where groove depth was 1.05 mm, 1.52 mm, and 3.20 mm. From this data, an optimum depth of approximately 1.52 mm was selected, providing approximately twice the oil delivery of rings having shallower or deeper grooves. The effects of variance in lubricant viscosity were determined based on experiments conducted with lubricants having SAE ratings of 10, 20, and 30 weight. Results indicated that the heavier lubricants showed marked increases in oil delivery, an important and desirable factor, especially in large bearing applications where the use of heavier lubricants and higher speeds are common.
It will be understood, of course, that while the form of the invention herein shown and described constitutes a preferred embodiment of the invention, it is not intended to illustrate all possible forms of the invention. It will also be understood that the words used are words of description rather than of limitation and that various changes may be made without departing from the spirit and scope of the invention herein disclosed. | A bearing lubrication device for use in ring-oiled journal bearings and the like in which a generally circular ring member is eccentrically disposed around the rotatable shaft in the bearing assembly. The ring has an outer surface, right and left sides extending downwardly from the outer surface at a predetermined angle, most preferably about 30 degrees, for a predetermined distance and then radially inwardly, generally perpendicular to the outer surface for a predetermined distance, and an inner surface, said inner surface having at least one, but preferably a plurality of grooves therein. As rotation occurs at high forward speeds, improved lubricant delivery, stability of operation and bearing performance capability are realized. | 5 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional applications Ser. No. 61/632,639 filed on Jan. 27, 2012 entitled “Portable blind-decoy with one-way mirror sight for hunters”, and No. 61/687,774 filed on May 1, 2012 entitled “Portable blind-decoy for hunting wild turkeys”, the disclosures of which are incorporated fully herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the invention
[0003] This invention relates generally to the field of hunting decoys and more particularly to a reflective decoy device for safe stalking and luring of wild turkeys. The device is attached to a hunting weapon and reflects the image of the turkey back to itself as well as hiding the hunter.
[0004] 2. Description of the Related Art
[0005] Native Americans have stalked wild turkeys throughout history. During turkey mating season, male turkeys (gobblers) may court female turkeys (hens). In a courting ritual, a gobbler will often spread out and raise his tail feathers (strut), blush his head to dark red and his neck to dark blue, then stretch them forward and gobble. Gobblers are often defensive of their mating territory, and they may confront and attack an intruding gobbler, particularly if the intruder is strutting and gobbling toward them or their hens. Hunters take advantage of that aggression to lure them in. A common technique is to set-up a decoy (see U.S. Pat. No. 7,784,213 to Primos) of a strutting gobbler, sit in a blind and wait. An alternative strategy is to locate the turkeys from a distance and stalk them. But, turkeys have extraordinary eyesight, which makes stalking difficult. To enhance successful stalking, hunters can hide behind hand-held strutted turkey tail feathers. This technique enables the hunter to get to about 70 yards from the turkey/s (not close enough for shooting which for a shotgun is under 40 yards and for a bow is under 20 yards). Then the hunter hides and sits still and hopes the gobbler will come closer. Another trick some hunters use is to crawl behind a full-body 3D turkey decoy and when the turkey sees it, to lie still and wait for the gobbler to come. Unfortunately, this method can result in having the hunter shot by another hunter.
[0006] Since the earliest attempts of hunting wild game, various forms of decoys and costumes have been used to help hunters stalk and lure animals. Hiding behind or inside a conventional decoy or an animal hide poses a risk to be mistakenly shot by another hunter.
[0007] It is therefore desirable to have a decoy sufficiently convincing to lure the animal without risking being shot by another hunter.
SUMMARY OF THE INVENTION
[0008] The present invention is a reflective decoy device employing a mirror with turkey tail feathers around it. The mirror is attached to a weapon substantially perpendicular to the line of fire. The mirror element is adapted for reflecting back to the turkey its own image when aimed. A partially reflecting sighting aperture is incorporated in the mirror for the purpose of aiming the mirror to the turkey.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of a first embodiment of the reflective decoy on shotgun;
[0010] FIG. 2 is an enlarged detailed perspective view of FIG. 1 showing attachment details for the reflective decoy;
[0011] FIG. 3 is a front view of the mirror element employed with the embodiments herein;
[0012] FIG. 4 is a side section view of the mirror along line 4 - 4 of FIG. 3 the sighting elements of the invention;
[0013] FIG. 5 is a pictorial representation of the overlay view as seen by the hunter in the sight;
[0014] FIG. 6 is a detail of the elements of the sighting aperture;
[0015] FIG. 7 is a perspective view of the reflective decoy on bow;
[0016] FIG. 8 is a perspective view of the bow and reflective decoy supported by a bipod;
[0017] FIG. 9 is a side view of the bow, reflective decoy and bipod of FIG. 8 ; and,
[0018] FIG. 10 is a detailed view of the bipod attachment.
DETAILED DESCRIPTION
[0019] FIG. 1 provides an example of an embodiment of a reflective decoy 100 on a shotgun 200 . While shown in the embodiment as a shotgun, alternative embodiments may employ a rifle or other hunting weapon. A glass mirror 110 , large enough to hide the hunter's head and reflect the distinctive features of a turkey (head, neck and beard), as will be described in greater detail subsequently. The mirror 110 is equipped with a half silvered sighting aperture 120 and a fan of turkey tail feathers 130 is mounted on mirror which is in turn mounted on the shotgun 200 via bracket 140 . While the embodiment described herein is adapted for hunting turkeys, the reflective decoy may be adorned with alternative supplemental elements and used to reflect the head of other game animals.
[0020] FIG. 2 provides a close up detail of the attachment elements of the glass mirror to the shotgun of FIG. 1 . In this embodiment the bracket 140 is designed to fit the Remington MODEL 11-87 12-gauge shotgun. Bracket 140 is equipped with a 1⅛″ diameter attachment hole 141 where a magazine cap 210 of the shotgun 200 is used to secure the bracket 140 to the gun. The mirror 110 is attached to the bracket 140 by hook and loop fasteners 112 . The feathers 130 may also be attached to the mirror with hook and loop fasteners 112 . The mirror 110 is substantially elliptic having minor and major axes of 9×16″ (230×400 mm) and is made from ¼″ (˜6 mm) mirror glass. A 2″ hole 150 in the mirror 110 is made for the barrel of the shotgun and a sighting aperture 120 , to be described in greater detail subsequently, is present. Rubber band 160 is employed for supplemental attachment of the mirror 120 and bracket 140 for shock absorption.
[0021] FIG. 3 shows a front view of the mirror 110 with the sighting aperture 120 and a partially silvered sighting element 122 . For an animal to see himself reflected in the glass mirror 110 , the mirror must be orthogonal to a line of sight between the hunter and the animal. This is not easily accomplished by merely pointing the weapon at the animal, particularly at longer ranges. The present embodiments therefore incorporate a dual reflective sighting system. In the glass mirror 110 , the coating is removed (not the glass) to expose the glass and form an optical window as the sighting aperture 120 .
[0022] FIG. 4 shows a one-way mirror (partially reflective, partially transparent) is formed by, for example using a reflective film 122 such as “Gila MIRROR PR5361” bonded to the sighting aperture 120 with reflective action between the hunter and the glass mirror (thicknesses in FIG. 4 are exaggerated for clarity). Alternatively, the glass mirror 110 may be partially silvered in the region of the sighting aperture 120 to create a one way reflective element as is known in the art. When aligned using a handle 170 (or the bracket 140 when attached to the shotgun 200 as shown in FIGS. 1 and 2 ), the hunter can see both, the animal or any desired target (partially transparent) and the reflection (partially reflective) of his own eye 48 . By aligning the eye with the partially reflective aperture as represented by ray 28 a an image of the eye then reflects back to the observer's eye 48 as ray 28 b and the target or animal 14 , aligned as represented by the ray of a line of sight 24 , is also visible in the aperture. When the first mirror element is brought to an orthogonal orientation with the animal by aligning the eye and animal images, the animal can see itself reflected in a first direction from the glass mirror 110 as represented by ray 29 . For the example embodiment with a turkey, seeing its own reflection, complete with movement of head, ears, eyes, neck and beard, the turkey interprets the mirror element (and the hunter behind) as a second animal of his own species and, therefore, as non-threatening or during mating season as a challenger.
[0023] FIG. 5 shows the self-reflected aiming eye of the hunter on the targeted turkey.
[0024] FIG. 6 shows a sighting element 120 incorporating a top portion of the sighting aperture designated 120 a which is unsilvered providing a clear unobstructed view for sighting a weapon such as a bow with the integral bow sights. A second intermediate portion of the sighting aperture is partially silvered for partial reflectance and partial transparence. This may be accomplished in example embodiments using one layer of reflective film 122 a to provide approximately 50% transmission and 50% reflection. A lower portion of the sighting aperture is additionally silvered for greater reflectance to accommodate conditions where the animal may be in direct sunlight but the hunter may be in shade therefore requiring additional reflection from the mirror to see his eye. This may be accomplished in example embodiments by using a second layer of the reflective film 122 b to provide approximately 25% transmission and 75% reflection.
[0025] FIG. 7 shows the reflective decoy 100 attached to a compound bow 300 .
[0026] FIG. 8 shows a bipod 150 having two legs 152 a and 152 b may also be added to the bow 300 in conjunction with the mounting of the reflective decoy 100 . The bipod allows the bow to be placed upright on the ground against the bow's cam 310 . By freeing his arms, the hunter can use box and/or slate calls to help lure the gobbler into the mirror's effective range.
[0027] FIG. 9 shows hook and loop fasteners 112 attach the glass mirror 110 of the reflective decoy 100 to the bow 300 via a bracket 142 , comparable in function to the bracket 140 (see FIGS. 1 and 2 ) employed with the shotgun. The bow's frontal standard 5/16-24 threaded hole 146 is used to connect the bracket 142 which is made of 5/16-24 threaded steel rod and aluminum plate, as will be described in greater detail subsequently, covered with a hook and loop fastener 112 . Another hook and loop fastener 112 is bonded to the front of the bow's sight 144 to provide the second attachment, preventing the glass mirror 110 from swinging. Rubber band 160 provides additional security and shock absorption. The bipod legs 152 a (and 152 b which is hidden in this view) are attached to the supporting bracket 142 in a manner allowing the legs to swivel to a horizontal position as represented by phantom leg 153 .
[0028] FIG. 10 shows a close-up view of the bracket 142 with its bipod leg 152 a. The bracket 142 includes a flat plate 153 and substantially square aluminum block 154 with edges oriented horizontally and vertically providing flats 156 angled at 45 degrees. Threaded bores in the flats receive bolts 158 which attach the legs ( 152 a shown) to the bracket. Each bipod leg may be fabricated from, for example, an aluminum L beam or angle with a first surface 159 a cut to create a relief 160 leaving a flat tab 161 on a second surface 159 b with a hole through which the bolt 158 is inserted. The unrelieved portion of the first surface 159 a engages a lower flat of the block 154 to limit forward travel of the bipod leg. Reward rotation about the bolt 158 allows the leg 152 a to be rotated to the horizontal position (shown as 153 in FIG. 9 ) and described above. Attachment of the bracket to the bow frontal standard hole (element 146 in FIG. 9 ) is accomplished with a threaded rod 162 extending from the block 154 with appropriate jam nuts 164 and 166 for adjustment of the overall length of the bracket. As previously described, a hook and loop fastener 112 is adhered to a front surface of the flat plate 153 for engaging the glass mirror.
[0029] Having now described various embodiments of the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims. | A reflective decoy device for hunting wild turkey employs a glass mirror and strutted gobbler feathers. The turkey decoy device is attached to a hunting weapon, such as a shotgun or compound bow, with its mirror element substantially vertical to the line of fire. A partially transparent, partially reflective one-way mirror, half-silvered sight is incorporated in the mirror decoy for aiming the mirror perpendicular to the line of sight. This device create an illusion of a 3D decoy which may be used as a big game decoy for various animals such as antelope, mule deer, white tail, and elk. | 0 |
REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application Ser. No. 60/079,300, filed Mar. 25, 1998 and futher claims the benefit of U.S. patent application Ser. No. 09/274,755, filed Mar. 23, 1999, now U.S. Pat. No. 6,137,657, issued Oct. 24, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to disk drive suspensions, and more particularly to improvements in limiter-featured disk drive suspensions comprising a load beam and attached thereto a flexure comprising a flexure frame and a flexure tongue adapted to carry a slider for increased load-unload efficiency. The invention provides an improved form of limiter structure to that blocks undue movement of the flexure tongue relative to the flexure frame by engaging the tongue free end with the frame in response to an undue excursion of the tongue. The tongue free end-flexure frame contact is localized to a single locus on the tongue free end. This locus is centrally located to avoid possible tipping of the tongue that can occur when outboard limiter structures at the edges of the tongue free end are employed owing to a possible difference in time of engagement. Non-simultaneous engaging contact of the limiters can tip the slider by first raising only one side of the tongue. This does not occur in this invention, since the limiter engagement locus is centrally located and unitary and thus incapable of not being uniform in time of engagement.
2. Related Art
Limiter structures are broadly known. They are generally designed to either prevent excessive excursions during shock events such as the jarring or dropping of the computer, or to prevent damage to the suspension during loading and unloading cycles. These two situations have different requirements. In load-unload, the slider is lifted from the disk against the forces holding it in position including spring loading by the suspension and the vacuum developed between the slider and the rotating disk. Load-unload cycles in present computers occur frequently, particularly in laptop computers, in an effort to conserve power and thus prolong battery life.
It has been suggested to limit flexure tongue travel with slot and tab arrangements with the tab interfitting the slot, the tab extending typically from the load beam and the slot in the tongue, or vice-versa, with fold-over tabs extending from the load beam and embracing the flexure so as to limit the flexure tongue travel, and with expandable ribbons linking the tongue free end with the opposing frame, or attached to the load beam, but these expedients are more complex to satisfactorily manufacture and may be too costly.
SUMMARY OF THE INVENTION
The repeating load-unload cycles of lifting and replacing the slider at the disk should not be a source of potential failure of the drive. Nonetheless, inadequate design in the lifter may cause failures. In U.S. Pat. No. 5,771,136, for example, a lifter is disclosed that has left and right sides intended to engage the flexure tongue at both its left and right edges with the opposing frame surfaces. Apparently intended primarily for shock situations, the disclosed lifter in an unloading situation must necessarily engage both left and right tongue edges simultaneously or risk tipping the tongue and thus the slider. Given the close proximity of the slider to the disk, tipping from non-simultaneous, and thus uneven engagement, is to be avoided. Manufacturing tolerances are unlikely to be capable of being held so tight, and manufacturing operations unlikely of being kept so free of mishandling that even a perfect design for simultaneous engagement is not proof against mishaps.
The present invention provides a single contact lifter that is incapable of separated-in-time contact by different parts of the lifter structure, that is thus highly suited to load-unload cycling, and which, in reducing failures, is more efficient as a lifter.
The invention, in particular, provides a disk drive suspension assembly of a flexure and a flexure support, the flexure having a tongue adapted to carry in gimbaling relation a slider in operating proximity to a disk, the flexure support and the flexure tongue defining cooperating structures inboard of the tongue edges, and preferably located within the middle third of the tongue free end width, which limit motion of the tongue relative to the disk to a predetermined range.
In preferred embodiments the cooperating structures comprise a relatively movable structure, such as a hook carried by the tongue and a relatively fixed structure such as the flexure frame surrounding the tongue. The specific form of the cooperating structures is not narrowly critical provided the motion of the tongue free end is restricted past a predetermined point and by a single structure of a single or double or divided wall located centrally of the flexure tongue free end.
More particularly, the invention provides a load-unload efficient disk drive suspension comprising a load beam having a base portion, a spring portion and a rigid portion, and a flexure secured to the load beam rigid portion, the flexure comprising a frame and a generally planar tongue cantilevered from the frame to have a free end spaced from the frame, a limiter structure limiting the relative movement of the flexure tongue and the flexure frame to a predetermined range, the limiter structure comprising a centrally located portion of the tongue free end bent to extend out of the plane of the tongue and shaped to extend beyond the tongue free end to intersect with the flexure frame to limit tongue movement relative to the frame to within the predetermined range.
In this and like embodiments, typically, the flexure tongue free end has an outermost tip, the tip being locally deflected to a plane generally normal to the tongue plane, the tongue free end centrally located portion lies within the central one-third of the lateral width of the tongue free end, or is centered on the tongue free end longitudinal axis of revolution.
In a further embodiment, typically, there is provided a load-unload efficient disk drive suspension comprising a load beam having a base portion, a spring portion and a rigid portion, and a flexure secured to the load beam rigid portion, the flexure comprising a frame and a generally planar tongue cantilevered from the frame to have a free end spaced from the frame, the flexure frame comprising first and second transverse portions and left and right side longitudinally disposed outriggers connected together to define a surrounded opening, the tongue extending into the surrounded opening in cantilevered relation, a limiter structure limiting the relative movement of the flexure tongue and the flexure frame to a predetermined range, the limiter structure comprising a centrally located portion of the tongue free end shaped to extend beyond the tongue free end to intersect with the flexure frame to limit tongue movement relative to the frame to within the predetermined range.
In a further embodiment the invention provides a load-unload efficient disk drive suspension comprising a load beam and a flexure having a tongue with a free end forming a limiter structure, including defining a cut along a transverse line inward of the tongue free end from a first edge of the tongue free end partway across the free end to the centrally located portion of the free end to free a flap of material from the tongue free end and leave an uncut remainder to the second edge of the tongue free end, defining the flap to have a head including the tongue free end first edge and a neck of reduced extent relative to the head such that the flap is hook-shaped and its head portion extends beyond the tongue free end remainder, and bending the flap into a substantially normal orientation relative to the tongue free end to have the head overlie the flexure frame transverse portion opposite the tongue free end in spaced relation corresponding to the predetermined range.
In this and like embodiments, typically, the first and second edges of the tongue free end are spaced laterally of the tongue free end central portion and free of limiter structure, the tongue free end centrally located portion lies within the central one-third of the width of the tongue free end, and the centrally located portion is centered on the tongue free end longitudinal axis of revolution.
In its method aspects, the invention includes the method of forming a limiter structure on a load-unload efficient disk drive suspension comprising a load beam and a flexure, the flexure comprising a frame and a tongue cantilevered from the frame and having a free end, the method including defining a cut along a transverse line inward of the tongue free end from a first edge of the tongue free end partway across the free end to the centrally located portion of the free end to free a flap of material from the tongue free end and leave an uncut remainder to the second edge of the tongue free end, the flap having a head including the tongue free end first edge and a neck of reduced extent relative to the head such that the flap is hook-shaped and its head portion extends beyond the tongue free end uncut remainder, and bending the flap into a substantially normal orientation relative to the tongue free end, whereby the head overlies a the frame transverse portion opposite the tongue free end in spaced relation corresponding to the predetermined range.
THE DRAWINGS
The invention will be further described in conjunction with the attached drawings in which:
FIG. 1 is an oblique view of a limiter structure-featured flexure according to the invention;
FIG. 2 is an oblique view of the invention flexure fixed to a load beam and carrying a slider;
FIG. 3 is a plan view of the invention flexure; and,
FIG. 4 is a view taken on line 4 — 4 in FIG. 3 .
DETAILED DESCRIPTION
The invention uses the flexure, the flexure tongue, the flexure outriggers and other structure in the vicinity of the flexure tongue to define cooperating structure which interacts with the tongue cooperating structure to limit range of the motion of the tongue to facilitate unloading, to avoid lift-off from the dimple in some cases, and to limit movement relative to, e.g. toward and/or away from the disk drive disk, so as to maintain a gimbaling capability over a predetermined range of movement, limited by a limiter that prevents or reduces movement beyond that range.
It will be noted that the central location of the limiter structure and the absence of limiter structure at the edges of the tongue free end enables the invention to uniformly limit the tongue in an unload situation and not possibly rock the tongue and its slider as can happen with dual contact limiters.
With reference now to the Figures, in FIGS. 1-4 the invention comprises a load-unload efficient disk drive suspension 10 comprising a load beam rigid portion 12 having edge rails 14 , and a flexure 16 carrying a slider 18 . The flexure 16 is secured to the load beam rigid portion 12 , and comprises a frame 22 having a proximate first transverse portion 24 , a distal second transverse portion 26 , left and right frame members 28 , 32 linked to the transverse portions to define the frame surrounding an open space 34 . Flexure 16 further comprises a generally planar tongue 36 cantilevered from the frame distal transverse portion 26 to project into the space 34 within the frame 22 . Tongue 36 , typically formed from the same resilient stainless steel material as the frame 22 , has a free end 38 spaced from the surrounding frame portions 24 , 26 and frame members 28 , 32 .
The tongue free end 38 terminates in a tip 42 defined by a final reduction in the tongue free end width and a configuring therefrom of the movable part 44 of the limiter structure 46 in a manner to intersect with the stationary part 48 of the limiter structure opposite the tongue free end 38 and defined by the proximate first transverse portion 24 of the frame 22 . Limiter structure 46 limits the relative movement of the flexure tongue free end 38 and the flexure frame 22 to a predetermined range equal to the gap G (FIG. 2) between the limiter structure movable part 44 and its (relatively) stationary part 48 . The limiter structure 46 is formed at a centrally located portion 52 of the tongue free end 38 , that is inboard of the tongue free end left- and right-hand edges 54 , 56 , and typically in the middle or central one-third of the lateral extent E (FIG. 2) of the tongue free end 38 . In FIG. 2 of the drawings the limiter structure 46 is shown centered on the tongue free end 38 longitudinal axis of revolution L., but it can be located to either side of this axis as long as the location is within the middle third of the tongue free end 38 width or lateral extent E.
Moving part 44 comprises the free end tip 42 cut into a flap 60 and locally deflected or bent to extend out of the predominant horizontal plane of the tongue 36 and generally normal thereto. The movable part 44 is shaped as shown to be hook-like with a relatively greater dimensioned head 58 and a reduced dimension neck 62 such that the head extends beyond the tongue free end 38 to intersect with the flexure frame first transverse portion 24 at locus 50 (FIG. 1 ), thereby to limit tongue 36 movement relative to the frame 22 . The head 58 is shown as a single panel, but may comprise multiple panels for added breadth of contact, all to be within the central portion 52 (FIG. 1) of the tongue free end 38 .
With particular reference to FIGS. 3 and 4, the limiter structure movable part 44 is defined from the tongue free end tip 42 by making a cut 64 , by etching or otherwise, transversely of the tip and inward of the tongue free end 38 from, e.g., the left-hand edge 54 of the tongue free end 38 partway across the free end to the centrally located portion 52 of the free end to free the flap 60 of material from the tongue free end and leave an uncut remainder 66 to the second or right-hand edge 56 of the tongue free end. Flap 60 is further cut at 68 to define the head 58 , including the tongue free end right-hand edge 56 and the neck 62 of reduced transverse extent relative to the head such that the flap is hook-shaped and its head 58 extends beyond the tongue free end remainder 66 . The flap 60 is bent into a substantially normal orientation e.g. 90°+/−10-15° relative to the tongue free end 38 to have the head 58 overlie the flexure frame transverse portion 24 opposite the tongue free end in spaced relation across gap G corresponding to the predetermined range that will limit undue travel of the tongue free end 38 during load-unload operations.
In an unload situation, a lifter shifts the load beam and flexure from the disk. Frequently the disk is spinning still and the slider must be forcibly lifted. The invention limiter enables the flexure tongue to lift the slider from the disk against the existing contrary forces while preventing overbending of the tongue and damage to the suspension. The single, central contact of the limiter 46 on the flexure frame 22 blocks rocking of the tongue 36 and flexure 16 that might otherwise occur as in dual limiter constructions, with possible contact of the resultantly tipped slider with the spinning disk. The present invention flexure and limiter is thus more efficient than the prior art.
The foregoing objects are thus met. | A disk drive suspension assembly of a flexure and a flexure support, the flexure having a tongue adapted to carry in gimbaling relation a slider in operating proximity to a disk, the flexure support and the flexure tongue defining cooperating structures which limit motion of the tongue relative to the disk to a predetermined range. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority from Japanese Patent Application No. 2009-297669 filed on Dec. 28, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a bearing structure in which a resin bush is inserted into a bearing hole formed in one constituent member, and a support shaft protruding from the other constituent member is inserted into the bearing hole through the resin bush so as to rotatably supported thereon.
[0004] 2. Description of the Related Art
[0005] JP-2005-287724-A discloses an armrest provided on a side of a vehicle seat. In JP-2005-287724-A, a support shaft extends from a backside frame of the vehicle seat, bearing holes are formed in facing frames of the armrest at a base portion, and the support shaft is inserted into the bearing holes to support the armrest in the width direction. The armrest is stored at a side of a seat back in an erected state and forwardly reclined from the erected state with the support shaft as a pivot.
[0006] In the armrest, an arc-like guide hole is formed in a plate face of the armrest frame with the support shaft as a center, a stopper pin for regulating a rotation range of the armrest is protruded from a plate face of the backside frame at a position apart from the support shaft and inserted into the guide hole, and a hook-like lock cam is provided to the backside frame to be engageable with the stopper pin to thereby store the armrest at the side of the seat back in the erected state.
[0007] In the armrest, metal bushes are mounted onto the stopper pin to smoothen engagement/disengagement of the lock cam with/from the stopper pin.
[0008] In the metal bushes, a cylindrical portion (main body) is fitted with the stopper pin, a flange is formed at one end of the cylindrical portion, an inner cylindrical surface of the cylindrical portion and a flange surface of the flange faced to the armrest frame are coated with a resin having a low frictional coefficient (see JP-2005-287724-A).
[0009] Here, when further bushes for the support shaft are provided in addition to the bushes for the stopper pin, a rotational movement of the armrest can be further smoothened.
[0010] However, when the metal bushes are mounted into bearing holes of the armrest frames for inserting the support shaft therethrough, since an excessive load is applied to the support shaft during the use of the armrest, the resin coating of the bushes may be easily abraded. Further, since the bushes are formed of metal, it is necessary to process the cylinder end of the cylindrical portion or the shaft end of the support shaft so as to prevent the bushes from dropping from the bearing holes, and workability for the assembly is deteriorated.
[0011] By using a resin bush instead of the metal bush, the above-mentioned drop-out prevention process may be omitted with a simple structure. However, when the resin bushes are mounted into the bearing holes for inserting the support shaft to support the armrest, since an excessive load is applied to the support shaft during the use of the armrest as described above, the bushes may be crushed and destroyed.
SUMMARY
[0012] One object of the invention is to provide, for example, in an armrest of a vehicle seat, a bearing structure using a resin bush for a support shaft to support the armrest while preventing the resin bush from being crushed and destroyed even when an excessive load is applied to the support shaft during the use of the armrest.
[0013] According to a first aspect of the invention, there is provided a bearing structure inserted into and fixed to a bearing hole formed in one constituent element for bearing a support shaft protruded from the other constituent element, the bearing structure including: a resin bush having a flange, at one end, formed to be brought into contact with a plate face of the one constituent member around the bearing hole from one side, a locking edge, at the other end, formed to be locked with the plate face of the one constituent member around the bearing hole from the other side, and a circular through-hole, at a enter, formed to bear the support shaft inserted therethrough, wherein, upon receiving a load applied to the support shaft, the entire resin bush is flexibly displaced so that an inner circumferential surface of the through-hole is aligned with a hole edge of the bearing hole and the support shaft is born by the hole edge of the bearing hole.
[0014] According to a second aspect of the invention, there is provided the bearing structure, wherein the resin bush further has a cylindrical body defining circular through-hole while being inserted into the bearing hole, the flange being formed at one end of the cylindrical body, the locking edge being formed at the other end of the cylindrical body, a partition cut formed to open through the locking edge, the cylindrical body and the flange, and thin-walled portions formed to extend from both sides of the partition cut along an outer circumferential surface of the cylindrical body with a reduced thickness, wherein, in the one constituent element, a protrusion is formed at the hole edge of the bearing hole to be positioned within the partition cut and not to reach the inner circumferential surface of the through-hole, and wherein, upon receiving the load applied to the support shaft, the cylindrical body is flexibly displaced at the thin-walled portions so that the inner circumferential surface of the through-hole is aligned with a protrusion end surface of the protrusion and the support shaft is born by the protrusion end surface of the protrusion.
[0015] According to a third aspect of the invention, there is provided the bearing structure, wherein the resin bush further has a cutout formed to open the cylindrical body except for the flange or the locking edge at a position apart from the partition cut.
[0016] According to a fourth aspect of the invention, there is provided the bearing structure, wherein the resin bush further has a bearing piece formed on the flange to rise from the hole edge of the through-hole so as to face the support shaft inserted through the through-hole, the locking edge being continuously extended from a protrusion end of the bearing piece, and a loophole formed in the flange around a rising base of the bearing piece, wherein, in the one constituent element, the bearing hole is formed so that the hole edge thereof does not reach a hole edge of the through-hole and a groove is formed around the hole edge of the bearing hole to receive the bearing piece, and wherein, upon receiving the load applied to the support shaft, the bearing piece is flexibly displaced into the groove through the loophole so that the inner circumferential surface of the through-hole is aligned with the hole edge of the bearing hole and the support shaft is born by the hole edge of the bearing hole.
[0017] According to a fifth aspect of the invention, there is provided the bearing structure, wherein the resin bush further has guide blades formed on both sides of the bearing piece to slidingly guide the flexible displacement of the bearing piece along both edges of the groove.
[0018] According to a sixth aspect of the invention, there is provided an armrest of a vehicle seat, using the above-mentioned bearing structure, wherein the one constituent element is one of an armrest frame of the armrest and a backside frame of the vehicle seat, and the other constituent element is the other of the armrest frame and the backside frame.
[0019] In the above-mentioned bearing structure and the above-mentioned armrest, a resin bush is used. In the resin bush, a flange coming in contact with the plate face of one constituent member around one hole edge of the bearing hole formed in the one constituent member (one of the armrest frame and the backside frame) is formed at one end thereof, a locking edge locked to the plate face of the one constituent member around the other hole edge of the bearing hole is formed at the other end thereof, and a circular through-hole for inserting the support shaft protruding from the other constituent member (the other of the armrest frame and the backside frame) therethrough is formed at the center thereof. As a result, the drop-out of the resin bush from the bearing hole is prevented by the flange and the locking edge.
[0020] According to the first aspect of the invention, the bush is inserted into and fixed to the bearing hole formed in one constituent member and the support shaft protruding from the other constituent member is inserted through the through-hole of the bush so as to rotatably bear the support shaft. Accordingly, by assembling the resin bush in which the entire bush is flexibly displaced with the load applied to the support shaft, the inner circumferential surface of the through-hole is aligned with the hole edge of the bearing hole, and the support shaft is born by the hole edge of the bearing hole, the bush can be assembled without being crushed and destroyed even when the resin bush bears the support shaft.
[0021] According to the second aspect of the invention, the resin bush includes a cylindrical body inserted into the bearing hole and defining the circular through-hole formed at the center between the flange and the locking edge. The bush is inserted into and fixed to the bearing hole and the support shaft is inserted through the through-hole of the bush so as to rotatably bear the support shaft. A partition cut opened through the locking edge, the cylindrical body and the flange and thin-walled portions with a reduced thickness of the cylindrical body extending from both sides of the partition cut to the outer circumferential surface of the cylindrical body are formed in the resin bush, a protrusion is formed at the hole edge of the bearing hole to be positioned within the partition cut and not to reach the inner circumferential surface of the through-hole, the cylindrical body is flexibly displaced at the thin-walled portions with the load applied to the support shaft, the inner circumferential surface of the through-hole is aligned with the protrusion end surface of the protrusion, and the support shaft is born by the protrusion end surface of the protrusion. Accordingly, the bush can be assembled without being crushed and destroyed even when the resin bush bears the support shaft. By providing the partition cut and the thin-walled portions, the entire bush can be made to be flexible and thus can be assembled into the bearing hole. Since the partition cut is formed correspondingly with the protrusion, the positioning is carried out well when inserting the bush into the bearing hole, thereby easily determining the assembly direction.
[0022] According to the third aspect of the invention, in the resin bush, a cutout is opened in the cylindrical body and one of the flange and the locking edge, at a position apart form the partition cut. Accordingly, the entire bush is allowed to be deformed at the cutout in accordance with the flexible displacement of the cylindrical body at the thin-walled portions, thereby further promoting the flexible displacement of the cylindrical body so that the bush is surely assembled without being crushed and destroyed.
[0023] According to the fourth aspect of the invention, a bearing piece faced to the support shaft inserted through the through-hole is formed on the flange of the bush so as to rise from the hole edge of the through-hole, a loophole is formed in the flange around the rising base of the bearing piece, and the through-hole of the resin bush having the hole edge not reaching the hole edge of the bearing hole and the groove recessed from the hole edge of the bearing hole to receive the bearing piece are formed. The bearing piece is flexibly displaced to the deep side of the groove through the loophole, the inner circumferential surface of the through-hole is aligned with the hole edge of the bearing hole, and the support shaft is born by the hole edge of the bearing hole. Accordingly, the bush can be assembled without being crushed and destroyed even when the resin bush bears the support shaft. By providing the flexible bearing piece, the entire bush can be made to be flexible and can be easily assembled into the bearing hole. Since the bearing piece is provided correspondingly with the groove, the positioning is carried out well when inserting the bush into the bearing hole, thereby easily determining the assembly direction.
[0024] According to the fifth aspect of the invention, guide blades are formed on both sides of the bearing piece for sliding along both edges of the groove when the bearing piece flexibly displaces. Accordingly, the bush can be assembled so that the bearing piece can be stably flexibly displaced to the loophole by the guide blades.
[0025] According to the sixth aspect of the invention, the armrest of the vehicle seat includes the bearing structure using the above-mentioned resin bush. Accordingly, when the resin bush is inserted into and fixed to the bearing hole formed in the backside frame and the support shaft of the armrest is inserted through the resin bush to be born, the bush can be prevented from being crushed and destroyed even when an excessive load is applied to the support shaft during the use of the armrest.
DRAWINGS
[0026] FIG. 1 illustrates the frame structure of an armrest of a vehicle seat assembled with a bearing structure using a resin bush according to a first embodiment.
[0027] FIG. 2 is an exploded perspective view of the bearing structure using a resin bush shown in FIG. 1 .
[0028] FIG. 3A is a front view of the resin bush shown in FIG. 2 .
[0029] FIG. 3B is a sectional view of the resin bush shown in FIG. 3A .
[0030] FIG. 4 is a front view of a bearing hole into which the bush shown in FIG. 3B is inserted.
[0031] FIG. 5 is a sectional view of the bearing structure using the resin bush shown in FIG. 1 .
[0032] FIG. 6 illustrates the bearing structure using the resin bush shown in FIG. 5 .
[0033] FIG. 7A partially illustrates the bearing structure using the resin bush shown in FIG. 5 .
[0034] FIG. 7B illustrates a state where a load is applied to the bearing structure using the resin bush shown in FIG. 7A .
[0035] FIG. 8A illustrates a first modified example of the bearing structure using the resin bush shown in FIG. 7A .
[0036] FIG. 8B illustrates a state where a load is applied to the bearing structure using the resin bush shown in FIG. 8A .
[0037] FIG. 9A illustrates a second modified example of the bearing structure using the resin bush shown in FIG. 7A .
[0038] FIG. 9B illustrates a state where a load is applied to the bearing structure using the resin bush shown in FIG. 9A .
[0039] FIG. 10 illustrates the frame structure of an armrest of a vehicle seat assembled with a bearing structure using a resin bush according to a second embodiment.
[0040] FIG. 11 is an exploded perspective view of the bearing structure using a resin bush shown in FIG. 10 .
[0041] FIG. 12A is a front view of the resin bush shown in FIG. 11 .
[0042] FIG. 12B is a side view of the resin bush shown in FIG. 12A .
[0043] FIG. 12C is a sectional view of the resin bush shown in FIG. 12A .
[0044] FIG. 13 is a front view of a bearing hole into which the bush shown in FIG. 12C is inserted.
[0045] FIG. 14 is a sectional view of the bearing structure using the resin bush shown in FIG. 12C .
[0046] FIG. 15 illustrates the bearing structure using the resin bush shown in FIG. 14 .
[0047] FIG. 16A partially illustrates the bearing structure using the resin bush shown in FIG. 12A .
[0048] FIG. 16B illustrates a state where a load is applied to the bearing structure using the resin bush shown in FIG. 16A .
[0049] FIG. 17 is a front view of a modified example of the resin bush shown in FIG. 12A .
[0050] FIG. 18 is a front view of a bearing hole into which the bush shown in FIG. 17 is inserted.
[0051] FIG. 19A illustrates the bearing structure using the resin bush shown in FIG. 17 .
[0052] FIG. 19B illustrates a state where a load is applied to the bearing structure using the resin bush shown in FIG. 19A .
DETAILED DESCRIPTION
[0053] An embodiment may be described with an armrest of a vehicle seat with a bearing structure using a resin bush as an example. In the embodiment, as shown in FIG. 1 , a laterally-extending support shaft 1 is hanged and fixed between armrest frames 2 a and 2 b faced to each other, a bush bearing hole (no reference numeral is shown in FIG. 1 ) to be described later is formed in bracket plates 4 a and 4 b of backside frames 3 a and 3 b located on one side of a seat back. Thus, the armrest can be stored at a side of the seat back in an erected state and forwardly reclined from the erected state. Further, arc-like guide holes 5 a and 5 b are formed in plate faces of the bracket plates 4 a and 4 b with the support shaft 1 as a center, and a stopper shaft 6 protruded from the plate faces of the armrest frames 2 a and 2 b at a position apart from the support shaft 1 are inserted into the guide holes 5 a and 5 b , thereby regulating a rotation range of the armrest.
[0054] As shown in FIGS. 1 and 2 (where only one side is shown), the bearing structure of the support shaft 1 using a resin bush is constructed by forming bush bearing holes 7 in the plate faces of the bracket plates 4 a and 4 b and inserting resin bushes 10 a and 10 b according to the first embodiment into the bearing holes 7 to be fixed thereto. The entire bushes 10 a and 10 b are formed of resins such as polyacetal, nylon, and polypropylene by molding.
[0055] In the first embodiment, each of the resin bushes 10 a and 10 b (hereinafter, the resin bush 10 a will mainly be described) includes a cylindrical body 11 inserted into the bearing hole 7 (see FIG. 2 ), a flange 12 disposed at one end of the cylindrical body 11 , a locking edge 13 disposed at the other end of the cylindrical body 11 , and a circular through-hole 14 extending from the flange 12 to the locking edge 13 through the cylindrical body 11 . The flange 12 has a disk-like shape and the locking edge 13 has a right-triangular sectional shape.
[0056] In the bush 10 a , a partition cut 15 opened from the locking edge 13 to the flange 12 through the cylindrical body 11 , and thin-walled portions 16 a and 16 b with a reduced thickness (see reference sign a<b in FIG. 3A ) of the cylindrical body 11 extending from both sides of the partition cut 15 to the outer circumferential surface of the cylindrical body 11 are formed. The partition cut 15 may have a V-shape in which the width decreases from the outer circumferential surface to the inner circumferential surface. The thin-walled portions 16 a and 16 b may be formed substantially over the hillside of the cylindrical body 11 .
[0057] As shown in FIG. 4 , in the hole edge of the bearing hole 7 , a protrusion 7 a is formed to be positioned in the partition cut 15 of the bush 10 b . The protrusion 7 a is formed not to reach the inner circumferential surface of the through-hole 14 of the bush 10 b (see FIG. 3A ). The projecting height of the protrusion 7 a may substantially correspond to the thickness of the thin-walled portions 16 a and 16 b of the bush 10 a , and the protrusion end surface may have an arc shape substantially corresponding to the circumferential surface of the support shaft 1 (see FIG. 1 ).
[0058] The protrusion 7 a receives a load applied to the support shaft 1 as described later. The load applied to the support shaft 1 downwardly acts on the bush 10 a due to the structure (see FIG. 1 ) in which the stopper shaft 6 regulating a rotation range of the armrest is protruded from the plate face of the armrest frame 2 a at apposition separated from the support shaft 1 and is inserted into the guide hole 5 a . Accordingly, the protrusion 7 a is disposed in the lower hole edge of the bearing hole 7 .
[0059] As shown in FIGS. 5 and 6 , the bush 10 a is assembled into the bracket plate 4 a without drop-out by engaging the cylindrical body 11 with the bearing hole 7 , bringing the flange 12 into contact with the plate face of the bracket plate 4 a around one hole edge of the bearing hole 7 , locking the locking edge 13 to the plate face of the bracket plate 4 a around the other hole edge of the bearing hole 7 , and inserting the support shaft 1 through the through-hole 14 . In the assembling, the bush 10 a is squeezed using the partition cut 15 , and inserted into the bearing hole 7 from the locking edge 13 . Since the partition cut 15 is faced to the protrusion 7 a , the positioning for inserting the bush 10 a into the bearing hole 7 can be carried out, thereby determining the assembly direction.
[0060] When the bush 10 a is assembled, as shown in FIG. 7A , the protrusion 7 a is positioned within the partition cut 15 and does not reach the inner circumferential surface of the through-hole 14 .
[0061] As shown in FIG. 7B , when a load (the downward straight arrow) applied to the support shaft 1 acts on the bush 10 a , the inner circumferential surface of the through-hole 14 is aligned with the protrusion end surface of the protrusion 7 a and the bush 10 a is flexibly displaced in the partition cut 15 so that the support shaft 1 is born by the protrusion end surface of the protrusion 7 a . Accordingly, even when the resin bush 10 a bears the support shaft, the bush 10 a can be assembled without being crushed and destroyed.
[0062] When the load is released from the support shaft 1 of the armrest, the cylindrical body 11 is spring-like restored at the thin-walled portions 16 a and 16 b and thus the support shaft 1 is born by the through-hole 14 of the cylindrical body 11 , as shown in FIG. 7A .
[0063] In the first embodiment, as shown in FIG. 8A , a cutout 17 may be further formed on the opposite side of the partition cut 15 to open the flange 12 and the cylindrical body 11 except for the locking edge 13 . While FIG. 8 a shows a case where the cutout 17 is formed from the flange 12 to the cylindrical body 11 , the cutout 17 may be formed from the locking edge 13 to the cylindrical body 11 .
[0064] By forming the cutout 17 , as shown in FIG. 8B , the entire bush 10 a is allowed to be displaced at the cutout 17 (in the upward arc arrow direction) in accordance with the flexible displacement of the cylindrical body 11 at the thin-walled portions 16 a and 16 b , thereby further promoting the flexible displacement of the cylindrical body 11 so that the bush 10 a is surely assembled without being crushed and destroyed.
[0065] As shown in FIG. 9A , two cutouts 17 a and 17 b may be formed at an angle interval of about 120° with respect to the partition cut 15 interposed therebetween. In this case, as shown in FIG. 9B , the entire bush 10 a is allowed to be displaced (in the upward arc arrow direction) at the cutouts 17 a and 17 b in accordance with the flexible displacement of the cylindrical body 11 at the thin-walled portions 16 a and 16 b.
[0066] Resin bushes 20 a and 20 b according to a second embodiment may be used instead of the resin bushes 10 a and 10 b according to the first embodiment. As shown in FIGS. 10 and 11 , the armrest can be attached to the seat back by using the resin bushes 20 a and 20 b according to the second embodiment. The same elements as shown in FIGS. 1 and 2 are referenced by like reference numerals and signs and the elements will not be described in detail.
[0067] In the second embodiment, as shown in FIGS. 12A to 12C , each of the resin bushes 20 a and 20 b (hereinafter, the resin bush 20 a will mainly be described) each includes a flange 22 having a circular through-hole 21 formed at a center thereof for inserting a support shaft 1 (see FIG. 10 ) therethrough and three bearing pieces 23 a to 23 c formed at regular intervals around the through-hole 21 on the flange 22 as a base. The entire bushes 20 a and 20 b are formed of a resin such as polyacetal or nylon by molding.
[0068] The bearing pieces 23 a to 23 c are provided to face the support shaft 1 inserted through the through-hole 21 and arranged at predetermined intervals around the through-hole 21 so as to rise to be flush with the hole edge of the through-hole 21 . From the protrusion ends of the bearing pieces 23 a to 23 c , locking edges 24 a to 24 c are continuously extended obliquely outward toward the flange 22 to each have an inversed fingertip shape with a stepped end.
[0069] In the flange 22 , loopholes 25 a to 25 c are formed around rising bases of the bearing pieces 23 a to 23 c . Both sides of the bearing pieces 23 a to 23 c are provided with guide blades 26 a and 26 b to 28 a and 28 b which can slide along both edges of grooves formed in a bearing hole 70 to be described later.
[0070] The bearing hole 70 is formed in the plate faces of the bracket plates 4 a and 4 b . The hole edge of the bearing hole 70 has a circular shape as shown in FIG. 13 , and grooves 71 a to 71 c are formed around the bearing hole 70 so as to be recessed from the hole edge correspondingly with the interval of the bearing pieces 23 a to 23 c . The grooves 71 a to 71 c allow the bearing pieces 23 a to 23 c to be flexibly displaced in the depth direction.
[0071] As shown in FIG. 14 , the bearing hole 70 has such a diameter that the hole edge of the through-hole 21 , through which the support shaft 1 is inserted, of the bush 20 a does not protrude into the hole. Specifically, it is set to satisfy the diameter φ 1 of the support shaft 1 <the diameter φ 2 of the through-hole 21 <the diameter φ 3 of the bearing hole 70 .
[0072] The grooves 71 a to 71 c of the bearing hole 70 receive the guide blades 26 a and 26 b to 28 a and 28 b of the bearing pieces 23 a to 23 c and have such a depth that the stepped ends of the locking edges 24 a to 24 c can be engaged with the deep edges.
[0073] As shown in FIGS. 14 and 15 , the bush 20 a is assembled into the bearing hole 70 by bringing the flange 22 into contact with one surface of the bracket plate 4 a , causing the bearing pieces 23 a to 23 c to protrude from the grooves 71 a to 71 c of the bearing hole 70 to the other surface of the bracket plate 4 a , and engaging the stepped ends of the locking edges 24 a to 24 c with the deep edges of the grooves 71 a to 71 c . The support shaft 1 is inserted through the through-hole of the flange 22 within the space between the bearing pieces 23 a to 23 c to be born with the bush 20 a.
[0074] In the bearing structure using the bushes 20 a and 20 b according to the second embodiment, in a normal state, as shown in FIG. 16A , the support shaft 1 is born by the hole edge of the through-hole 21 and the bearing pieces 23 a to 23 c so that the armrest smoothly rotates about the support shaft 1 .
[0075] When the armrest is forwardly reclined from the side of the seat back, the stopper shaft 6 comes in contact with the upper hole edge of the guide hole 5 a , and an excessive load is applied to the support shaft 1 of the armrest. On this occasion, the bearing pieces 23 b and 23 c are downwardly pressed by the support shaft 1 from the hole edge of the through-hole 21 and flexibly displaced (in the arrow direction) into the loopholes 25 b and 25 c as shown in FIG. 16B , whereby the support shaft 1 can be born by the hole edge of the bearing hole 70 .
[0076] Accordingly, even when the support shaft 1 is born by the bushes 20 a and 20 b according to the second embodiment, the bushes 20 a and 20 b can be assembled without being crushed and destroyed.
[0077] In addition, since the bearing pieces 23 a to 23 c protrude from the grooves 71 a to 71 c of the bearing hole 70 and the locking edges 24 a to 24 c are engaged with the deep edges of the grooves 71 a to 71 c , the positioning of the centers of the bushes 20 a and 20 b with the hole center of the bearing hole 70 can be carried out, and the drop-out of the bushes 20 a and 20 b from the bearing hole 70 can be prevented. Since the bearing pieces 23 a to 23 c are formed to be flexible, the entire bush can be flexed and easily assembled into the bearing hole 70 . Since the bearing pieces 23 a to 23 c are faced to the grooves 71 a to 71 c , the positioning for inserting the bushes 20 a and 20 b into the bearing holes 70 is carried out, thereby easily determining the assembly direction.
[0078] When the bearing pieces 23 b and 23 c are flexibly displaced into the loopholes 25 b and 25 c from the hole edge of the through-hole 21 through which the support shaft 1 is inserted, the guide blades 27 a , 27 b , 28 a , and 28 b formed on both sides of the bearing pieces 23 b and 23 c slide along both edges of the grooves 71 b and 71 c . That is, the guide blades 27 a , 27 b , 28 a , and 28 b guide the flexible displacement of the bearing pieces 23 b and 23 c into the loopholes 25 b and 25 c from the hole edge of the through-hole 21 through which the support shaft 1 is inserted.
[0079] When the load is released from the support shaft 1 of the armrest, the locking edges 24 b and 24 c pressed by the deep edges of the grooves 71 b and 71 c and flexed toward the bearing pieces 23 b and 23 c are restored spring-like, and thus the support shaft 1 can be born by the hole edge of the through-hole 21 and the bearing pieces 23 a to 23 c as shown in FIG. 16A .
[0080] As shown in FIG. 17 , two bearing pieces 23 a and 23 b and two locking edges 24 a and 24 b may be provided on both sides, or four bearing pieces and four locking edges (not shown) may be provided to be located oblique in the vertical direction at intervals of about 90°. In this case, as shown in FIG. 18 , the grooves 71 a and 71 b corresponding to the number of the bearing pieces and the locking edges can be formed around the bearing hole 70 .
[0081] In this case, in a normal state, as shown in FIG. 19A , the support shaft 1 is born by the hole edge of the through-hole 21 and the bearing pieces 23 a and 23 b so that the armrest can smoothly rotates about the support shaft 1 .
[0082] When an excessive load is applied to the support shaft 1 , the bearing pieces 23 a and 23 b are pressed downwardly by the support shaft 1 from the hole edge of the through-hole 21 through which the support shaft 1 is inserted and are flexibly displaced (in the arrow direction) into the loopholes 25 a and 25 b , as shown in FIG. 19B , thereby bearing the support shaft 1 with the hole edge of the bearing hole 70 . Accordingly, even when the support shaft 1 is born by the bushes 20 a and 20 b according to this modified example, the bushes 20 a and 20 b can be assembled without being crushed and destroyed.
[0083] In the above-mentioned embodiments, the support shaft is fixed to the armrest frame and the bearing hole is formed in the plate faces of the bracket plates. However, the support shaft may be fixed to protrude laterally from the plate faces of the bracket plates and the bearing hole may be formed in the plate faces of the armrest frames.
[0084] While the examples where the bush is applied to the support shaft of the armrest is described, the bearing structure may be applied also to a case where a rear side of a seat cushion is axially attached to a base bracket fixed to a vehicle floor, a case where a link bar of a height adjusting device of a vehicle seat is axially attached, and the like.
[0085] The bearing structure can be applied not only to the vehicle but also to various mechanisms in which a resin bush is inserted into and fixed to a bearing hole and a support shaft is inserted through and born by the resin bush. And, the invention can be also applied to a case where a load applied to the support shaft acts upward. | According to a first aspect of the invention, there is provided a bearing structure including: a resin bush having a flange formed to be brought into contact with a plate face around a bearing hole from one side, a locking edge formed to be locked with the plate face around the bearing hole from the other side, and a circular through-hole formed to bear the support shaft inserted therethrough, wherein, upon receiving a load applied to the support shaft, the entire resin bush is flexibly displaced so that an inner circumferential surface of the through-hole is aligned with a hole edge of the bearing hole and the support shaft is born by the hole edge of the bearing hole. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to control of product purity in a pressure swing adsorption system; and, more particularly, to a method and apparatus for automatically controlling product purity without risking unacceptable impurity breakthrough as the feedstock changes, yet providing rapid response and high stability.
Pressure swing adsorption (PSA) provides an efficient and economical means for separating a multicomponent gas stream containing at least two gases having different adsorption characteristics. The more-strongly adsorbable gas can be an impurity which is removed from the less-strongly adsorbable gas which is taken off as product; or, the more-strongly adsorbable gas can be the desired product, which is separated from the less-strongly adsorbable gas. For example, it may be desired to remove carbon monoxide and light hydrocarbons from a hydrogen-containing feed stream to produce a purified (99+%) hydrogen stream for a hydrocracking or other catalytic process where these impurities could adversely affect the catalyst or the reaction. On the other hand, it may be desired to recover more-strongly adsorbable gases, such as ethylene, from a feed to produce an ethylene-rich product.
In pressure swing adsorption, a multicomponent gas is typically fed to one of a plurality of adsorption beds at an elevated pressure effective to adsorb at least one component, while at least one other component passes through. At a defined time, feed to the adsorber is terminated and the bed is depressurized by one or more cocurrent depressurization steps wherein pressure is reduced to a defined level which permits the separated, less-strongly adsorbed component or components remaining in the bed to be drawn off without significant concentration of the more-strongly adsorbed components. Then, the bed is depressurized by a countercurrent depressurization step wherein the pressure on the bed is further reduced by withdrawing desorbed gas countercurrently to the direction of feed. In multi-bed systems there are typically additional steps, and those noted above may be done in stages. U.S. Pat. Nos. 3,176,444 to Kiyonaga, 3,986,849 to Fuderer et al, and 3,430,418 to Wagner, among others, describe multi-bed, adiabatic pressure swing adsorption systems employing both cocurrent and countercurrent depressurization, and the disclosures of these patents are incorporated by reference in their entireties.
It is known that controlling product impurity level, e.g., in the less-strongly adsorbed component, to the maximum allowable level results in the highest system efficiency. It is also known that the primary means for controlling product impurity level is to adjust the time each adsorber spends in the adsorption step. If the product impurity level is too high, the adsorption step is shortened, and vice versa. However, when processing feedstocks of a variable nature, e.g., a feedstock comprised of several different streams which may not all be present at all times, it is difficult to control the product purity concentration without unacceptable impurity breakthrough as the feedstock changes.
In conventional systems, the operator monitors the product impurity level and manually adjusts the adsorption step time. This manual process can be automated through a feedback control system. In such a system, the product impurity level would be sensed, and a controller would adjust the adsorption step time depending on the difference between the actual and desired impurity level. Such a system, however, suffers from the usual disadvantage of feedback control; that is, corrective action can only be taken after the undesired event (too high or low impurity level in the product) has occurred.
A feedforward control system could be used alone or in conjunction with the above feedback control system. The feedforward system would be much more complex. The feed composition and flow would have to be measured on-line and the measurements would have to be input into a process model in order to determine the magnitude of the corrective action. The feedforward system has several disadvantages, including the following: (1) feedforward control systems are inherently less stable than feedback control systems; (2) a system which can accurately analyze the concentrations of the components in a multi-component system would be extremely complex and expensive; and (3) an overly-simple and inaccurate process model would have to be used due to practical process control system limitations.
There remains a present need for a method and apparatus for automatically controlling the quality of product from a pressure swing adsorption system which could maximize system efficiency not only for feeds of constant composition but also for feeds which vary in composition and/or flow rate, pressure levels, or temperature, as well as systems operating with other variable process parameters.
SUMMARY OF THE INVENTION
The present invention provides such a method and apparatus for controlling product purity from a pressure swing adsorption process including a cocurrent depressurization step. The process comprises: sensing a characteristic of the effluent from said cocurrent depressurization, and taking corrective action responsive to the sensed characteristic, said action being effective to vary the impurity concentration in the product gas in the direction necessary to obtain desired product purity. The apparatus comprises: means for sensing said characteristic, and means for taking said corrective action.
The corrective actions taken to force the actual impurity level in the cocurrent depressurization gas to the target level include, but are not limited to, the following: (1) adjusting the adsorption step time or other variable to control the impurity loading of each adsorbent bed; (2) adjusting the cocurrent depressurization termination pressure to control the impurity breakthrough at the product end of each adsorbent bed; and/or (3) adjusting the amount of purging gas received by each adsorbent bed to control the extent of regeneration.
After a target impurity level or other physical characteristic in the cocurient depressurization gas is reached within a defined tolerance, the product gas impurity level is preferably measured. If the product gas impurity level is not at the desired value, the difference between the actual and desired level is used to calculate a new target value for the impurity level in the cocurrent depressurization gas. The larger the difference, the larger the change in the target value.
This type of cascade control eliminates the need for a priori determination of the target value, and accommodates changes in the correct ratio of the impurity levels in the cocurrent depressurization gas and product gas resulting from changes in feed composition.
The control system of the invention has the advantages of both the feedback and feedforward control systems, without the disadvantages. An unacceptable impurity breakthrough will always occur in the cocurrent depressurization gas before it occurs in the product gas, and corrective action is taken according to the invention before the undesired event has occurred. The control system does not depend upon accurate feed component analyses and process models. It is also more stable than a feedforward system.
The invention enables automatic adjustment of internal operating parameters of a PSA unit to maintain product purity under changing operating conditions. A physical characteristic of the cocurrent depressurization effluent, such as the impurity concentration near the end of the cocurrent depressurization step, is measured, and controlled through cycle time and/or other adjustments to a target value. The target value is determined such that the desired product impurity level is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and its advantages will become more apparent when the following detailed description is read with reference to the accompanying drawings wherein:
FIG. 1 is a schematic of a single adsorption bed system showing representative adsorbed gas loading at various stages of a single cycle of operation;
FIG. 2 is a graph showing a pressure profile of a single adsorption bed system for a single cycle of operation; FIG. 3 is a schematic showing a four-bed PSA system; and
FIG. 4 is a chart showing a representative sequencing of a four-bed PSA system through a complete cycle of operation.
DETAILED DESCRIPTION
The pressure swing adsorption process is an essentially adiabatic process for separating a multicomponent fluid containing at least one selectively-adsorbable component. FIG. 1 shows feed fluid stream 10 comprising an admixture of impurity and product fluids, entering adsorption zone 12 containing a bed 14 of adsorbent material capable of selectively adsorbing the impurity from the feed fluid stream.
The term "impurity" denotes the component or components which are more-strongly adsorbed in the process. Thus the material described as impurity is not limited to a common definition of the term which denotes something unwanted and to be discarded. The term "product" denotes the less-strongly adsorbed fluid in the feed fluid stream and does not necessarily mean that this component is the desired component to which the process is directed.
The bed, because of the packing of the adsorbent material, contains non-selective voids. The feed fluid stream is introduced and contacted with the bed at an inlet end 16 of the adsorption zone at a first elevated pressure, thereby adsorbing the impurity in the adsorbent material and trapping part of the product fluid in the voids. An impurity-depleted product fluid 18 is discharged from the opposite end 20 of the adsorption zone.
As feed to the bed progresses, an impurity adsorption front is established at the inlet end of the adsorption zone and progressively moves longitudinally through the adsorption zone toward the discharge end to the predetermined level 22 within the zone. The introduction of the feed fluid is then terminated.
The product fluid trapped in the voids is then removed through the discharge end 20 of the adsorption zone by cocurrently depressurizing the adsorption zone from the first elevated pressure to a lower but still elevated pressure. This cocurrent depressurization causes the impurity adsorption front to advance toward the discharge end of the bed to a new level 26. Preferably, one or more intermediate steps of pressure equalization are comprised in cocurrent depressurization to bring the front to level 24, with the final stage of cocurrent depressurization advancing the front to level 26. In multi-bed systems the cocurrent depressurization stage provides purge gas to a bed undergoing regeneration. Thus, this step can be termed a provide purge step and is so referred to in FIG. 4.
According to the invention, a characteristic of the effluent from said cocurrent depressurization is sensed; and corrective action is taken responsive to the sensed characteristic. The corrective action will be any action effective to vary the impurity concentration in the product gas in the direction necessary to obtain desired product purity. Among those corrective actions which may be taken to force the actual impurity level in the cocurrent depressurization gas to the target level are the following: (1) adjusting the adsorption step time or other variable to control the impurity loading of each adsorbent bed; (2) adjusting the cocurrent depressurization termination pressure to control the impurity breakthrough at the product end of each adsorbent bed; and/or (3) adjusting the amount of purging gas received by each adsorbent bed to control the extent of regeneration. Other actions may also be effectively employed.
The invention enables automatic adjustment of internal operating parameters of a PSA unit to maintain product purity under changing operating conditions, such as variation in feed composition. A physical characteristic of the cocurrent depressurization effluent is measured, and controlled through cycle time and/or other adjustments to a target value. The target value is determined such that the desired product impurity level is achieved. Any physical characteristic of the effluent which is related to its purity, e.g., density, level of impurity, thermal conductivity or product component purity can be measured. The preferred characteristic is concentration of impurity.
It is an advantage of the invention that corrective action can be taken before the undesired event has occurred. By recognizing that unacceptable impurity breakthrough, or other measured physical characteristic, appears first in the cocurrent depressurization effluent, especially near the end of the stage, and will be of greater magnitude than the desired product impurity level, it is possible according to the invention to control product impurity level based upon analysis of the cocurrent depressurization gas.
The target impurity, or other physical characteristic, level in the cocurrent depressurization gas is always of greater magnitude than the desired product impurity level. A typical ratio of gas:product gas impurity concentration is approximately 10:1 for hydrogen PSA systems producing 99+ mol percent purity. However, this ratio will vary depending on the type of cycle, feed conditions, product purity, and the like, and is extremely difficult to predict under certain conditions, such as varying feed composition. Therefore, after the target impurity level or other physical characteristic in the cocurrent depressurization gas is reached within a defined tolerance, the product gas impurity level is preferably measured. If the product gas impurity level is not at the desired value, the difference between the actual and desired product impurity level is used to calculate a new target value for the impurity level in the cocurrent depressurization gas. The larger the difference, the larger the change in the target value.
This type of cascade control eliminates the need for a priori determination of the target value, and accommodates changes in the correct ratio of the impurity levels in the cocurrent depressurization gas and product gas resulting from changes in feed composition or other system parameters.
Referring again to FIG. 1, means 32 for sensing a physical characteristic of fluid flowing through line 18 is suitably positioned to sample the fluid in line 18. Also provided are means 34 for taking corrective action responsive to the sensed characteristic which performs the necessary control comparisons, calculations, and actions. In an exemplary situation the sensor is a gas analyzer, such as an infared analyzer, which can measure the concentration of a carbon monoxide impurity in a hydrogen-rich stream. In the illustrated single bed system, a single analyzer can be used for both cocurrent depressurization effluent and final product; it will be recognized, however, that certain systems may require at least separate sensors for each.
As a first step in the control sequence, the means 32 senses the level of carbon monoxide in the effluent from the cocurrent depressurization step. This sensed value is then processed by means 34, such as a process computer or programmable controller, operated by suitable software including a control algorithm. Means 34 then directs corrective action responsive to the sensed characteristic. For example, feed valve 36 may be timed to close earlier or later during the next adsorption stage. The action will be effective to vary the impurity concentration in the cocurrent depressurization gas in the direction necessary to obtain desired target impurity level. Preferably, after this level has been achieved within a defined tolerance, the purity of the product gas is also sensed by means 32 and means 34 then directs corrective action, which will typically involve changing the target value for cocurrent depressurization effluent impurity.
Following cocurrent depressurization, the adsorption zone is desorbed countercurrently to the direction of feed by further decreasing the pressure in the bed and withdrawing desorbed gas at 16. This step brings the front to level 28. Finally, the bed is cocurrent depressurization effluent from another bed, or purged with pure product, to bring the front to level 30. Representative stage times for a single bed and associated pressures for each stage are shown in FIG. 2.
EXAMPLE
This Example describes the operation of a four-bed pressure adsorption system as shown in FIG. 3 for purification of a hydrogen-rich gas stream from a steam reformer (typically, on a molar basis, 75% hydrogen, 4% methane, 3% carbon monoxide, 0.5% nitrogen, with the balance being carbon dioxide, and being saturated with water) to produce 99+ mole percent hydrogen, with minimal, e.g., less than 10 parts per million, concentration of carbon monoxide. Each of the four beds will have a lower layer of activated carbon and an upper layer of zeolite and undergoes each of the noted stages through a complete cycle. The invention is, however, applicable to other multibed systems and can be employed also where the more-strongly adsorbed gas is the product gas.
FIG. 4 is a chart showing the direction of flow within each of the beds shown in FIG. 3 during each of the stages of the cycle and the sequencing of all of the beds through one complete cycle of adsorption and regeneration.
FIG. 4 is based on a 15-minute cycle time. Cycle time is defined as the time that is required for all four adsorbers to go through a complete cycle of adsorption and regeneration. FIG. 4 describes in detail the twelve time periods that each adsorber goes through during one complete cycle. A single process step may cover several time periods. The arrows showing in FIG. 4 show the direction of flow for the first time period. Flow from this pattern will change as the time periods advance as described below. The graph in FIG. 2 shows representative pressures versus time for each step in the cycle for a single adsorber. In the following description, unless the valves are indicated as being open, they are closed.
Time Period 1:
(a) Simultaneously, valves 1A and 2A open to begin adsorption in adsorber A while valves 1C and 2C close to stop adsorption in adsorber C.
(b) Valves 5C and 5D open to begin equalization from adsorber C to adsorber D. During pressure equalization, the adsorber is depressurized cocurrently through valve 5C to an intermediate pressure. The gas released flows directly to adsorber D undergoing repressurization (see FIGS. 3 and 4) to provide gas for partial repressurization of that adsorber. The impurity front advances during this step, e.g., to a degree represented as level 24 in FIG. 1. During the repressurization stage, the adsorber is repressurized to adsorption pressure in two stages:
(1) Pressure equalization and product gas enter the top of the adsorber through valve 5 of the adsorber being repressurized as described in (b) above; and
(2) After the pressure equalization is completed, repressurization is continued with product gas only through valve 5 of the adsorber which is being repressurized. The final portion of repressurization occurs as the vessel switches to the adsorption step.
(c) Part of the product flow is diverted through valves 49, 48, and 5D for product repressurization of adsorber D.
(d) Valves 4B and 37 open to begin the countercurrent depressurization (blowdown) step of adsorber B. During blowdown, the adsorber is depressurized out of the bottom of the vessel (countercurrently) through valves 4B and 37 to waste stream pressure. Impurities are desorbed and vented, and the impurity front drops, say proportional to level 28 in FIG. 1.
Time Period 2:
(a) Adsorber A continues adsorption.
(b) Adsorber B continues blowdown.
(c) Valve 5C closes, ending equalization between adsorbers C and D. Adsorber C remains in a hold condition through the rest of the step.
(d) Adsorber D continues product repressurization.
Time Period 3:
(a) Adsorber A continues adsorption.
(b) Adsorber D continues product repressurization.
(c) Adsorber B is purged by the effluent from the last stage of cocurrent depressurization of adsorber C. Adsorber C provides essentially clean hydrogen gas (e.g., 30-100 ppm) through valves 3C, 39, and 3B. The clean hydrogen gas purges adsorber B and flows out, together with desorbed impurities, through valves 4B and 37. The purge stops when the termination pressure for cocurrent depressurization is reached. See FIG. 2 for example. During this stage the impurity front advances towards the top of the depressurizing adsorber (e.g., level 26 in FIG. 1).
(e) During time period 3, sensing means 132 receives cocurrent depressurization gas from manifold 118 through 3-way valve 130. The impurity level is measured and transmitted to control unit 134. Control unit 134 calculates the difference between the measured impurity level and a target impurity level. If the difference is greater than a predetermined tolerance, e.g, 5%, a new cycle time is calculated and effected by control unit 134, by changing time periods. The control unit effects larger changes to the time periods when there is a larger difference between the measured and target impurity levels and smaller changes when there is a smaller difference. By way of example, a 15% difference might result in a 5% change in cycle time.
If the difference between the measured and target impurity level in the cocurrent depressurization gas is within the predetermined tolerance, the product impurity level is measured in time period 4.
Time Period 4:
(a) Simultaneously, valves 1D and 2D open to begin adsorption in adsorber D while valves 1A and 2A close to stop adsorption in adsorber A.
(b) Valves 5A and 5B open to begin equalization from adsorber A to adsorber B.
(c) Part of the product flow is diverted through valves 49, 48, and 5B for product repressurization of adsorber B.
(d) Valve 4C and 37 open to begin blowdown of adsorber C.
(e) During time period 4, if the difference between the measured and target impurity levels in the cocurrent depressurization gas in time period 3 was within the predetermined tolerance, the product impurity level is measured. Sensing means 132 receives product gas from manifold 138 through 3-way valve 130. The measured impurity level is transmitted to control unit 134, which calculates the difference between the measured product impurity level and the maximum acceptable product impurity level. If the difference is greater than a predetermined tolerance, e.g., 3%, the target value for the impurity level in the cocurrent depressurization gas is changed. By way of example, a 3% difference might change the target level by 10%. This new target level would be used in time period 6.
Time Period 5:
(a) Adsorber D continues adsorption.
(b) Adsorber C continues blowdown.
(c) Valve 5A closes ending equalization between adsorbers A and B. Adsorber A remains in a hold condition through the rest of the step.
(d) Adsorber B continues product repressurization.
Time Period 6:
(a) Adsorber D continues adsorption.
(b) Adsorber B continues product repressurization.
(c) Adsorber C is purged by the effluent from cocurrent depressurization of adsorber A. Adsorber A provides clean hydrogen gas through valves 3A, 39, and 3C. The clean hydrogen gas purges adsorber C and flows out through valves 4C and 37.
(d) Adsorber A provides purge gas until the pressure drops to the cocurrent termination pressure.
(e) During time period 6, sensing means 132 receives cocurrent depressurization gas from manifold 118 through 3-way valve 130. The signal is transmitted to control unit 134 which performs the functions described in time period 3.
Time Period 7:
(a) Simultaneously, valves 1B and 2B open to begin adsorption in adsorber B while valves 1D and 2D close to stop adsorption in adsorber D.
(b) Valves 5C and 5D open to begin equalization from adsorber D to adsorber C.
(c) Part of the product flow is diverted through valves 49, 48, and 5C for product repressurization of adsorber C.
(d) Valves 4A and 37 open to begin the blowdown step of adsorber A.
(e) During time period 7, if the difference between the measured and target impurity is within the predetermined tolerance, the product impurity level is measured. Sensing means 132 receives product gas through 3-way valve 130. The measured impurity level is transmitted to control unit 134, which performs the functions described in time period 4.
Time Period 8:
(a) Adsorber B continues adsorption.
(b) Adsorber A continues blowdown.
(c) Valve 5D closes ending equalization between adsorbers D and C. Adsorber D remains in a hold condition through the rest of the step.
(d) Adsorber C continues product repressurization.
Time Period 9:
(a) Adsorber B continues adsorption.
(b) Adsorber C continues product depressurization.
(c) Adsorber A is purged by adsorber D. Adsorber D provides clean hydrogen gas through valves 3D, 39, and 3A. The clean hydrogen gas purges adsorber A and flows out through valves 4A and 37.
(d) Adsorber D provides purge gas until the pressure drops to the cocurrent termination pressure.
(e) During time period 9, sensing means 132 receives cocurrent depressurization gas from 3-way transmitted to control unit 134 which performs the functions described in time period 3.
Time Period 10:
(a) Simultaneously, valves 1C and 2C open to begin adsorption in adsorber C while valves 1B and 2B close to stop adsorption in adsorber B.
(b) Valves 5A and 5B open to begin equalization from adsorber B to adsorber A.
(c) Part of the product flow is diverted through valves 49, 48, and 5A for product repressurization of adsorber A.
(d) Valves 4D and 37 open to begin the blowdown step of adsorber D.
(e) During time period 10, if the difference between the measured and target impurity is within the predetermined tolerance, the product impurity level is measured. Sensing means 132 receives product gas through 3-way valve 130. The measured impurity level is transmitted to control unit 134, which performs the functions described in time period 4.
Time Period 11:
(a) Adsorber C continues adsorption.
(b) Adsorber D continues blowdown.
(c) Valve 5B closes ending equalization between adsorbers B and A. Adsorber B remains in a hold condition through the rest of the step.
(d) Adsorber A continues product repressurization.
Time Period 12:
(a) Adsorber C continues adsorption.
(b) Adsorber A continues product pressurization.
(c) Adsorber D is purged by adsorber B. Adsorber B provides clean hydrogen gas through valves 3B, 39, and 3D. The clean hydrogen gas purges adsorber D and flows out through valves 4D and 37.
(d) Adsorber B provides purge gas until the pressure drops to the cocurrent termination pressure. At the end of time period 12, the system returns to time period 1 and the cycle is repeated.
(e) During time period 12, sensing means 132 receives cocurrent depressurization gas from manifold 118 through 3-way valve 130. The signal is transmitted to control unit 134 which performs the functions described in time period 3.
This process can be performed with any suitable adsorbent, such as zeolitic molecular sieves, activated carbon, silica gel, activated alumina, and the like, as set forth in the above-referenced Kiyonaga patent, having a selectivity for the impurity over the product fluid.
The above description is for the purpose of teaching the person of ordinary skill in the art how to practice the present invention, and it is not intended to detail all those obvious modifications and variations of it which will become apparent to the skilled worker upon reading the description. It is intended, however, that all such obvious modifications and variations be included within the scope of the present invention which is defined by the following claims. | The present invention provides a method and apparatus for automatically controlling product purity in a pressure swing adsorption process without risking unacceptable impurity breakthrough as the feedstock changes, yet providing rapid response and high stability. The process comprises sensing a characteristic of the effluent from cocurrent depressurization, and taking corrective action responsive thereto. Any action can be taken which is effective to vary the impurity concentration in the product gas in the direction necessary to obtain desired product purity. Among the suitable corrective actions are the following: (1) adjusting the adsorption step time to control the impurity loading of each adsorbent bed; (2) adjusting the cocurrent depressurization termination pressure to control the impurity breakthrough at the product end of each adsorbent bed; and/or (3) adjusting the amount of purging gas received by each adsorbent bed to control the extent of regeneration. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a novel and useful foundation system for securing a superstructure such as a tower monopole or antenna.
Towers and antennas are used throughout the world for supporting power transmission wires, signs, and electronic mechanisms, such as communications devices, which either transmit or receive communication signals. To support such superstructures, anchors or foundations must be provided to ensure proper operation of the same.
In the past, foundations have been cast and poured in the usual manner requiring the transportation of building materials to a site, provision of foundation erecting equipment, and the necessary manpower to achieve this task. Unfortunately, superstructures, such as antennas and towers, are often required in remote areas. Providing a proper foundation for such superstructures has proved expensive and difficult.
Many prior, foundation structures for superstructures have been proposed. For example, U.S. Pat. Nos. 4,723,128, 4,799,642, 4,899,500, 4,912,893, 4,951,433, and Japanese Patent 57-14003 depict mounting structures using beams and struts constructed of steel which are fastened to a surface.
U.S. Pat. Nos. 1,134,897, 1,271,751, 3,292,329, 4,649,675, 4,714,225, 4,918,891, and 5,612,176 depict foundation structures for superstructures, such as antennas, which use poured in monolithic concrete bases that are either surface mounted or are imbedded in a surface.
U.S. Pat. No. 5,584,151 describes a pre-fabricated building panel which employs frame members which are connected together to form a building.
U.S. Pat. Nos. 3,415,475 and 5,142,293 shows weighted bases for superstructures that are composed of multiple members.
U.S. Pat. Nos. 2,982,380, 3,722,159, and 4,798,036 illustrate pre-fabricated concrete structures which use interlocking blocks to form a foundation or footing.
U.S. Pat. No. 592,146 reveals a fence post structure using a series of stacked blocks which are placed in a ground surface along with rods that support superstructures such as a fence post.
U.S. Pat. Nos. 657,867 and 3,962,088 teach block assemblies which are stacked together and include tension rods to hold the blocks together.
U.S. Pat. No. 4,922,264 depicts an antenna mounting apparatus that utilizes a quartet of feet formed of blocks that are independently tied together. The antenna structure in the central portion of the mounting foundation utilizes metallic frame which is tied to the foundation feet by struts.
Unfortunately, the prior art systems for supporting superstructures do not use pre-fabricated monolithic foundation structures which are capable of supporting superstructures such as antennas adequately in various environmental conditions.
SUMMARY OF THE INVENTION
In accordance with the present invention a novel and useful foundation system for securing a superstructure is herein provided.
The system of the present invention utilizes a plurality of blocks, each including a top, bottom, and sidewall portion. Each of the blocks is also provided with at least a first chase extending from one place at the sidewall portion to another place at the sidewall portion of the block. In its essential condition, the foundation system of the present invention would utilize first, second, and third blocks which are disposed adjacent one another. In this condition, the chases of the first, second, and third blocks are alignable. Means is provided for compressing the first, second, and third blocks into a foundation unit with a top surface that is contiguous. The top surface is formed by the tops of the first, second, and third blocks. The compressing means may take the form of an elongated member which passes through the aligned chases of the first, second, and third blocks. Means is also included for tensioning the elongated members in this configuration to compress the blocks into a monolithic unit.
In certain cases, other blocks may be employed along side the aligned first, second, and third blocks to form larger foundation structures. In this arrangement, the first, second, and third blocks may include second chases which are angularly disposed relative to the first chases therethrough. Means is provided for compressing the lateral blocks to the first, second, and third blocks, in the same manner through the angularly disposed chases which are also alignable. Moreover, additional blocks may be used as needed to form larger and larger foundation structures in all directions, as desired.
Support means is also provided in the present invention for holding a superstructure at the top surface of the foundation unit formed by the multiplicity of compressed blocks. The support means for holding the superstructure may be placed in the foundation structure without interfering with the means for compressing the multiplicity of blocks together.
In addition, the system of the present invention utilizes interlocking means for linking the multiplicity of blocks together to form a common and contiguous top surface. Such interlocking means may take the form of protrusions and indents, generally cast into the block structures.
The blocks used in the system of the present invention may be filled with liquid or solid material (precasting) to provide the necessary mass to support the superstructure being supported at the top surface of the foundation unit formed by such blocks. For example, concrete would be a particularly useful material, in this regard.
It may be apparent that a novel and useful foundation system for securing a superstructure has been described.
It is therefore an object of the present invention to provide a foundation system for securing a superstructure which is relatively cheap to manufacture and assemble.
Another object of the present invention is to provide a foundation system for securing a superstructure which is easily manufactured under quality control conditions.
A further object of the present invention is to provide a foundation system for securing a superstructure which is not susceptible to unruly weather conditions during its manufacture.
Yet another object of the present invention is to provide a foundation system for securing a superstructure which is easily transported and assembled to particular sites, such as remote sites.
A further object of the present invention is to provide a foundation system for securing a superstructure which is versatile in size and weight to provide adequate anchoring of superstructures of various sizes.
Another object of the present invention is to provide a foundation system for securing a superstructure which requires minimal removal of material from a site and results in minimal damage to the same.
Another object of the present invention is to provide a foundation system for securing a superstructure which does not require the formation of piers.
The invention posses other objects and advantages especially as concerns particular characteristics and features, thereof, which will become apparent as the specification continues.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a typical block used in the foundation system of the present invention.
FIG. 2 is a right end view of a typical block using the foundation system of the present invention.
FIG. 3 is a top plan view of the block depicted in FIGS. 1 and 2 prior to filling with bulk material.
FIG. 4 is a sectional view showing a trio of blocks tensioned together to form a foundation unit.
FIG. 5 is a foundation structure utilizing nine blocks, each constructed similarly to the block depicted in FIGS. 1 and 2.
FIG. 6 is a sectional view showing a typical superstructure support which may be employed in the block depicted in FIGS. 1 and 2.
FIG. 7 is an enlarged sectional view taken along line 7--7 of FIG. 1.
FIG. 8 is a top plan view of yet another arrangement of blocks to support a superstructure, with the tensioning rods depicted schematically.
For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various aspects of the present invention will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the previously detailed drawings.
The invention as a whole is depicted in the drawings by reference character 10. System 10 includes as one of its elements a block 12. Block 12 may be of a rectangular solid configuration, as shown in FIGS. 1 and 2, or may take other configurations to permit the same to lie in side-by-side configuration, which will be explained in greater detail as the specification continues.
Block 12 is formed with a top 14, bottom 16, and sidewall portion 18, which extends completely around block 12. Bottom 16 is intended to sit on a ground surface 20, FIG. 4. Block 12 is typical of the multiplicity or plurality of blocks used in the system 10 of the present invention. As shown in FIGS. 1 and 2, block 12 includes chases 22, 24, 26, and 28 which pass through sidewall portion 18 at two distinct places. In addition, FIG. 2, chases 29, 30, and 32 extend through sidewall portion 18 of block 12 in another direction, generally at right angles to chases 22, 24, 26, and 28. Each of the chases, above-identified, may include a sleeve formed of pipe-like material such as polyvinyl chloride, polypropylene, metal, and the like.
With reference to FIG. 3, block 12 is illustrated in its open condition. Sleeves 34 and 36 are associated with chases 22 and 28, respectively. Also, sleeves 38, 40, and 42 are associated with chases 28, 30, and 32, respectively. Block 12 also is formed with lifting rings 44 and 46 to aid in the movement of the same, since block 12 is intended to be pre-fabricated under controlled conditions prior to transportation for use in a particular environment. Conduit 45 permits the use of cabling 46 or other wire extending from the bottom 16 of block 12 to top 14, thereof, which will be used with the eventual superstructure antenna. Reinforcing bars 52 are also employed within cavity 54 of block 12. Concrete, represented by concrete portion 56, completely fills cavity 54 in the construction of block 12. Electrical cabling blocks 59 are also utilized within block 12 and are optionally tied to reinforcing bars 52 within cavity 54.
Means 58 is also shown in the present invention for compressing a plurality of blocks, similar to block 12, together, FIG. 4. Returning again to FIGS. 1-3 it may be observed that elongated members, such as threaded rods, wire ropes and the like, shown as threaded rods 60, 62, 64, and 66, may be employed as a portion of means 58. Rods 60, 62, 64, and 66 pass through chases 29, 32, 28, and 24, respectively. It should be noted that elongated threaded rods 64 and 66 are angularly disposed relative to rods 60 and 62, and the chases associated with such rods.
It should be seen that chases 22, 26, and 30 are not being used in FIGS. 1-4, but may be employed, if desired, to accommodate other threaded rods used as a part of compressing means 58. In any case, each threaded rod shown in the drawings has an associated plate and nut which may be employed to tension rods 60, 62, 64, and 66, thus, compressing a multiplicity of blocks together. FIG. 7 depicts a detail of a typical elongated rod 60 in which plate 68 is pressed against sidewall portion 18 of block 12. Plate 68 may be precast into block 12. Nut 70 is internally threaded to threadingly engage threaded rod or elongated member 60. It should be realized that, hydraulic means may be used to tension elongated members through the chases noted above.
Turning to FIG. 4, it may be observed that blocks 72, 74, and 76 are placed against, or nested, to one another as depicted. Compressing means 58 is employed with respect to elongated members or threaded rods 78, 80, 82, 84, 86, 88, 90, 92, and others not shown. In essence, such threaded rods extend completely through blocks 72, 74, and 76. For example, chase 96 accommodates threaded rod 78 while chase 94 accommodates threaded rod 80, in this manner. The tightening of the nuts, associated with such threaded rods is depicted in FIG. 4, tensions such rods and compresses blocks 72, 74, and 76 together, forming a foundation unit 97.
In addition, interlocking means 98 is shown in FIGS. 1-4. Interlocking means 98 may take the form of a multiplicity of protrusions and indents on adjacent blocks that mate with one another. For example, block 72 includes a protrusion 100 which mates with an indent 102 on block 74. Interlocking means 98 provides a contiguous upper surface 104 on foundation unit 97, which serves as an ideal platform for superstructure 106. Returning again to block 12, FIGS. 1 and 2, it may be observed that an indent 108 and a protrusion 110 is shown thereat and constitutes part of interlocking means 98.
Turning to FIG. 5, it may be apparent that additional blocks 108, 110, 112, 114, 116, and 118 are depicted relative to block 72, 74, and 76. Compressing means 58 is partially and schematically depicted by dashed lines 120, 122, 124, and 126. It should be understood, that elongated members or threaded rods pass through each of the blocks depicted in FIG. 6 in at least two directions forming a monolithic unit 128, according to compressing means 58 heretofore described. Force arrows 130, 132, 134, and 136 generally depict the compression of the blocks depicted in FIG. 5. together into monolithic unit 128. Superstructure 106 is shown as being placed in central block 74. Corner blocks 108, 112, 114, or 118 may also serve as support for superstructure 106 on surface 104. In fact, any of the blocks depicted in FIG. 5 may support superstructure 106.
FIG. 8 shows another configuration of blocks forming a monolithic structure 140 according to the principles of the present invention. For example, blocks 142, 144, 146, and 148 may be employed in this regard. The circles shown in FIG. 8 may serve as a place for a foot or leg of a lattice type tower. Adjacent blocks 146 and 148 may be unitary and of a similar construction to block 142. Again, the tensioning rods of compressing means 58 is shown schematically by dashed lines.
Turning to FIG. 6, a typical mounting structure 150 is illustrated with respect to superstructure 106. Superstructure 106 is welded to a plate 152 which is placed on threaded rods 154 and 156. Plurality of nuts 158 and 160 adjust the height of plate 152 and, thus, superstructure 106 above top surface 162 of a monolithic unit formed by a plurality of blocks such as block 164. Plate 166 is imbedded in the concrete portion of block 164 and is clear of sleeve 168 of chase 170, as well as tensioning rod 172 thereof. Mortar or concrete mass 174 may be used to fill the space beneath plate 152. Of course, other mounting structures may be used to hold superstructure 106, such as precast pipes or tubes.
In operation, the user transports blocks, such as block 12, to a particular site for the support of superstructure 106. Superstructure 106 may take the form of an antenna, or similar item. Plurality of blocks are then assembled together as shown in FIGS. 4, 5, or 8, or in any other particular format desired. The number of blocks would depend on the mass and moment requirements associated with superstructure 106. The superstructure 106 anchor may be placed to any one of the blocks shown in FIGS. 4, 5, and 8 by suitable means such as mounting structure 150 depicted in FIG. 6. It should be noted that other methods of supporting superstructure 106 may be employed. Compression means 58 is then used to compress the plurality of blocks depicted in FIGS. 4, 5, or 8 together with the use of elongated tensioning rods and the chases formed in the plurality of blocks. Such tensioning takes place in multiple directions to form a monolithic unit in any case, typically such as the monolithic unit 128 depicted in FIG. 5. System 10 then permits the placement of superstructure 106 to mounting structure 150. System 10 is usable in various terrains and environments since each block used in any particular arrangement of the present invention is pre-fabricated under controlled conditions.
While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention. | A foundation structure for supporting a superstructure utilizing a first block and a second block, with a third block disposed between the first and second blocks. Each block includes a top, bottom, and sidewall portion, as well as an interlocking mechanism. At least one chase extends through each of the blocks. The chases are alignable with one another to permit use of an elongated member such as a rod or wire rope which passes through all of the blocks when they are placed in side-by-side orientation. The elongated members are tensioned, causing compression of the blocks into a foundation unit with a contiguous top surface. A superstructure is supported to the top surface of the foundation unit. | 7 |
FIELD OF THE INVENTION
This invention relates to the field of apparatus for extinguishing fires and more particularly a highly effective halon extinguishing apparatus having both automatic and manual operation modes.
BACKGROUND OF THE INVENTION
Present day fire extinguisher equipment suffers from several defects resulting in inferior performance and greater cost to the consumer.
First, present day fire extinguishers are often not designed to release the maximum amount of extinguishing fluid stored within the extinguisher. The extinguishing fluid is expelled through a rigid tube having an opening at the center of the lowest part of the extinguisher. While this configuration will release most of the extinguishing fluid when the extinguisher maintains an upright position, the bottom of the rigid tube loses contact with the extinguishing fluid when the extinguisher is rotated from an upright position. In the case of an extinguisher in a horizontal position, nearly half of the extinguishing fluid may remain within the extinguisher's container. Some extinguishers have been designed using a weight to bend the end of the tube toward the lowest point of the extinguisher regardless of orientation. Although this method increases the amount of extinguishing fluid released, it suffers from increased weight and cost of the fire extinguisher.
A second problem concerning the fire extinguisher, especially those using a Halon extinguishing compound, is improper dispersion of the extinguishing compound through the nozzle. Halon compound are neither gas nor liquid when discharged, but rather, miniature droplets surrounded by an atmosphere of gas. Previous discharge nozzles are ineffective, being designed for either gas or liquid.
A further problem associated with fire extinguishers is that they are generally not designed for both automatic (automatically releasing the extinguishing compound when a certain predetermined temperature is reached) and manual (releasing the extinguishing compound upon an action performed by the operator) operation. It is very desirable that an extinguisher can be used for both automatic and manual operation, without resulting in excessive cost to the consumer.
Therefore, a need has arisen for a fire extinguisher which is capable of releasing all of its extinguishing compound regardless of orientation, and is capable of either automatic or manual operation. Furthermore, a need has arisen for a nozzle which is effective in dispersing Halon extinguisher compounds.
SUMMARY OF THE INVENTION
The present invention relates to a new and improved fire extinguisher apparatus that is simple and inexpensive in construction, and which may be actuated either automatically or manually. The apparatus is particularly well suited for dispersing chemical fire extinguishing agents stored under pressure in a suitable container through a unique discharge nozzle assembly. A removable tank discharge head enables repeated filling, seals the container and mounts an internal flexible metal discharge conduit or dip tube to insure complete discharge of the liquid contents through the discharge nozzle assembly regardless of container orientation during use. To insure sufficent flexibility for proper gravity positioning, the dip tube diameter to length ratio is maintained as low as possible consistent with providing an adequate liquid discharge flow rate. The helically spiraled aluminum dip tube is screwed into a mating helix in the discharge head. Such sealing and securing fit is achieved by simultaneous forcible insertion and rotational make up of the dip tube into a complementary unthreaded cylindrical recess formed in the discharge head.
The discharge nozzle assembly includes a tubular adapter, a discharge nozzle, a movable flow closure member, a temperature sensing bulb and a holding spring. The thermal responsive bulb is mounted between the spring and closure member to provide for automatic operation or actuation by releasing the closure member of a preselected temperature. The resiliently deformable leaf spring is secured within the discharge nozzle assembly and, if desired, a hand pull cable actuation means is secured to the spring. Removal of the spring also enables release of the closure member for providing manual actuation. Such manual actuation can be remotely initiated by a pull cable without a decrease in operation reliability. The discharge nozzle is slotted to enable escape of the spring, closure member and bulb fragments after actuation to avoid any restriction on extinguishing flow.
The discharge nozzle is tailored for the most efficient discharge pattern of a Halon chemical agent, such as those sold under the trademark "HALONITE". The nozzle is provided with a converging arcuate throat openings and a frontal deflector to achieve to a highly effective vapor flow pattern of miniature droplets surrounded by a flow of an inert gas vapor atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which:
FIG. 1 is a side view, partially in section, of the fire extinguishing apparatus of the present invention;
FIG. 2 is a side view, partially in section, of the discharge nozzle assembly;
FIG. 3 is a view taken along line 3--3 of FIG. 2; and
FIG. 4 is a view taken along lines 4--4 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the present invention is best understood by referring to FIGS. 1-4 of the drawings, like numerals being usef for like and corresponding parts of the various drawings.
The fire extinguishing apparatus of the present invention, generally designated A, is illustrated in FIG. 1. The apparatus A includes a fire extinguishing fluid storage container means, designated 10, which may be operably connected by a flow conduit 12 to a discharge nozzle assembly, generally designated 14. The flow conduit 12 provides a pressurized flow path from the container means 10 to the discharge nozzle assembly 14 for delivering a quantity of a fire extinguishing fluid F to extinguish the fire. The preferred fire extinguishing fluid F is stored under pressure within the container means 10 to maintain the fluid F in a compact liquid state. The apparatus A is actuated either manually or automatically to release the liquid fluid F from the discharge nozzle assembly 14 where the liquid partially converts to a vapor to extinguish the fire in the known manner.
The container means 10 includes a metal hollow pressure vessel or tank 20 having a filling valve 22 which is operably positioned in a removable discharge head 24. The tank 20 forms an enclosed chamber 26 in which the pressurized liquid fire extinguishing fluid F is stored prior to use. A preferred fire extinguishing fluid F used with the present invention is commercially sold under the registered trademark "HALONITE" or is selected from one of the other various "HALON" products that are commercially available for this purpose from a number of sources.
Stored under pressure in the enclosed chamber 26, the bulk of these chemical fluids F remain in the compact dense liquid state providing a gas-liquid interface or liquid level L. This characteristic enables the container means 10 to be small, light in weight, and thereby portable without reducing the effective capacity of the apparatus A. The metal hollow pressure vessel 20 is formed of sufficient strength to contain the pressurized fluid F in the chamber 26 in compliance with all applicable codes.
The chamber 26 can be refilled with extinguishant through filling valve 22. Filling valve 22 is seated in valve opening 22a in discharge head 24. End cap 22b covers the exposed end of filling valve 22.
The discharge head 24 is formed with an internal flow passage 28 for enabling controlled fluid F flow from the chamber 26. The internal flow passage 28 is preferably formed by drilling intersecting inlet 28a and outlet 28b openings or holes in the discharge head 24 at right angles followed by the forming of helical threads 28c on the outlet 28b. These drilling and threading operations are relatively inexpensive and significantly reduce the cost of manufacturing the discharge head 24. The discharge head 24 is also formed with a downwardly extending sleeve projection 24b having an inner helix 24c concentrically aligned with the inlet flow passage 28a.
In order to provide for complete discharge of the pressurized liquid contents in the chamber 26, a flexible inlet dip tube 30 is provided. The inlet dip tube 30 has an upper end 30a which is forcibly secured within the inner helix 24c of sleeve projection 24b of the discharge head 24. The free open inlet end 30b of the dip tube 30 extends downwardly in the chamber 26 to a location adjacent the lower portion of the chamber 26 and substantially below liquid level L.
The dip tube 30 is preferably formed out of helically corrugated aluminum conduit to provide sufficient flexibility to enable continuous gravity positioning of the free inlet end 30b. By providing a small diameter to length ratio (tube diameter divided by tube length) of the dip tube 30 the desired gravity movement enabling flexibility is achieved without having to use a costly positioning weight on the lower end of the dip tube 30. As the pressurized fire extinguishing fluid F in the chamber 26 is maintained in the dense liquid state, the flow rate volume through the dip tube 30 is relatively low to enable the use of a slender dip tube 30. The dip tube 30 construction also prevents the pressurized gases in the upper part of the chamber 26 from escaping directly through leakage paths in the corrugated walls of the dip tube 30 caused by flexing which would render the fire extinguishing apparatus A less efficient.
The flexible aluminum conduit dip tube 30 is secured to the discharge head 24 by screwing it into the inner helix 24c of the sleeve projection 24b.
If desired, the intermediate flow conduit 12 may be eliminated and the discharge nozzle assembly 14 connected directly to the container means 10 using threads 28c. Alternatively, the flow conduit 12 may form a flow distribution network communicating with a plurality of discharge nozzle assemblies 14. It will also be understood that flow conduit 12 may be either rigid in construction or a flexible hose. The exact arrangement of the intermediate flow conduit 12, if used, will be tailored to a specific preselected situation.
As best illustrated in FIGS. 1 and 2, the discharge nozzle assembly 14 includes a tubular connecting adapter 32, a discharge nozzle 34, a biasing spring 36, a thermal bursting bulb 38 and a releasable closure member 40. The bulb 38 is of conventional temperature sensing construction for automatically rupturing or bursting at a desired temperature to release the closure member 40. The bulb 38 is positioned between the closure member 40 and spring 36 and held in that position of FIG. 2 by the resilient biasing spring 36 which helps to isolate the bulb 38 from thermal and mechanical forces for ensuring proper thermal operation of the bulb 38. Due to the automatic mode of operation provided by the bulb 38, locating the discharge nozzle assembly 14 at a location which can be protected is important. By use of conduit 12, the tank 20 need not be so located.
The tubular connecting adapter 32 is provided with an unrestricted central flow passage 32a that communicates with the flow passage 28 of the discharge head 24 directly or through conduit 12 for receiving the supply of fluid F. The outer surface 32b is provided with an external helical thread that is used to connect with either conduit 12 or threads 28c on the discharge head 24. An integral collar 32c (FIG. 2) or a conventional separate lock nut 33 (FIG. 1) may be provided for assistance and assurance in securing the adapter 32 to the discharge head 24 and discharge nozzle 34.
The releasable closure member 40 is partially received in the flow passage 32a for blocking flow of the fluid F therethrough prior to actuation. The closure member 40 is provided with an outwardly extending collar 40a which engages the adapter 32 to limit or block further movement of the member 40 within the flow passage 32a. The closure member 40 also forms an annular recess 40b in which is securely positioned a conventional sealing o-ring 42. When inserted into the flow passage 32a, the o-ring 42 is resiliently deformed to block leakage of the fluid F between the closure member 40 and the adapter 32. The pressure of the stored fluid F acting on the closure member 40 is sufficient to force or move the closure member 40 from the flow passage 32a once it is released or no longer held in the pressure sealing position of FIG. 2.
As shown in FIGS. 2 and 4, the discharge nozzle 34 is formed with a ring-like base 34a having internal helical threads 34b for securing with the outer threads 32b formed on adapter 32. Protruding or extending outwardly from the base 34a is a plurality of circumferentially spaced support extensions or fingers 34c formed by cutting or machining elongated slots 34d therebetween. The slots 34d are provided and dimensioned to enable escape of the closure member 40, o-ring 42, bulb 38 fragments thereof and the spring 36 when the apparatus is actuated to enable flow and to assist in forming the discharge flow pattern from the discharge nozzle 34. The support fingers 34c terminate in a discharge nozzle disc 34e.
Upon discharge, the spring 36 and the bulb 38 fall out of the nozzle 34. The closure member 40 is forced to the end of the nozzle 34, where it acts as a small deflector to the Halon extinguishant.
Halon, when stored under pressure, is a liquid. As it is discharged, it turns into a gas. Thus, as it is discharged rapidly, the Halon extinguishant is a combination of small droplets of liquid surrounded by an atmosphere of gas.
Prior art Halon extingusihers have used a sprinkler type head, as is used for water-based systems. Since water remains a liquid after discharge, the splash plate of a sprinkler type head is necessary to distribute the water. However, because of the gaseous aspect of Halon, the sprinkler head is not effective in distributing Halon.
The present invention allows the Halon to escape from the slots 34d in the nozzle 34 as it is released through the adaptor 32. The discharge nozzle disc 34e and closure member 40 act as deflectors to force the Halon outward, resulting in a wide distribution of Halon for more effective coverage.
The biasing leaf spring means 36 is formed of a support base 36a and a cantilevered resilient leaf 36b which are secured or fixed together at one end 36c (FIG. 3). The other end of the resilient leaf 36b engages the base 36a but is freely movable thereon to provide the desired flex. The central portion 36d of the leaf 36b is spaced from the base 36a and is indented on recess at disc portion 36e to maintain engagement with the bulb 36. The discharge nozzle disc 34e is provided with an internal support surfaces flats 34g for receiving and holding the support base 36a. The support base 36a is preferably formed with a pair of keeper projections or lugs 36f and 36g (FIG. 3) that engage both sides of the disc portion 36e of the discharge nozzle 34 when the spring is operably positioned on the flat 34g to prevent inadvertent sliding release of the biasing spring 36 from vibration or the like.
As long as the discharge nozzle assembly 14 is in the ready condition of FIG. 2, discharge flow is blocked by the closure member 40 and the fluid F contained in the chamber 26 maintained under pressure. Bursting of the bulb 38 in response to a sensed temperature will enable movement of the closure member 40 from the adapter 32 to automatically enable actuation of the apparatus A. Manual actuation is achieved in a similar manner, but by slideably removing the spring 36 with a side pull. The flex of the leaf 36b enables projection 36g to move across the support flat 34g in response to a firm pull. Preferably, the spring 36 is removed using a pull cable means arrangement.
The manual pull cable means C is partially illustrated in FIG. 3 where the attachment of one end of the movable pull cable 44 to the spring 36 is shown. The exact manner of attachment to the spring 36 is not critical as long as the spring 36 is removed from the discharge nozzle 34 to release the bulb 38 and closure member 40 to enable flow in the manner described. The other or handle release actuating end of the pull cable 44 is placed at any desired safe location for actuating the apparatus A. As illustrated in FIG. 3, an attachment strap 46 may be secured to the discharge head 24 if desired to support the manual operating pull cable 44 adjacent the tank 20.
As illustrated in FIG. 1, the pull cable mechanism C for remotely manually activating the apparatus is illustrated. A preferable form of the invention includes a stationary protective cable jacket 48 (FIG. 3) in which is positioned the movable operating cable 44. One end 44a of the operating cable is attached to the leaf spring 36 while the other or handle operating end 44b is secured to an actuating pull handle 50. Manual pull manipulation of the handle 50 will extract the spring 36 from the discharge nozzle 34 to actuate extinguishing flow. The handle 50 may be located either at the tank 10 using attachment strap 46 or remotely from any desired or convenient suitable location 46a for securing the cable jacket 48.
The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made without departing from the spirit or scope of the invention. | A fire extinguishing apparatus (A) actuated either manually or automatically for dispensing a stream of pressurized fire extinguishing fluid (F) in a preferred pattern. The apparatus includes a storage tank (10) for the extinguishing medium which is operably connected with a discharge nozzle assembly (14). A conventional flexible dip tube (30) is secured within the tank in a novel manner to insure complete discharge of the tank contents which is preferably selected from various Halon agents. The discharge nozzle assembly (14) is sealed by a closure member (40) which is held in the discharge blocking position by a temperature sensitive bulb (38) and a leaf spring (36). Operation of the temperature sensitive bulb (38) enables automatic extinguisher operation which manual actuation removes the leaf spring. Either actuation releases the closure member to effect operation. The extinguishing fluid is released through slots (34d) on the sides of the nozzle (34). | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part application of International Application No. PCT/CN2012/073661 filed Apr. 9, 2012, which was published in the Chinese language on Dec. 6, 2012, under International Publication No. WO 2012/163179 A1, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to the field of pharmaceutical chemistry and chemotherapy. Specifically, the present invention relates to a hexahydro-dibenzo[a,g]quinolizine compound (I) with novel structure and derivatives, preparation method thereof, pharmaceutical composition and use thereof for the preparation of medicaments for treating neurological diseases relating to dopamine receptor and serotonin receptor, in particular Parkinson's disease, schizophrenia, drug addiction, migraine headaches and the like.
BACKGROUND ART
[0003] Nervous system disease is one of prevalent diseases in contemporary society. However, many types of nervous system diseases have not yet been effectively addressed in clinical practice. In particular, the treatments for neurological diseases such as schizophrenia, Parkinson's disease and the like are still very far from achieving satisfactory results. In recent years, studies have shown that schizophrenia is considered as the result of D 1 receptor dysfunction of medial prefrontal cortex (mPFC) and thus enhancing the activity of D 2 receptor of the ventral tegmental area (VTA) and the nucleus accumbens region (NAc). By carrying out working memory experiments for animals and patients, short-term experiments reflecting the function of medial prefrontal cortex and clinical trials, scientists have demonstrated that the inactivation of D 1 receptor is related to the negative symptoms of schizophrenia and high activity of D 2 receptor generates the positive symptoms. Based on such hypothesis, if a class of medicaments can effectively excite the activity of D 1 receptor, and antagonize activity of D 2 receptor in the meantime, such medicaments should have good prospects for the treatment of schizophrenia.
[0004] Parkinson's disease is a chronic progressive degenerative diseases with brain dopaminergic neuron loss as main feature. For a long time, L-Dopamine is a “gold standard” for the treatment of Parkinson's disease. However, long-term administration of L-Dopamine is often accompanied by high incidence of treatment-related complications, such as dyskinesias, efficacy loss and “on-off” phenomenon and the like, which are named as “L-Dopamine long-term syndrome” and can not delay disease progression.
[0005] DA receptor agonist is one of various substitutive therapies for Parkinson's disease and mainly used with L-Dopamine in Parkinson patients having dyskinesia. DA receptor agonist is superior to L-Dopamine, the mechanism of which is that in the later stages of Parkinson's disease, dopamine decarboxylase activity of the nigrostriatal DA system is depleted, therefore, exogenous L-Dopamine can not be transformed into DA through decarboxylation, and at that time, even a large dose of L-Dopamine preparations is ineffective; however, the function of DA receptor agonist is irrelevant to DA synthesis and does not depend on the activity of dopa decarboxylase, the molecular conformation thereof is similar to that of DA, DA receptor agonist works by directly acting on striatal synaptic DA receptor, primarily D 1 receptor, in part on D 2 receptors; therefore, the combination of DA receptor agonist can further improve motor symptoms of Parkinson's disease. Based on such theory, if D 1 receptor agonist with selectivity can be developed, it is possible to provide a class of medicaments with good effect for the treatment of Parkinson's disease. Currently, some companies have developed various D 1 receptor selective agonists with selectivity, many of which have been studied in clinical trail, but many medicament candidates have low selectivity and obvious side effect. Therefore, the development of D 1 receptor selective agonist with high selectivity and little side effect will undoubtedly have huge advantages for the treatment of Parkinson's disease.
[0006] The hexahydrodibenzo[a,g]quinolizine compounds are a class of alkaloids extracted from traditional Chinese medicine Corydalis Tuber and Stephania genus plants, which have a common chemical nucleus containing two-isoquinoline structure and having —OCH 3 in C 2 , C 3 , C 9 , and C 10 or substituted by —OH. Such alkaloids have various biological activities, including anti-inflammatory effect, antibacterial effect, anti-leukemia effect, anti-cancer effect and so on. Academician Jin GuoZhang, et al. have systematically studied the pharmacological effects of hexahydrodibenzo[a,g]quinolizine compounds and demonstrated that levorotatory tetrahydropalmatine has good analgesic effect accompanied by sedation, tranquillizing effect and hypnotic effect, while dextrorotatory tetrahydropalmatine has no significant analgesic effect. It is also demonstrated that the target of levorotatory tetrahydropalmatine or other hexahydrodibenzo[a,g]quinolizine alkaloids is dopamine receptor. Jin Guozhang has also reported for the first time that l-Stepholidine (l-SPD), one of hexahydrodibenzo[a,g]quinolizine compounds (THPBs), is a lead compound with the dual role of D 1 agonist and D 2 antagonistic activity (Jin G Z. TIPS, 2002, 23-24). l-SPD, in clinical trials, has shown good therapeutic effects on positive and negative symptoms and has non-classical stabilizer features, and can be likely developed into a new class of antipsychotic medicaments. Shen Jingshan, Yang Yushe et al. disclosed a preparation method and use of l-SPD derivatives and levorotatory Chloroscoulerine with antipsychotic effect, wherein Scoulerine methanesulfonate has good water solubility and stability (WO2008/014661, CN03151464, and CN1900076). However, the structures of these compounds are not greatly modified, most of the compounds have weak activity on D 2 receptor, and many compounds have no 5-HT activity, poor solubility and low bioavailability. Meanwhile, these compounds showed a certain degree of selectivity in D 1 receptor vs D 2 receptor. Therefore, it is significant to continually modify hexahydrodibenzo[a,g]quinolizine compounds, especially to develop compounds with better D 2 activity or develop D 1 receptor agonists with better selectivity, thereby providing beneficial help for treating Parkinson's disease.
[0007] The present invention provides the synthesis and use of a class of hexahydro-dibenzo[a,g]quinoline compounds with novel structures. Some compounds with such structures show good selectivity in D 1 vs D 2 wherein many compounds also have 5-HT activity. Other compounds have dual pharmacological activities of good D 1 agonist and D 2 antagonist and good solubility, and can be used in the preparation of the medicaments for treating neurological diseases, especially dopamine receptors and serotonin receptor-associated neurological disease.
SUMMARY OF THE INVENTION
[0008] One object of the present invention is to provide a hexahydrodibenzo[a,g]quinoline compound of general formula (I), enantiomer, diastereoisomer, racemate and mixtures thereof, the pharmaceutically acceptable organic salt or inorganic salt, crystalline hydrate and solvate thereof.
[0009] Another object of the present invention is to provide a preparation method for the compound of general formula (I).
[0010] Another object of the present invention is to provide a pharmaceutical composition containing the compound of general formula (I), enantiomer, diastereomer, racemate and mixtures thereof, the pharmaceutically acceptable organic salt or inorganic salt, crystalline hydrate and solvate thereof.
[0011] A further object of the present invention is to provide a use of the compound of general formula (I) in the preparation of medicaments for treating the diseases relating to dopamine receptors and serotonin receptors.
[0012] Based on above objects, the invention relates to a hexahydrodibenzo[a,g]quinoline compound of general formula (I), enantiomer, diastereoisomer, racemate and mixtures thereof, the pharmaceutically acceptable organic salt or inorganic salt, crystalline hydrate and solvate thereof,
[0000]
[0013] wherein R 2 is a hydroxy, a hydroxy-substituted C1-C6 alkyl, a substituted or unsubstituted C1-C6 alkoxy, a halogen, a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C2-C6 alkenyl, a substituted or unsubstituted C2-C6 alkynyl, a substituted or unsubstituted C3-C6 cycloalkyl, a substituted or unsubstituted C1-C6 alkanoyl, a substituted or unsubstituted C6-C20 aryl, a substituted or unsubstituted benzyl, an amino acid or N-protected amino acid, or —(CO) R 9 ;
[0014] when R 2 is a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C1-C6 alkoxy, a substituted or unsubstituted C2-C6 alkenyl, a substituted or unsubstituted C2-C6 alkynyl, or a substituted or unsubstituted C3-C6 cycloalkyl, a substituent for substitution can be a halogen or COOR 10 ;
[0015] when R 2 is a substituted or unsubstituted C1-C6 alkanoyl, a substituted or unsubstituted C6-C20 aryl, or a substituted or unsubstituted benzyl, a substituent for substitution can be selected from the following group: C1-C6 alkyl, a halogen, and C1-C6 alkoxy;
[0016] wherein R 9 is a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C2-C6 alkenyl, a substituted or unsubstituted C2-C6 alkynyl, a substituted or unsubstituted C6-C20 aryl, or heteroaryl selected from thiazolyl, pyrazolyl, imidazolyl, thienyl, furyl, pyrrolyl, or pyridyl;
[0017] when R 9 is a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C2-C6 alkenyl, or a substituted or unsubstituted C2-C6 alkynyl, a substituent for substitution can be a carboxyl, a substituted or unsubstituted C6-C20 aryl, or heteroaryl selected from thiazolyl, pyrazolyl, imidazolyl, thienyl, furyl, pyrrolyl, or pyridy;
[0018] when R 9 is a substituted or unsubstituted C6-C20 aryl, a substituent for substitution can be a C1-C6 alkyl, a halogen or a C1-C6 alkoxy;
[0019] R 10 is H, a C6-C20 alkyl substituted or unsubstituted C1-C6 alkyl, a C2-C6 alkenyl, or a C2-C6 alkynyl;
[0020] when R 2 is an amino acid or N-protected amino acid, the amino acid can be D-amino acid, L-amino acid or racemate;
[0021] each of R 3 , R 4 is independently H, a halogen substituted or unsubstituted C1-C6 alkyl, a halogen substituted or unsubstituted C1-C6 alkoxy, a C2-C6 alkenyl, a C2-C6 alkynyl, a halogen, COOR 11 , or CONR 12 R 13 , wherein R 11 is H, a substituted or unsubstituted C1-C6 alkyl, a C2-C6 alkenyl, a C2-C6 alkynyl, a substituted or unsubstituted C6-C20 aryl, or a substituted or unsubstituted benzyl;
[0022] when R 11 is a substituted or unsubstituted C6-C20 aryl, or a substituted or unsubstituted benzyl, a substituent for substitution can be a C1-C6 alkyl, a halogen or a C1-C6 alkoxy;
[0023] when R 11 is a substituted or unsubstituted C1-C6 alkyl, a substituent for substitution can be a halogen; each of R 13 , R 12 is independently selected from H, or a substituted or unsubstituted C1-C6 alkyl, or they and nitrogen atom together form azetidine, pyrrolidinyl, piperazinyl, or morpholinyl; when R 13 or R 12 is a substituted or unsubstituted C1-C6 alkyl, a substituent for substitution can be a halogen;
[0024] each of R 1 , R 5 , R 6 , R 7 , R 8 is independently H, a hydroxy, a hydroxy-substituted C1-C6 alkyl, a halogen-substituted or unsubstituted C1-C6 alkyl, a halogen substituted or unsubstituted C1-C6 alkoxy, a halogen, a C3-C6 cycloalkyl, a halogen substituted or unsubstituted C2-C6 alkenyloxy, a halogen-substituted or unsubstituted C3-C6 alkynyloxy, a substituted or unsubstituted benzyloxy, a substituted or unsubstituted C6-C20 aryl, R 14 COO—, R 15 R 16 N—; when R 1 , R 5 , R 6 , R 7 , or R 8 is a substituted or unsubstituted benzyloxy, or a substituted or unsubstituted C6-C20 aryl, a substituent for substitution can be a C1-C6 alkyl, a halogen, or a C1-C6 alkoxy; wherein R 14 is H, a halogen-substituted or unsubstituted C1-C6 alkyl; each of R 15 and R 16 is independently selected from H, a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C2-C6 alkenyl, or a substituted or unsubstituted C2-C6 alkynyl, or they and nitrogen atom together form azetidine, pyrrolidinyl, piperazinyl, or morpholinyl; when R 15 or R 16 is a substituted or unsubstituted C1-C6 alkyl, a substituted or unsubstituted C2-C6 alkenyl, a substituted or unsubstituted C2-C6 alkynyl, a substituent for substitution can be a C1-C6 alkyl, a halogen or a C1-C6 alkoxy;
[0025] R 1 and R 2 can together form a substituted or unsubstituted 5-7 membered heterocycle, wherein a substituent for substitution can be a halogen, or a halogen-substituted or unsubstituted C1-C6 alkyl, C2-C6 alkenyl, or C2-C6 alkynyl; and the heterocycle contains 1-3 heteroatom(s) selected from N, O or S;
[0026] any two adjacent substituents of R 5 , R 6 , R 7 and R 8 can together form a substituted or unsubstituted 5-7 membered heterocycle, wherein a substituent for substitution can be a halogen, or a halogen-substituted or unsubstituted C1-C6 alkyl, C2-C6 alkenyl, or C2-C6 alkynyl; and the heterocycle contains 1-3 heteroatom(s) selected from N, O or S;
[0027] and the configuration of chiral carbon atom in the compound of general formula (I) is R or S configuration.
[0028] Preferably, with the proviso that when the compound of general formula (I) is racemate, the following conditions should be fulfilled:
[0029] (a) when R 2 is methoxyl, R 3 is H, R 4 is H or methyl, and at least one of R 5 , R 6 , R 7 , and R 8 is methoxyl or R 6 and R 7 together form —O—CH 2 —O—, R 1 can not be H, methoxyl or BnO;
[0030] (b) when R 1 and R 2 together form —O—CH 2 —O—, and R 7 or R 8 is methoxyl, R 5 can not be methoxyl;
[0031] (c) when R 6 and R 7 together form —O—CH 2 —O— and R 5 and R 8 are H, R 2 can not be methoxyl and R 1 and R 2 can not together form —O—CH 2 —O—; and
[0032] (d) the compound of general formula (I) is not DC037027,
[0000]
[0033] Preferably, in the compound, R 1 is H, a halogen-substituted or unsubstituted C1-C6 alkyl, a halogen-substituted or unsubstituted C1-C6 alkoxy, a hydroxy, a hydroxy-substituted C1-C6 alkyl or a halogen-substituted or unsubstituted benzyloxy; R 2 is a hydroxy, a hydroxy-substituted C1-C6 alkyl, a halogen substituted or unsubstituted C1-C6 alkyl, or a halogen substituted or unsubstituted C1-C6 alkoxy, or a halogen; R 3 is H, or a halogen substituted or unsubstituted C1-C6 alkyl; R 4 is H, a halogen substituted or unsubstituted C1-C6 alkyl, or a halogen substituted or unsubstituted C1-C6 alkoxy; R 5 is H, a halogen substituted or unsubstituted C1-C6 alkyl, a halogen substituted or unsubstituted C1-C6 alkoxy or a halogen; R 6 is H, a halogen-substituted or unsubstituted C1-C6 alkyl, a halogen-substituted or unsubstituted C1-C6 alkoxy, a hydroxy, or a hydroxy-substituted C1-C6 alkyl; R 7 is H, a halogen-substituted or unsubstituted C1-C6 alkyl, a halogen-substituted or unsubstituted C1-C6 alkoxy, a hydroxy, or a hydroxy-substituted C1-C6 alkyl; R 8 is H, a hydroxy, a hydroxy-substituted C1-C6 alkyl, a halogen-substituted or unsubstituted C1-C6 alkoxy, a halogen-substituted or unsubstituted C1-C6 alkyl or a halogen;
[0034] or R 1 and R 2 can together form a C1-C6 alkyl-substituted or unsubstituted 5-7 membered heterocycle, and the heterocycle contains 1-2 heteroatom(s) selected from N, O or S;
[0035] R 6 and R 7 can together form a fluoro-, chloro- or bromo-substituted 5-7 membered heterocycle, and the heterocycle contains 1-2 heteroatom(s) selected from N, O or S.
[0036] More preferably, R 1 is H, a C1-C6 alkyl, a C1-C6 alkoxy, a hydroxy, a hydroxy-substituted C1-C6 alkyl or benzyloxy; R 2 is a hydroxy, a hydroxy-substituted C1-C6 alkyl, a C1-C6 alkyl, a C1-C6 alkoxy or a halogen; R 3 is H or a C1-C6 alkyl; R 4 is H, a C1-C6 alkyl, or a C1-C6 alkoxy; R 5 is H, a C1-C6 alkyl, a C1-C6 alkoxy or a halogen; R 6 is H, a C1-C6 alkyl, a C1-C6 alkoxy, a hydroxy, or a hydroxy-substituted C1-C6 alkyl; R 7 is H, a C1-C6 alkyl, a C1-C6 alkoxy, a hydroxy, or a hydroxy-substituted C1-C6 alkyl; R 8 is H, a hydroxy, a hydroxy-substituted C1-C6 alkyl, a C1-C6 alkoxy, a C1-C6 alkyl or a halogen; the halogen is F, Br or Cl;
[0037] R 1 and R 2 can together form a C1-C6 alkyl-substituted or unsubstituted 5- or 6-membered heterocycle, and the heterocycle contains 1-2 heteroatom(s) selected from N, O or S;
[0038] R 6 and R 7 can together form a fluoro-, chloro- or bromo-substituted or unsubstituted 5- or 6-membered heterocycle, and the heterocycle contains 1-2 heteroatom(s) selected from N, O or S.
[0039] In another preferable embodiment, the configuration of chiral C atom which is not linked with R 3 or R 4 in the parent nucleus of compound of general formula (I) is S.
[0040] In another preferable embodiment, the configuration of chiral C atom which is not linked with R 3 or R 4 in the parent nucleus of compound of general formula (I) is R.
[0041] In another preferable embodiment, the compound of general formula (I) is chiral compound.
[0042] In another preferable embodiment, R 5 is methoxyl, and R 6 is hydroxyl.
[0043] In another preferable embodiment, R 3 is a halogen substituted or unsubstituted C1-C6 alkyl, a halogen substituted or unsubstituted C1-C6 alkoxy, a C2-C6 alkenyl, a C2-C6 alkynyl, a halogen, COOR 11 , or CONR 12 R 13 , i.e. R 3 is not H.
[0044] In another preferable embodiment, R 8 is a hydroxy-substituted C1-C6 alkyl, or a halogen.
[0045] In another preferable embodiment, one to four of R 5 , R 6 , R 7 , and R 8 is a hydroxy-substituted C1-C6 alkyl or C1-C6 alkyl.
[0046] Most preferably, the hexahydrodibenzo[a,g]quinoline compound according to the invention, enantiomer, diastereoisomer and racemate thereof are selected from the following compounds:
[0000]
[0047] The “pharmaceutically acceptable organic salt or inorganic salt” is a slat formed from the reaction of the compound of general formula (I) with inorganic acid, such as hydrochloric acid, hydrobromic acid, hydroiodic acid, hydrofluoric acid, sulfuric acid, nitric acid or phosphoric acid and the like, or with organic acid, such as formic acid, acetic acid, propionic acid, oxalic acid, malonic acid, maleic acid, tartaric acid, malic acid, fumaric acid, methanesulfonic acid, citric acid, ethanesulfonic acid, benzenesulfonic acid, citric acid, lactic acid, aspartic acid or glutamic acid and the like, or a sodium, potassium, calcium or ammonium salt which is formed from the reaction of the compound of general formula (I) with alkali, such as sodium hydroxide, potassium hydroxide, calcium hydroxide or ammonia.
[0048] The present invention also provides a preparation method for the compound of general formula (I) and intermediates thereof. The raw materials and reagents used in the present invention are commercially available unless otherwise specified.
[0049] Wherein, R1-R4 and R8 are defined as above. When each of R5 and R6 is independently a halogen-substituted or unsubstituted C1-C6 alkoxy, a substituted or unsubstituted benzyloxy (a substituent for substitution is a C1-C6 alkyl, a halogen or a C1-C6 alkoxy), and R7 is H; or when R5 is a halogen-substituted or unsubstituted C1-C6 alkoxy, a substituted or unsubstituted benzyloxy (a substituent is a C1-C6 alkyl, a halogen or a C1-C6 alkoxy), R6 is a hydroxy, and R7 is H, the compounds of general formula (I), including compounds DC037051, DC037052, DC037073, DC037074, DC037081, DC037082 and DC037083, are prepared according to the second reaction route; other compounds of general formula (I) are prepared according to the first reaction route.
[0050] The first reaction route:
[0000]
[0051] Reagents and reaction conditions: a) acetic acid, nitromethane, ammonium acetate, 80° C.; b) lithium aluminum hydride, anhydrous tetrahydrofuran, reflux; c) ammonium formate, anhydrous methanol, palladium carbon, hydrogen, room temperature; d) 1-ethyl-3-(3-dimethylpropylamine) carbodiimide, anhydrous dichloromethane, triethylamine, room temperature; e) nitrogen protection, phosphorus oxychloride, acetonitrile, reflux; and f) catalyst (Noyori), N, N-dimethylformamide, triethylamine/formic acid or sodium borohydride; g) aldehyde, acid conditions.
[0052] The preparation method according to the first reaction route is described in detail as follows.
[0053] The preparation of Compound 2a: 10 mmol of substrate (1a, purchased from Alpha Aisha Company) is dissolved in an appropriate amount of glacial acetic acid, to which 1.2-2.0 equivalent of ammonium acetate is added to form a mixture. At room temperature, 5-10 equivalent of nitromethane is added to the mixture and reacted in an 80° C. oil bath for 10 hours. Then the reaction system is cooled to room temperature and a large amount of solid is precipitated. After filtered, Compound 2a is obtained.
[0054] The preparation of Compound 3a: 20 mmol of lithium aluminum hydride is suspended in an appropriate amount of anhydrous tetrahydrofuran and placed in an ice water bath. And a solution of unsaturated nitro-compound (2a) in anhydrous tetrahydrofuran is slowly added dropwise. After the addition is completed, the reaction solution is transferred into an oil bath, refluxed for 3 hours, and then cooled to room temperature. The defined amount of water is added slowly and a clear solution is obtained by filtration. After dried over anhydrous sodium sulfate and evaporated to dryness, an oily Compound 3a is obtained.
[0055] The preparation of Compound 5a: 10 mmol of substrate (4a, purchased from Sigma-Aldrich Company) is dissolved in an appropriate amount of anhydrous methanol, and 1.5-3.0 equivalent of ammonium formate is added. 10% palladium carbon is added under stirring and hydrogen is ventilated at the same time. The reaction is carried out at room temperature overnight. After the palladium carbon is removed by filtration, the solution is evaporated to dryness to give an oily Compound 5a.
[0056] The preparation of Compound 6a: at room temperature, substrate 3a or 5a is condensed with R5-, R6-, R7-, and R8-substituted phenylacetic acid in the presence of 1-ethyl-3(3-dimethyl-propylamine) carbodiimide or triethylamine, and anhydrous dichloromethane. The product is purified by column chromatography or recrystallized by using ethanol to give Compound 6a with high yield.
[0057] The preparation of Compound 7a: under N 2 , substrate 6a in acetonitrile used as solvent is refluxed under the action of phosphorus oxychloride to obtain Compound 7a with high yield. For compound 7a, further purification is not necessary, the operation is simple and the reaction is quick.
[0058] The preparation of Compound 8a: Compound 7a can be reduced by using sodium borohydride to form racemic Compound 8a, if necessary. The chiral reducing reagent, such as catalyst (Noyori, J. Am. Chem. Soc. 1996, 118, 4916-4917), N,N-dimethylformamide, triethylamine/formic acid, can also be used to carry out the asymmetric reduction reaction, thereby obtaining Compound 8a with a single configuration.
[0059] The preparation of Compound 9a: the intermediate Compound 8a is reacted with aldehyde under acidic condition to obtain Compound 9a with satisfactory yield and selectivity.
[0060] The second reaction route:
[0000]
[0061] Wherein, R9′ is a C1-C6 alkyl, R5′ is a halogen-substituted or unsubstituted C1-C6 alkyl, or a substituted or unsubstituted benzyl, R6′ is a halogen-substituted or unsubstituted C1-C6 alkyl, or a substituted or unsubstituted benzyl, wherein a substituent for substitution can be a C1-C6 alkyl, a halogen or a C1-C6 alkoxy.
[0062] Reaction reagents and conditions: a) room temperature, acetic acid, liquid bromine; b) alkylating reagent/benzylating reagent, solvent, organic alkali/inorganic alkali; c) catalyst containing copper or copper ion, alkaline condition, water, 90° C. to 150° C. of reaction temperature, pH 1-3; d) phenylboronic acid, toluene, paraformaldehyde and water; e) solvent, alkylating reagent/benzylating reagent, organic alkali/inorganic alkali; f) nitrating reagent; g) phenethylamine containing at least one electron-donating substituent, ethanol, reflux; h) solvent, acylating reagent, inorganic/organic alkali; i) solvent, condensing agent; j) sodium borohydride, sodium cyanoborohydride or sodium acetoxy borohydride/catalyst (Noyori), N, N-dimethylbenzamide, triethylamine and formic acid; k) solvent, inorganic alkali; l) solvent, halogenating reagent, organic/inorganic alkali; m) reflux, concentrated hydrochloric acid, ethanol/BCl 3 , dichloromethane.
[0063] The preparation method according to the second reaction route is described in detail as follows.
[0064] The preparation of Compound 10a: at room temperature, Compound 1b (purchased from Accela ChemBio Co., Ltd.) is reacted with liquid bromine. The reaction is finished in 1 to 2 hours. The product is poorly dissolved in acetic acid. The post-processing is simple so that pure product Compound 10a can be obtained conveniently.
[0065] The preparation of Compound 11a: in an appropriate solvent, Compound 10a is reacted with an alkylating reagent (such as dimethyl sulfate, methyl iodide, diazomethane, methyl trifluoromethanesulfonate or other alkylating reagent) or a benzylating reagent (such as substituted benzyl chloride, benzyl bromide or other benzylating reagent) under the action of organic/inorganic alkali to obtain Compound 11a. Said solvent is selected from the following group: methanol, ethanol, acetone, N, N-dimethylformamide, dimethyl sulfoxide, tetrahydrofuran, dichloromethane, chloroform, dioxane, preferably, acetone, tetrahydrofuran, and N, N-dimethyl formamide. Said inorganic alkali is selected from the following group: sodium hydroxide, potassium hydroxide, cesium hydroxide, barium hydroxide, potassium hydride, sodium hydride, sodium tert-butoxide, potassium tert-butoxide, potassium carbonate, sodium carbonate and calcium carbonate. Said organic alkali is selected from triethylamine, diisopropylethylamine, pyridine, N, N-dimethylaniline, N, N-dimethyl-pyridine. The benzyl chloride, benzyl bromide, methyl iodide, dimethyl sulfate and potassium carbonate are preferable.
[0066] The preparation of Compound 12a: a catalyst used in the reaction is relatively inexpensive and can be one or two of the following: copper sulfate, copper oxide, copper powder, copper chloride, copper bromide, copper iodide, copper carbonate, copper nitrate, copper hydroxide and the like, preferably, one or the combination of two of copper sulfate, copper oxide, and copper powder. The reaction is conducted in the presence of alkali, such as sodium hydroxide, potassium hydroxide, cesium hydroxide, calcium hydroxide, barium hydroxide or quaternary ammonium hydroxide, preferably, sodium hydroxide, potassium hydroxide, or cesium hydroxide. The reaction can be (but not necessarily) finished with the help of microwave. The reaction temperature is between 90° C. and 150° C. The method is very effective for preparing phenolic hydroxyl group. Relatively pure Compound 12a can be obtained by adjusting the pH value of reaction mixture to 1-3 after the reaction is finished. If further purification is necessary, recrystallization can be carried out by using one or mixed solvent of two of the following solvents: ethyl acetate, n-hexane, benzene, toluene, petroleum ether, ethanol, isopropyl alcohol, methanol, chloroform, xylene, preferably, benzene, toluene, xylene.
[0067] The preparation of Compound 13a: referring to Richard J. Spangler, Brian G. Beckmann, Jong Ho Kim. J. org. chem., 1977, 42, 2989-2996. Mark Cushman, Frederick W. Dekow. J. org. chem., 1979, 44, 407-409. 2.0-3.0 equivalent of phenylboronic acid is refluxed in toluene for 1 hour, and then paraformaldehyde is added and reacted in toluene at the temperature of 100° C. for 46 hours. The solvent is evaporated and the reaction is conducted in water for 2 hours. Then the reaction mixture is extracted with dichloromethane. Then the extract liquid is dried over sodium sulfate and the solvent is evaporated. After stirred in diethyl ether for 3 hours, Compound 13a is obtained by filtration.
[0068] The preparation of Compound 14a: in an appropriate solvent, Compound 13a is reacted with an alkylating reagent (such as dimethyl sulfate, methyl iodide, diazomethane, methyl trifluoromethanesulfonate or other alkylating reagent), an acylating reagent (acetyl chloride, acetic anhydride, benzoyl chloride, trifluoroacetic acid anhydride) or a benzylating reagent (such as substituted benzyl chloride, benzyl bromide or other benzylating reagent) under the action of organic/inorganic alkali to obtain Compound 14a. Said solvent is selected from the following group: methanol, ethanol, acetone, N, N-dimethylformamide, dimethyl sulfoxide, tetrahydrofuran, dichloromethane, chloroform, dioxane, preferably, acetone, tetrahydrofuran, and N, N-dimethyl formamide. Said inorganic alkali is selected from the following group: sodium hydroxide, potassium hydroxide, cesium hydroxide, barium hydroxide, potassium hydride, sodium hydride, sodium tert-butoxide, potassium tert-butoxide, potassium carbonate, sodium carbonate and calcium carbonate. Said organic alkali is selected from triethylamine, diisopropylethylamine, pyridine, N,N-dimethylaniline, N,N-dimethyl-pyridine. The benzyl chloride, benzyl bromide, methyl iodide, dimethyl sulfate and potassium carbonate, acetyl chloride, and acetic anhydride are preferable.
[0069] The preparation of Compound 15a: under the action of conventional nitrating reagent, Compound 15a (nitration product) is obtained from Compound 14a. The reaction temperature is between 0° C. and 25° C., and the reaction time is 10 minutes to 12 hours. Said nitrating reagent can be a mixture of concentrated sulfuric acid and nitric acid, a mixture of nitric acid, concentrated sulfuric acid and sodium nitrate, a mixture of concentrated sulfuric acid and potassium nitrate, a mixture of concentrated sulfuric acid and sodium nitrite, a mixture of acetic acid and concentrated nitric acid and the like, with the mixture of acetic acid and concentrated nitric acid being preferred. The mixing ratio is not particularly limited.
[0070] The preparation of Compound 16a: referring to Mark Cushman, Frederick W. Dekow. J. org. chem., 1979, 44, 407-409. 10 mmol of Compound 15a with the same equivalent of amine are added to an appropriate amount of ethanol and refluxed overnight. The solvent is evaporated, and the crude product is recrystallized by using a suitable solvent. The solvent for recrystallization is selected from one or two of the followings: ethyl acetate, n-hexane, benzene, toluene, petroleum ether, ethanol, isopropanol, methanol, chloroform, and xylene, preferably, toluene, xylene and ethanol.
[0071] The preparation of Compound 17a: 6 mmol of Compound 16a is dissolved in 20 mL of suitable solvent and 9 mmol of organic/inorganic alkali is added. 9 mmol of acylating agent is slowly added at 0° C. Then the reaction is performed at room temperature for one hour and appropriate amount of water is added. The reaction mixture is extracted for three times with dichloromethane and dichloromethane layer is washed with saturated saline solution. The extract liquid is dried over sodium sulfate to and evaporated to dryness, thereby obtaining Compound 17a. Compound 17a can be directly used in the next reaction without further purification. Said acylating agent can be, such as acetic anhydride, acetyl chloride, trifluoroacetic anhydride, trichloroacetic anhydride, methyl chloroformate, ethyl chloroformate, etc. Said organic alkali can be, such as triethylamine, diisopropyl ethylamine, pyridine, N, N-dimethylaniline, N, N-dimethyl pyridine, etc. And said inorganic alkali can be, such as potassium carbonate, sodium carbonate, sodium bicarbonate, potassium bicarbonate, sodium hydroxide and potassium hydroxide etc. Preferably, said acylating agent is acetic anhydride, acetyl chloride, said organic base is triethylamine, pyridine, diisopropylethylamine, and said solvent is dichloromethane, tetrahydrofuran, diethyl ether, toluene etc.
[0072] The preparation of Compound 18a: 5 mmol of Compound 17a is dissolved in an appropriate amount of suitable solvent and heated to reflux. 30 mmol of condensing reagent is added to the reaction solution. The reaction is monitored by TLC. Most of solvent is evaporated, and the reaction solution is neutralized with saturated sodium bicarbonate, extracted for three times with dichloromethane, dried over sodium sulfate and evaporated to dryness. The product is directly used in the next reaction without further purification. The suitable solvent can be anhydrous acetonitrile, anhydrous toluene, benzene and the like, and the condensing reagent can be phosphorus oxychloride, phosphorus oxybromide, phosphorus pentoxide and the like, wherein said condensing reagent is preferably phosphorus oxychloride, and said solvent is preferably anhydrous acetonitrile.
[0073] The preparation of Compound 19a: The imine Compound 18a obtained above is asymmetrically reduced by using Noyori catalyst in anhydrous N,N-dimethylformamide in the presence of triethylamine and formic acid to obtain chiral amine 19a. The reaction is carried out at room temperature for 7 to 12 hours. After the reaction is finished, the reaction solution is neutralized with saturated aqueous sodium bicarbonate solution, extracted with ethyl acetate, and dried over sodium sulfate. In addition, the achirality reduction can also be conducted by using sodium borohydride, sodium cyanoborohydride or sodium acetoxy borohydride.
[0074] The preparation of Compound 20a: 3 mmoL of Compound 19a is dissolved in a suitable solvent and an appropriate amount of inorganic alkali is added to the above solution. The reaction is conducted at room temperature for 3 hours and solid precipitates. The precipitate is filtered and dried, thereby obtaining the target Compound 20a. Said inorganic alkali can be sodium hydroxide, potassium hydroxide, cesium hydroxide or potassium carbonate, and the like, preferably, sodium hydroxide. The solvent may be a mixture of water and one of ethanol, methanol, N, N-dimethylformamide, preferably, a mixture of water and ethanol or methanol.
[0075] The preparation of Compound 21a: in a suitable solvent, Compound 20a can be halogenated with a halogenating agent under alkaline condition, and then the product 21a is obtained through ring-closing reaction. Said halogenating agent is thionyl chloride, thionyl bromide, phosphorus trichloride, phosphorus tribromide, phosphorus pentachloride, phosphorus pentabromide, and the like. The solvent is dichloromethane, tetrahydrofuran, diethyl ether, chloroform and the like. Said alkali is an organic alkali or an inorganic alkali, wherein the organic alkali is preferably triethylamine, pyridine, diisopropylethylamine, and the inorganic alkali is preferably potassium carbonate, sodium carbonate, sodium bicarbonate, potassium bicarbonate, sodium hydroxide, potassium hydroxide, calcium carbonate, ammonia, etc.
[0076] The preparation of Compound 22a: Compound 21a is dissolved in ethanol and concentrated hydrochloric acid is added to reflux or BCl 3 and dichloromethane is added to reflux at low temperature in order to remove R6′ protective group for giving Compound 22a. Preferably, ethanol or concentrated hydrochloric acid is used to remove R6′ protective group.
[0077] Further, the inventors have found that the compound of general formula (I) has excellent D 1 receptor selectivity and 5-HT receptor activity through experiments. The compounds of the invention can be used for the preparation of medicament used in experiment model relating to dopamine receptor and 5-HT receptor or for the preparation of medicament for treating and preventing the diseases relating to dopamine receptor and 5-HT receptor.
[0078] The invention also provides a pharmaceutical composition which comprises a therapeutically effective amount of the compound of general formula (I), enantiomer, diastereomer, racemate and mixtures thereof, or a pharmaceutically acceptable salt thereof and one or more pharmaceutically acceptable carriers. The pharmaceutical composition may further include conventional additives, such as odorant, flavoring agent and so on.
[0079] The pharmaceutical composition provided in the invention contains preferably 1-99% of the compound of general formula (I) by weight as active ingredient. Preferably, the compound of general formula (I) as active ingredient is 65%˜99% of pharmaceutical composition based on the total weight of pharmaceutical composition, and the remainders are the pharmaceutically acceptable carriers and/or conventional additives.
[0080] The compound and pharmaceutical composition provided in the invention can be various forms, such as tablet, capsule, powder, syrup, solution, suspension, aerosol etc., and may be present in a suitable solid or liquid carrier or diluent and suitable disinfector for injection or instillation.
[0081] The various dosage forms of pharmaceutical composition of the present invention can be prepared according to conventional methods in pharmaceutical field. The unit dose of formulation contains 0.05-200 mg of the compound of general formula (I), preferably 0.1 mg-100 mg of the compound of general formula (I).
[0082] The compound and pharmaceutical composition of the invention can be used clinically in mammal including humans and animals, and can be delivered through mouth, nose, skin, lung, or gastrointestinal tract and other routes. The most preferable administration route is oral. Most preferable daily dose is 0.01-200 mg/kg body weight for once administration, or 0.01-100 mg/kg body weight in divided doses. Regardless of administration method, the optimal dose for individual should be established based on specific therapeutic regime. Usually start from small dose and gradually increase the dose until the most suitable dose is found.
BRIEF DESCRIPTION OF DRAWINGS
[0083] FIG. 1 is a curve graph of functional assay of part of the test compounds on D- 2 receptor.
[0084] FIG. 2 a - 2 c is a plasma concentration vs time curve after DC037029 is intravenously and orally administered in rats.
DETAILED DESCRIPTION
[0085] The present invention will be further illustrated in the following examples. These examples are intended to illustrate the invention, but not limit the invention in any way. All parameters of the examples as well as the rest of the description are described based on the weight unless otherwise indicated.
Example 1
S-(−)-2-hydroxy-3,9,12-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037030) (prepared according to the first reaction route)
1.1 Preparation of 3-methoxy-4-benzyloxy-ω-nitrostyrolene (Compound 2)
[0086] The preparation was conducted with reference to org. Lett., 2008, 8(8), 1525-1528. Firstly, the hydroxyl of vanillin (purchased from Alfa Aesar company) was protected with benzyl. And then protected vanillin and nitromethane were refluxed in ammonium acetate and acetic acid to obtain the target product. Two-step yield: 75%; melting point: 117-118° C. 1 H NMR (CDCl 3 ): 1 H NMR (CDCl 3 , 300 MHz): δ 7.95 (d, J=13.2 Hz, 1H), 7.51 (d, J=13.2 Hz, 1H), 7.42-7.32 (m, 5H), 7.10 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.02 (d, J=1.8 Hz, 1H), 6.92 (d, J=8.4 Hz, 1H), 5.22 (s, 2H), 3.92 (s, 3H); ESI-MS m/z 251 [M+H] + .
1.2 Preparation of 3-methoxy-4-benzyloxyphenylethylamine (Compound 3)
[0087] Under N 2 , lithium aluminum hydride (6.0 g) was suspended in anhydrous tetrahydrofuran (50 mL) Compound 2 (22.5 g) was dissolved in 30 mL of anhydrous tetrahydrofuran and the resulting solution was slowly added into above suspension dropwise. Upon addition, the reaction solution was moved in an oil bath and refluxed for 3 hours. After the reaction was finished, the reaction solution was cooled to room temperature and then the same equivalent of water as excessive lithium aluminum hydride was added to quench the reaction. The precipitate was filtered off and then the filtrate was evaporated to dryness. Yield: 85%. 1 H NMR (CDCl 3 , 300 MHz): δ 8.20 (br, 2H), 7.46-7.33 (m, 5H), 6.99 (d, J=8.4, 1 H), 6.92 (d, J=1.5, 1 H), 6.75 (dd, J=8.4, J=1.5, 1H), 5.06 (s, 2H), 3.79 (s, 3H), 3.01 (t, 2H), 2.85 (m, 2H); ESI-MS m/z 258 [M+H] + .
1.3 Preparation of N-(3′-methoxy-4′-benzyloxyphenylethyl)-2,5-dimethoxy phenylacetamide (Compound 6)
[0088] 2,5-dimethoxyphenylacetic acid (392 mg, purchased from Sigma Aldrich Company) was dissolved in anhydrous dichloromethane (10 mL) Compound 3 (514 mg), EDCI (573 mg) and triethylamine (433 μL) was added, respectively. The reaction was conducted overnight under N 2 . After completion of the reaction, the reaction solution was washed with 1 N diluted hydrochloric acid, then the organic phase was washed once with saturated sodium bicarbonate solution and finally washed once with saturated salt solution. After dried over sodium sulfate, the organic phase was evaporated and product 6 was obtained by column chromatography. 1 H NMR (CDCl 3 ): δ 7.46-7.26 (m, 5H), 6.80-6.51 (m, 5H), 6.49 (d, J=2.1, 1H), 5.83 (m, 1H), 5.14 (s, 2H), 3.75 (s, 3H), 3.74 (s, 3H), 3.73 (s, 3H), 3.65 (s, 2H), 3.47-3.36 (m, 2H), 3.64-3.59 (m, 2H); ESI-MS m/z 436 [M+H] + .
1.4 Preparation of 1-(2′,5′-dimethoxy)benzyl-6-methoxy-7-benzyloxy-3,4-dihydro-isoquinoline (Compound 7)
[0089] Under N 2 , Compound 6 (435 mg) was dissolved in 15 mL of anhydrous acetonitrile and POCl 3 (546 μL) was added to above solution. The reaction mixture was refluxed for 30 min and then cooled. The reaction solution was concentrated to give oily liquid. The oily liquid was dissolved in dichloromethane, neutralized with saturated sodium bicarbonate, and extracted three times. The organic phase was washed once with saturated saline solution, dried and evaporated to dryness. 1 H NMR (CDCl 3 ): δ 7.48-7.32 (m, 5H), 7.00 (s, 1H), 6.80-6.68 (m, 4H), 6.6 (s, 1H), 3.99 (s, 2H), 3.82 (s, 3H), 3.80 (s, 3H), 3.70-3.60 (m, 5H), 2.65-2.60 (m, 2H); ESI-MS m/z 418 [M+H] + .
1.5 Preparation of 1-(2′,5′-dimethoxy)benzyl-6-methoxy-7-benzyloxy-1,2,3,4-tetrahydro-isoquinoline (Compound 8)
[0090] Compound 7 (418 mg) freshly prepared was dissolved in DMF (5 mL), 1% of (R,R)-Noyori catalyst, a mixed solution of triethylamine and formic acid was added separately and the resulting solution was stirred overnight at room temperature. After the completion of the reaction, the reaction solution was neutralized with saturated sodium bicarbonate, and extracted with ethyl acetate for three times. The organic phase was washed once with saturated saline solution, dried and concentrated. The product can be used in the next reaction without further purification. ESI-MS m/z 420 [M+H] + .
1.6 S-(−)-2-benzyloxy-3,9,12-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (Compound 9)
[0091] Compound 8 (419 mg) was mixed with aqueous formaldehyde and formic acid and stirred to react at 90° C. for 2 hours. After the completion of the reaction, most of liquid was evaporated and the remainder liquid was neutralized with saturated sodium bicarbonate, and extracted with ethyl acetate for three times. The organic phase was washed once with saturated saline solution, dried and evaporated to dryness. And then the produce was purified by column chromatography. 1 H NMR (CDCl 3 ): δ 7.44-7.34 (m, 5H), 6.73 (s 1H), 6.70 (s, 1H), 6.66 (m, 2H), 5.14 (s, 2H), 4.19 (m, 1H), 3.78 (s, 3H), 3.77 (s, 3H), 3.76 (s, 3H), 3.52-3.30 (m, 3H), 3.21-3.12 (m, 2H), 2.66-2.50 (m, 3H); ESI-MS m/z 432 [M+H] + .
Preparation of S-(−)-2-hydroxy-3,9,12-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037030)
[0092] Compound 8 (300 mg) was dissolved in 5 mL of ethanol and 7 mL of concentrated hydrochloric acid was added with stirring. The reaction was carried out at 90° C. for 1.5 hours. After the completion of the reaction, the reaction solution was cooled to room temperature and most of liquid was evaporated. The remainder liquid was neutralized with aqueous ammonia and the aqueous phase was extracted with dichloromethane for many times until there is no product in aqueous phase. The dichloromethane layer was washed with saturated saline solution, dried and evaporated to dryness. And then the product was purified by column chromatography. 1 H NMR (CDCl 3 ): δ 6.90 (s, 1H), 6.63 (s, 2H), 6.58 (s, 1H), 4.18-4.13 (m, 1H), 3.86 (s, 3H), 3.78 (s, 3H), 3.77 (s, 3H), 3.49-3.34 (m, 3H), 3.19-3.07 (m, 2H), 2.67-2.49 (m, 3H); ESI-MS m/z 342 [M+H] + .
Example 2
(±)-2,3,10,11-tetramethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037001)
[0093] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.67 (s, 1H), 6.61 (s, 1H), 6.57 (s, 1H), 3.93 (m, 1H), 3.89 (s, 3H), 3.87 (s, 3H), 3.86 (s, 3H), 3.85 (s, 3H), 3.75-3.59 (m, 2H), 3.28-3.12 (m, 3H) 2.89-2.63 (m, 3H); ESI-MS m/z 356 [M+H] + .
Example 3
(±)-2,3,9,10,11-pentamethoxyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037002)
[0094] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.70 (s, 1H), 6.60 (s, 1H), 6.47 (s, 1H), 4.10 (m, 1H), 3.88 (s, 3H), 3.87 (s, 3H), 3.85 (s, 3H), 3.82 (s, 3H), 3.81 (s, 3H), 3.55-3.42 (m, 2H), 3.25-3.12 (m, 3H), 2.85-2.78 (m, 1H), 2.66-2.61 (m, 2H); ESI-MS m/z 386 [M+H] + .
Example 4
[0095] (±)-2,3,9,12-tetramethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037003)
[0096] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.80 (s, 1H), 6.67 (s, 1H), 6.65 (s, 1H), 6.61 (s, 1H), 4.18 (m, 1H), 3.91 (s, 3H), 3.87 (s, 3H), 3.80 (s, 6H), 3.52-3.37 (m, 3H), 3.21-3.19 (m, 2H), 2.69-2.62 (m, 3H); ESI-MS m/z 356 [M+H] + .
Example 5
(8S,14S)-2,3,10,11-tetramethoxy-8-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037004)
[0097] Compound DC037004 was prepared according to Example 1 except for reacting 686 mg of 1-(3,4-bimethoxy)benzyl-6,7-bimethoxy-1,2,3,4-bihydroisoquinoline, acetaldehyde (10 mL) and formic acid (15 mL) at 90° C. for 2 hours. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.67 (s, 1H), 6.61 (s, 1H), 6.57 (s, 1H), 4.12-4.06 (m, 2H), 3.93 (s, 3H), 3.91 (s, 3H), 3.89 (s, 3H), 3.87 (s, 3H), 3.75-3.62 (m, 2H), 3.28-3.14 (m, 2H), 2.89-2.68 (m, 2H); ESI-MS m/z 370 [M+H] + .
Example 6
(8R,14S)-2,3,10,11-tetramethoxy-8-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037005)
[0098] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.67 (s, 1H), 6.61 (s, 1H), 6.57 (s, 1H), 4.12-4.06 (m, 2H), 3.93 (s, 3H), 3.91 (s, 3H), 3.89 (s, 3H), 3.87 (s, 3H), 3.75-3.62 (m, 2H), 3.28-3.14 (m, 2H), 2.89-2.68 (m, 2H); ESI-MS m/z 370 [M+H] + .
Example 7
S-(−)-2,3,9,10,11-pentamethoxyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037006)
[0099] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.70 (s, 1H), 6.60 (s, 1H), 6.47 (s, 1H), 4.10 (m, 1H), 3.88 (s, 3H), 3.87 (s, 3H), 3.85 (s, 3H), 3.82 (s, 3H), 3.81 (s, 3H), 3.55-3.42 (m, 2H), 3.25-3.12 (m, 3H), 2.85-2.78 (m, 1H), 2.66-2.61 (m, 2H); ESI-MS m/z 386 [M+H] + .
Example 8
(±)-3,9,10,11-tetramethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037007)
[0100] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.16 (d, J=8.4, 1H), 6.79 (m, 1H), 6.67 (s, 2H), 6.58 (s, 1H), 3.95 (m, 1H), 3.83 (s, 6H), 3.80 (s, 3H), 3.64-3.56 (m, 2H), 3.32-3.13 (m, 3H), 2.85-2.63 (m, 3H); ESI-MS m/z 356 [M+H] + .
Example 9
S-(−)-2,3,9,12-tetramethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037008)
[0101] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.09 (d, J=8.4, 1H), 6.97 (s, 1H), 6.72 (d, J=8.4, 1H), 6.51 (s, 1H), 4.18 (m, 1H), 3.87 (s, 3H), 3.84 (s, 3H), 3.83 (s, 3H), 3.82 (s, 3H), 3.52-3.37 (m, 3H), 3.21-3.19 (m, 2H), 2.69-2.62 (m, 3H); ESI-MS m/z 356 [M+H] + .
Example 10
(±)-3,10,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037009)
[0102] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.16 (d, J=8.4, 1H), 6.79 (m, 1H), 6.67 (s, 2H), 6.58 (s, 1H), 3.95 (m, 1H), 3.83 (s, 6H), 3.80 (s, 3H), 3.64-3.56 (m, 2H), 3.32-3.13 (m, 3H), 2.85-2.63 (m, 3H); ESI-MS m/z 326 [M+H] + .
Example 11
S-(−)-3,10,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037010)
[0103] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.18 (d, J=9.0, 1H), 6.78 (m, 1H), 6.66 (s, 2H), 6.57 (s, 1H), 3.94 (m, 1H), 3.83 (s, 6H), 3.80 (s, 3H), 3.65-3.58 (m, 2H), 3.30-3.12 (m, 3H), 2.86-2.62 (m, 3H); ESI-MS m/z 326 [M+H] + .
Example 12
S-(−)-2,3-bimethoxy-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037011)
[0104] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.72 (s, 1H), 6.63 (m, 1H), 6.61 (s, 1H), 6.55 (s, 1H), 5.90 (s, 2H), 3.94 (m, 1H), 3.89 (s, 3H), 3.87 (s, 3H), 3.67-3.55 (m, 2H), 3.25-3.11 (m, 3H), 2.70-2.60 (m, 3H); ESI-MS m/z 340 [M+H] + .
Example 13
S-(−)-2,3,10,11-bimethylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037012)
[0105] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.72 (s, 1H), 6.60 (m, 1H), 6.58 (s, 2H), 6.53 (s, 1H), 5.91 (s, 2H), 5.90 (s, 2H), 3.92-3.87 (m, 1H), 3.65-3.51 (m, 2H), 3.19-3.10 (m, 3H), 2.83-2.59 (m, 3H); ESI-MS m/z 324 [M+H] + .
Example 14
S-(−)-2,3-methylenedioxy-9,12-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037013)
[0106] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.81 (s, 1H), 6.65 (s, 2H), 6.59 (s, 2H), 5.91 (s, 2H), 4.17 (m, 1H), 3.78 (s, 3H), 3.77 (s, 3H), 3.51-3.32 (m, 3H), 3.20-3.13 (m, 2H), 2.68-2.50 (m, 3H); ESI-MS m/z 340 [M+H] + .
Example 15
(±)-2,3-bimethoxy-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037014)
[0107] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.63 (m, 1H), 6.58 (s, 1H), 6.56 (s, 1H), 5.91 (s, 2H), 3.92-3.89 (m, 1H), 3.84 (s, 3H), 3.83 (s, 3H), 3.63-3.51 (m, 2H), 3.20-3.09 (m, 3H), 2.82-2.76 (m, 1H), 2.66-2.57 (m, 2H); ESI-MS m/z 340 [M+H] + .
Example 16
S-(−)-2,3-methylenedioxy-10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037015)
[0108] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.72 (s, 1H), 6.63 (m, 1H), 6.58 (s, 1H), 6.56 (s, 1H), 5.90 (s, 2H), 3.92 (m, 1H), 3.84 (s, 3H), 3.83 (s, 3H), 3.68-3.52 (m, 2H), 3.21-3.07 (m, 3H), 2.84-2.75 (m, 1H), 2.66-2.57 (m, 2H); ESI-MS m/z 340 [M+H] + .
Example 17
S-(−)-2,3-methylenedioxy-9,10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037016)
[0109] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.72 (s, 1H), 6.63 (m, 1H), 6.56 (s, 1H), 5.90 (s, 2H), 3.93-3.90 (m, 1H), 3.86 (s, 3H), 3.85 (s, 3H), 3.83 (s, 3H), 3.68-3.58 (m, 2H), 3.24-3.07 (m, 3H), 2.85-2.77 (m, 1H), 2.66-2.54 (m, 2H); ESI-MS m/z 370 [M+H] + .
Example 18
S-(−)-2,3-bimethoxy-9,11-dimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037017)
[0110] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.09 (s, 1H), 6.97 (s, 1H), 6.72 (s, 1H), 6.51 (s, 1H), 4.18-4.02 (m, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.51-3.38 (m, 3H), 3.22-3.10 (m, 2H), 2.69-2.54 (m, 3H), 2.36 (s, 3H), 2.34 (s, 3H); ESI-MS m/z 308 [M+H] + .
Example 19
(±)-2,3-bimethoxy-9,11-dimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037018)
[0111] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 7.09 (s, 1H), 6.97 (s, 1H), 6.72 (s, 1H), 6.51 (s, 1H), 4.18-4.02 (m, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.51-3.38 (m, 3H), 3.22-3.10 (m, 2H), 2.69-2.54 (m, 3H), 2.36 (s, 3H), 2.34 (s, 3H); ESI-MS m/z 324 [M+H] + .
Example 20
(8S,14S)-2,3,9,10,11-pentamethoxyl-8-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037019)
[0112] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.67 (s, 1H), 6.52 (s, 1H), 4.12-4.06 (m, 2H), 3.90 (s, 3H), 3.89 (s, 3H), 3.87 (s, 3H), 3.86 (s, 3H), 3.85 (s, 3H), 3.69-3.58 (m, 2H), 3.28-3.14 (m, 2H), 2.89-2.68 (m, 2H); ESI-MS m/z 400 [M+H] + .
Example 21
(8S,14S)-2,3-bimethoxy-8-methyl-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037020)
[0113] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.66 (s, 1H), 6.61 (m, 1H), 6.56 (s, 1H), 6.55 (s, 1H), 5.91 (s, 2H), 4.37-4.24 (m, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.15-2.79 (m, 7H), 1.45 (d, J=7.2, 3H); ESI-MS m/z 354 [M+H] + .
Example 22
(±)-2,3-methylenedioxy-10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037021)
[0114] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.73 (s, 1H), 6.64 (m, 1H), 6.59 (s, 1H), 6.57 (s, 1H), 5.92 (s, 2H), 3.96-3.91 (m, 1H), 3.86 (s, 3H), 3.85 (s, 3H), 3.69-354 (m, 2H), 3.23-3.08 (m, 3H), 2.86-2.77 (m, 1H), 2.67-2.56 (m, 2H); ESI-MS m/z 340 [M+H] + .
Example 23
(±)-2,3-bimethoxy-10,11-bihydroxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037022)
[0115] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 6.70 (s, 1H), 6.69 (m, 1H), 6.53 (s, 1H), 6.44 (s, 1H), 5.92 (s, 2H), 4.24-4.20 (m, 1H), 3.84 (s, 3H), 3.82 (s, 3H), 3.40-337 (m, 1H), 3.16-3.10 (m, 1H), 3.01-2.70 (m, 1H), 2.67-2.56 (m, 2H); ESI-MS m/z 328 [M+H] + .
Example 24
(±)-2,3-bimethoxy-8-methyl-10,11-bihydroxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037023)
[0116] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.89 (s, 1H), 6.67 (s, 1H), 6.58 (s, 1H), 6.53 (s, 1H), 4.26-4.05 (m, 1H), 3.79 (s, 3H), 3.76 (s, 3H), 3.73-3.67 (m, 1H), 3.09-2.62 (m, 6H), 1.34 (d, J=6.6, 2H); ESI-MS m/z 342 [M+H] + .
Example 25
(±)-2,3-bihydroxy-10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037024)
[0117] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 7.04 (s, 1H), 6.95 (s, 1H), 6.76 (s, 1H), 6.53 (s, 1H), 4.18-4.06 (m, 1H), 3.85 (s, 3H), 3.84 (s, 3H), 3.51-3.36 (m, 3H), 3.21-3.19 (m, 2H), 2.69-2.62 (m, 3H); ESI-MS m/z 328 [M+H] + .
Example 26
(8S,14S)-2,3-bihydroxy-8-methyl-10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037025)
[0118] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 6.55 (s, 1H), 6.53 (s, 1H), 6.48 (s, 1H), 6.44 (s, 1H), 4.55-4.48 (m, 1H), 3.84 (s, 3H), 3.82 (s, 3H), 3.30-3.05 (m, 4H), 2.93-2.86 (m, 2H), 1.62 (d, J=6.8, 2H); ESI-MS m/z 342 [M+H] + .
Example 27
(8R,14R)-2,3-bihydroxy-8-methyl-10,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037026)
[0119] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.55 (s, 1H), 6.53 (s, 1H), 6.48 (s, 1H), 6.44 (s, 1H), 4.55-4.48 (m, 1H), 3.84 (s, 3H), 3.82 (s, 3H), 3.30-3.05 (m, 4H), 2.93-2.86 (m, 2H), 1.62 (d, J=6.8, 2H); ESI-MS m/z 342 [M+H] + .
Example 28
(±)-2,3-bihydroxy-9,10,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037027)
[0120] The preparation method was described in Example 5. 1 H NMR (CDCl 3 ): δ 6.95 (s, 1H), 6.76 (d, J=8.4, 1H), 6.51 (s, 1H), 4.18-4.06 (m, 1H), 3.85 (s, 3H), 3.84 (s, 3H), 3.51-3.36 (m, 3H), 3.21-3.19 (m, 2H), 2.69-2.62 (m, 3H); ESI-MS m/z 328 [M+H] + .
Example 29
(±)-2,3-bihydroxy-8-methyl-9,10,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037028)
[0121] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.50 (s, 1H), 6.45 (s, 1H), 6.35 (s, 1H), 4.61-4.37 (m, 2H), 3.93 (s, 3H), 3.87 (s, 6H), 3.49-3.39 (m, 1H), 3.18-2.84 (m, 5H), 1.52 (d, J=6.0, 2H); ESI-MS m/z 342 [M+H] + .
Example 30
S-(−)-2-hydroxy-3-methoxy-10,12-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037029)
[0122] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.81 (s, 1H), 6.61 (s, 1H), 6.59 (s, 1H), 6.54 (s, 1H), 5.90 (s, 2H), 3.92-3.87 (m, 1H), 3.87 (s, 3H), 3.65-3.48 (m, 2H), 3.23-3.09 (m, 3H), 2.83-2.55 (m, 3H); ESI-MS m/z 326 [M+H] + .
Example 31
S-(−)-2-hydroxy-3-methoxy-9,11-dimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037031)
[0123] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.83 (s, 2H), 6.82 (s, 2H), 6.60 (s, 1H), 4.07-4.00 (m, 1H), 3.85 (s, 3H), 3.59-3.47 (m, 2H), 3.26-3.18 (m, 2H), 2.93-2.89 (m, 1H), 2.70-2.63 (m, 2H), 2.28 (s, 3H), 2.20 (s, 3H); ESI-MS m/z 310 [M+H] + .
Example 32
2,3-bimethylenedioxy-9,12-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037032)
[0124] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.94 (s, 1H), 6.89 (s, 1H), 6.67 (d, J=8.4, 1H), 6.65 (d, J=8.4, 1H), 5.92 (s, 2H), 4.12-4.06 (m, 1H), 3.88 (s, 3H), 3.84 (s, 3H), 3.54-3.47 (m, 2H), 3.31-3.20 (m, 3H), 2.86-2.78 (m, 1H), 2.65-2.56 (m, 2H); ESI-MS m/z 354 [M+H] + .
Example 33
S-(−)-2,3-methylenedioxy-9,12-dimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037033)
[0125] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.91 (d, J=8.4, 1H), 6.87 (d, J=8.4, 1H), 6.65 (s, 1H), 6.63 (s, 1H), 5.90 (s, 2H), 4.17-4.06 (m, 1H), 3.82 (s, 3H), 3.80 (s, 3H), 3.51-3.32 (m, 3H), 3.20-3.13 (m, 2H), 2.68-2.50 (m, 3H), 2.37 (s, 3H), 2.34 (s 3H); ESI-MS m/z 340 [M+H] + .
Example 34
S-(−)-9,12-bimethoxy-2,3,5,8,13,13a-hexahydro-8H-benzo[3,2,a,g]furanquinolizine (DC037034)
[0126] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.11 (s, 1H), 7.01 (s, 1H), 6.65 (d, J=8.1, 1H), 6.58 (d, J=8.1, 1H), 4.31 (m, 2H), 4.16-4.08 (m, 1H), 3.85 (s, 3H), 3.83 (s, 3H), 3.53-3.34 (m, 2H), 3.20-3.02 (m, 4H), 2.79-2.50 (m, 4H); ESI-MS m/z 338 [M+H] + .
Example 35
S-(−)-2,3-bihydroxy-9,12-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037035)
[0127] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 7.04 (d, J=8.4, 1H), 6.95 (s, 1H), 6.76 (d, J=8.4, 1H), 6.53 (s, 1H), 4.18-4.06 (m, 1H), 3.85 (s, 3H), 3.84 (s, 3H), 3.51-3.36 (m, 3H), 3.21-3.19 (m, 2H), 2.69-2.62 (m, 3H); ESI-MS m/z 328 [M+H] + .
Example 36
S-(−)-2-bihydroxy-3,12-bimethoxy-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037036)
[0128] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.92 (s, 1H), 6.86 (s, 1H), 6.61 (s, 1H), 5.81 (s, 2H), 4.13-4.08 (m, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.84 (s, 3H), 3.54-3.48 (m, 2H), 3.32-3.23 (m, 3H), 2.83-2.77 (m, 1H), 2.63-2.54 (m, 2H); ESI-MS m/z 356 [M+H] + .
Example 37
S-(−)-2-hydroxy-3-methoxy-(2′,2′-bifluoro-10,11-methylenedioxy)-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037037)
[0129] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.91 (s, 1H), 6.84 (s, 1H), 6.81 (s, 1H), 6.63 (s, 1H), 4.12-4.09 (m, 1H), 3.87 (s, 3H), 3.56-3.48 (m, 2H), 3.34-3.24 (m, 3H), 2.82-2.76 (m, 1H), 2.64-2.55 (m, 2H); ESI-MS m/z 362 [M+H] + .
Example 38
S-(−)-2-hydroxy-3-methoxyl-9-chloro-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037038)
[0130] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.92 (s, 1H), 6.86 (s, 1H), 6.61 (s, 1H), 5.81 (s, 2H), 4.13-4.08 (m, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.84 (s, 3H), 3.54-3.48 (m, 2H), 3.32-3.23 (m, 3H), 2.83-2.77 (m, 1H), 2.63-2.54 (m, 2H); ESI-MS m/z 3602 [M+H] + .
Example 39
S-(−)-2-hydroxy-3-methoxyl-9-fluoro-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037039)
[0131] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ 6.98 (s, 1H), 6.83 (s, 1H), 6.63 (s, 1H), 5.84 (s, 2H), 4.12-4.09 (m, 1H), 3.86 (s, 3H), 3.55-3.49 (m, 2H), 3.34-3.22 (m, 3H), 2.84-2.77 (m, 1H), 2.63-2.52 (m, 2H); ESI-MS m/z 344 [M+H] + .
Example 40
S-(−)-2-hydroxy-3-methoxyl-10,11-methylenedioxy-12-fluoro-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037040)
[0132] The preparation method was described in Example 1. ESI-MS m/z 344 [M+H] + .
Example 41
S-(−)-2-hydroxy-3-methoxyl-10,11-methylenedioxy-12-chloro-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037041)
[0133] The preparation method was described in Example 1. ESI-MS m/z 360 [M+H] + .
Example 42
S-(−)-2,3-methylenedioxy-10,11-methylenedioxy-12-fluoro-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037042)
[0134] The preparation method was described in Example 1. ESI-MS m/z 342 [M+H] + .
Example 43
S-(−)-2,3-methylenedioxy-(2′,2′-bifluoro-10,11-methylenedioxy)-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037043)
[0135] The preparation method was described in Example 1. ESI-MS m/z 360 [M+H] + .
Example 44
S-(−)-2-hydroxy-3-fluoro-9,12-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037044)
[0136] The preparation method was described in Example 1. ESI-MS m/z 330 [M+H] + .
Example 45
S-(−)-2-hydroxy-3-chloro-9,12-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037045)
[0137] The preparation method was described in Example 1. ESI-MS m/z 346 [M+H] + .
Example 46
S-(−)-2-hydroxy-3-chloro-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037046)
[0138] The preparation method was described in Example 1. ESI-MS m/z 330 [M+H] + .
Example 47
S-(−)-2-hydroxy-3-fluoro-10,11-methylenedioxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037047)
[0139] The preparation method was described in Example 1. ESI-MS m/z 314 [M+H] + .
Example 48
S-(−)-2,3-methylenedioxy-10,11-methylenedioxy-12-chloro-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037048)
[0140] The preparation method was described in Example 1. ESI-MS m/z 358 [M+H] + .
Example 49
(6R,14S)-3,9,10,11-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037049)
[0141] Compound DC037049 was prepared according to the method described in Example 1 except that 1.64 g of 3-methoxypropiophenone was dissolved in 40 mL of anhydrous methanol, 0.924 mg of ammonium acetate was added to above solution, and 3-methoxyphenyl-propanamine was obtained by hydrogenation under the catalytic action of palladium carbon. 1 H NMR (CDCl 3 ): δ 7.13-7.15 (d, J=8.4, 1H), 6.74-6.77 (dd, J=8.4, J=2.4, 1H), 6.60-6.61 (d, J=2.4, 1H), 6.45 (s, 1H), 4.39-4.43 (d, J=15.2, 1H), 3.89 (s, 3H), 3.82 (s, 3H), 3.81 (s, 3H), 3.78 (s, 3H), 3.60-3.64 (m, 1H), 3.18-3.28 (m, 2H), 2.83-2.87 (m, 2H), 2.65-2.69 (m, 2H), 1.35-1.37 (d, J=6, 3H); ESI-MS m/z 370 [M+H] + .
Example 50
(6S,14S)-3,9,10,11-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037050)
[0142] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 7.15-7.17 (d, J=8.4, 1H), 6.76-6.78 (dd, J=8.4, J=2.4, 1H), 6.62-6.63 (d, J=2.4, 1H), 6.47 (s, 1H), 4.41-4.45 (d, J=15.2, 1H), 3.91 (s, 3H), 3.84 (s, 3H), 3.83 (s, 3H), 3.62-3.67 (m, 1H), 3.20-3.30 (m, 2H), 2.85-2.89 (m, 2H), 2.67-2.71 (m, 2H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 370 [M+H] + .
Example 51
(6R,14S)-2,3,9,10-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037051) (prepared according to the second reaction route)
[0143] Compound DC037051 was prepared according to the following Example 81 except that 1.74 g of 2,3-bimethoxypropiophenone was dissolved in 40 mL of anhydrous methanol, ammonium acetate was added to above solution, and 2,3-bimethoxyphenyl-propanamine was obtained by hydrogenation under the catalytic action of palladium carbon. 1 H NMR (CDCl 3 ): δ 6.86-6.89 (d, J=8.4, 1H), 6.77-6.80 (d, J=9, 1H), 6.72 (s, 1H), 6.58 (s, 1H), 4.52-4.57 (d, J=15.9, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.85 (s, 3H), 3.85 (s, 3H), 3.59-3.64 (m, 1H), 3.24-3.33 (m, 2H) 2.79-2.95 (m, 2H), 2.61-2.65 (m, 2H), 1.38-1.40 (d, J=6.8, 3H); ESI-MS m/z 370 [M+H] + .
Example 52
(6S,14S)-2,3,9,10-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037052) (prepared according to the second reaction route)
[0144] The preparation method was described in Example 81. 1 H NMR (CDCl 3 ): δ 6.85-6.88 (d, J=9, 1H), 6.77-6.80 (d, J=8.4, 1H), 6.71 (s, 1H), 6.58 (s, 1H), 4.52-4.57 (d, J=15.9, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.85 (s, 3H), 3.85 (s, 3H), 3.59-3.64 (m, 1H), 3.24-3.33 (m, 2H), 2.79-2.95 (m, 2H), 2.61-2.65 (m, 2H), 1.38-1.40 (d, J=6.8, 3H); ESI-MS m/z 370[M+H] + .
Example 53
(6R,14S)-2,3,9,10,11-pentamethoxyl-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037053)
[0145] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.71 (s, 1H), 6.58 (s, 1H), 6.48 (s, 1H), 6.58 (s, 1H), 4.41-4.46 (d, J=15, 1H), 3.89 (s, 3H), 3.88 (s, 3H), 3.86 (s, 3H), 3.84 (s, 3H), 3.84 (s, 3H), 3.62-3.65 (m, 1H), 3.20-3.29 (m, 2H), 2.79-2.90 (m, 2H), 2.61-2.66 (m, 2H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 400 [M+H] + .
Example 54
(6S,14S)-2,3,9,10,11-pentamethoxyl-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037054)
[0146] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.71 (s, 1H), 6.59 (s, 1H), 6.48 (s, 1H), 6.58 (s, 1H), 4.41-4.46 (d, J=15, 1H), 3.90 (s, 3H), 3.88 (s, 3H), 3.86 (s, 3H), 3.84 (s, 3H), 3.84 (s, 3H), 3.62-3.64 (m, 1H), 3.19-3.27 (m, 2H), 2.79-2.91 (m, 2H), 2.61-2.66 (m, 2H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 400 [M+H] + .
Example 55
(6R,14S)-2,3,9,11-tetramethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037055)
[0147] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.91 (s, 1H), 6.63 (s, 1H), 6.49 (s, 1H), 4.58-4.70 (m, 2H), 4.32-4.37 (d, J=15, 1H), 3.87 (s, 3H), 3.84 (s, 3H), 3.83 (s, 3H), 3.81 (s, 3H), 3.58-3.65 (m, 1H), 3.50-3.54 (m, 1H), 3.06-3.11 (m, 1H), 2.70-2.82 (m, 2H), 2.59-2.65 (m, 2H), 1.30-1.33 (d, J=6, 3H); ESI-MS m/z 400 [M+H] + .
Example 56
(6S,14S)-2,3,9,11-tetramethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037056)
[0148] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.92 (s, 1H), 6.63 (s, 1H), 6.50 (s, 1H), 4.58-4.70 (m, 2H), 4.31-4.36 (d, J=15, 1H), 3.86 (s, 3H), 3.84 (s, 3H), 3.83 (s, 3H), 3.80 (s, 3H), 3.58-3.64 (m, 1H), 3.50-3.53 (m, 1H), 3.06-3.11 (m, 1H), 2.70-2.82 (m, 2H), 2.59-2.65 (m, 2H), 1.30-1.33 (d, J=6, 3H); ESI-MS m/z 400 [M+H] + .
Example 57
(6R,14S)-3,9,11-trimethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037057)
[0149] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 7.20-7.23 (d, J=8.7, 1H), 6.75-6.79 (dd, J=8.7, J=2.4, 1H), 6.61-6.62 (d, J=2.4, 1H), 6.34 (s, 1H), 4.64-4.74 (m, 2H), 4.37-4.42 (d, J=15, 1H), 3.85 (s, 3H), 3.84 (s, 3H), 3.79 (s, 3H), 3.62-3.65 (m, 1H), 3.50-3.51 (m, 1H), 3.13-3.18 (m, 1H), 2.89-2.90 (m, 2H), 2.67-2.70 (m, 2H), 1.38-1.40 (d, J=6, 3H); ESI-MS m/z 370 [M+H] + .
Example 58
(6S,14S)-3,9,11-trimethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037058)
[0150] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 7.20-7.23 (d, J=8.7, 1H), 6.76-6.80 (dd, J=8.7, J=2.4, 1H), 6.60 (d, J=2.4, 1H), 6.34 (s, 1H), 4.63-4.74 (m, 2H), 4.37-4.42 (d, J=15, 1H), 3.85 (s, 3H), 3.84 (s, 3H), 3.80 (s, 3H), 3.62-3.65 (m, 1H), 3.50-3.51 (m, 1H), 3.13-3.18 (m, 1H), 2.89-2.90 (m, 2H), 2.66-2.70 (m, 2H), 1.38-1.40 (d, J=6, 3H); ESI-MS m/z 370 [M+H] + .
Example 59
(6R,14S)-2-hydroxy-3,9,10,11-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037059)
[0151] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.91 (s, 1H), 6.67 (s, 1H), 6.45 (s, 1H), 4.40-4.45 (d, J=15, 1H), 3.93 (s, 3H), 3.87 (s, 3H), 3.82 (s, 6H), 3.61-3.63 (m, 1H), 3.18-3.23 (m, 2H), 2.82-2.91 (m, 2H), 2.66-2.70 (m, 2H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 386 [M+H] + .
Example 60
(6S,14S)-2-hydroxy-3,9,10,11-tetramethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037060)
[0152] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.90 (s, 1H), 6.67 (s, 1H), 6.46 (s, 1H), 4.40-4.45 (d, J=15, 1H), 3.92 (s, 3H), 3.87 (s, 3H), 3.83 (s, 6H), 3.61-3.63 (m, 1H), 3.18-3.24 (m, 2H), 2.83-2.91 (m, 2H), 2.66-2.70 (m, 2H), 1.38-1.40 (d, J=6, 3H); ESI-MS m/z 386 [M+H] + .
Example 61
(6R,14S)-2-hydroxy-3,9,11-trimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037061)
[0153] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.97 (s, 1H), 6.75 (s, 1H), 6.66 (s, 1H), 6.36 (s, 1H), 4.37-4.42 (d, J=15, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.79 (s, 3H), 3.53-3.59 (m, 1H), 3.43-3.50 (m, 1H), 3.08-3.12 (m, 1H), 2.73-2.81 (m, 2H), 2.62-2.68 (m, 2H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 356 [M+H] + .
Example 62
(6S,14S)-2-hydroxy-3,9,11-trimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037062)
[0154] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.98 (s, 1H), 6.77 (s, 1H), 6.65 (s, 1H), 6.36 (s, 1H), 4.39-4.44 (d, J=15, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.79 (s, 3H), 3.53-3.58 (m, 1H), 3.42-3.48 (m, 1H), 3.06-3.11 (m, 1H), 2.73-2.80 (m, 2H), 2.62-2.68 (m, 2H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 356 [M+H] + .
Example 63
(6R,14S)-2-hydroxy-3,9,11-trimethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037063)
[0155] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.97 (s, 1H), 6.66 (s, 1H), 6.36 (s, 1H), 4.57-4.76 (m, 2H), 4.37-4.42 (d, J=15, 1H), 3.86 (s, 3H), 3.85 (s, 3H), 3.81 (s, 3H), 3.57-3.64 (m, 1H), 3.42-3.49 (m, 1H), 3.10-3.15 (m, 1H), 2.77-2.88 (m, 2H), 2.64-2.71 (m, 2H), 1.35-1.37 (d, J=6, 3H); ESI-MS m/z 386 [M+H] + .
Example 64
(6S,14S)-2-hydroxy-3,9,11-trimethoxy-6-methyl-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037064)
[0156] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.99 (s, 1H), 6.67 (s, 1H), 6.36 (s, 1H), 4.58-4.76 (m, 2H), 4.37-4.42 (d, J=15, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.81 (s, 3H), 3.57-3.65 (m, 1H), 3.44-3.49 (m, 1H), 3.10-3.14 (m, 1H), 2.77-2.88 (m, 2H), 2.65-2.71 (m, 2H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 386 [M+H] + .
Example 65
(6R,14S)-2,3-bimethoxy-6,9,11-trimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037065)
[0157] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.85 (s, 1H), 6.83 (s, 1H), 6.73 (s, 1H), 6.58 (s, 1H), 3.99-4.14 (m, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.63-3.66 (m, 1H), 3.25-3.28 (m, 2H), 2.82-2.96 (m, 2H), 2.62-2.71 (m, 2H), 2.28 (s, 6H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 340 [M+H] + .
Example 66
(6S,14S)-2,3-bimethoxy-6,9,11-trimethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037066)
[0158] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ 6.84 (s, 1H), 6.83 (s, 1H), 6.72 (s, 1H), 6.58 (s, 1H), 4.01-4.15 (m, 1H), 3.88 (s, 3H), 3.86 (s, 3H), 3.63-3.65 (m, 1H), 3.24-3.28 (m, 2H), 2.82-2.95 (m, 2H), 2.61-2.70 (m, 2H), 2.27 (s, 6H), 1.37-1.39 (d, J=6, 3H); ESI-MS m/z 340 [M+H] + .
Example 69
(S)-2,3,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037067)
[0159] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.99-7.02 (d, J=9, 1H), 6.75 (s, 2H), 6.72 (s, 1H), 6.62 (s, 1H), 4.01-4.13 (m, 1H), 3.91 (s, 3H), 3.88 (s, 3H), 3.79 (s, 3H), 3.56-3.68 (m, 2H), 3.28-3.35 (m, 1H), 3.12-3.19 (m, 2H), 2.80-2.94 (m, 1H), 2.62-2.70 (m, 2H); ESI-MS m/z 326 [M+H] + .
Example 68
(S)-2-hydroxy-3,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037068)
[0160] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.97-7.00 (d, J=9, 1H), 6.85 (s, 1H), 6.69-6.74 (m, 2H), 6.60 (s, 1H), 4.00-4.12 (m, 1H), 3.87 (s, 3H), 3.78 (s, 3H), 3.57-3.69 (m, 2H), 3.26-3.32 (m, 1H), 3.10-3.16 (m, 2H), 2.84-2.93 (m, 1H), 2.63-2.69 (m, 2H); ESI-MS m/z 312 [M+H] + .
Example 69
(S)-2-benzyloxy-3,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037069)
[0161] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ7.46-7.47 (m, 2H), 7.39-7.40 (m, 2H), 7.31-7.33 (m, 1H), 6.97-7.00 (d, J=9, 1H), 6.76 (s, 1H), 6.70-6.74 (m, 1H), 6.64-6.66 (m, 2H), 5.15 (s, 2H), 3.94-3.99 (m, 1H), 3.88 (s, 3H), 3.79 (s, 3H), 3.62-3.66 (m, 1H), 3.50-3.54 (m, 1H), 3.11-3.16 (m, 2H), 2.77-2.81 (m, 1H), 2.60-2.69 (m, 2H); ESI-MS m/z 402 [M+H] + .
Example 70
(S)-2,3-methylenedioxy-11-methoxyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037070)
[0162] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ6.98-7.01 (d, J=9, 1H), 6.69-6.74 (m, 3H), 6.59 (s, 1H), 5.92 (s, 2H), 3.94-3.99 (m, 1H), 3.79 (s, 3H), 3.56-3.68 (m, 2H), 3.22-3.29 (m, 1H), 3.09-3.16 (m, 2H), 2.83-2.92 (m, 1H), 2.60-2.67 (m, 2H); ESI-MS m/z 310 [M+H] + .
Example 71
(6R,14S)-2-hydroxy-3,9,12-trimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037071)
[0163] The preparation method was described in Example 49. 1 H NMR (CDCl 3 ): δ6.89 (s, 1H), 6.64 (s, 2H), 6.55 (s, 1H), 4.44-4.48 (m, 1H), 3.86 (s, 3H), 3.79 (s, 3H), 3.78 (s, 3H), 3.52-3.60 (m, 1H), 3.38-3.42 (m, 1H), 3.14-3.22 (m, 1H), 2.78-2.86 (m, 1H), 2.58-2.66 (m, 3H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 356[M+H] + .
Example 72
(6S,14S)-2-hydroxy-3,9,12-trimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037072)
[0164] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.88 (s, 1H), 6.64 (s, 2H), 6.54 (s, 1H), 4.43-4.47 (m, 1H), 3.86 (s, 3H), 3.80 (s, 3H), 3.79 (s, 3H), 3.53-3.60 (m, 1H), 3.38-3.43 (m, 1H), 3.15-3.24 (m, 1H), 2.77-2.84 (m, 1H), 2.58-2.67 (m, 3H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 356[M+H] + .
Example 73
(6S,14R)-2,10-bihydroxy-3,9-bimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037073) (prepared according to the second reaction route)
[0165] Compound DC037073 was prepared according to the following Example 81 except that 1.74 g of 2,3-bimethoxypropiophenone was dissolved in 40 mL of anhydrous methanol, 0.96 mg of ammonium acetate was added to above solution, and 2,3-bimethoxyphenyl-propanamine was obtained by hydrogenation under the catalytic action of palladium carbon. 1 H NMR (CDCl 3 ): δ6.80-6.82 (m, 3H), 6.56 (s, 1H), 5.30-5.50 (m, 2H), 4.49-4.56 (m, 1H), 3.87 (s, 3H), 3.82 (s, 3H), 3.58-3.62 (m, 1H), 3.24-3.35 (m, 2H), 3.15-3.24 (m, 1H), 2.77-2.88 (m, 2H), 2.60-2.66 (m, 2H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 342[M+H] + .
Example 74
(6S,14S)-2,10-bihydroxy-3,9-bimethoxy-6-methyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037074) (prepared according to the second reaction route)
[0166] The preparation method was described in Example 81. 1 H NMR (CDCl 3 ): δ6.80-6.82 (m, 3H), 6.56 (s, 1H), 5.28-5.49 (m, 2H), 4.50-4.56 (m, 1H), 3.86 (s, 3H), 3.81 (s, 3H), 3.56-3.61 (m, 1H), 3.24-3.34 (m, 2H), 3.16-3.24 (m, 1H), 2.76-2.85 (m, 2H), 2.58-2.64 (m, 2H), 1.36-1.38 (d, J=6, 3H); ESI-MS m/z 342[M+H] + .
Example 75
(S)-2,3,9,11-tetramethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037075)
[0167] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.72 (s, 1H), 6.60 (s, 1H), 6.30 (s, 2H), 4.07-4.12 (d, J=15, 1H), 3.87 (s, 3H), 3.85 (s, 3H), 3.78 (s, 3H), 3.77 (s, 3H), 3.55-3.59 (m, 1H), 3.35-3.40 (m, 3H), 3.15-3.28 (m, 2H), 2.63-2.67 (m, 2H); ESI-MS m/z 356 [M+H] + .
Example 76
(S)-2,3,9,11-tetramethoxy-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037076)
[0168] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.77 (s, 1H), 6.60 (s, 1H), 6.35 (s, 1H), 4.60-4.76 (m, 2H), 4.08-4.13 (d, J=15, 1H), 3.88 (s, 3H), 3.85 (s, 6H), 3.81 (s, 3H), 3.51-3.55 (m, 2H), 3.35-3.46 (m, 2H), 3.12-3.17 (m, 2H), 2.60-2.67 (m, 2H); ESI-MS m/z 386 [M+H] + .
Example 77
(S)-2,3-methylenedioxy-9,11-bimethoxy-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037077)
[0169] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.78 (s, 1H), 6.58 (s, 1H), 6.35 (s, 1H), 5.88 (s, 2H), 4.60-4.76 (m, 2H), 4.09-4.14 (d, J=15, 1H), 3.87 (s, 3H), 3.84 (s, 3H), 3.47-3.55 (m, 2H), 3.35-3.43 (m, 2H), 3.11-3.18 (m, 2H), 2.58-2.67 (m, 2H); ESI-MS m/z 370 [M+H] + .
Example 78
(S)-2,3-methylenedioxy-9,11-bimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037078)
[0170] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.73 (s, 1H), 6.59 (s, 1H), 6.30 (s, 2H), 5.90 (s, 2H), 4.07-4.12 (d, J=15, 1H), 3.82 (s, 3H), 3.79 (s, 3H), 3.52-3.56 (m, 1H), 3.35-3.40 (m, 1H), 3.06-3.24 (m, 3H), 2.80-2.89 (m, 1H), 2.57-2.68 (m, 2H); ESI-MS m/z 340 [M+H] + .
Example 79
(S)-2-hydroxy-3,9,11-trimethoxy-5,8,13,13a-tetrahydro-6H-dibenzo-[a,g]quinolizine (DC037079)
[0171] The preparation method was described in Example 1. 1 H NMR (CDCl 3 ): δ6.81 (s, 1H), 6.59 (s, 1H), 6.29 (s, 2H), 4.07-4.12 (d, J=15, 1H), 3.87 (s, 3H), 3.79 (s, 3H), 3.78 (s, 3H), 3.52-3.58 (m, 1H), 3.36-3.42 (m, 1H), 3.06-3.26 (m, 3H), 2.79-2.89 (m, 1H), 2.58-2.69 (m, 2H); ESI-MS m/z 342 [M+H] + .
Example 80
(S)-2-hydroxy-3,9,11-trimethoxy-12-hydroxymethyl-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037080)
[0172] The preparation method was described in Example 1.
Example 81
S-(−)-9-methoxyl-10-hydroxy-2,3,5,8,13,13a-hexahydro-8H-benzo[3,2,a,g]furanquinolizine (DC037081) (prepared according to the second reaction route)
2.1 Preparation of methyl 3-bromo-4-hydroxy-phenylacetate (Compound 10)
[0173] Methyl 3-hydroxy-phenylacetate (16.6 g, purchased from Accela ChemBio Co., Ltd.) was dissolved in glacial acetic acid (100 mL) and liquid bromine solution in glacial acetic acid (16 g in 50 mL glacial acetic acid) was dropwise added to above solution. The reaction was conducted for 2 hours and the product was obtained by filtering.
[0174] 1 H NMR (CDCl 3 , 300 MHz): δ 7.39 (d, J=1.5 Hz, 1H), 7.11 (dd, J=8.4 Hz, J=1.5 Hz, 1H), 6.93 (d, J=8.4 Hz, 1H), 3.70 (s, 3H), 3.54 (s, 2H).
2.2 Preparation of methyl 3-bromo-4-benzyloxy-phenylacetate (Compound 11)
[0175] Compound 10 (12.3 g) was dissolved in 100 mL acetone and 7.6 g of potassium carbonate was added. 8.6 g of benzyl bromide was added with stirring. The solid was removed by suction filtration and the liquid was evaporated to product 11.
[0176] 1 H NMR (CDCl 3 , 300 MHz): δ 7.51-7.33 (m, 6H), 7.15 (dd, J=8.4 Hz, J=2.4 Hz, 1H), 6.89 (d, J=8.4 Hz, 1H), 5.15 (s, 2H), 3.70 (s, 3H), 3.55 (s, 2H).
2.3 Preparation of 3-hydroxy-benzyloxyphenylacetic acid (Compound 12)
[0177] The substrate 11 (3.4 g), 6 mL of water, 1.5 g of KOH and 150 mg Cu powder were loaded into a microwave reaction tube and stirred at room temperature for half an hour. The obtained mixture was degassed by ultrasound. At 140° C., the microwave reaction proceeded for 50 minutes. The undissolved substance was filtered off. The pH value of the solution was adjusted to 1-3 by concentrated hydrochloric acid. The crude product was obtained by filtration. The product was recrystallizated with toluene to obtain Compound 12.
[0178] 1 H NMR (CDCl 3 , 300 MHz): δ 7.43-7.38 (m, 5H), 6.90 (s, 1H), 6.89 (dd, J=8.1 Hz, J=2.1 Hz, 1H), 6.74 (d, J=8.1 Hz, 1H), 5.10 (s, 2H), 3.56 (s, 2H).
2.4 Preparation of Compound 13
[0179] The substrate 12 (3 g), phenylboronic acid (2.7 g) and 60 mL of anhydrous toluene were added to the reaction bottle. The reaction mixture was placed in 110° C. oil bath for reacting for 2 hours. The reaction mixture was poured into a sealed tube while 3 g of paraformaldehyde and appropriate amount of molecular sieves were added. The reaction proceeded at 100° C. for 46 hours. After completion of the reaction, the molecular sieves were filtered off while they were hot and toluene was evaporated to obtain a slightly yellow solid. 50 mL of water was added and the reaction proceeded in 100° C. oil bath for 2 hours. After cooled, the reaction mixture was extracted with dichloromethane until there is no product in aqueous phase. The dichloromethane phase was dried over anhydrous sodium sulfate and evaporated to dryness to obtain a slightly yellow solid. An appropriate amount of anhydrous ether was added, stirred for 3 hours at room temperature, and then filtered to give a white solid, i.e. Compound 13.
[0180] The preparation was carried out with reference to Richard J. Spangler, Brian G. Beckmann, Jong Ho Kim. J. org. chem., 1977, 42, 2989-2996. Mark Cushman, Frederick W. Dekow. J. org. chem., 1979, 44, 407-409.
2.5 Preparation of Compound 14
[0181] Compound 13 (2.7 g) was dissolved in acetone (50 mL) Potassium carbonate (6.2 g) and iodomethane (15.5 g) were added. The reaction mixture was refluxed for 2 hours. The insoluble substances were filtered off and the solvent was evaporated. Product 14 was obtained by column chromatography.
[0182] 1 H NMR (CDCl 3 , 300 MHz): δ 7.45-7.34 (m, 5H), 6.92 (d, J=8.2 Hz, 1H), 6.85 (d, J=8.2 Hz, 1H), 5.40 (s, 2H), 5.12 (s, 2H), 3.91 (s, 3H), 3.62 (s, 2H).
2.6 Preparation of Compound 15
[0183] Compound 14 (2.84 g) was dissolved in glacial acetic acid and a solution of concentrated nitric acid in glacial acetic acid (630 mg in 6 mL of glacial acetic acid) was added slowly to above solution. The reaction was conducted for 2 hours and product 15 was obtained by column chromatography.
2.7 Preparation of Compound 16
[0184] Compound 15 (658 mg) and 2-[5-(2,3-dihydrobenzofuranyl)]-ethylamine (516 mg) were dissolved in 7 mL of anhydrous ethanol. The reaction mixture was refluxed overnight, and cooled to precipitate solid. Product 16 was obtained by filtration.
[0185] 1 H NMR (CDCl 3 , 300 MHz): δ 7.48-7.32 (m, 5H), 6.93 (d, J=8.4, 1 H), 6.86 (d, J=8.4 Hz, 1H), 6.74 (d, J=8.1 Hz, 1H), 6.65 (d, J=1.8, 1H), 6.54 (dd, J=8.1, 1.8 Hz, 1H), 6.10 (m, 1H), 5.07 (s, 2H), 4.61 (s, 2H), 4.26 (t, 2H), 3.84 (s, 3H), 3.51 (s, 2H), 3.46-3.40 (q, J=6.8 Hz, 2H), 2.97 (t, 2H), 2.67 (t, J=6.8 Hz, 2H).
2.8 Preparation of Compound 17
[0186] Compound 16 (930 mg) was dissolved in anhydrous dichloromethane (25 mL) while anhydrous pyridine (0.24 mL) and a catalytic amount of DMAP were added. In an ice bath, a solution of acetyl chloride in dichloromethane was slowly added. After addition, the reaction was continued at room temperature for 1 hour and an appropriate amount of water was added. The reaction mixture was extracted with dichloromethane for three times. The dichloromethane layer was washed with saturated saline solution, dried over sodium sulfate and evaporated to dryness to give Compound 17 which can be directly used in next reaction without further purification.
[0187] 1 H NMR (CDCl 3 , 400 MHz): δ 7.44-7.32 (m, 5H), 6.92 (d, J=8.4, 1 H), 6.89 (d, J=8.4 Hz, 1H), 6.72 (d, J=8.0 Hz, 1H), 6.61 (d, J=1.6, 1H), 6.53 (dd, J=8.0, 1.6 Hz, 1H), 5.40 (m, 1H), 5.08 (s, 2H), 5.02 (s, 2H), 4.26 (t, 2H), 3.83 (s, 3H), 3.82 (s, 2H), 3.44-3.39 (q, J=6.8 Hz, 2H), 2.96 (s, 2H), 2.67-2.63 (t, J=6.8 Hz, 2H), 1.92 (s 3H).
2.9 Preparation of Compound 18
[0188] Compound 17 (760 mg) was dissolved in anhydrous acetonitrile (15 mL), to which phosphorus oxychloride (1.1 mL) was added. The reaction solution was refluxed for 30 min and then cooled to room temperature. Most of the solvent and the phosphorus oxychloride were evaporated. The reaction solution was neutralized by using saturated sodium bicarbonate solution and extracted with dichloromethane for three times. Most of the solvent was evaporated, and the reaction solution was neutralizated with saturated sodium bicarbonate solution, extracted for three times with dichloromethane. The extract phase was dried over sodium sulfate and evaporated to dryness to give Compound 18 which can be directly used in next reaction without further purification.
[0189] 1 H NMR (CDCl 3 , 400 MHz): δ 7.43-7.31 (m, 5H), 6.96 (s, 1H), 6.83 (d, J=8.4 Hz, 1H), 6.77 (s, 1H), 6.73 (d, J=8.4 Hz, 1H), 5.20 (s, 1H), 5.02 (s, 2H), 4.68 (s, 2H), 4.28 (t, 2H), 4.01-3.98 (t, J=7.6 Hz, 2H), 3.84 (s, 2H), 2.97 (t, 2H), 3.09-3.06 (t, J=7.6 Hz, 2H), 2.00 (s, 3H).
2.10 Preparation of Compound 19
[0190] Compound 18 (489 mg) and R type of Noyori catalyst (7 mg) were dissolved in DMF (5 mL) A mixture of triethylamine and formic acid (v/v=5:2) was added into the reaction mixture and the reaction was conducted overnight at room temperature. The reaction solution was neutralizated with saturated aqueous sodium bicarbonate solution to alkalinity and the mixture was extracted with ethyl acetate. The ester phase was washed once with saturated saline solution, dried and evaporated to dryness to give product 19.
[0191] 1 H NMR (CDCl 3 , 400 MHz): δ 7.43-7.31 (m, 5H), 7.01 (d, J=8.4, 1 H), 6.92 (d, J=8.4 Hz, 1H), 6.66 (s, 1H), 6.59 (s, 1H), 5.30 (m, 2H), 5.02 (s, 2H), 4.26 (t, 2H), 4.02-3.99 (m, 1H), 3.90 (s, 3H), 3.22-3.16 (m, 2H), 2.95 (t, 2H), 2.90-2.80 (m, 2H), 2.74-2.71 (m, 2H), 2.01 (s, 3H).
2.11 Preparation of Compound 20
[0192] Compound 19 (491 mg) was dissolved in ethanol (4.5 mL), and to the solution, water (1.5 mL) and sodium hydroxide (80 mg) were added. The solution was reacted at room temperature for 3 hours and solid precipitated. The target product 20 was obtained by filtration.
2.12 Preparation of Compound 21
[0193] Compound 20 (447 mg) was dissolved in anhydrous dichloromethane. Under N 2 , thionyl chloride (0.53 mL) was added slowly to the solution cooled in ice-bath. After addition, the reaction proceeded at room temperature for 2 hours. A saturated sodium bicarbonate solution was added into the reaction solution to alkalinity and the reaction proceeded at room temperature for 2 hours. The dichloromethane layer was separated and the aqueous phase was extracted for three times with dichloromethane. The ester phase was washed once with saturated sodium chloride solution, dried over sodium sulfate and evaporated to dryness. And then product 21 was obtained by column chromatography.
[0194] 1 H NMR (CDCl 3 , 400 MHz): δ 7.47-7.31 (m, 5H), 6.83 (d, J=8.1, 1 H), 6.78 (d, J=8.1 Hz, 1H), 6.75 (s, 1H), 6.64 (s, 1H), 5.14 (s, 2H), 4.27 (t, 2H), 4.25-4.19 (m, 1H), 3.87 (s, 3H), 3.54-3.45 (m, 2H), 3.21-3.06 (m, 3H), 2.76-2.59 (m, 5H).
2.13 Preparation of S-(−)-9-methoxyl-10-hydroxy-2,3,5,8,13,13a-hexahydro-8H-benzo[3,2,a,g]furanquinolizine
[0195] Compound 21 (431 mg) was dissolved in ethanol, and concentrated hydrochloric acid was slowly added. The mixture was refluxed for 1.5 hours and then cooled to room temperature. Most of hydrochloric acid was evaporated and the residue was neutralized with aqueous ammonia to alkalinity. The resulting mixture was extracted with dichloromethane until no product remains in aqueous phase. And then the product was obtained by column chromatography.
[0196] 1 H NMR (CDCl 3 ): δ 6.83 (m, 3H), 6.59 (s, 1H), 4.34-4.29 (m, 1H), 4.26 (t, 2H), 3.86 (s, 3H), 3.67-3.61 (m, 2H), 3.30-3.24 (m, 3H), 2.97 (t, 2H), 2.93-2.71 (m, 3H); ESI-MS m/z 324 [M+H] + .
Example 82
S-(−)-2,3-bimethylenedioxy-9-methoxyl-10-hydroxy-5,8,13,13a-tetrahydro-6H-dibenzo[a,g]quinolizine (DC037082)
[0197] The preparation method was described in Example 81.
[0198] 1 H NMR (CDCl 3 ): δ 6.87 (m, 2H), 6.76 (s, 1H), 6.60 (s, 1H), 4.34-4.29 (m, 1H), 4.28 (m, 4H), 3.85 (s, 3H), 3.31-3.25 (m, 3H), 2.97 (t, 2H), 2.92-2.70 (m, 3H); ESI-MS m/z 340 [M+H] + .
Example 83
S-(−)-2′-methyl-9-methoxyl-10-hydroxy-2,3,5,8,13,13a-hexahydro-8H-benzo[3,2,a, g]furanquinolizine (DC037083)
[0199] The preparation method was described in Example 81.
[0200] 1 H NMR (CDCl 3 ): δ 6.82 (m, 3H), 6.61 (s, 1H), 4.33-4.28 (m, 1H), 4.24 (m, 1H), 3.87 (s, 3H), 3.64-3.57 (m, 2H), 3.30-3.24 (m, 3H), 2.97 (t, 2H), 2.93-2.71 (m, 3H); ESI-MS m/z 338 [M+H] + .
Pharmacological Experiments
[0201] 1. In the present invention, the pharmacological experiments were conducted to study the affinity of hexahydrodibenzo[a,g]quinolizine compound of general formula I and derivatives thereof on dopamine D 1 , dopamine D 2 , 5-HT 1A , and 5-HT 2A receptor. The experimental materials required for pharmacological experiments were commercially available unless otherwise specified.
[0202] (1). Determination of the affinity of hexahydrodibenzo[a,g]quinolizine compound of general formula I and derivatives thereof on dopamine D1, dopamine D2, 5-HT 1A , and 5-HT 2A receptor.
[0203] 1) The Experimental Method
[0204] Different concentrations (10 −5 M-10 −11 M) of the compound of the invention and corresponding isotope receptor ligand as well as receptor protein were loaded into the reaction tube and incubated in 30° C. water bath for 60 minutes. The reaction was terminated in a refrigerator. The reaction mixture was put in a Millipore filter (millipore) cell sample collector, filtered through suction filtration using GF/C glass fiber filter paper, and dried. The resulting sample was placed into 0.5 mL tube. 500 μL liquid scintillation fluid was added and intensity of radioactivity was determined by counting.
[0205] 2) The Experimental Materials
[0206] {circle around (1)} Construction of receptor and materials for cell culture: Escherichia coli . DH5α strain; insect virus transfer vector pVL1393 plasmid; BaculoGold linear Chinese baculovirus DNA, purchased from ParMingen company; mkD1RcDNA; rD2R cDNA; various restriction endonucleases, TaqDNA polymerase, T4 ligase, etc., LB medium; insect cell culture TNM-FH.
[0207] {circle around (2)} The Experimental Materials for Receptor Binding
[0208] For dopamine D1 receptor: isotope receptor ligands [3H] SCH23390 (85.0 Ci/mmol) (D1-selective, purchased from Amersham Corporation), D1 receptor protein expressed in HEK-293 cells;
[0209] For D2 dopamine receptor: isotope receptor ligands [3H] Spiperone (77.0 Ci/mmol) (D2-selective, purchased from Amersham Corporation); D2 receptor protein expressed in HEK-293 cells;
[0210] For 5-HT1A receptor: isotope receptor ligands [3H] 8-OH-DPAT; 5-HT1A receptor protein expressed in HEK-293 cells;
[0211] For 5-HT2A receptor: isotope receptor ligands [3H]-Ketanserin; 5-HT2A receptor protein expressed in HEK-293 cells;
[0212] Firstly, the above receptor proteins are dissolved in DMSO and then diluted with double distilled water to the appropriate concentration (10 −5 M-10 −11 M).
[0213] (+) Butaclamo purchased from RBI company, GF/C glass fiber filter paper purchased from Whatman Co., scintillation fluid (dopamine D1, D2 receptors)/liposoluble scintillation fluid (5-HT1A, 5-HT2A receptor), Beckman LS-6500 multi-function liquid scintillation counter.
[0214] 3) The experimental results are showed in table 1 and 3.
[0215] 2. Determination of the inhibition property of hexahydrodibenzo[a,g]quinolizine compound of general formula I and derivatives thereof on dopamine D 2 receptor.
[0216] (1) The Experimental Method
[0217] Each medicament was dissolved in serum-free F12 culture medium containing 100 μM of IBMX. CHO cells which can stably express D2 receptor were pre-incubated at 37° C. for 10 min, and then 10 μM Forskoline and 10 μM Dopanie were added at the same time to react for 10 min 100 μL of pre-cooled 1 M of HClO 4 was added and the reaction was terminated at 4° C. for 1 hour. 20 μL of 2 M K 2 CO 3 was added to neutralize the reaction. The resulting mixture was centrifugated at 3000 rpm for 15 min, and the precipitate KClO 4 was discarded. A certain amount of the supernatant was taken for cAMP detection. Spiperone and Quinpirole were used as positive control.
[0218] (2) The experimental materials
[0219] (3) The experimental results are showed in table 2 and FIG. 1 .
[0000]
TABLE 1
Determination results of the affinity of some representative
compounds on dopamine D1, and D2 receptors
Com-
D 1 receptor
D 2 receptor
pound
inhibition
IC 50
inhibition
IC 50
No.
ratio (%)
Ki (nM)
(nM)
ratio (%)
Ki (nM)
(nM)
DC037001
58.95
ND
ND
14.7
ND
ND
DC037002
77.95
ND
ND
27.05
ND
ND
DC037003
98.0
246.86
370.30
75.75
ND
ND
DC037006
91.75
320.11
648.23
48.0
ND
ND
DC037007
87.65
1003.72
2032.50
49.05
ND
ND
DC037008
101.0
50.07
101.39
92.8
334.38
1727.60
DC037009
−13.6
ND
ND
0.35
ND
ND
DC037010
66.8
ND
ND
51.5
ND
ND
DC037011
59.3
ND
ND
41.7
ND
ND
DC037012
95.8
147.91
299.52
89.3
239.90
1239.4
DC037013
103.4
23.65
47.90
85.6
485.43
2508.05
DC037014
58.2
ND
ND
25.8
ND
ND
DC037015
59.2
ND
ND
59.3
ND
ND
DC037016
95.5
376.83
763.07
66.2
ND
ND
DC037017
94.5
337.78
684.01
97.4
223.61
1155.30
DC037018
82.5
1440.62
2917.20
77.4
ND
ND
DC037019
10.3
ND
ND
65.3
ND
ND
DC037020
47.3
ND
ND
57.1
ND
ND
DC037021
56.5
ND
ND
44.5
ND
ND
DC037022
89.0
497.87
1008.16
10.6
ND
ND
DC037024
91.3
740.67
1499.85
76.2
ND
ND
DC037027
92.0
522.03
1057.10
64.7
ND
ND
DC037029
99.63
4.20
8.19
100.08
32.16
91.11
DC037030
99.89
3.70
7.22
74.27
ND
ND
DC037031
98.99
28.91
56.37
90.10
160.99
456.13
DC037032
99.21
25.25
49.23
28.67
ND
ND
DC037033
91.94
208.21
416.4
13.75
ND
ND
DC037034
95.30
248.04
483.67
17.36
ND
ND
DC037035
99.68
6.72
13.27
84.30
ND
ND
DC037081
22.60
ND
ND
73.07
ND
ND
DC037082
99.32
7.51
14.65
63.94
ND
ND
DC037075
97.88
64.12
113.81
39.50
ND
ND
DC037077
97.33
182.41
323.79
41.75
ND
ND
DC037078
97.79
74.50
141.58
1.02
ND
ND
DC037079
99.99
5.18
9.85
76.21
ND
ND
SCH-
100
1.24
2.52
ND
ND
ND
23390
Spiperone
ND
ND
ND
100
0.50
2.56
ND: the test was not conducted.
[0000]
TABLE 2
Determination results of the inhibition of some representative
compounds on dopamine D2 receptor
D 2 receptor
Compound No.
Antagonist IC50
agonist IC50
DC037003
3.30 μM
—
DC037008
4.03 μM
—
DC037013
9.74 μM
—
DC037017
16.19 μM
—
DC037018
15.61 μM
—
DC037024
0.591 μM
—
Spiperone
0.0014 μM
—
Quinpirole
—
0.462 μM
—: no agonist activity
[0000]
TABLE 3
Determination results of the affinity of some representative
compounds on hydroxyptamine 5-HT 1A and 5-HT 2A receptor
5-HT 1A receptor
5-HT 2A receptor
Compound
inhibition
inhibition
No.
ratio (%)
Ki (nM)
IC 50 (nM)
ratio (%)
Ki (nM)
IC 50 (nM)
DC037013
86.93
ND
ND
41.32%
ND
ND
DC037029
60.97
ND
ND
49.91
ND
ND
DC037030
80.41
493.48
626.40
39.99
ND
ND
DC037034
83.77
497.43
631.40
26.46
ND
ND
DC037032
95.36
40.59
51.53
37.75
ND
ND
DC037075
90.77
730.02
922.44
54.04%
ND
ND
DC0370077
88.63
599.89
758.03
45.63%
ND
ND
5-HT
100
0.62
0.79
ND
ND
ND
Spiperone
ND
ND
ND
100
2.94
5.67
ND: the test was not conducted.
[0220] It can be seen from the tables that the tested compounds, for example Compound DC037029, DC037030, DC037031, DC037032, DC037035, DC037079, and DC037082, have strong affinity on dopamine D1, D2 receptors. Further, some compounds of the present invention exhibit a certain affinity on 5-HT1A.
[0221] 2. Results of In Vivo Pharmacokinetic Experiment of Rats
[0222] Pharmacokinetic properties of Compound DC037029 in rats were preliminarily studied in this experiment. After the tested compound was delivered to rats by intravenous administration and intragastric administration, respectively, the whole blood samples were collected at different time point and the plasma was separated. The concentration of compound in plasma was determined by liquid chromatography-tandem mass spectrometry.
[0223] (1) Administration Regimen
[0224] Six healthy male SD rats with the weight of 200-220 g were randomly divided into 2 groups, each of which has three rats. The rats in each group were administrated with the tested compound by gavage or intravenous injection, respectively. Details are shown in table 4.
[0000]
TABLE 4
administration regimen
Number
Adminis-
Adminis-
of
tration
Administration
tration
Group
animals
Compound
route
dose
volume
1
3
DC037029
gavage
20
10
2
3
DC037029
vein
10
5.0
[0225] The compound was dissolved in 10% DMSO/10% Tween/10% normal saline.
[0226] The rats are fasted for 12 h and can drink water ad libitum before test. 2 h after dosing, the rats ate all together. The time point for collecting blood samples and the sample processing are listed as follows.
[0227] Intragastric administration time: 0.25, 0.5, 1.0, 2.0, 3.0, 5.0, 7.0, 9.0 and 24 h after administration.
[0228] Intravenous administration time: 5 min, 0.25, 0.5, 1.0, 2.0, 3.0, 5.0, 7.0, 9.0 and 24 h after administration. At above time point, 0.3 ml venous blood was taken from retrobulbar venous plexus of the rat and loaded into heparinization tube. After centrifuged at 1000 rpm for 5 min, the plasma was separated and frozen at −20° C. in a refrigerator.
[0229] (2) Pharmacokinetic Results
[0230] After the rats were administrated with DC037029 by gavage or intravenous injection, respectively, the concentrations of the medicament in plasma were showed in table 5 and 6, the corresponding pharmacokinetic parameters were showed in table 7 and 8, and the curves of plasma concentration vs time were showed in FIG. 2 a - 2 c.
[0231] After 20 mg/kg of DC037029 was administered through gavage, the time T max for the plasma concentration in rats reaching the peak concentration is 0.67±0.29 h, the peak concentration C max is 453±147 ng/ml, the area AUC 0-t below the curve of plasma concentration vs time is 2867±798 ng·h/ml, and the elimination half-life t 1/2 is 3.26±0.82 h.
[0232] After 10 mg/kg DC037029 was administered through intravenous injection, AUC 0-t is 4196±141 ng·h/ml, t 1/2 is 5.44±0.85 h, plasma clearance rate CL is 2.38±0.08 L/h/kg, steady state distribution volume Vss is 3.49±0.24 L/kg;
[0233] After 20 mg/kg of DC037029 was administered through gavage in rat, absolute bioavailability is lavage 34.2%.
[0000]
TABLE 5
Plasma concentration (ng/mL) of rats after 20 mg/kg of DC037029 was
administered through gavage
the number
time (h)
of the animal
0.0
0.25
0.5
1.0
2.0
3.0
5.0
7.0
9.0
24.0
1
BLQ
416
494
455
326
207
236
80.3
41.3
1.26
2
BLQ
493
553
575
492
431
330
118
113
1.90
3
BLQ
268
289
230
218
231
233
169
91.9
9.67
average
392
445
420
345
289
266
122
82.2
4.28
standard
114
139
175
138
123
55
44
37.1
4.68
deviation
[0000]
TABLE 6
Plasma concentration (ng/mL) of rats after 10 mg/kg of DC037029 was
administered through intravenous injection
the number
time (h)
of the animal
0.083
0.25
0.5
1.0
2.0
3.0
5.0
7.0
9.0
24.0
4
4169
2766
1788
1047
527
294
83.7
21.1
9.26
1.61
5
3837
2874
1984
1365
596
243
77.2
21.7
7.41
1.41
6
4576
3010
2055
1211
590
228
65.0
19.2
7.31
2.26
average
4194
2883
1942
1207
571
255
75.3
20.7
8.00
1.76
standard
170
122
138
159
38
34
9.5
1.3
1.10
0.45
deviation
[0000]
TABLE 7
Pharmacokinetic parameters of rats after 20 mg/kg of DC037029 was
administered through gavage
the number
C max
AUC 0-t
of the
T max
(ng/
(n · g/
AUC 0-∞
MRT
t 1/2
F
animal
(h)
mL)
mL)
(ng · h/mL)
(h)
(h)
(%)
1
0.50
494
2260
2265
4.00
2.89
2
1.00
575
3771
3779
4.67
2.70
3
0.50
289
2570
2629
6.45
4.20
average
0.67
453
2867
2891
5.04
3.26
34.2
standard
0.29
147
798
790
1.27
0.82
deviation
CV (%)
43.3
32.6
27.8
27.3
25.1
25.1
[0000]
TABLE 8
Pharmacokinetic parameters of rats after 10 mg/kg of DC037029 was
administered through intravenous injection
the number
AUC 0-t
of the
(ng · h/
ALC 0-∞
MRT
t 1/2
CLz
Vss
animal
mL)
(ng · h/mL)
(h)
(h)
(L/h/kg)
(L/kg)
4
4034
4046
1.53
5.01
2.47
3.78
5
4262
4272
1.42
4.88
2.34
3.33
6
4292
4313
1.46
6.42
2.32
3.38
average
4196
4210
1.47
5.44
2.38
3.49
standard
141
144
0.05
0.85
0.08
0.24
deviation
CV (%)
3.4
3.4
3.6
15.7
3.5
7.0
[0234] The above results for pharmaceutical experiments indicate that the compounds of the invention have better metabolic properties than l-SPD, especially higher bioavailability and action time, thereby overcoming the defects of l-SPD, such as difficulties in oral absorption, low bioavailability and the like. Especially, oral bioavailability of the compounds of the invention is improved nearly five times compared with that of prodrug thereof (according to CN101037436, the oral bioavailability of l-SPD is 6.83%), which facilitates the preparation of compounds with better drug properties.
Radioligand Binding Assays
[0235] The affinity of compounds to D 1 and D 2 dopamine receptors were determined by competition binding assays. Membrane homogenates of HEK293T cells were stably transfected with D 1 , or D 2 receptors. Duplicated tubes were incubated at 30° C. for 50 mins (for D 1 , and D 2 ) with increasing concentrations of respective compound and with [ 3 H]SCH23390 (for D 1 dopamine receptors), or [ 3 H]Spiperone (for dopamine D 2 receptor) in a final volume of 200 μL binding buffer containing 50 mM Tris, 4 mM MgCl 2 , pH 7.4. Nonspecific binding was determined by parallel incubations with either 10 μM SCH23390 for D 1 , or Spiperone for D 2 receptors respectively. The reaction was started by addition of membranes (15 ng/tube) and stopped by rapid filtration through Whatman GF/B glassfiber filter and subsequently washed with cold buffer (50 mM Tris, 5 mM EDTA, pH 7.4) using a Brandel 24-well cell harvester. Scintillation cocktail was added and the radioactivity was determined in a MicroBeta liquid scintillation counter. The IC 50 and Ki values were calculated by nonlinear regression (PRISM, Graphpad, San Diego, Calif.) using a sigmoidal function. The inhibition and Ki values of tested compounds are listed in Table 9.
[0000]
TABLE 9
The Ki values of tested compounds
Compound
D 1
D 2 Inhibition
No.
configuration
Inhibition (%) or K i (nM)
(%) or K i (nM)
DC037078
S
64.12 ± 4.43
39.50%
DC037076
S
74.51 ± 3.85
1.02%
DC037079
S
2.53 ± 0.16
83.31%
DC037081
S
17.29 ± 0.54
146.9 ± 10.2
DC037031
S
28.91 ± 2.73
160.9 ± 21.1
DC037013
S
23.65 ± 1.18
85.6%
DC037030
S
3.70 ± 0.26
74.27%
DC037035
S
6.72 ± 0.34
84.30%
[ 35 S]GTPγS Binding Assays
[0236] For detecting the agonism action of the compounds, the [ 35 S]GTPγS binding assay was performed at 30° C. for 40 mins in reaction buffer containing 50 mM Tris, pH 7.5, 5 mM MgCl 2 , 1 mM EDTA, 100 mM NaCl and 1 mM (DL)-dithiothreitol (DTT). The assay mixture (200 μL) contained 30 μg of membrane protein, 0.1 nM [ 35 S]GTPγS, and 40 μM guanosine triphosphate (GDP) with various concentration of the compound. The D 1 receptor agonist SKF38393 and antagonist SCH23390 were used for reference. Non specific binding was measured in the presence of 100 μM 50-guanylimidodiphosphate (Gpp(NH)p). The reaction was terminated by adding 3 mL of ice-cold washing buffer (50 mM Tris, pH 7.5, 5 mM MgCl 2 , 1 mM EDTA, and 100 mM NaCl) and was rapidly filtered with GF/C glass fiber filters (Whatman) and rinsed for three times. Filters were dried and radioactivity was determined by liquid scintillation counting. The results are summarized in Table 10. The results show that DC037030 and DC037079 have good D 1 receptor selectivity and D 1 receptor antagonistic activity.
[0000]
TABLE 10
[ 35 S]GTPγS binding assays of DC037030 and DC037079 for D 1 receptor
D1 agonist
D1 antagonist
Compound No.
EC 50 (nM)
Emax %
IC 50 (μM)
Imax %
DC037030
—
—
1.9 ± 0.4
86.8 ± 1.6
DC037079
—
—
1.4 ± 0.2
94.2 ± 1.5
SKF38393
247.5 ± 26.1
100
—
—
SCH23390
—
—
0.74 ± 0.05
81.0 ± 2.7
INDUSTRIAL APPLICABILITY
[0237] Hexahydrodibenzo[a,g]quinolizine compounds of the invention have relatively low toxicity and good solubility.
[0238] The preparation method for hexahydrodibenzo[a,g]quinolizine compounds of the invention has many advantages, such as mild reaction condition, abundant and readily-available raw materials that can be easily found, simple operation and post-processing, good selectivity, etc.
[0239] Hexahydrodibenzo[a,g]quinolizine compounds of the invention have excellent selectivity among different subtypes of serotonin receptors and dopamine receptors.
[0240] Therefore, the compounds of the invention can be used in preparing medicaments for treating the diseases relating to nervous system, especially to the dopamine receptors D 1 and D 2 as well as serotonin receptors 5-HT 1A and 5-HT 2A . | The present invention relates to a novel hexahydrodibenzo[a,g]quinoline compound represented by general formula (I) and its derivatives, enantiomer, diastereoisomer, raceme and mixtures thereof, as well as pharmaceutically acceptable salts thereof. The present invention further relates to a method for preparing the compound, and the compound has good prevention and treatment effect on neurological diseases, especially diseases associated with dopamine receptor and 5-hydroxytryptamine receptor. The bioactivity experiment demonstrates that, the compound is expected to be developed into a novel and potent chemical entity for treating diseases associated with dopamine receptor and 5-hydroxytryptamine receptor, especially schizophrenia, Parkinson's disease, drug addiction, migraine and so on. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The following applications, filed on Jun. 30, 1997 contain material related to the subject matter of this application, and are incorporated herein by reference:
"Intelligent Compilation of Procedural Functions for Query Processing Systems", Ser. No. 08/884,998 now is pending and
"Intelligent Compilation of Scripting Language for Query Processing Systems", Ser. No. 08/884,820, now is pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to systems for automatic query optimization and execution in parallel relational database management systems and particularly to a system for efficiently executing complex queries across a plurality of nodes of a distributed relational database management system while maintaining database integrity.
2. Description of the Related Art
A relational database management system (RDBMS) is a computer-implemented database management system that uses relational techniques for storing and retrieving data. Relational databases are computerized information storage and retrieval systems in which data in the form of tables (formally denominated "relations") are typically stored for use on disk drives or similar mass data stores. A "table" includes a set of rows (formally denominated "tuples" or "records") spanning several columns. Each column in a table includes "restrictions" on the data contents thereof and may be designated as a primary or foreign key. Reference is made to C. J. Date, An Introduction to Database Systems, 6th edition, Addison-Wesley Publishing Co. Reading, Mass. (1994) for a comprehensive general treatment of the relational database art.
A RDBMS is structured to accept statements to store, retrieve and delete data using high-level query languages such as the Structured Query Language (SQL). The term "query" denominates a set of statements for retrieving data from a stored database. The SQL standard has been promulgated by the International Standards Association since 1986. Reference is made to the SQL-92 standard "Database Language SQL" published by the ANSI as ANSI X3.135-1992 and published by the ISO as ISO/IEC 9075:1992 for the official specification of the 1992 version of the Structured Query Language. Reference is also made to James R. Groff et al. (LAN Times Guide to SQL, Osborne McGraw-Hill, Berkeley, Calif., 1994) for a lucid treatment of SQL-92, and to Don Chamberlin, Using the New DB2, Morgan Kaufmann Publishers, San Francisco, 1996, for a discussion of that language, which implements SQL. Finally, reference is also made to several IBM technical publications, to include definitions for some of the terminology used herein:
IBM Systems Journal, Vol. 34, No. 2, 1995.
DB2 AIX/6000 Admin. Guide, SC09-1571.
DB2 Parallel Edition for AIX Admin. Guide and Reference, SC09-1982.
DB2 Parallel Edition for AIX Performance and Tuning Guide, SG24-4560.
The phenomenal growth rate and use of client/server networks and database systems, as well as recent technological advances in parallel computing have given rise to the use of commercial parallel database systems by many major corporations. Businesses and other users today require database management systems that can sustain the burgeoning demands of decision support, data mining, trend analysis, multimedia storage, and the use of complex queries in a variety of applications. Parallel processing systems provide the availability, reliability, and scalability that previously were available only from traditional mainframe systems.
There currently exist several hardware implementations for parallel computing systems, including but not necessarily limited to:
Shared-memory approach--processors are connected to common memory resources; all inter-processor communication can be achieved through the use of shared memory. This is one of the most common architectures used by systems vendors. Memory bus bandwidth can limit the scalability of systems with this type of architecture.
Shared-disk approach--processors have their own local memory, but are connected to common disk storage resources; inter-processor communication is achieved through the use of messages and file lock synchronization. I/O channel bandwidth can limit the scalability of systems with this type of architecture.
Shared-nothing approach--As shown in prior art FIG. 1, in a shared-nothing implementation 100, processors 102 have their own local memory 104 and their own direct access storage device (DASD) such as a disk 106; all inter-processor communication is achieved through the use of messages transmitted over network protocol 108. A given processor 102, in operative combination with its memory 104 and disk 106 comprises an individual network node 110. This type of system architecture is referred to as a massively parallel processor system (MPP). While this architecture is arguably the most scalable, it requires a sophisticated inter-processor communications facility to send messages and data between processors. One shared-nothing implementation of IBM's DB2 Parallel Edition approaches near-linear performance scale-up as nodes are added to a parallel system.
Exploiting MPP architecture
DB2 currently executes on at least IBM's AIX/6000 platform, and supports the execution of multiple database servers (or nodes) on a number of processors including the SP2 and on multiple RISC/6000 processors connected via basic LAN communication facilities. DB2 instances that run on the SP2 using the high performance switch have significant performance gains and broader processor scalability than instances running on RISC/6000 clusters. Both of these hardware architectures apply the multiple-instruction, multiple-data (MIMD) approach to parallelism.
MIMD-based Parrallism
This approach to parallelism calls for multiple instruction streams to be simultaneously applied to multiple data streams. The biggest challenges facing database systems that use the MIMD form of parallelism are:
a. implementing a distributed deadlock detection and multi-phase commit protocol
b. handling inter-processor communications effectively and efficiently
c. breaking a processing request into manageable, independent components.
DB2 PE (Parallel execution) was developed as an extension to DB2 for the AIX/6000 Version 1 product. The non-parallel version is now referred to as DB2 Standard Edition. The DB2 PE extension, hereafter simply referred to as DB2, constituted, in the most basic terms, a replication of the database and database server components into an array of nodes or a database and Database Manager partition. Data is distributed across one or more nodes in a parallel configuration and the Database Manager at each node manages its part of the database independently from all other nodes. The ratio of processors to nodes can be one-to-one or one-to-many. The nodes defined in a one-to-many configuration are referred to as logical nodes. The parallel extension includes a function shipping strategy to send individual work requests to each of the nodes in a transaction.
The DB2 function shipping strategy involves decomposing a SQL statement into smaller parts, or sub-requests, and then routing the sub-requests to the nodes that are responsible for a portion of the table. Sub-requests are run in parallel; each node sends back qualifying rows to the initiator of the request which, in turn, builds the final answer set that is returned to the user or application.
Flow diagrams of a SQL statement that has been fully decomposed or partitioned on both a parallel and a non-parallel DB2 server, as detailed in prior art FIG. 1, are shown at prior art FIGS. 2A and 2B. In a serial implementation of DB2, the query plan is executed on a single node, as shown in FIG. 2A. A parallel implementation of DB2 enables the decompositioning, or partitioning of a query plan into a plurality of subplans, also referred to as subqueries, which are executed on the several nodes of the network, as shown in FIG. 2B.
The monolithic query plan which executes a complex query on a single node (UNI) is shown at FIG. 3A as 300. In contrast, a shared nothing MPP query executing the same plan on a number of nodes is shown in FIG. 3B.
Parallel Transactions
Having reference to the latter figure, plan 300 is partitioned by the DBMS into a number of subqueries, also referred to as subplans, or sections, 302-308. The subplans are logically connected to one another by means of table queues (TQs), 402-408. Each subplan is executed on a specified node or nodegroup. A nodegroup consists of 1-n nodes.
Referring now to FIG. 4, subplan 306 is shown to include at least one, and typically a plurality of operators 402-408, forming a strongly-connected component called a cycle, 410. It wil be understood by those having ordinary skill in the art that not all strongly-connected components are cycles. This cycle is in the query flow, and must be completed on tables T1 and T2, and the results passed to subquery 304. Each of the logical data connections between the several subplans, as well as between the subplans and their respective base tables are made by means of tables queues (TQs). DB2 supports both types of SQL decomposition because it allows tables to be defined on one or on many nodes. The physical distribution of data by DB2 is completely transparent to a user or to an application that accesses the data via SQL.
SQL statements executed by a parallel DB2 server are decomposed and processed using a master-slave agreement between processes and processors. A sample DB2 processing model created by an application that issues a simple query against a table with data spread out across several nodes is shown at prior art FIG. 5. When an application 500 initiates a connection to a parallel database at a node (the coordinating node, 502), a master process, or coordinating agent A1 504, is created to delegate work to subordinate processes or parallel agents A2, A3, A4 (506-510 respectively), located on both coordinating node 502 and other parallel nodes 512 and 514. Each node has access to a partition of the table, 516. The coordinating node and agent remain associated with an application until the application completes.
Coordinating Node
A database connection can emanate from any node in a parallel system, regardless of the location of tables processed by the application. The node at which a connection is started automatically becomes the coordinating node for that application. Consider the location and the frequency of database connects carefully when designing application systems. A large database system could experience bottlenecks at the coordinating node that is required to do heavy sorting when running queries. The coordinating node for a for a given application is a single node. Different applications executed on the same parallel system may have different designated coordinating nodes.
Distributing Data for Query Performance
DB2 allows you to divide tables across all of the nodes in a configuration or across subsets of nodes. This latter type of distribution is referred to as partial declustering. The rows of a table are distributed to the nodes defined in a nodegroup list specified on the CREATE TABLE statement. To distribute a row to the appropriate node, a hash partitioning strategy is used.
Each table in a multi-node nodegroup uses a partitioning key specified or defaulted to when the table was created. When a table row is inserted, a hashing algorithm is applied to the partitioning key value to produce an index into a partitioning map, which is an array of 4096 entries. Each entry in the partitioning map contains a node number where the row is to be stored. IBM has implemented a share-nothing version of its DB2 Parallel Edition, referred to as DB2, which approaches near-linear performance scale-up as nodes are added to a parallel system.
Choosing an appropriate partitioning key is important because it has a direct impact on performance. This has a direct bearing on the join strategies that the optimizer uses. The optimizer selects join strategies based on a lowest-cost strategy. Prior art FIGS. 6-8 provide an illustration of the different join methods used by DB2. The join methods, in lowest to highest computational cost order, are:
collocated--referring to FIG. 6, joined tables 604 and 604' are located on the same node 402 and each corresponding partitioning column is in an equal predicate; this type of join is done at the node-level and requires less communications overhead;
directed--referring to FIG. 7, joined tables 704 and 704' are sent from their nodes, 506 and 508 respectively, to another node, 710, where the local join is done
repartitioned--referring to FIG. 8, rows from both tables are redistributed to a single node and repartitioned on the joining attributes; and
broadcast--again referring to FIG. 8, all of the rows of one table are broadcast to the rows of the other table; this type of join incurs a high amount of communications overhead and should be avoided if possible.
As used herein, a "query" refers to a set of statements for retrieving data from the stored database. The query language requires the return of a particular data set in response to a particular query but the method of query execution ("Query Execution Plan") employed by the DBMS is not specified by the query. There are typically many different useful execution plans for any particular query, each of which returns the required data set. For large databases, the execution plan selected by the DBMS to execute the query must provide the required data return at a reasonable cost in time and hardware resources. Most RDBMSs include a query optimizer to translate queries into an efficiently executable plan. According to the above-cited Date reference, the overall optimization process includes four broad stages. These are (1) casting the user query into some internal representation, (2) converting to canonical form, (3) choosing prospective implementation procedures, and (4) generating executable plans and choosing the cheapest, or most computationally efficient of these plans.
For example, prior art FIG. 9 shows a query translation process known in the art. Queries written in SQL are processed in the phases shown, beginning with lexing at step 913, parsing and semantic checking at step 914, and conversion to an internal representation denoted the Query Graph Model (QGM) 915, which is a command data-structure that summarizes the semantic relationships of the query for use by the query translator and optimizer components. A query global semantics (QGS) process 917 adds constraints and triggers to QGM 915. A QGM optimization procedure 916 then rewrites the query into canonical form at the QGM level by iteratively "rewriting" one QGM 915 into another semantically equivalent QGM 915. Reference is made to U.S. Pat. No. 5,367,675 issued to Cheng et al., entirely incorporated herein by this reference, for a discussion of a useful QGM rewrite technique that merges subqueries. Also, reference is made to U.S. Pat. No. 5,276,870 wherein Shan et al. describe a QGM optimization technique that introduces a "view" node function to the QGM to permit base table references to "VIEWs" by other nodes. This conditions the QGM to permit the execution plan optimizer 918 to treat a view like a table. Finally, reference is made to U.S. Pat. No. 5,546,576 for a discussion of a Query Optimizer System which detects and prevents mutating table violations of database integrity in a query before generation of an execution plan. QGM 15 used in the Query Rewrite step 16 can be understood with reference to Pirahesh et al. ("Extensible/Rule-Based Query Rewrite Optimization in Starburst", Proc. A CM-SIGMOD Intl. Conf on Management of Data, San Diego, Calif., pp. 39-48, June 1992).
A useful QGM known in the art, and described in the '576 reference is now described in detail. FIG. 15 provides a QGM graphical representation of the following SQL query:
______________________________________SELECT DISTINCT Q1.PARTNO, Q1.DESCR, Q2.PRICEFROM INVENTORY Q1, QUOTATIONS Q2WHERE Q1.PARTNO=Q2.PARTNO AND Q2.PRICE > 100______________________________________
A SELECT box 1524 is shown with a body 1526 and a head 1528. Body 1526 includes data-flow arcs 1530 and 1532, which are also shown as the internal vertices 1534 and 1536. Vertex 1536 is a set-former that ranges on (reads from) the box 1538, which provides records on arc 1532. Similarly, vertex 1534 ranges on box 1540, which flows records on data-flow arc 1530. The attributes to be retrieved from the query, PARTNO 1546, DESC 1548 and PRICE 1550, are in head 1528. Boxes 1538 and 1540 represent the base tables accessed by the query, INVENTORY 1542 and QUOTATIONS 1544, respectively. Box 1524 embraces the operations to be performed on the query to identify the PARTNOs that match in the two base tables, as required by the join predicate 1552 represented as an internal predicate edge joining vertices 1534 and 1536. Vertex 1534 also includes a self-referencing predicate 1554 to identify prices of those PARTNOs that exceed 100.
For the purposes of this invention, note that each box or node (formally denominated "quantifier node", or QTB) in FIG. 15 is coupled to one or more other nodes by data-flow arcs (formally denominated "quantifier columns" or QUNs). For instance, base table node 1538 is coupled to select node 1524 by data-flow arc 1532 and base table node 1540 is connected to select node 1524 by data-flow arc 1530. The activities inside select node 1524 produce a new stream of data records that are coupled to the TOP node 1556 along a data-flow arc 1558. TOP node 1556 represents the data output table requested by the query.
The object of several known QGM optimization procedures is to merge one or more nodes where possible by eliminating (collapsing) data-flow arcs. For instance, the above-cited Pirahesh et al. reference describes a set of rules for merging any number of nodes into a single SELECT node, with certain restrictions on non-existential or non-Boolean factor subqueries, set operators, aggregates and user-defined extension operators such as OUTER JOIN. Thus those skilled in the art know that QGM optimization step 916 usually rewrites the QGM to eliminate numerous nodes and data-flow arcs even before considering useful query execution plans in plan optimization step 918 (FIG. 9). Also, most execution plans usually pipeline data along the data-flow arcs without waiting to complete execution of a node before flowing data to the next node.
QGM optimization procedure 916 rewrites QGM 915 to simplify the subsequent plan optimization process 918, which produces Query Execution Plans (QEPs). Plan optimization procedure 918 generates alternative QEPs and uses the best QEP 920 based on estimated execution costs. The plan refinement procedure 922 transforms optimum QEP 920 by adding information necessary at run-time to make QEP 920 suitable for efficient execution. Importantly, the QGM optimization step 916 is separate and distinct from the QEP optimization in step 918. Reference is made to U.S. Pat. No. 5,345,585 issued to Iyer et al., entirely incorporated herein by this reference, for a discussion of a useful join optimization method suitable for use in QEP optimization step 918. Reference is made to U.S. Pat. No. 5,301,317 issued to Lohman et al., entirely incorporated herein by the reference, for a description of an adaptive QEP optimization procedure suitable for step 918.
QGM 915 used in the Query Rewrite step 916 can be understood with reference to Pirahesh et al. ("Extensible/Rule-Based Query Rewrite Optimization in Starburst", Proc. A CM-SIGMOD Intl. Conf on Management of Data, San Diego, Calif., pp. 39-48, Jun. 1992).
The concept of a "trigger" is well-known in the art, although triggers are not explicitly included in the SQL-92 or SQL-93 standard promulgated by the ISO. For any event that causes a change in contents of a table, a user may specify an associated action that the DBMS must execute. The three events that can "trigger" an action are attempts to INSERT, DELETE or UPDATE records in the table. The action triggered by an event may be specified by a sequence of SQL statements. Reference is made to the above-cited Owens et al. reference and the above-cited Groff et al. reference for detailed examples of row-level and statement-level triggers. Reference is made to Chamberlin, previously cited, for a discussion of triggers, and to "Integrating Triggers and Declarative Constraints in SQL Database Systems", Proc. of the 22 nd Int. Conf. On Very Large Databases (1996) (Cochrane, et al.), for a discussion of the basis for the model of SQL-3 triggers.
The single overriding problem with implementing some complex queries on shared nothing parallel database systems (MPP), is that it is very difficult to perform actions that require local computation or local coordination of computation on data that is distributed among many nodes. Examples of such actions include, but are not necessarily limited to: recursive statements; the assignment of values to variables; the execution of the several statements of a row-level trigger; correlations to common subexpressions; the performance of any function that cannot be run in parallel (including those functions which must be run at the catalog node because they access catalog structures); the use of special registers use in buffered inserts; the provision for scrollable cursors which are a result of queries on distributed data; and, the checking of unique indexes which are distributed in MPP. These problems are briefly expounded below:
Recursion
By its very nature, recursion has an implied control flow that implements "until no more data, continue computing the query". This control flow is difficult to coordinate among nodes in a distributed system.
Assignment Statements
The assignment of a value to a variable must be performed on the node on which the target buffer location exists and will be used in the future. Further, a solution to this particular problem should allow several instances of the operations to run in parallel as long as a given assignment remains in the same node with its associated buffer.
Row-level Triggers
The statements of a row-level trigger must be performed for one row at a time. However, as long as there are not any semantic conflicts between the statements in a trigger, the statements of the trigger can be executed in parallel for each row.
Correlation to Common Subexpression
If a common subexpression is correlated, then all individual consumers of the expression must be collocated. Otherwise, the correlation values would be arriving at the common subexpression from diverse paths and it would be difficult to coordinate these correlation values.
Non-parallelizable and Catalog Functions
Any function that cannot be run in parallel (as dictated by the user during the CREATE FUNCTION) must be run on a single node. A special subclass of non-parallelizable functions must be run at the catalog node because they access catalog structures.
Special Register use in Buffered Insert
A discussion of the general topic of buffered inserts will be found in IBM Technical Publication DB2 Parallel Edition for AIX Admnin. Guide and Reference, SC09-1982. Since special register values exists in each section, these values are normally picked up directly from the section that uses them. However, for buffered insert, these values must come from a single node which is the coordinator. The reason is that each SQL statement creating a row to be inserted may have new values for special registers. Therefore, the value of special registers must be sent, via a TQ, to the nodes that execute the buffered insert.
Scrollable Cursors
In order to provide scrollable cursors that are a result of queries on distributed data, the results of the query must be shipped and stored at the coordinator node.
Deferred Unique
For FIPS, unique index checking is only performed at the end of a statement. This is after all other constraints are enforced, in particular cascaded referential integrity constraints. The check is verified by calling a data manager routine to perform the check for unique preservation on the index. However, indexes are distributed in MPP, and hence this function must be evaluated on each node where the potentially violated indices reside.
Each of the preceeding complex query component issues illustrates a common problem in the processing of complex queries across the several nodes of a shared nothing parallel database system (MPP): it is very difficult to perform actions that require local computation or coordination of computation on data that is distributed among many nodes. In performing complex queries which incorporate any of the previously discussed computational actions, a user has heretofore been faced with a difficult choice: either limit the scope of the allowed query to preclude those actions which require local computation and thus enable use of the several nodes of the network; or enable those actions, but only to tables that are not partitioned across nodes, thereby losing the computational power of the distributed system.
What is needed then is a methodology, and an apparatus for practicing the methodology, which enables the power and flexibility inherent in shared nothing parallel database systems (MPP) to be utilized on complex queries which have, heretofore, contained query elements requiring local computation or local coordination of data computation performed acrons the nodes of the distributed system.
What is further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries which include recursive statements.
What is also needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries which include the assignment of value to a variable.
What is yet further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries which include the use of row-level triggers.
What is still further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries which include correlation to a common subexpression.
What is moreover further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries containing non-parallelizable functions and catalog functions.
What is still further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries containing special registers useable in buffered inserts.
What is yet further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of scrollable cursors resulting from queries on distributed data.
What is finally further needed is a methodology which enables, on shared nothing parallel database systems (MPP), the performance and execution of complex queries which enable the deferral of uniques checking until the logic end of a statement is completed.
These unresolved problems and deficiencies are clearly felt in the art and are solved by this invention in the manner described below.
SUMMARY OF THE INVENTION
The present invention provides, a methodology, and an apparatus for practicing the methodology, which enables the power and flexibility inherent in shared nothing parallel database systems (MPP) to be utilized on complex queries which have, heretofore, contained query elements requiring local computation or local coordination of data computation performed across the nodes of the distributed system. The present invention provides these features and advantages by identifying and marking the subgraphs performing the above operations as "no TQ zones" in the preparation phase prior to optimization. When the optimizer sees the markings, it builds a plan that will force the computation of the marked subgraphs to be in the same section. This preparation phase also provides the partitioning information for all inputs to the "no TQ zones". This allows the bottom-up optimizer to correctly plan the partitioning for the "no TQ zones". These partitionings can force the operation to a single-node, the coordinator node, the catalog node, or to a particular partition class on multiple nodes, or nodegroups.
The foregoing, together with other objects, features and advantages of this invention, can be better appreciated with reference to the following specification, claims and accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
For a more complete understanding of this invention, reference is now made to the following detailed description of the embodiments as illustrated in the accompanying drawing, wherein:
FIG. 1 is view of a prior art MPP shared-nothing parallel architecture.
FIG. 2 is a prior art comparison between a complex database query implemented on a single computer, and the same query implemented on a network implementing an MPP shared-nothing parallel architecture.
FIG. 2A is a serial implementation of DB2.
FIG. 2B is a parallel implementation of DB2.
FIG. 3 is a prior art comparison between the query plan implementing a query on a single computer, and the same query plan implemented on a network implementing an MPP shared-nothing parallel architecture, whereby the query plan is partitioned into a plurality of sub-queries.
FIG. 3A is a monolithic query plan which executes a complex query on a single node.
FIG. 3B is a shared nothing MPP query executing the same plan or a number of nodes.
FIG. 4 is a prior art detail of one subquery, showing its interconnections to its base tables and its related subqueries.
FIG. 5 is a prior art sample DB2 processing model created by an application that issues a simple query against a table with data spread out across several nodes
FIG. 6 is a block diagram of a prior art collocated join methodology.
FIG. 7 is a block diagram of a prior art directed join methodology.
FIG. 8 is a block diagram of a prior repartitioned or broadcast join methodology.
FIG. 9 is a block diagram of a prior art query graph model.
FIG. 10 is a block diagram of a database system capable of implementing the principles of the present invention.
FIG. 11 is a block diagram of an overview of the principles of the present invention.
FIG. 12 is a modification to the query graph required by a deferred unique.
FIG. 13 is a flow diagram of a deferred unique which is implemented with a function that is called once for all indices.
FIG. 14 is a block diagram of an overview of the principles of the present invention further implementing a threaded code generator.
FIG. 15 is a block diagram of a QGM graphical representation of a SQL query.
Table 1 is a pseudocode representation of one embodiment of the present invention detailing QGM processing of no-TQ zones.
Table 2 is a pseudocode representation of one embodiment of optimizer support for force partition and no-TQ zones.
Table 3 is a pseudocode representation of of one embodiment of threaded code generation and runtime support for common subexpressions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The System of the Invention
FIG. 10 shows a functional block diagram of a computer-implemented database processing system 1068 suitable for practicing the procedure of this invention. This exemplary configuration is described for illustrative purposes only and it should be appreciated that the process and system of this invention can be embodied within system 1068 in many different useful fashions, including the arrangement depicted in FIG. 4. System 1068 includes a central processing unit (CPU) 1070, which is coupled to a parallel bus 1072. The query input terminal 1074 allows the user to enter queries into system 1068, either from a remote terminal or through any other useful method known in the art. As used herein, a "user query" includes a combination of SQL statements intended to produce one or more output data tables according to specification included in the query. The data output terminal 1076 displays the query results to the user and may be physically co-located with query input terminal 1074. A network interface 1077 connects this system to a network of similar systems, each of the systems forming a node of the network.
System 1068 includes the address space 1078, which is shown schematically as containing program objects and data objects. The base table 1080 is an example of a data object pulled into address space 1078 from the external mass store 1082 by way of bus 1072. The view definition 1084 is another data object representing a "virtual table" made up of elements from one or more base tables in accordance with a VIEW definition statement. External mass store 1082 includes a generally large plurality of base tables, exemplified by base tables 1086 and 1088. These base tables are moved partially or entirely between memory space 1078 and external mass store 1082 in a manner well-known in the art for database management systems.
Address space 1078 also includes the control program object 1090, which manages the other components of system 1068. These components include a query parser 1092 for accepting the query input from terminal 1074 and forwarding it to the Query Graph Model (QGM) optimizer 1094.
QGM optimizer 1094, with the participation of a query global semantics (QGS) processing module 1090, rewrites the QGM representation of the user query to provide a "canonical form" of the QGM for output to the query optimizer 1098. For instance, a QGM canonical form may include a large cyclical join graph organized within a single select node having data-flow arcs from many base tables, subject to the restrictions applied by QGS processing module 1096 and data-flow dam processing module 1097 on the QGM rewrite process. After query optimizer 1098 receives the canonical "database-integral" (DI) QGM from QGM optimizer 1094, a generally large number of useful plans for executing the DI-QGM are generated and tested for "cost" in accordance with a predetermined cost formula. Each of these execution plans is database-integral because the canonical QGM is database-integral. After identifying an "optimal" query execution plan, optimizer 1098 produces this plan as a program object, depicted as query execution plan 1100 in address space 78. Plan 1100 is finally executed with the assistance of control program 1090 and the resulting table is forwarded to data output of display 1076, or to other nodes of the network via net interface 1077, upon completion. It can be appreciated by those skilled in the art that the description of system 1068 in FIG. 4 is exemplary and that the system and process of this invention, may be incorporated in any RDBMS that uses a QGM optimization process.
Referring now to FIG. 11, a broad overview of the principles of the present invention is shown. At the start of execution, the Query Graph Model (QGM) identifies and marks, at 1102, those subgraphs of the query which must be executed on a given node or nodegroup as "No TQ Zones", or NTQZs. Optionally, QGM pushes out of the NTQZ any special predicates which require access to the RDBMS' base tables at 1104. This option is taken when special predicates are in an NTQZ which require access to the REBMS' base tables, or when desirable for increased system performance. Responsive to step 1104, at step 1106 the query optimizer recognizes the marks generated at step 1102, and, responsive to this recognition, generates the query plan at step 1108 which forces the computation of the marked subgraphs to be in the same section. This allows the bottom-up optimizer to correctly plan the partitioning for the "no TQ zones". These partitionings can force the operation to a single-node, the coordinator node, the catalog node, or to a particular partition class on multiple nodes, or nodegroups. Execution of the program, including execution of the query plan follows at 1110.
QGM Support
The actions of the QGM in support of the several specialized query elements requiring computation on a single node or nodegroup are illustrated with reference to the pseudocode implementation given at Table 1, and discussed as follows:
Recursion
Reference is made to U.S. Pat. No. 5,546,570 for a discussion of some of the underlying terminology dealing with recursion in the present invention. QGM marks all boxes that participate in the recursion, and all arcs connecting such boxes as participating in a no-TQ-zone (NTQZ). That is, all boxes that are in the same strongly connected component of the query graph, and all quantifiers (QUNs) that connect these boxes are marked NTQZ. All QUNs to a strongly connected component are marked with the same forced partitioning.
In addition, QGM marks all recursive QUNs that range over common subexpressions (CSE's) with the same forced partitioning.
Set Statements
Set statements are the assignment statements that assign a given value to a target buffer location that is represented as a correlated reference (target qnc). Reference in made to copending applications identified as Docket No. ST9-97-072, "Intelligent Compilation of Procedural Functions for Query Processing Systems", Ser. No. 08/884,998 and Docket No. ST9-97-043, "Intelligent Compilation of Scripting Language for Query Processing Systems", Ser. No. 08/884,820, for a discussion of set statements. The assign function must be in the same logical unit (subsection) as its target qnc. and thus the path from the ASSIGN function to its target QNC must be NTQZ.
Accordingly, all boxes and QUNs on the path between the assignment statement and the box that contains the correlation variable are marked NTQZ by the QGM. All input QUNs to this path are marked with the same forced partitioning.
Having reference now to FIG. 12, ql.cl is a correlated reference to a column of Box B. All boxes and QUNs on the path between and including Box C and Box A are marked NTQZ. Any QUNs that are not on the path but are input to the boxes on the path are marked with the same forced partitioning.
Row-level Triggers
QGM forces the partitioning from the triggering operation to the trigger control box to a single node. This will synchronize the execution of the trigger body for each row of the trigger operation.
Correlation to Common Subexpression
QGM creates a NTQZ for each common subexpression that contains correlated references to boxes outside the CSE. The NTQZ is the portion of the graph from the correlated CSE to its nearest dominator in the graph. All inputs to this NTQZ are then marked with the same forced partitioning.
Non-parallelizable/Catalog Functions
Any function that cannot be run in parallel (as dictated by the user during CREATE FUNCTION) must be run on a single node. Catalog functions must only be run on the catalog node. As much as possible, QGM attemps to isolate the catalog functions/non-parallelizable functions from other functions of data access. QGM then marks the box containing the function(s) as NTQZ and marks the input QUN with forced partitioning to either: (1) the coordinator node if none of the functions are catalog functions: or, (2) the catalog node if at least one of the functions is a catalog function.
Special Register use in Buffered Insert
For a buffered insert, QGM marks the entire subgraph that computes the values to be inserted as NTQZ with forced partitioning to the coordinator.
Scrollable Cursors
In order to provide scrollable cursors that are a result of queries on distributed data, the results of the query must be shipped and stored at the coordinator node. However, all other computations of the query can be performed in parallel as chosen by the optimizer. Accordingly, QGM adds a select box to the top of the query graph, forces a temporary table to be created between this box and the remainder of the graph, marks the box to be NTQZ, and forces the partitioning of the input QUN of the box to the coordinator.
Deferred Unique
The deferred unique is implemented with a function that is called once for all indices. It is necessary to call it once for each set of tables that are modified by the query. We will have one of the graphs shown in FIG. 12 for each table modified by the query.
This is accomplished as shown in FIG. 13: QGM marks the box containing the function (any -- dups) as NTQZ and forces the partitioning of the "values(1)" box to be broadcast to the PMID of the table which the function any -- dups is checking. It is necessary to call it once for each patititon that contains the tables marked by the query. PMID is the partition where the function any -- dups must be run.
Pushout for Performance/Correctness
UPDATE/DELETE/INSERT functions must be free to be evaluated on the nodes on which the target table resides. In an MPP environment, large tables can be expected; large enough that they may not be processable by a single node. Anytime a NTQZ is forced, especially to a single node, we may incur a large overhead in moving data around to the point that the system may not be able to handle the query. To avoid this whenever possible, it is possible to reduce the NTQZ by pushing out operations that are within NTQZ but need not be.
An example could be a scan of table T with a restrictive predicate in a recursive cycle. If the scan with the restrictive predicate is pushed out of the recursion, the amount of data that must be sent to the nodes where the recursion is being performed is potentially reduced.
Overview of Optimizer Support for NTQZ and Force Partition
The preceding section describes how each of the aforementioned constructs are solved in isolation using a combination of no-TQ zones and forced partitionings. When several constructs occur simultaneously, the no-TQ zones can overlap. For example, a recursive cycle may contain references to non-parallelizable functions. A second example is that a deferred unique box can occur within a no-TQ zone for a correlated common subexpression.
The following three steps comprise the QGM processing for no-TQ zones. First, all no-TQ zones for any constructs requiring no-TQ zones are marked. Second, operations from no-TQ zones are pushed out where required for correctness or where available for performance. Third, partitionings are chosen for each no-TQ zone and all input arcs to the no-TQ zone is marked accordingly. Table 2 contains a pseudocode representation which illustrages these three steps. Note that setting the partitioning is highly dependent on the configuration of the MPP system and the types of no-TQ zone constructs. Accordingly, the pseudocode listed for this step is one solution for the example constructs discussed herein. It will be immediately apparent to those having ordinary skill in the art that the principles disclosed herein are eminently capable of modification to support alternative hardware configurations.
Prior to making the final pass over the QGM graph to create the access plan, the optimizer scans the QGM graph to gather and store information about the QGM entities. In this phase, the optimizer will note directions from QGM on partition class requirements. The two mechanisms used to communicate these requirements are the "no TQ zone (NTQZ)" flag on the boxes (QTBs) and the "Force Partition" flag on the quantifiers (QUNs), within the QTBs. In the planning pass over the QGM, the collected information is used to intelligently partition the data according to the QGM requests.
Details of Optimizer Support for NTQZ
As the optimizer scans each QGM box, it looks to see if the NTQZ flag is turned on for the box. If it is, the information is stored for efficient access.
The optimizer compiles a list of partition classes that it should try to move the input stream to before an operation is done. This list consists of partitions that have been previously determined as interesting for the current operation or possibly for an operation in the future. If an input plan does not exist with the requested partition class, an operation to move the data is attached to the plan, this operation is a TQ. As the optimizer plans each operation it checks the NTQZ information on the box that is currently being planned. If the box has been indicated as a NTQZ, the optimizer does not add partitions to the partition class list that do not already have an existing input plan. The optimizer trusts the QGM to have ensured that all of the operations within the NTQZ box can be done without moving data so the partition classes that naturally propagate with the input plans should be sufficient to create the access plan for the box. The NTQZ is over-ridden in by a "Force Partition" on a QUN within the box.
Details of Optimizer Support for Force Partition
At the same time the NTQZ is recognized, the QUNs with "Force Partition" flag set are identified. For each QUN that has the "Force Partition" flag set, the optimizer gathers the information for the requested partition class off of the QGM QUN and stores it with other information that it needs about the QUN.
The optimizer recognizes when it is completing the access plan for a QUN with "Force Partition" and only requests input plans and creates output plans with the previously stored partition class. Plans with other partition classes are not created for that QUN, this is how the QUN is forced to the one partition that was dictated by QGM. As with the NTQZ, the optimizer assumes that QGM will not force the partition classes such that the operations cannot be done.
Optimizations
The optimizer builds interesting partition classes prior to the planning phase. The "Force Partition" information is used to help in this optimization.
TCG/Runtime Support for Common Sub-Expression (CSE) and Recursion in MPP
Support for Common Sub-Expression (CSE) in MPP requires that access to the CSE be synchronized when the production of the subgraph and its accesses are from different logical units (subsection). This is achieved via a semaphore mechanism. Access to the CSE must wait until the semaphore is set, and it is only set when the production of the CSE is finished. In accordance with one embodiment illustrating this principle of the present invention, Table 3 discloses a pseudocode representation of one embodiment for generating the threaded code to perform the preceding actions, further shown in FIG. 14. Runtime support for common sub-expressions involves both producing the common sub-expression and accessing the common sub-expression.
Recursion in MPP has at least one, and possibly multiple, CSEs within a single recursive loop. In those cases, all non-recursive access to any of the CSEs must be synchronized. Furthermore, this synchronization must happen for the entire recursion since any CSE within a recursive loop may not be fully materialized until the whole recursion is materialized. To achieve this, a single access semaphore is used for the entire recursion, and all non-recursive access to any of CSEs must wait on this semaphore. This is detailed in FIG. 14. Again, in accordance with the principles of the present invention shown in this illustrative embodiment, Table 3 discloses a pseudocode representation of one embodiment for generating the threaded code to perform the preceding actions.
Note that all of the CSEs in a recursion share the same semaphore. Hensce, the semaphore associated with a CTE that is in a recursion is the semaphore associated with the outermost recursion that contains the CTE.
The present invention has been particularly shown and described with respect to certain preferred embodiments of features thereof. However, it should be readily apparent to those of ordinary skill in the art that various changes and modifications in form and detail may be made without departing from the spirit and scope of the invention as set forth in the appended claims. The invention disclosed herein may be practiced without any element which is not specifically disclosed herein. | An automated methodology, and an apparatus for practicing the methodology, which enables the power and flexibility inherent in shared nothing parallel database systems (MPP) to be utilized on complex queries which have, heretofore, contained query elements requiring local computation or local coordination of data computation performed across the nodes of the distributed system. The present invention provides these features and advantages by identifying and marking the subgraphs containing these types of query elements as "no TQ zones" in the preparation phase prior to optimization. When the optimizer sees the markings, it builds a plan that will force the computation of the marked subgraphs to be in the same section. This preparation phase also provides the partitioning information for all inputs to the "no TQ zones". This allows the bottom-up optimizer to correctly plan the partitioning for the "no TQ zones". These partitionings can force the operation to a single-node, the coordinator node, the catalog node, or to a particular partition class on multiple nodes, or nodegroups. | 8 |
BACKGROUND
This invention relates to improvements in the design for downhole equipment used in the completion of petroleum wells. More particularly, it relates to an improved design for a device used to create perforations in the well casing through which oil and gas are extracted from a reservoir.
In most conventional oil and gas wells the well is completed by cementing a string of steel casing in the well across the production zone near the bottom of the hole. Once this casing is in place production of the oil or gas is permitted by perforating holes in the casing opposite the production zone using shaped explosive charges known as a perforating gun.
Perforating guns for this purpose are normally lowered down the hole inside the casing on a cable (with an electrical connection) until the explosive charges are opposite the production zone. The electrical wires are energized to ignite the charges which pierce holes in the casing (and any surrounding cement) into the rock formation and allow the flow of the oil or gas into the well. These techniques are old and well known in the industry.
However, a problem often arises that with the explosion of the perforating charges the gun and attached cables and wires are often explosively driven up the well casing where they become tangled and jammed in the casing bore so that they cannot be removed by merely hoisting the cable. This often requires an expensive and time-consuming “fishing” operation to release the entanglement and retrieve the debris.
SUMMARY
It is therefore the purpose of this invention to provide a mechanism which may be attached to and lowered with a perforating gun and will effectively prevent the upward recoil of the equipment and the above-mentioned problems associated therewith.
More specifically, it is the purpose of this invention to provide a tool which may be attached to a perforating gun and will serve to grip the inner walls of the casing with enough resistance to create a breaking effect and prevent the upward recoil of the equipment and suspending cables immediately after the firing of the perforating gun.
It is also the purpose of this invention to provide a simple and relatively inexpensive mechanism which will automatically activate when the gun is fired and released shortly thereafter without elaborate control mechanism and without creating further problems in the retrieval of this equipment from the hole after the perforating operation is completed.
These objects and other advantages are achieved by the present invention which provides a brake mechanism for use in association with a petroleum well perforating gun and comprises a body with an outer shell having openings therein, brake plugs mounted in said openings to engage the casing of said well, a piston movable within said body and having a tapered portion designed to engage said plugs and move said plugs in the radial direction, orifice means to communicate pressure from said perforating gun to said piston to activate said plugs when the perforating gun is fired. The invention also has spring bias means to disengage said piston from said brake plugs when explosive pressure is not applied. The brake plugs may be released from engagement by a retractive spring means.
DESCRIPTION
The invention may be better understood by a detailed description of one embodiment thereof with reference to the attached drawings in which:
FIG. 1 is a schematic illustration of a perforating gun with an attached brake of the present invention positioned within an oil well casing to be perforated;
FIG. 2 is a vertical cross-section of the brake mechanism illustrated in FIG. 1;
FIG. 3 is a horizontal cross-section through the apparatus in FIG. 2 .
FIG. 1 illustrates a perforating gun 2 which is suspended downhole inside a steel casing 4 opposite a petroleum production zone 6 by means of a suspending cable (not shown) above.
The cylindrical recesses 8 in the perforating gun represent locations where shaped charges are attached which are designed to explode with a directional force sufficient to perforate the steel casing and penetrate into the production zone from which oil or gas is to be extracted. These charges are usually ignited by means of a wire connection which is lowered with the gun and is also not shown.
At the bottom of the perforating gun is a connecting sub 10 which is threadably fastened to the bottom of the perforating gun by threads at 12 and has threadably attached at its lower end by threads 14 a brake mechanism 16 which is designed in accordance with the present invention. A bull plug 18 having a solid tapered nose 20 is attached to the bottom to facilitate the downward travel of the equipment as it enters the well.
In FIG. 3 the cylindrical outer barrel 22 of the body of the brake mechanism 16 is illustrated with three circumferentially spaced window openings 24 , each containing a rectangular plug 26 having an outer surface 28 with a curvature similar to the outer barrel 22 and having a set of serrated teeth best seen in the illustration of FIG. 2 .
The serrated surface 28 of the plugs 26 are designed to engage the inner wall of the casing 4 to prevent the mechanism from excessive movement after the perforation gun has fired and they are operated by means of the mechanism best illustrated in the cross-sectional view of FIG. 2 .
As shown in FIG. 2, the connecting sub 10 has male threads 30 which connect to corresponding female threads 32 at the lower end of the perforating gun and seal rings 34 to create a fluid tight connection between the inner bore and the outer surfaces of the equipment. A central orifice 35 runs from the upper end to the lower end of the connecting sub. The brake body 38 is connected to the lower end of the connecting sub by means of threads 39 and has at its lower end the bull plug 18 as illustrated in FIG. 1 .
As previously mentioned in connection with FIG. 3, the barrel 22 of the brake mechanism has windows 24 containing plugs 26 with serrated teeth 28 designed to engage the inner surface of the casing when activated.
To activate the plugs 26 a tapered piston 36 is provided with an upper end 40 which is exposed to the orifice 35 . This connection is sealed in the inactivated position illustrated by means of the seals 42 in the upper surface 40 of the piston 36 .
Beneath the plugs 26 the lower end of the piston 36 is supported by a disc 44 which is urged upwards by a compression spring 46 mounted between the lower shaft 48 of the disc 44 and the cup 50 mounted at the bottom of the brake bore and held in place by the bull plug 18 .
From the foregoing illustrations, it will be readily apparent that when the perforating charges 8 are fired the explosive pressures will travel down the inner orifice 35 of the connecting sub 10 to the upper surface 40 of the piston 36 which will then be driven downward against the disc 44 and against the compressive forces of the spring 46 until the tapered surface 52 of the piston 36 engages the corresponding tapered surfaces 54 of the plugs 26 at which point it will have the effect of driving the plugs 26 radially outward until they engage the inner surface of the casing 4 . This will prevent the downhole equipment, including the perforating gun, the connecting sub, the brake mechanism, and the suspending cable from being driven up the hole.
This engagement will take place immediately upon the firing of the perforating gun in response to the explosive forces without any separate activation.
It is possible, if desired, to dimension the brake device so that the space between the bottom of the lower shaft 48 and the bottom of the cup 50 is dimensioned to provide a limited travel of the piston 36 and therefore will limit the amount of outward movement of the brake plugs 26 according to the internal dimension of the casing.
As soon as the explosive forces have dissipated, the compression spring 46 will force the tapered piston 36 upwards and will release the plug 26 from engagement with the wall of the casing so that the entire string of equipment can be readily retrieved from the hole by the suspending cable.
Once the tapered piston 36 has moved back to its inactive upper position as illustrated, the plugs 26 can be retracted by means of a circumferential retractive spring as illustrated at 56 in FIG. 2 .
Thus, by means of the relatively simple, inexpensive, rugged and uncomplicated equipment illustrated, the problems referred to above can be eliminated by a mechanism which activates automatically and disengages automatically. Furthermore, the mechanism is, except for the outer surface of the plugs 26 , contained within the interior of the barrel of the brake mechanism where the moving parts are protected from damage and isolated from rock cuttings and debris which might interfere with their operation.
Thus, under normal circumstances, the brake mechanism may be used over and over without repair or reconditioning.
It will, of course, be realized that numerous modifications and variations of the illustrated embodiment may be employed without departing from the inventive concept herein. | A brake mechanism for use with a perforating gun to prevent the explosive forces from causing recoil comprising a cylindrical body with openings permitting brake plugs to engage the well casing in response to pressure against an axially moving piston driven by the explosive force of the perforating gun and having a tapered side wall to drive the plugs against the casing. A bias spring disengages the axial piston and a retractive spring withdraws the plugs from engagement. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present embodiments relate to food freezer tunnel apparatus for cryogenically chilling for example food products, and related processes therefore.
[0002] Food freezing tunnels, such as for example those that use cryogenic substances to chill and/or freeze food products, are limited in their capacity by the overall heat transfer co-efficient that they can use on the products. For example, many food freezing tunnels rely upon increasing heat transfer effect by correspondingly increasing air flow velocity across the product for which the heat transfer is to be applied. There are, unfortunately, practical and economic limitations in many of these apparatus and methods and therefore, the increased heat transfer effect is not fully realized, especially with large scale industrial operations. The food processing industry would benefit from increased heat transfer effect with food freezing applications, because greater heat transfer effect results in being able to use smaller apparatus or conversely, using apparatus which can increase the production or flow through rate of products to be chilled or frozen.
[0003] Some improvements have found their way into food freezing tunnels. For example spray nozzles are now used to increase the overall heat transfer effecting during the freezing process by spraying liquid nitrogen (N 2 ) through the nozzles directly onto the surface of the food product to contact same with droplets of the cryogenic substance. These small nitrogen droplets contact the warm food product and evaporate quickly, thereby removing or transferring heat immediately from the surface of the food product to chill and further freeze same.
[0004] Other apparatus and systems use high pressure liquid nitrogen to provide heat transfer at the surface of the food product. However, this is an expensive process and can result in an unusually large amount of the nitrogen product which must therefore be lost to waste or alternatively additional equipment provided to recycle the nitrogen. In both instances, increased costs and a larger footprint of the food freezing tunnel is necessary, thereby making this type of application less desirable.
SUMMARY OF THE INVENTION
[0005] There is provided herein a pulsed heat transfer effect apparatus and method for products, such as for example food products, wherein a high pressure nitrogen gas is pulsed into a liquid nitrogen flow stream, which stream thereafter is sprayed from nozzles thereby increasing turbulence on a surface of a food product to facilitate and promote increased heat transfer effect at the food product. The combination of the nitrogen gas, liquid nitrogen, and pulsing of same, results in extremely small nitrogen droplets which evaporate more quickly and therefore result in a higher evaporative surface cooling (heat transfer effect) at the surface of the food product. In addition, the pulsed spray results in increasing turbulence of the cryogenic substance on the surface of the product which accordingly promotes increased heat transfer, i.e. heat removal from the product. Carbon dioxide may be used instead of nitrogen.
[0006] There is therefore provided an apparatus embodiment for providing a liquid-gas entrained cryogen mixture onto a food product which includes a first pipe through which is provided a flow of liquid cryogen; a second pipe through which is provided a flow of gaseous cryogen, the second pipe in fluid communication with the first pipe at a mixing region; and a pulsing valve disposed at an interior of the second pipe upstream of the mixing region, the pulsing valve adapted for releasing the gaseous cryogen into the liquid cryogen at select intervals of time to provide a pulsating flow of the liquid-gas entrained cryogen mixture downstream of the mixing region for contacting the food product.
[0007] Another apparatus embodiment calls for the pulsing valve including an axle spanning an internal diameter of the second pipe and rotatably mounted therein; a planar member mounted to the axle and having a surface area substantially similar to a cross-sectional diameter of the second pipe; and a motor operatively connected to the axle for rotation of said axle and the planar member mounted thereto.
[0008] Various valves and backflow preventers are used to control and restrict flow of the cryogen liquid and gas.
[0009] There is also provided a method embodiment of providing a flow of a liquid-gas entrained cryogen mixture onto a food product which includes providing a first flow of liquid cryogen to the food product; providing a second flow of a gaseous cryogen to contact the first flow at a mixing region of the first and second flows; and repetitively interrupting the second flow upstream of the mixing region to provide a pulsating flow of the gaseous cryogen into the liquid cryogen for providing a pulsating flow of a liquid-gas entrained cryogen mixture to the food product.
[0010] The liquid and gaseous cryogen may be selected from nitrogen (N 2 ) and carbon dioxide (CO 2 ).
[0011] Other features of the present embodiments are described hereinafter.
BRIEF DESCRIPTION OF THE DRAWING
[0012] For a more complete understanding of the present invention, reference may be had to the following description of exemplary embodiments considered in connection with the accompanying drawing FIGURE, which FIGURE shows a pulsed liquid-gas entrained cryogen flow generator apparatus to be used with for example food products.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Before explaining the inventive embodiments in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, if any, since the invention is capable of other embodiments and being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
[0014] Referring to the FIGURE, an apparatus is shown generally at 10 for pulsing liquid nitrogen droplets from nozzles onto a food product or products being conveyed for providing increased heat transfer effect at the food product to chill and/or freeze same. In certain applications, carbon dioxide (CO 2 ) can be used instead of nitrogen (N 2 ). By way of example only, nitrogen (in liquid and gaseous phase) will be referred to herein when describing the present embodiments.
[0015] The present embodiments provide for the mixing of gaseous nitrogen and liquid nitrogen to produce an arrangement of pulsing spray jets of the nitrogen to provide a high heat transfer effect at food products being conveyed or transported in close proximity to the spray nozzles. The gaseous nitrogen may be provided at 200 psig, while the liquid nitrogen (LIN) can be provided at 30 psig.
[0016] For purposes herein, the nitrogen droplets emitted from the nozzles have a diameter of approximately 20 to 100 μm.
[0017] Referring to the FIGURE, the apparatus 10 of the present embodiments and related method embodiments can be used in conjunction with or retrofitted to a food freezing tunnel such as that shown generally at 12 . The tunnel 12 has an interior space 14 or chamber for chilling and freezing, and through which product 16 , such as for example food products, are transported on a conveyor belt 18 . The conveyor belt 18 transits the space 14 in a direction represented by arrow 20 , by way of example only. The tunnel 12 is also provided with an inlet (not shown) and an outlet (not shown) in communication with the space 14 for introducing the food product 16 on the conveyor belt 18 through the space. The food freezing tunnel 12 can be disposed for operation in many different types of food processing plants and facilities. The tunnel 12 includes a housing having a sidewall 22 which defines the space 14 . At a region of the sidewall 22 , usually at an upper area of the sidewall, there is provided an aperture 24 or port therein.
[0018] Referring more specifically to the apparatus 10 of the present embodiments, said apparatus includes a pipe 26 having an upper end with an opening 28 into which can be introduced by gravity or otherwise liquid nitrogen (LIN) 30 . The pipe 26 extends through the aperture 24 in the sidewall 22 of the freezing tunnel 12 and terminates in another opening 32 in the space 14 . At the opening 32 of the pipe 26 , said opening splits into a “T” for branches 34 , 36 which are in fluid communication with an internal space 38 of the pipe 26 . Each one of the branches 34 , 36 has at least one corresponding nozzle 40 or nozzle 42 , respectively. The nozzles 40 , 42 are also disposed in the space 14 , each nozzle having a respective opening 44 , 46 in close proximity to the conveyor belt 18 and food product 16 being transported thereon.
[0019] The LIN pipe 26 has disposed within the internal space 38 a back flow preventer 48 and, further downstream in the pipe 26 , a control valve 50 . Accordingly, the LIN 30 introduced through the opening 28 into the pipe 26 travels through the internal space 38 where its flow rate is controlled by the control valve 50 , while the backflow preventer 48 prevents the LIN, regardless of pressure in the internal space or the chamber 14 , from being exhausted or regurgitated upstream and back through the opening 28 and into the plant or other processing facility.
[0020] The LIN flow 30 being introduced into the pipe 26 flows continuously through the internal space 38 as indicated generally at 52 , until such time as the LIN flow comes in contact with gaseous nitrogen, as will be explained below.
[0021] The apparatus 10 includes another pipe 60 having an opening 62 into which gaseous nitrogen 64 can be introduced into an internal space 66 of the pipe. The pipe 60 extends to have another opening 68 . The pipe 60 is constructed to join in fluid communication with the internal space 38 of the pipe 26 . The region where the opening 68 of the pipe 60 is in fluid communication with the internal space 38 of the pipe 26 is shown generally at 70 . A flow of the gaseous nitrogen is shown generally by arrows 72 .
[0022] Disposed in the internal space 66 of the pipeline 60 is a modulating valve 74 and an on/off valve 76 . As is shown in the FIGURE, the modulating valve 74 is disposed upstream of the on/off valve 76 in the internal space 66 .
[0023] Downstream in the internal space 66 from the on/off valve 76 and upstream of the opening 68 there is disposed a pulsing valve 78 . The pulsing valve 78 is disposed slightly upstream from the opening 68 and the region 70 , just before the gaseous nitrogen 64 is introduced into the LIN flow 52 travelling through the pipe 26 . The pulsing valve 78 includes a planar member 79 , such as for example a circular disc, mounted to an axle 81 or spindle which is connected to a motor 82 or other power source to rotate the axle. The disc has a diameter slightly less than a diameter of the internal space 66 , and a circumference slightly less than a cross-sectional circumference of the internal space 66 so that the disc can freely rotate therein. The pulsing valve 78 operates by rotating the flat circular disk in the pipe 60 at a selected speed to provide the pulse rate of gas flow 72 into the LIN flow stream 52 . That is, a higher rotational speed of the disk will result in a higher pulse rate, while a lower rotational speed of the disk will result in a lower pulse rate.
[0024] The modulating valve 74 is used to control the flow of the gaseous nitrogen 64 , while the on/off valve 76 is used to shut off the flow completely or allow same to pass.
[0025] The region 70 where the pipelines 26 and 60 are in fluid communication is shown as a “Y” junction for the gaseous nitrogen to be “pulsed” into the LIN flow 52 . The region 70 could alternatively be constructed as a “T” junction.
[0026] The operation of the apparatus 10 will now be described. The LIN control valve 50 is opened to permit liquid nitrogen to begin flowing along the internal space 38 of the pipe 26 in a direction to the food freezing tunnel 12 . The LIN flow 52 flows into the spray manifold which consists of the branches 34 , 36 in fluid communication with the pipe 26 and thereafter through the nozzles 40 , 42 , whereupon the LIN is deposited onto the food product 16 being transported on the conveyor belt 18 through the space 14 .
[0027] After the LIN flow 52 is established, a pulsed atomized flow of gaseous nitrogen is produced by actuating the pulsing valve 78 , after which the modulating valve 74 and the on/off valve 76 are also opened. High pressure gaseous nitrogen 64 at a pressure higher than the LIN flow 52 travels down the pipeline 60 and into the LIN flow 52 . The pulsing valve 78 opens and closes at a fixed or variable rate. When the pulsing valve 78 is closed, a minimal gas flow into the LIN flow 52 occurs. However, when the pulsing valve 78 is opened, the gaseous nitrogen 64 flows into and contacts the LIN flow 52 at the region 70 . The rate of rotation of pulsing valve 78 determines the frequency of liquid/gas pulsing 80 to be sent from the nozzle openings 44 , 46 to the underlying food product 16 . The pulsing valve 78 is a butterfly valve which is constructed for this application to attain high speed, continuous rotation. An actuator or motor for the valve 78 can be speed controlled, and also stopped for the valve to be in either open or closed positions with respect to the internal space 66 .
[0028] The apparatus 10 also provides for maintaining the pulsing valve 78 in an open or closed position or “unbalanced durations” in order to vary a degree of liquid or gas pulse composition to be used for the particular application. It is also possible to use the modulating valve 74 and control valve 50 to control the gas-liquid mixture ratio to occur at the region 70 . This ratio can determine the degree of atomization and the resulting nitrogen droplet size to be present in the liquid gas pulses 80 emitted from the nozzle openings 44 , 46 . This arrangement permits the apparatus 10 to, in effect, provide a pocket of gas followed by a pocket of liquid repetitively and continuously as necessary for the liquid-gas pulses 80 to flow from the region 70 through the nozzles 40 , 42 and the nozzle openings 44 , 46 .
[0029] When liquid and gaseous nitrogen are used, the gaseous nitrogen 64 must always be at a higher pressure than the LIN 30 to prevent a backflow of the LIN into the internal space 66 of the pipe 60 .
[0030] In those applications where carbon dioxide is used, both liquid and gaseous carbon dioxide must be maintained at a pressure exceeding 100 psig so that the liquid CO 2 can be delivered in the apparatus. However, the gaseous CO 2 delivered to the pipe 60 must always be at a pressure above a pressure of the liquid CO 2 delivered through the pipe 26 to similarly prevent a backflow of the liquid CO 2 from entering into the internal space 66 of the pipe 60 .
[0031] The pipes 26 , 60 can be manufactured from stainless steel, copper, aluminum or any other material suitable for being exposed to fluids at a cryogenic temperature.
[0032] The apparatus 10 and related method of the present embodiments increases overall heat transfer effect to cryogenic tunnel freezers and therefore, increases the overall efficiency of freezing applications.
[0033] It will be understood that the embodiments described herein are merely exemplary, and that one skilled in the art may make variations and modifications without departing from the spirit and scope of the invention. All such variations and modifications are intended to be included within the scope of the invention as described and claimed herein. Further, all embodiments disclosed are not necessarily in the alternative, as various embodiments of the invention may be combined to provide the desired result. | An apparatus for providing a liquid-gas entrained cryogen mixture onto a food product includes a first pipe through which is provided a flow of liquid cryogen; a second pipe through which is provided a flow of gaseous cryogen, the second pipe in fluid communication with the first pipe at a mixing region; and a pulsing valve disposed at an interior of the second pipe upstream of the mixing region, the pulsing valve adapted for releasing the gaseous cryogen into the liquid cryogen at select intervals of time to provide a pulsating flow of the liquid-gas entrained cryogen mixture downstream of the mixing region for contacting the food product. A related method is also provided. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to security screen devices for protecting persons and property and, more particularly, it relates to security screens which can be activated upon occurrence of a predetermined event to protect persons and property from injury and/or damage that could be inflicted by high velocity projectiles such as bullets, shrapnel, and fragments resulting from deliberate or accidental explosions.
2. Description of the Prior Art
In these uncertain times of increased terrorism and crime, it has become more difficult to provide protection of persons and property in response to a life-threatening event. The need to protect persons during performance of their jobs and duties is of utmost importance in an effort to save lives and reduce massive property destruction. Conventional devices such as bulletproof vests, blankets, and glass, have been provided in an effort to protect these persons during a crisis event. Unfortunately, these devices are typically quite heavy and cumbersome and require these devices to be permanently deployed in anticipation of the event. When protecting persons and property within vehicles, aircraft, or buildings, use of these devices which must be deployed at all times substantially detract from the aesthetic appearance of the property and often restrict free access.
Accordingly, there exists a need for a security screen device for protecting persons and property which effectively maintains the safety of the person and property when needed, without permanently blocking access to the area. Additionally, a need exists for a security screen device for protecting persons and property which is deployable and retractable to minimize aesthetic deteriation of the protected property. Furthermore, there exists a need for a security screen device for protecting persons and property which is automatically deployable upon command or the occurrence of a predetermined event to protect the person and/or property.
SUMMARY
The present invention is a security screen device for protecting persons and property. The security screen device comprises an enclosed screen housing defining a screen storage area and having one side hinged and latched to allow deployment of the screen. A screen material is receivable within the screen housing in an undeployed condition with the screen material having a first edge and a second edge. The first edge is secured within the screen receiving area and the second edge is attached to a weighted bar. Activation means open the latches holding the hinged side of the housing, allowing the weighted bar and screen to be deployed such that the bar and the screen material travel in a direction generally away from the housing. Movement of the weighted bar and screen material is accomplished by gravity or some powered mechanical means.
Additionally, the present invention includes a system for inhibiting persons from entering a cockpit in an aircraft. The system comprises a container mounted near the ceiling of the cockpit. U-shaped guide channels are secured to the container adjacent the walls of the cockpit and extend from the container to the floor of the cockpit. A projectile resistant material and locking bar is receivable within the container in an undeployed condition and movable within the guide channels into a deployed condition. Activation means automatically activating the material from the undeployed condition to the deployed condition upon the occurrence of a command or some other predetermined event.
The present invention further includes a method for automatically deploying a security screen upon the occurrence of a command or some other predetermined event. The method comprises providing a projectile resistant screen material having a first edge and a second edge, securing the first edge of screen material within an enclosed container, and the second edge attached to a weighted rod, also within the enclosed container. The weighted rod has a first end and a second end and the screen material and the weighted rod are automatically deployed from the container upon the occurrence of a predetermined event. The first end of the weighted rod travels through one of the U-shaped channels and the second end travels through the opposite U-shaped channel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view a security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed within a cockpit of an aircraft;
FIG. 2 is a top sectional view of the security screen device for protecting persons and property of FIG. 1, constructed in accordance with the present invention;
FIG. 3 is a perspective view of the security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed in an office environment;
FIG. 4 is a front view of the security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed as a movable screen;
FIG. 5 is a perspective view of the security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed on a military vehicle;
FIG. 6 is a perspective view of the security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed on a bus; and
FIG. 7 is an elevational side view of the security screen device for protecting persons and property, constructed in accordance with the present invention, with the security screen device being deployed on a limousine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As illustrated in FIG. 1, the present invention is a security screen device, indicated generally at 10 , for protecting persons and property from projectiles and/or explosive fragments. The security screen device 10 is designed to protect areas or walls, windows, and doorways that would not normally be sufficient structural strength to withstand high velocity impacts. The security screen device 10 can be configured for fixed areas or attached to mobile devices and vehicles. In fact, the security screen device 10 of the present invention can be used to protect in a variety of protection scenarios including, but not limited to, pilots within a cockpit of an aircraft, office personnel within an office or other work environment, occupants of a private residence, police or other emergency personnel when entering a potentially dangerous situation, military personnel within a military vehicle and the fuel supply of the military vehicle, drivers and passengers on buses or other mass transit vehicles, important officials and dignitaries within limousines or other vehicles and the fuel supply of these vehicles, etc.
The security screen device 10 can be permanently mounted over spaces, windows, doors, or easily penetrated walls, but are preferably mounted for rapid deployment in the event of an emergency situation. For rapid deployment modes, the security screen device 10 of the present invention includes a substantially enclosed screen housing 12 mounted directly to the property and a screen material 14 stored within and deployable from the screen housing 12 through a hinged door 15 , having hinges 17 , formed in the screen housing 12 . The hinged door is maintained in position, until released, by a latch mechanism or a pin roller.
The screen material 14 has a first edge 20 and a second edge 22 with the first edge 20 secured within the screen housing 12 . The screen material 14 can be rolled or accordion folded into the screen housing 12 with a deployment mechanism or device 18 that provides automatic rapid release of the screen material 14 to drop over the desired vertical surface.
A weighted bar or rod 24 is secured to the second edge 22 of the screen material 14 and provides the screen material 14 with sufficient weight to move quickly toward the ground or floor when deployed from the screen housing 12 . The screen housing 12 maintains the screen material 14 in a folded or rolled configuration prior to deployment of the screen material 14 .
In an alternative embodiment allows the weighted bar 24 to be suspended outside the screen housing 12 with the screen material 14 extending out through a slot in one side of the screen housing 12 .
In certain embodiments, the screen housing 12 further includes a screen track 26 secured to the screen housing 12 . The screen track 26 preferably comprises channels at both sides of the screen housing 12 which constrain and guide the edges of the screen material 14 and the weighted bar or rod 26 and, if appropriate, to lock the weighted bar or rod 26 in position. Gravity deployment actuation may be accomplished with manual, electromagnetic, or electrochemical actuators mounted and/or connected to the screen housing 12 . For other configurations, non-vertical orientations, or for higher speed actuation, gas generators (similar to automotive air bags), pneumatic, or hydraulic means can be used to deploy the screen material 14 from the screen housing 12 . Initiation of the deployment actuators can be accomplished by a manual switch, a radio control or a microprocessor located in or connected to the screen housing 12 that can automatically respond to physical shock, audio sound profiles like those produced by high speed projectiles, gunshots, breaking glass, or voice commands (using word recognition software).
As mentioned above, the screen track 26 is preferably a pair of substantially U-shaped channels extending generally away from and perpendicular to the screen housing 12 . As the screen material 14 is deployed, the edges of the weighted bar or rod 24 and the screen material 14 stored within the screen housing 12 travel in a substantially downward manner along and within the screen track 26 . The screen track 26 enables the screen material 14 to inhibit undesired persons from pushing or otherwise forcing the screen material 14 open to gain access to the protected area. Actual examples of mounting the screen housing 12 and screen track 26 to property and deployment of the screen material 14 will be discussed in greater detail below.
The screen material 14 of the security screen device 10 of the present invention is preferably comprised of one or more layers of high tensile strength fabric, rigid folding panels or a combination of the fabric and panels to shield, deflect, vaporize and/or dissipate the kinetic energy of projectiles or explosive fragments. The screen material 14 can be constructed from a wide range of materials such as Kevlar, carbon fiber, and/or glass fibers, epoxies, hybrid combinations of materials weaves, weights, and layering options thereby allowing the screen material 14 to be designed for specific ranges of projectile types and velocities or for various ranges of impact resistance and operating environments. The fiber materials of the screen material 14 can be rigidized for certain applications by the use of epoxy materials to impregnate the fibers to form composites of various shapes and configurations.
The screen material 14 of the present invention is much stronger, lighter, and more adaptable than equivalent armor plate and can be used to provide supplemental protection to aircraft, automobiles, buses, trucks, watercraft, armored vehicles or other armored structures such as fuel tanks, as discussed above.
The screen material 14 can also be constructed from material developed by NASA to protect spacecraft from hypervelocity impacts of micrometeorites or orbital debris. The screen material 14 additionally provides protection from low velocity impacts and attempts to cut or push through by undesirable persons. For very high velocity projectiles, the first layer of the screen material 14 can fragment or partially vaporize the projectile causing the penetrating fragments to be spread over a larger area of the second layer. The process continues for each successive layer penetration until the resulting particles are rendered harmless. For lower velocity impacts, the structural integrity and flexural response of the screen materials dissipates the energy of the projectile or force applied in the form of limited motion and heat. The strength of the materials used in the screen material 14 and the weave of the fabrics and panels makes it extremely difficult for a person to cut or force his or her way through the screen material 14 .
After deployment of the screen material 14 , re-stowage of the screen material 14 and the weighted bar 24 into the screen housing 12 for subsequent use can be accomplished manually or with the aid of electromagnetic, pneumatic, or hydraulic actuators which retract the screen material 14 and the weighted bar 24 into the screen housing 12 ready for the next deployment event.
As discussed above, the security screen device 10 of the present invention can be utilized in many different scenarios. The examples listed below are listed as examples only and the person skilled in the art will understand that other scenarios for using the security screen device 10 are within the scope of the present invention.
Example 1
As illustrated in FIGS. 1 and 2, the security screen device 10 can be retrofit into an existing airliner or built into new aircraft to protect the pilot's cockpit from intrusion by hijackers. The screen housing 12 is mounted near the cockpit ceiling 28 above the cockpit door 30 extending the entire, feasible width of the aircraft's cabin. The U-shaped screen track 26 is attached to each side of the screen housing 12 , extending from near cockpit floor 32 to near the cockpit ceiling 28 and can actually be used to help support the screen housing 12 to the ceiling 28 of the cockpit. The screen housing 12 and the screen track 26 are both firmly attached to aircraft structural components to provide additional structural strength. In normal circumstances, the security screen device 10 is unobtrusive, out of the way for normal access to the cockpit and much lighter than armor plating of equivalent protection.
In the event of a hijack attempt or other threatening disturbance in the aircraft's main cabin, a switch (not shown) located in the cockpit or a microphone and microprocessor in the security screen device 10 responding to specific sound profiles (gunshots, loud screams) or specific words (hijack, gun, knife, etc.) initiates an audio and/or visual alarm to the crew and deployment of the screen material 14 from the screen housing 12 . The weighted bar or rod 24 at the second edge 22 of the screen material 14 drops within the side U-shaped screen track 26 and is automatically or manually locked to the floor 32 of the aircraft by a locking mechanism 34 . The screen material 14 , extending from the floor 32 to the ceiling 30 and effectively the full width of the cabin, blocks the hijacker's view of the cockpit and prevents entry. Because of the bullet and cutting resistance of the screen material 14 , the pilots and flight controls are inaccessible to the hijackers, allowing time for emergency descent and landing. Automatic locking of the drop bar 24 to the cockpit floor 32 could be used to enforce non-negotiation security policies by preventing the pilots from opening the screen material 14 , without ground crew support, in response to the hijacker's threats to harm crew and/or passengers.
Example 2
As illustrated in FIG. 3, the security screen device 10 of the present invention can be installed at the entryway and/or at critical doors or windows for government or business office that are at risk from any number of hazards. The screen housing 12 can be mounted above the critical areas and decorated to blend into office interior design. Actuation of dropping the screen material 14 in an emergency situation is preferably accomplished by the office burglar/fire alarm, by manual commands, or by the automatic devices built into the security screen device 10 such as audio profile recognition (gunshots, projectile acoustics, breading glass, explosion sounds) or voice recognition commands (help, gun, knife, etc.). Various deployment safety overrides (optical sensors, obstruction sensors) and warning signals would be used to prevent harm to the authorized occupants during deployment of the screen 10 .
Example 3
The security screen device 10 of the present invention can be installed at the entryway or at critical doors or windows for a private residence that are at risk from any number of hazards. The screen housing can be mounted above the critical areas and decorated to blend into the residence interior design. Actuation of dropping the screen material 14 in an emergency is preferably accomplished by the residence burglar/fire alarm, by manual commands, or by the automatic devices built into the security screen device 10 such as audio profile recognition (gunshots, projectile acoustics, breaking glass, explosion sounds) or voice recognition commands (help, gun, knife, etc.). Various safety overrides (optical sensors, obstruction sensors) and warning signals can be used to prevent deployment that would present a risk to the authorized occupants during deployment of the screen 10 .
Example 4
As illustrated in FIG. 4, the security screen device 10 of the present invention can be mounted on a folding, wheeled-support structure 36 for utilization by police, SWAT teams, or military personnel to protect themselves while approaching an armed assailant. A mirror (not shown), mounted at the top of the screen material 14 , could provide visibility without exposing the users to the assailant. Two or more of the security screen devices 10 could be used in conjunction to protect the users from gunfire from more than a single direction.
Example 5
As illustrated in FIG. 5, the security screen device 10 of the present invention can be mounted and deployed on unarmored or lightly armored military vehicles 38 as required for protection of the passengers. Mirrors, more elaborate optical periscopes, or all light level video systems could provide visibility for maneuvering and gun turret control.
Example 6
The security screen device 10 of the present invention can be mounted and deployed on armored vehicles with the security screen devices 10 being mounted internally to provide additional protection to driver and passengers during emergency situations.
Example 7
As illustrated in FIGS. 6 and 7, one or more security screen devices 10 of the present invention could be mounted to the sides, front, and rear of automobiles 40 and buses 42 operating in hazardous areas and deployed as necessary for protection of the passengers. Mirrors or other devices could provide driver visibility when deployed.
The foregoing exemplary descriptions and the illustrative preferred embodiments of the present invention have been explained in the drawings and described in detail, with varying modifications and alternative embodiments being taught. While the invention has been so shown, described and illustrated, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention, and that the scope of the present invention is to be limited only to the claims except as precluded by the prior art. Moreover, the invention as disclosed herein, may be suitably practiced in the absence of the specific elements which are disclosed herein. | A security screen device for protecting persons and property is provided. The security screen device comprises an enclosed screen housing defining a screen receiving area. A screen material made of high strength fibers is receivable within the screen housing in an undeployed condition with the screen material having a first edge and a second edge. The first edge is secured within the screen receiving area and a weighted bar is secured to the second edge of the screen material. An activation mechanism opens one side of the screen housing releasing the screen material from the housing into a deployed condition such that the second edge of the screen material travels in a direction generally away from the enclosed screen housing thereby pulling the screen material from the enclosed screen housing. | 4 |
[0001] The following is a description of exampled embodiments, which is further described by the included drawings. The embodiments are examples, and are in such detail for clear communication of the specification. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures. The descriptions and drawings below are designed to make such embodiments obvious to a person of ordinary skill in the art.
BACKGROUND
[0002] Early in the 1990's the evolution of scalar type armor was reinvented using 1″ diameter 0.032 thick titanium alloy discs in an imbricated pattern applied to an adhesive coated high strength fabric substrate(s). This eliminated rivets, wires, or sewn envelops as was the method of affixing tiles or coins in a scalar armor format using the prior art. Further evolution of this method involved using larger high toughness metallic or high hardness ceramic 2″ diameter disks formed into a discus shape to limit weight and thickness of the redundant overlaps inherent in scalar armor. The problem however with scalar rifle resistant armor systems has always been the excessive thickness and weight caused by the redundant two and three tile overlaps present over the entire system. These overlapped areas when flexed caused weak areas of the system, and a weight penalty that is no longer competitive in the current art of today's modern ballistic armor systems. Thus there is a need to reduce the weight and thickness while improving flexibility of an armor system meant to defeat rifle rounds in the modern era of armor meant for body protection, vehicles, aircraft, and structures.
BRIEF DESCRIPTION OF DRAWINGS
[0003] FIG. 1 is an example shape of the tile used for first embodiment.
[0004] FIG. 2 is a top view or a tile array and a side angle view of the same tile array using a high hardness and/or high tensile strength material adhered to a depressible substrate, and a protective surface substrate.
[0005] FIG. 3 is another example embodiment using a two layer high hardness and/or a high toughness material adhered to a depressible substrate.
[0006] FIG. 4 is a layer composite view of the textile backing system and construction, and a side angle view of the various textile packs.
[0007] FIG. 5 is a layer composite view of the alternate textile backing system and construction.
[0008] FIG. 6 is a side view of the final flexible composite with all the panels of the above figures placed in order as the product is designed to function.
[0009] FIG. 7 is a side view of applying the completed armor apparatus to a structure.
[0010] FIG. 8 is a top view of the various body armor protection panels.
DETAILED DESCRIPTION OF THE INVENTION
[0011] “This Non-Provisional application claims the benefit of U.S. Provisional Application No. 62/122,442 filed on Oct. 22, 2014”
[0012] FIG. 1 depicts a shape of a high hardness and/or high toughness material that comprises the component used as the strike face of the armor system, and is designed to blunt and/or tear apart the bullet for the remainder of the system to catch the resulting fragmentation. In typical rigid uniform planular hard plates or scalar armor meant for defeat of rifle projectiles the strike face material is typically comprised of ceramic, and is usually a large tile or monolith; even mosaic tile systems are usually at least 1″ in diameter representing a large width to thickness ratio. In these described typical embodiments of the prior art, the high hardness and/or tough material(s) are usually laminated to a rigid textile substrate to restrict the movement of the strike face components so as to prevent the material from flying apart too quickly during the ballistic event. The energy dispersal pattern with these large width tiles is described as expending and propagating energy horizontally from the bullets impact location, and this phenomenon is referred to as shock wave propagation. The invention herein called Non-Scalar Flexible Rifle Defeating Armor uses a different shape component, such that the thickness is closer in proportion to the width of said component, which can be comprised of a high hardness ceramic materials, cermet's, nanomaterials, metals, or really any material that has mechanical properties high in hardness, tensile and/or modulus strength.
[0013] For the purposes of describing this embodiment the component is comprised of silicon carbide as an example. When the shape of the strike face component has a ratio whereby the thickness is closer in proportion to the width the directional shock wave forces tend to move along with the directional path of the projectile through the component tile material, and thus causes less collateral damage and thereby increases repeat hit capability. In testing to the NIJ 0101.03 standard a complete flexible panel inclusive of all the substrates and arrays as shown in FIG. 2 was able to defeat 11 M-80 FMJ projectiles in a row on a small 10×12 flex panel. After the post mortem was conducted on the shot panel it was obvious that there was significant room for more shots which is something not achievable with a rigid ceramic textile composite representative of the prior art. The typical ceramic tile used for a rigid armor plate is a 50.8 mm wide square for mosaic designs and the thickness is anywhere from 4.2 mm-5 mm for NIJ threat level 3, and 50.8 mm wide and 9 mm-11 mm thick for NIJ threat level 4. The ratios created are greater than 4.6:1, whereas in the instant invention the ratio of component tile 10 is less than 4.6:1 ratio between the thickness of the component tile and the width of the same tile. In FIG. 1 tile 10 and tile 20 illustrate ratios of less than 4.6:1, and this ratio can be further reduced as it is economically viable. Additionally the typical high hardness material like silicon carbide that many rifle resistant systems are comprised of have a method of containing the ceramic tile using a fiber and epoxy induced wrap in order to prevent the ceramic from flying apart on impact maximizing the time the ceramic is involved in the ballistic event in order to create the most damage to the projectile. Tile 10 and tile 20 in FIG. 1 requires no epoxy and fiber induced wrapping to achieve maximum performance of the strike face component, and can be affixed to a high temperature resistant, high peel strength adhesive coated high tensile strength fabric material as described in FIG. 2 , thus eliminating expensive and time consuming autoclave and epoxy prepreg layups. Tile 10 and 20 are shown as a hexagon and square respectively, but any shape that can butt up to a contiguous or adjacent side of a another identical tile and expose no foraminous areas of the array(s) are suitable, for example, a triangular tile is within the spirit and scope of the invention as the shape for the strike face component including partial shaped finish pieces.
[0014] FIG. 2 depicts an angled top view of the strike face component tile 10 along with other identical strike face components fitted butt to butt with each other to create a tile array 30 . Additionally, we view the tile array from the side view depicting the thickness of the strike face component 40 . The tile array 30 is achieved by placing the strike face components tile 10 butt to butt including finish pieces 50 to complete the desired final shape of the armor panel, and is adhered to with at least 1 mil thick adhesive coated high tenacity substrate material 60 comprised of at least 1 layers of high strength woven or UD aramid fabric, although any high strength fabric can be used for this purpose. The next substrate 70 is a depressible medium that has a shock absorbing effect, and is designed to allow tile component 10 independent movements within the tile array 30 with respect to the path of the bullet's impact direction. This causes energy dissipation through the tile as the bullet impacts the tile components 10 enabling a longer amount of time the bullet is in contact with the high hardness and/or high toughness strike face component 10 . This effectively also causes a yaw of the bullet's direction at impact as components 10 although fitted butt to butt with other identical tiles tend to move independently of other tiles when impacted by a projectile. The next pack of high strength textile material 80 is usually comprised of UD polyethylene, but can use any high strength fabric. This is the area where the bullet fragments are caught after passing through the high hardness facing material 30 and depressible substrate 70 . The final substrate is a surface protector 90 to preserve the integrity of the strike face component 10 and the surface array 30 from damage due to dropping the plate or from low velocity objects impacting the surface. As a method of completing armor array 100 at least one retaining strap 110 is used, which is comprised of the same adhesive coated high strength fabric 60 , and wraps around any side of the armor panel to couple substrates 30 , 60 , 70 , 80 , and 90 together. This coupled armor panel array 100 is then housed in a water proof nylon bag ready for use. Depending on how much high tenacity textile layers in pack 80 is used determines whether this finished armor panel array 100 is an “in conjunction with” flexible armor panel or a “stand alone” flexible armor panel. If it is layered to be a “in conjunction with” armor panel then it will have to be fitted in front of a NIJ 0101.06 Level 3-A soft armor panel to function.
[0015] FIG. 3 depicts an alternative embodiment comprised of two different sizes of the original strike face component tile 25 having the width/thickness ratio greater than 4.6:1 and a second strike face component tile 35 with a width/thickness ratio of less than 4.6:1. Tiles 25 and 35 in the two layer array requires that the overall desired thickness is split into 2 or slightly greater so as not to be excessively heavy, therefore tiles 25 and 35 require a change in the width/thickness to maintain the desired ratio as stated above for this two layer array. The larger than 4.6:1 ratio strike face component tile 25 serves as the strike face of the two layer array, and tile 25 is again fitted with a number of other tile 25 components to create tile array 120 . Then as before tile 25 is affixed to at least one adhesive coated high strength fabric substrate 60 , and then to another substrate 70 comprised of a depressible spaced foam or other suitable shock absorbing spacer material of at least 1 mm in thickness. The second array layer utilizes the strike face component tile 35 which is less than the 4.6:1 width to thickness ratio along with other identical strike face components 35 fitted butt to butt with each other to create a tile array 140 . Additionally, The tile array 140 is achieved by placing the strike face components tile 35 butt to butt to the desired final shape of the armor panel, and then adhered to an adhesive layer 65 usually comprised of at least 1 mil in thickness. The two arrays achieve a complimentary energy transfer by combining horizontal and vertical energy dissipation patterns by combining the energy dissipation tendencies of the two different width/thickness ratio tiles and their respective arrays. The ballistic event begins by the projectile impacting tile array 120 and at this instance the energy is dispersed horizontally from the impact location, while simultaneously blunting the projectile. The next tile array 140 being spaced on the other side of the depressible substrate 70 remains relatively unscathed, and therefore allows the second part of the ballistic event causing vertical energy dissipation in the strike face component 35 and a significant yaw of the bullet. This second tile array 140 energy dissipation is in a complimentary direction as compared to tile array 120 . The tile array 140 simultaneously causes significant damage to the projectile and/or the projectile penetrative core. The two finished tile arrays 120 and 140 with the other cited substrates are stacked and then pressed with a silicon elastomer rubber adhesive to create the shape and final tile array 160 flexible armor panel, or can be used as loose tile arrays coupled by traditional attachment comprised of sewing, adhesive strips etc. and are then ready for placement in front of a suitable high strength package 80 comprised of aramid and/or UDPE, which flexibly catches any resulting fragmentation that pierces the tile arrays 160 . Prior to pressing the two layers together as an option, “tabs” 150 comprised of high strength aramid fabric or other suitable materials can be placed in between the tile array 120 and 140 and the various substrates to be sandwiched permanently affixed during the pressing and curing process, and then used as a sewing medium to apply these resulting flexible coupled arrays to a soft armor backing 80 meant to catch fragmentation. Typically this textile fragment catch 80 would be considered an NIJ level 3-A panel, but it can be comprised of any textile configurations using a variety of materials to enhance fragmentation resistance, and is always placed behind the tile array(s) of any composition defined in the spirit and scope of this invention.
[0016] FIG. 4 illustrates an example of a high fragmentation resistant armor panel comprised of a variety of the most advanced high strength fabrics on the market. Depending on the application the combination can change, but in every exampled embodiment a high strength fabric meant for ballistics is used. In this example we have a side view, and side view of a square armor panel to illustrate the construction. The first pack 170 is comprised of a KEVLAR® 129−1420 denier fabric impregnated with a silicone elastomer rubber material 175 of at least 0.10 mm thickness and comprises 20% of the overall package; The second pack 180 is comprised of the latest generation UDPE flexible laminates comprising a 60% portion of the overall package. Finally the last pack 190 is comprised of KEVLAR® KM2+600 denier stitched in a diamond square pattern and no resin impregnation. All the packs 170 , 175 , 180 , and 190 are combined together making pack 200 . Pack 200 weighs at least 1 Lbs./Sq. Ft, but allows for a 20% increase in fragmentation and small arms (9 mm) ballistics, which exceeds military Mil Spec 662F specification for the current military offerings, and any and all addendums to this test specification. Typically this package would either have the aforementioned tile array packs tack stitched onto this textile soft armor package 200 described as integrated, or the textile soft armor package 200 would be housed in a protective NYLON® cover and the tile array packs would be used as a separate panels and considered “in conjunction with” to achieve the high threat flexible NIJ level 3 and/or 4 performance with the soft armor pack 200 behind aforementioned tile arrays packages.
[0017] FIG. 5 illustrates a composite side view of an alternate textile backing comprised of 100% aramid fabrics, pre impregnated with silicone elastomer rubber or similar flexible resins or agents that secure the layers together, but do not impede the fabrics from elasting to their full tensile strength. There are many configurations that can work using this method, but the one illustrated is comprised of two of the top aramid fibers for fragmentation, and one of which, possesses high performance ballistic grade capabilities as well. Since this is a soft ballistic flexible textile system, the intension is that it could be used by itself without combining it with any of the aforementioned tile arrays for defeat of pistol rounds and high velocity frags of varying sizes. The first pack is comprised of at least one ply of KEVLAR® 1420 denier fabric 210 impregnated with curable silicon rubber 220 of at least 1 mil on a side or on both sides, and is stacked to make up about 50% of the weight of the soft textile package. The next pack is a comprised of at least one ply of KEVLAR® KM2+600 denier fabric 230 again impregnated with a curable silicon rubber 220 of at least 1 mm on a side or either side. The various silicon elastomer impregnated aramid layers 210 are stacked consistent with achieving the desired threat protection with the KEVLAR® 1420 denier 210 as the intended strike face and the KM2+600 denier 230 as the wearers side into one package, and then all the layers are pressed and heated to cure the silicone rubber and to compress the layers together into a solid flexible composite 240 . Once cured the textile package can be cut to size, and can either be placed behind the aforementioned tile arrays as the fragment catch for the remains of rifle rounds that pass through the tile array(s), or these soft textile packs can be used to make a fragmentation liner for vehicles, aircraft, buildings, or body armor. This embodiment is particularly effective against broken tungsten penetrators and the most likely solution for placement behind the aforementioned tile array panel(s) designed for NIJ level 4 as opposed to level 3 projectiles.
[0018] FIG. 6 illustrates two examples of how the various parts of the system described above are comprised to complete the rifle defeating system. The first finished tile array 100 , which is the strike face of the system is applied to the finished textile pack 200 , either by stitching tabs 150 extending from inside the finished tile array 200 or by placement of at least one adhesive coated strap(s) 110 in the horizontal and/or vertical direction and wrapping the strap(s) 155 around the body of the armor panel arrays and substrates 100 and 200 . Typically stitching is performed to tack the finished tile array 100 to the finished textile pack 200 when the systems is integrated or standalone meeting the threat as a complete unit, or is strapped with adhesive coated strap(s) as mentioned above and then placed in a separate protective cover and used to upgrade a soft armor system as an “in conjunction with” upgrade creating an scalable modular system that can be upgraded or scaled down as desired by the wearer. Additionally, it is possible to just press the tile arrays and substrates together, and use a pressed and cured unit ready to be housed in a protective cover eliminating tabs, straps, or stitching to complete the finished panel(s). The methods above are examples of typical embodiments and should not limit the contemplations of final use of the inventions described above.
[0019] FIG. 7 shows the final tile array “strike face” and the final textile package and tile pack array now 240 coupled with an adhesive film against the interior of a structure, as an example an airplane fuselage 250 using an adhesive film and release paper 260 . In this example the release film has been removed prior to adhering the armor panel 240 to the fuselage 250 . There is no need to press to shape as long as the parts are the right two dimensional size, the flexible nature of the panels allows easy install. This method is an instant invention described as “peel and stick” high threat flexible rifle and/or fragmentation armor.
[0020] FIG. 8 shows a top view of an exampled front panel of body armor with the finished tile array 100 tack stitched through tabs 150 , and also through the finished textile package 200 illustrating an integrated system where the rifle defeating area is smaller than the textile package 200 , and the whole complete composite is housed in one protective cover prior to be inserted into a carrier system for suspension around the body. The “in conjunction with” method would involve placement of the finished tile array 100 into a separate protective cover, and then into a separate pocket as the strike face in front of textile pack 200 which is also inserted into a typical tactical carrier or concealable carrier. The flexible rifle defeating areas only exist within the perimeter of the tile array 100 “in conjunction with” pack 200 . Areas of the textile pack 200 that do not have coverage of the tile array composite 100 are only effective against fragmentation and small arms pistol threats. | The invention combines tiles with an optimal width to thickness ratio together into array(s), and then affixes the array(s) to a depressible adhesive coated substrate. This combination of array(s) and substrates compliments the optimal tile thickness to width ratio to create a more advantageous directional shift of energy dissipation that creates a yaw of the bullet's direction, and subsequent increase of ceramic thickness that the projectile must pass through. The invention eliminates hard epoxies and rigid fiber induced wraps to create a truly flexible matrix that can be applied for use to protect the body with traditional concealable or tactical carriers, or can be used as a “peel and stick” high threat armor system that can be easily field mounted to a vehicle, structure, or aircraft. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §DE 10 2009 027 200.3 filed Jun. 25, 2009, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The invention relates to a process for roughening metal surfaces in order to improve the adhesion of layers thermally sprayed thereon.
[0004] 2. Background Art
[0005] WO 2007087989 A1 discloses a process for roughening metal surfaces in order to improve the adhesion of layers thermally sprayed thereon, wherein uniform grooves, e.g. rectangular or trapezoidal grooves, are introduced into the metal surface and resulting ridges are plastically deformed in order to form undercuts along the ridges. A disadvantage of this process is that the ridges are plastically deformed over their entire length. This requires a relatively large effort, it being possible to make the shape of the undercuts constant only with difficulty. Furthermore, the formation of the undercuts over the entire length of the grooves ensures that the grooves are filled completely by the spraying material only to a limited extent, since the adjacent undercuts form a narrow point through which only some of the spraying material can penetrate into a groove.
SUMMARY
[0006] Since the degree of plastic deformation of the ridges varies regularly in the longitudinal direction of the grooves, the undercuts can be introduced into the ridges in a targeted manner at regular portions. For this purpose, the ridges are each locally deformed by suitable tools in such a way that these undercuts are produced. As seen in the longitudinal direction of the grooves, this leads to a constant, but regular, variation in the shape of the undercuts. In this case, some of the undercuts may not even occur at all since, at certain points, the degree of plastic deformation is only low or no plastic deformation is present at all.
[0007] This regular variation in the groove shape means that the undercuts which then occur regularly can be introduced into the ridges with relatively little effort since, overall, only a small degree of plastic deformation of the ridges is required. Furthermore, the undercuts can be introduced with increased accuracy. As a result, these are produced regularly with identical dimensions along the grooves. This is a major advantage for uniform adhesive strength of the sprayed layer subsequently applied. It is also advantageous that the spraying material to be applied can fill the grooves very well since these regularly do not have any undercuts or have at least relatively small undercuts. In these regions, the spraying material penetrates very well into each groove and can then easily fill the directly adjacent groove regions with the undercuts.
[0008] In one advantageous embodiment, the plastic deformations are knurls on the top face of the ridges. For this purpose, a known knurling tool is moved along the groove. Depending on the form of the knurling tool, this produces the uniform plastic deformations according to the flute shape of the knurling tool.
[0009] In a further embodiment, the plastic deformations are local indentations on the top face of the ridges. This can be introduced by a roller having corresponding projections, points or needles.
[0010] In both cases, the undercuts are produced by pressing the groove with such a force on the top face that the groove is pressed in plastically and, as a result, the groove flanks are deformed plastically toward the side—transversely with respect to the longitudinal direction of the groove.
[0011] In another embodiment, the plastic deformations are local mortices in the ridges transversely with respect to the direction of the grooves. This can be done by moving a roller in the groove, this roller having regular projections, points or shoulders on the radial circumference which deform the groove transversely with respect to the longitudinal direction of the groove. The groove is then bent over plastically transversely with respect to the longitudinal direction thereof. Since the ridges remain undeformed in the groove root, the ridges are subjected to more severe deformation, and virtually inclined, in the transverse direction as their height increases, as a result of which the undercuts are produced in the grooves.
[0012] The plastic deformations can be local indentations of the ridge edges. This can be implemented by appropriately pressing in or crimping the ridge edges at regular intervals, as a result of which the undercuts are produced on the groove flanks.
[0013] A tool for introducing the plastic deformations can have at least one punch. This punch can advantageously move in a cyclic manner. When the tool is guided over the grooves, the moving punch produces the corresponding plastic deformations of the ridges. In this case, the punch can have an appropriately shaped punch head, and the punch can act on the grooves in any suitable direction in order to produce the optimum shape of undercuts on the ridges. By way of example, the punch can act directly perpendicularly on the top face of the ridges, as a result of which the ridges are pressed from above and the ridge material thereby flows in the transverse direction. However, the punch can also act in the transverse direction with respect to the grooves at a shallow angle, as a result of which the ridges are deformed transversely with respect to the longitudinal direction thereof.
[0014] A tool for introducing the plastic deformations may be guided in, on, or by a groove. Therefore, it is possible for the tool to always be aligned precisely with respect to the ridges and for only one of the adjacent ridges to be machined. Since the tool is guided on, by, or in the grooves, the ridges are always deformed relative to the groove and the deformation can thus be carried out with high precision and repeatability.
[0015] It is particularly advantageous if the plastic deformations in the second process step are introduced in the same operation as the first process step. By way of example, a tool for the plastic deformation can be arranged downstream of a turning, drilling or milling tool. In this case, the tools for the first and second process steps are advantageously mounted on the same tool carrier, e.g. a milling or turning spindle. Therefore, the first and second process steps take place virtually at the same time or in brief succession. In addition to reduced time (no further operation is necessary), the outlay in terms of measurement or apparatus is also reduced for the second process step. Both tools are coupled directly to each other and have to be aligned with respect to each another only once.
[0016] The described methods for producing the plastic deformations and the undercuts can be suitably combined. By way of example, plastic indentations from above can alternate with indentations in the transverse direction and/or deformations of the groove flanks. A tool can introduce various plastic deformations and/or a mixture or superposition of said plastic deformations. It is also possible to suitably combine a plurality of tools for carrying out the second process step in order to produce the most beneficial undercuts possible.
[0017] The disclosed method is particularly suitable for machining and preparing the coating of cylinder blocks of internal combustion engines. The process is readily useable in the relatively small cylinder bore since it is possible to reliably introduce the undercuts required into the ridges in a very uniform manner with little effort.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further advantageous embodiments of the invention are illustrated in the drawings, in which:
[0019] FIG. 1 shows a section through a workpiece and two tools for carrying out a surface roughening process;
[0020] FIG. 2 shows a plan view of the arrangement shown in FIG. 1 ;
[0021] FIG. 3 shows the enlarged excerpt A from FIG. 1 ;
[0022] FIGS. 4 a - d show sections through ridges with different deformations;
[0023] FIGS. 5 a - d show perspective views of the deformed ridges shown in FIG. 4 ;
[0024] FIGS. 6 a - b show a side view and a section of a roller for indentations;
[0025] FIGS. 7 a - b show a side view and a section of a roller for ridge edge deformations;
[0026] FIGS. 8 a - c show a side view and sections of a roller for transverse deformations;
[0027] FIGS. 9 a - b show a side view and a section of a punch tool for ridge edge deformations;
[0028] FIGS. 10 a - c show a section and plan views of a punch tool for transverse deformations; and
[0029] FIGS. 11 a - c show a section and plan views of a twin roller for transverse deformations.
DETAILED DESCRIPTION
[0030] FIGS. 1 to 3 show an arrangement for carrying out a surface roughening. The workpiece may be, for example, a cylinder block 1 and has a metal surface 2 which is prepared by means of the process in order to make it possible to apply a sprayed layer. A tool holder 5 , which bears a turning tool 6 , is fastened to a tool spindle 4 . Since the tool spindle 4 rotates and slowly moves downward into the cylinder bore 3 , the turning tool 6 produces, in the metal surface 2 , the grooves 7 which run in the circumferential direction and have the intermediate ridges 8 .
[0031] A rotatable knurling roller 9 is arranged on the tool holder 5 and acts on the ridges 8 by means of regular projections 10 which are arranged on the circumference and, when the rotary spindle 4 rotates, plastically deform the ridges 8 at regular intervals in the form of knurls or flutes 11 . These flutes 11 in turn produce the undercuts 13 on the groove flanks 12 of the ridges 8 .
[0032] The knurling roller 9 is set back axially—as seen in the axial direction of movement of the rotary spindle—with respect to the turning tool 6 , as a result of which the knurling roller 9 always interacts only with a ridge 8 which has just been produced.
[0033] FIGS. 4 a to 4 d show sections through ridges with different deformations and FIGS. 5 a to 5 d show the associated perspective views.
[0034] FIGS. 4 a , 5 a show the plastic deformation of a ridge 8 a , into the top face 15 of which regular central indentations 14 are introduced. The indentations 14 result in plastic deformations, as a result of which the regular undercuts 13 are formed on the groove flanks 12 . In this context, regular means that the indentations or undercuts always occur at roughly the same intervals, as seen in the longitudinal direction of the grooves.
[0035] FIGS. 4 b , 5 b show plastic deformations of a ridge 8 b which are produced by a knurling roller, as has also already been shown in FIG. 3 . The depressions or knurls or flutes 11 which are produced result in plastic deformation of the ridge material in the transverse direction with respect to the grooves, as a result of which the undercuts 13 are formed.
[0036] FIGS. 4 c , 5 c show the plastic deformations of the ridge edges 16 . Since the ridge edges 16 are regularly pressed in, the regular undercuts 13 are formed.
[0037] FIGS. 4 d , 5 d show the plastic deformations of the ridge 8 d itself, in that said ridge is regularly and alternately bent toward the side in one direction and the other in the transverse direction with respect to the longitudinal direction of the grooves. As a result, the undercuts 13 are formed alternately—as seen in the longitudinal direction of the grooves—on the groove flanks 12 .
[0038] Various tools for producing the ridges as described herein are shown in the subsequent Figures. These tools can also be combined with each other such that different deformations are produced by one tool; however, it is also possible for a plurality of these tools to be arranged alongside each other or in succession, in order to obtain different plastic deformations.
[0039] FIGS. 6 a and 6 b show a roller 9 a which can be used to introduce indentations 14 into the top face 15 of a ridge 8 . In FIG. 6 a , the roller 9 a is cut in its center plane.
[0040] FIG. 6 b shows the section A-A shown in FIG. 6 a . Cone points 17 are integrally formed on the outer circumference of the roller 9 a at regular intervals. When the roller 9 a rolls on the top face 15 of a ridge 8 a in the direction of the grooves, the indentations 14 are formed as plastic deformations in the ridge 8 a and form the undercuts 13 already described in FIGS. 4 a and 5 a . The roller 9 a is guided on the ridge 8 a via two radially protruding guide disks 18 a which are arranged on the sides of the roller 9 a . Therefore, the roller 9 a centers itself with respect to the middle of the ridge 8 a , and it is ensured that the indentations 14 are always made precisely in the middle of the top face 15 . So that the guide disks 18 a do not become blocked with the plastically deformed ridge 8 in the region of the indentations 14 , the guide disks 18 a are cut out radially and axially in the region of the cone points 17 .
[0041] FIGS. 7 a and 7 b show a roller 9 c which is used to plastically deform ridge edges 16 . In FIG. 7 a , the roller 9 c is cut in its center plane. FIG. 7 b shows the section B-B shown in FIG. 7 a . The roller 9 c is also guided on the ridge 8 c via two radially protruding guide disks 18 c which are arranged on the sides of the roller 9 c . Triangular shoulders 19 are integrally formed on the outer circumference of the roller 9 c at regular intervals. The guide disks 18 c and roller 9 c are expediently formed integrally so as to provide the shoulders with a higher strength. When the roller 9 c rolls on the top face 15 of a ridge 8 a in the direction of the grooves, the ridge edges 16 are plastically deformed at regular intervals. These deformations are indentations or crimped portions of the ridge 8 c and the ridge edges 16 , as a result of which the undercuts 13 already described in FIGS. 4 c and 5 c are formed.
[0042] FIG. 8 a shows a side view of a roller 9 d which can be used to plastically deform the ridges 8 d in the transverse direction. FIG. 8 b shows the section A-A, and FIG. 8 c the section B-B, shown in FIG. 8 a . The roller 9 d has a central guide disk 18 d which is integrated in the roller 9 d and is guided in a groove 7 ′. At regular intervals, the guide disk 18 d has conical projections 20 which start on the outer circumference, i.e. are not yet present there, and then increase toward the axis of rotation of the roller 9 d -radially inward. When the roller 9 d , guided by the guide disk 18 d , rolls in a groove 7 , the conical projections 20 result in regular plastic deformation of the ridges 8 d , in such a manner that the latter are bent toward the side in the region of the projections 20 , as a result of which the undercuts 13 are produced.
[0043] In order that a ridge 8 d is bent both to the right and to the left, it is necessary, when the roller 9 d is guided in the groove 7 ″ adjacent to the groove 7 ′, for the ridge 8 d to be deformed by the projections 20 on the other side of the roller 9 d in a correspondingly different direction. This can be seen in FIG. 8 b , where the roller 9 d is guided in the first groove 7 ′ and bends the ridge 8 d ′ to the left and the ridge 8 d ″ to the right. In FIG. 8 c , the roller 9 d passes through the groove 7 ″ adjacent to the groove 7 ′ and accordingly deforms the ridge 8 d ″ to the left and the ridge 8 d ″′ to the right. In order for this bending to take place alternately to the right and left in a ridge, the rotation of the roller 9 d is aligned between the grooves 7 ′ and 7 ″. This is carried out in that the guide disk 18 d , in the region between two projections 20 , always has a recess 21 which corresponds to the ridge 8 d ″ bent over to the right. Therefore, the right-hand shoulder 20 ′ can only ever bend the ridge 8 d ″ to the left between two bending movements of the ridge 8 d ″ to the right.
[0044] FIG. 9 a shows the section through a punch tool 22 for the plastic deformation of the ridge edges 16 (not shown). A punch 23 is mounted in a spring-elastic manner in the punch tool 22 and periodically extends when the punch tool 22 moves along a ridge 8 . The movement of the punch can be produced by any suitable actuator or else mechanically by cam disks which are arranged, for example, on the rotary spindle. The punch head 24 has the negative form for the plastic deformation which the punch is intended to exert on the ridge edges 16 . FIG. 9 b shows the front view of the punch head 24 .
[0045] FIG. 10 a shows the section through a punch tool 22 ′ for the plastic transverse deformation of a ridge 8 . Two punches 23 a and 23 b are mounted in a spring-elastic manner in the punch tool 22 ′ and periodically alternately extend when the punch tool 22 moves along the ridge 8 . The punches 23 a, b are arranged so as to be inclined in the transverse direction with respect to the grooves 7 , in order that the punch heads 24 a, b can move at least partially into the groove 7 in order to hit the ridge 8 . In this case too, the movement of the punch can be produced by any suitable actuator or mechanically. The plan view of the punch tool 22 ′ in FIG. 10 b shows the extended punch 23 a which deforms the ridge 8 upward. FIG. 10 c shows—in the meantime, the punch tool 22 ′ has moved on along the ridge 8 —the downward deformation of the ridge 8 by the punch 23 b.
[0046] FIGS. 11 a - 11 c show a further embodiment for transverse deformation. A twin-roller tool 25 has the two skew rollers 26 a , 26 b . The two skew rollers are arranged on both sides of the ridge 8 to be deformed. They are inclined in relation to each other and engage one into the other with their undulating circumferential profile 27 , the ridge 8 to be deformed being arranged between the skew rollers 26 a , 26 b . When the twin-roller tool 25 moves along the ridge 8 and the skew rollers 26 a , 26 b rotate, the ridge 8 is alternately bent upward and downward, as can be seen from the plan views in FIGS. 11 b and 11 c. | A method of roughening metal surfaces of a workpiece such as a cylinder bore of an internal combustion engine to improve the adhesion of layers thermally sprayed thereon. Uniform grooves are formed in the surface and ridges are arranged between the grooves. The grooves may be formed by a process such as turning, drilling, milling or rolling. The ridges are plastically deformed in order to form undercuts in the grooves, with the degree of plastic deformation of the ridges varying regularly in the longitudinal direction of the grooves. Local deformations are produced in the ridge, and these bring about regular undercuts in the groove. This makes it possible to produce the undercuts in identical dimensions with little effort. Furthermore, since the groove is now not completely constricted by undercuts, it can be filled more effectively with spraying material. | 5 |
TECHNICAL FIELD
The present invention relates to pressure equalization in a proportionally regulated fluid system and more particularly, to the equalization of pressure between distinct channels of a split fluid system that operates with independent proportional valve pressure control.
BACKGROUND OF THE INVENTION
Proportional regulation in a fluid system is the action of a mechanism to vary fluid output pressure relative to the fluid input pressure in response to one or more varying control factors. The output pressure is generally controlled to effect a desired response from a fluid actuated element. This type of a control mechanism has useful application in the control of automotive braking systems.
It is typical for an automotive braking system to operate in a traditional base brake mode wherein manual actuation of a master cylinder effects a desired application of the wheel brakes. In addition to the base brake mode, braking systems are often capable of controlling vehicle deceleration through anti-lock operation, controlling vehicle acceleration through traction control operation and improving lateral and longitudinal vehicle stability through stability enhancement systems which provide a level of dynamic handling augmentation. Such multi-functional brake systems are becoming increasingly more common and therefore, providing an effective and economical multi-functional system is desirable.
Brake apply system designs are known wherein the pressure applied to a vehicle's wheel brakes is controlled by an electronic unit that evaluates several parameters and delivers a control signal to a hydraulic modulator that sets the wheel brake pressure. A key parameter used to determine the appropriate braking pressure is the driver's command, delivered as an input on the brake pedal. Braking systems that provide several distinct operating modes require a mechanism to "modulate" the braking pressure at the wheel brakes based on parameters other than, or in addition to, the driver's application of force to the brake pedal. A modulator typically includes a pressure generation mechanism and a means of controlling delivery of the generated pressure to the wheel brakes. This may take the form of a pump and proportional hydraulic valve, a pump with a pair of two way valves or a movable-piston variable pressure chamber device. The number and arrangement of these elements included in a braking system is determined by the system layout and selected control scheme.
There are many operating conditions to consider in designing a multi-functional braking system. During braking operation on a uniform road surface for a vehicle moving in a substantially straight line, the friction characteristic at the tire to road interface is similar for all four wheels. If the brakes are applied to slow the vehicle, it is preferable for the application rate to be consistent between the left and the right sides of the vehicle, to inhibit the introduction of brake induced yaw. If brakes are applied according to an automatic control mechanism for target path correction of the vehicle in maneuvering situations, then the application rates are selected to purposely introduce a yaw moment. Additionally, anti-lock and traction control braking operation often varies braking pressure between the individual wheel brakes of a vehicle. Therefore, it is preferable to have the ability to provide consistent braking pressure across the sides of a vehicle and also to have the ability to vary the braking pressure across the sides of a vehicle. The operating conditions are complicated by friction coefficient variances between wheels of the vehicle and other operational conditions.
SUMMARY OF THE INVENTION
In accordance with an aspect of the present invention, a braking system generally provides pressure equalization between the sides of a split braking circuit. The amount of equalization provided is limited to enable the introduction of purposely induced pressure variances. A result is that pressure variations are moderated and intentional target pressure variations are easily obtainable. The braking system provides power braking operation in response to a manually actuated master cylinder and in response to a motor driven pump.
A preferred embodiment of the present invention includes a manually actuated and power boosted master cylinder that operates to pressurize dual braking circuits. Fluid pressure is transmitted through isolation valves directly to the wheel brakes. A check valve feature preferably prevents the transmission of pressure to those parts of the braking circuits that include the pressure equalization effecting devices. This isolates the compliancy introduced by the devices from the master cylinder and the wheel brakes during base brake operation.
In automatic power braking operation of the braking system to slow the associated vehicle, a powered pump delivers pressurized fluid through a controllable supply valve. When the supply valve is open, the isolation valve(s) are shifted to provide open fluid communication paths between proportional pressure control valves and the wheel brakes. The check valve features prevent the transmission of fluid pressure to the master cylinder during automatic power braking operation.
Providing fluid pressure to actuate the wheel brakes is achieved by actuating the proportional valves which are controlled to effect a target braking pressure. The target braking pressure is set by a programmable electronic controller which utilizes various data. Any side to side pressure variation that could result by independent operation of the proportional valves is avoided by operation of the pressure equalization effecting devices. Therefore, during automatic power braking operation to slow the vehicle, the fluid pressure applied to the front wheel brakes is substantially equal. Similarly, the fluid pressure applied to the rear wheel brakes is substantially equal.
BRIEF DESCRIPTION OF THE DRAWINGS
The FIGURE is a diagrammatic illustration of a vehicle braking system in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figure, illustrated is a fluid pressure regulation system embodied as brake system 10. Brake system 10 is capable of conventional manual base brake operation and is also capable of electrically controlled brake operation in response to manual actuation or various sensed vehicle operational parameters for traditional braking, anti-lock braking, traction control operation, vehicle handling augmentation through a stability enhancement system, and automatic power braking operation.
The braking system 10 includes a conventional master cylinder 12 with an associated fluid reservoir 14. The master cylinder 12 is manually actuated in response to the application of force to the brake pedal 15 through the push rod 17. A hydraulic power booster 11 is associated with the master cylinder 12 to intensify the force applied by the brake pedal 15 and apply the intensified force to the master cylinder 12. The master cylinder 12 includes two output ports 16 and 18. Through the output ports 16 and 18, the master cylinder 12 is capable of actuating two braking channels through the master cylinder pressure input lines 21 and 22.
The braking system 10 is arranged in a diagonally split manner so that the master cylinder pressure input line 21 supplies left front wheel brake 25 and right rear wheel brake 27. Similarly, master cylinder pressure input line 22 supplies right front wheel brake 24 and left rear wheel brake 26. Although the system is arranged in a diagonally split manner, a plurality of other braking supply arrangements are possible and the present embodiment is intended merely to demonstrate the manner of fluid pressure regulation provided by the present invention.
The master cylinder pressure input lines 21 and 22 do not extend directly to the wheel brakes 24-27 themselves, but rather are routed through isolation valves 30, 31, 32 and 33. The isolation valves 30-33 are spring biased to a normal position wherein the master cylinder pressure input line 21 is in communication, through isolation valve 31 and pressure output line 36, with wheel brake 25, and through isolation valve 33 and pressure output line 38, with wheel brake 27. Similarly, the master cylinder pressure input line 22 is normally in communication, through isolation valve 30 and pressure output line 35, with wheel brake 24, and through isolation valve 32 and pressure output line 37, with wheel brake 26. In the "three way" isolation valves 30-33, pressure is certain to be directed to the wheel brakes 24-27 because of the integral check feature 61-64. In this base brake mode, which is the default mode, a normally open connection to the wheel brakes 24-27 through the isolation valves 30-33 is provided so that manual actuation of the master cylinder 12 through the application of force to brake pedal 15 as intensified by hydraulic power booster 11 is certain to provide vehicle braking.
The hydraulic power booster 11 includes an open fluid line 8 that communicates with the fluid reservoir 14 for fluid make-up and return requirements. The power supply for the hydraulic power booster 11 includes an accumulator 42 which maintains fluid pressure generated by pump assembly 40. When the brake pedal is actuated, fluid pressure is transmitted through line 23 and applied to an internal piston (not illustrated), of the hydraulic power booster 11 for power operation of the master cylinder 12.
In addition to the capability of manually actuating the braking system 10 through the master cylinder 12 and hydraulic power booster 11, a system of power operation exists which is capable of automatic control. Powered brake actuation is provided through the motor driven pump assembly 40. The input of the pump assembly 40 is connected to the reservoir 14 through line 71 to provide necessary fluid make-up and return requirements. The outlet of the pump assembly 40 is connected to port 80 of accumulator 42.
Accumulator 42 comprises a gas chamber 81 and a fluid chamber 82 separated by a slidable piston 83. In addition to the port 80, the accumulator includes a second port 84 that serves as an outlet downstream of the port 80 in the pump pressure input line 41. Providing a two-port accumulator 42 results in pump noise attenuation at the accumulator 42. This is accomplished by means of routing all output fluid from the pump assembly 40 into the fluid chamber 82 which permits volumetric expansion by movement of the piston 83 to compress the gas chamber 81. Noise damping occurs in the fluid chamber 82. Therefore, the accumulator 42 provides the dual functions of attenuating pump noise and providing a fluid pressure reservoir for the pressure input line 41.
Fluid pressure in the pump pressure input line 41 is monitored by pressure transducer 86 for use in establishing a desired level of pressure charge in the fluid chamber 82 of accumulator 42. The pressure charge is maintained by a positive shut-off feature of the supply valve 47 which is positioned in pump pressure input line 41 downstream of accumulator 42. The supply valve 47 separates the pressure rail side 88 of pump pressure input line 41 from the charged side 87 of pump pressure input line 41. A pressure regulation line (not illustrated), may extend between the charged side 87 of pump pressure input line 41 and the system return 89.
In the deenergized position, supply valve 47 ensures that the charged side 87 of pump pressure input line 41 is securely sealed off from the pressure rail side 88. The pressure rail side 88 distributes the pump pressure input line 41 to proportional valves 51, 52, 53 and 54. The pump pressure input line 41 extends through its pressure rail side 88 to the proportional valves 51-54 resulting in control of the fluid pressure reaching the isolation valves 30-33. Pressure in the modulated pump pressure input line segments 56, 57, 58 and 59 is controlled by operation of the proportional valves 51-54. Pressure balancing lines 67 and 68 extend between the modulated segments 56,57 and 58,59 respectively, of pump pressure input line 41. A spring centered piston unit 70 ensures fluid separation in the pressure balancing line 67. Similarly, a spring centered piston unit 71 ensures fluid separation in the pressure balancing line 68.
The spring centered piston unit 70 includes a body 72 having a main bore 73. A spool shaped piston 74 is slidably and sealingly carried in the bore 73. The segment 75 of pressure balancing line 67 communicates between modulated segment 56 and chamber 76 defined in bore 73. The segment 69 of pressure balancing line 67 communicates between modulated segment 57 and chamber 77 defined in bore 73. A third chamber 78 is defined by the piston 74 in bore 73. The chamber 78 continuously communicates with the reservoir 14 through the return 89 and vent line 91. Any fluid pressure inadvertently passing the seals (not shown), of piston 74 from chambers 76 or 77 to chamber 78 is vented to the reservoir 14.
Piston 74 is normally held in a centered position in bore 73, relative to the stops 92,93 by springs 94 and 95. When a pressure differential exists between modulated segments 56 and 57 the piston 74 slides, compressing the spring 94 or 95 to balance the pressure. When the pressure differential exceeds a predetermined value, the piston 74 engages the stop 92 or 94 so that an intended target pressure differential is achievable.
The spring centered piston unit 71 is substantially the same as the spring centered piston unit 70. A piston 101 separates out three chambers 102-104 within the spring centered piston unit 71. The segment 105 of pressure balancing line 68 communicates between modulated segment 58 and chamber 102. The segment 106 of pressure balancing line 67 communicates between modulated segment 59 and chamber 103. Chamber 104 continuously communicates with the reservoir 14 through the return 89 and the vent line 79.
Piston 101 is normally held in a centered position, relative to the stops 107,108 by a pair of springs. When a pressure differential exists between modulated segments 58 and 59 the piston 101 slides to balance the pressure. When the pressure differential exceeds a predetermined value, the piston 101 engages the stop 107 or 108 so that an intended target pressure differential is achievable.
In normal base brake operation of the braking system 10, the manual application of force on the brake pedal 15 results in actuation of the wheel brakes 24-27. The manual force is transmitted through the push rod 17 to the hydraulic power booster 11. The hydraulic power booster 11 utilizes the fluid pressure maintained by accumulator 42 to intensify the manually applied force for power actuation of the master cylinder 12. The manually actuated and power boosted operation of master cylinder 12 results in pressurization of the master cylinder pressure input lines 21 and 22 through the output ports 16 and 18. Fluid pressure is transmitted through the isolation valves 30-33 directly to the wheel brakes 24-27. The integral checks 61-64, prevent the transmission of pressure to the modulated segments 56-59. This isolates the spring centered piston units 70 and 71 from the master cylinder 12 and the wheel brakes 24-27. Therefore, movement of the pistons 74 and 101 does not affect the base brake design and operation.
In automatic power braking operation of the braking system 10, to slow the associated vehicle, the motor 40 is powered into operation and the supply valve 47 is energized and shifted to its open position. This pressurizes the pressure rail side 88 of the pump pressure input line 41. The isolation valves 30-33 are energized and shifted to provide open fluid communication between the modulated segments 56-59 and the pressure output lines 35-38. The integral check features 61-64 prevent the transmission of fluid pressure to the master cylinder 12 and the master cylinder pressure input lines 21 and 22.
Providing fluid pressure to actuate the wheel brakes 24-27 is achieved by operating the proportional valves 51-54 which are actuated to effect a target braking pressure. The target braking pressure is set by a programmable electronic controller (not illustrated), which utilizes various data. Open communication is provided through the isolation valves 30-33 since they have been shifted to an actuated position. Any side to side pressure variation that could result by independent operation of the proportional valves 51-54 is avoided by operation of the spring centered piston units 70 and 71. Therefore, during automatic power braking operation to slow the vehicle, the fluid pressure applied to the front wheel brakes 24 and 25 is substantially equal. Similarly, the fluid pressure applied to the rear wheel brakes 26 and 27 is substantially equal.
The accumulator 42, which is provided to cooperate with the pump 40 in maintaining a consistent minimum pressure in charged side 87 of pump pressure input line 41, ensures that upon the immediate actuation of supply valve 47, pressure exists to charge the pressure rail side 88 and is available for braking needs to the wheel brakes 24-27 without waiting for pressure to build in response to the operation of pump 40. The securely closing supply valve 47 ensures that the pressure maintained on charged side 87 is not lost during braking inactivity.
In addition to normal base brake operation, the braking system 10 is capable of providing anti-lock braking, traction control, vehicle handling augmentation through stability enhancement control, and automatic power braking operation to slow the vehicle. For anti-lock braking functions during base brake applies, the proportional valves 51-54 are independently shiftable to control pressure release from the wheel brakes 24-27. This is effected while the necessary isolation valve(s) 30-33 are energized to provide an open flow path between the involved pressure supply line(s) 35-38 and the respective modulated segment(s) 56-59.
For traction control operation, automatic response to various vehicular sensors (not illustrated) independent of actuation of the brake pedal 15 the pump 40 is provided. The braking system 10 is pressurized through the supply valve 47 which is shifted to its actuated position charging the pressure rail side 88 of pump pressure input line 41. Braking pressure is available at the proportional valves 51-54, each of which is independently actuated to effect braking pressure at any selected wheel brake 24-27 through its associated isolation valve 30-33 which is shifted to its actuated position by the electronic controller.
Essentially the same actuation of the wheel brakes 24-27 is effected in response to various sensor inputs to enhance vehicle stability and maneuverability. The traction control and stability enhancement control operation is enhanced by the rapid response time of the system wherein the charged side 87 of the pump pressure input line 41 remains available to effect braking response at any of the wheel brakes 24-27 without waiting for pressure build to occur as a result of operation of pump 40.
In operation, the proportional valves 51-54, provide braking pressure to the wheel brakes 24-27 in response to the electronic controller which receives various sensor input data including that from the pressure transducer 19. Operation of the isolation valves 30-33, helps provide an effective and low cost method of isolating the master cylinder 12 from the wheel brakes 24-27, automatic power braking function operation in a relatively simple manner. The positive shut-off feature provided by the discharge valve 47 ensures that the braking system 10 is capable of responding quickly to any brake actuation requirements. During ABS release operation, any apply pressure feed from the master cylinder 12, through the integral check feature of the isolation valves 30-33 is released to the system return 89 through the corresponding proportional valve(s) 51-54. | A braking system generally provides pressure equalization between the sides of a split braking circuit. The amount of equalization provided is limited to enable the introduction of purposely induced pressure variances. A result is that unintentional pressure variations are moderated and intentional target pressure variations are easily obtainable. The braking system provides power braking operation in response to a manually actuated master cylinder. Fluid pressure is transmitted through isolation valves directly to the wheel brakes. The braking system also provides power operation in response to a powered pump. The pump delivers pressurized fluid through a controllable supply valve. When the supply valve is open, the isolation valve(s) are shifted to provide open fluid communication path between proportional pressure control valves and the wheel brakes. The pressure equalization effecting device is isolated from the master cylinder pressurized circuit during base brake operation. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of Japanese Patent Application No. 2006-053065 filed Feb. 28, 2006 in the Japan Patent Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
The present invention relates to an image forming apparatus including: an image carrier unit integrally having a plurality of image carriers, which respectively carries an image; and a unit containing portion which removably contains the image carrier unit. The present invention also relates to a technique associated with the image forming apparatus.
Some type of a conventional laser printer includes a photoreceptor unit, having a plurality of photoreceptor drums integrally aligned in one direction, and a unit containing portion, wherein the photoreceptor unit can be removably contained along the alignment direction of the photoreceptor drums.
In this type of laser printer, drum gears are provided and respectively connected to the photoreceptor drums so as to transmit driving force to the photoreceptor drums for rotating the drums. Moreover, a plurality of driving gears is provided in the unit containing portion. The driving gears are engaged with the respective drum gears so as to transmit driving force to the drum gears from a motor.
Generally, in this type of laser printer, when the photoreceptor unit is removed while a user lifting an end portion of the photoreceptor unit in a downstream side of the removal direction, the drum gears and the driving gears are disengaged in a consecutive manner from the downstream side.
The drum gears and the driving gears are formed in such a manner that the center of each circle works as the center of rotation. However, in a precise sense, the center of rotation slightly deviates from the center of the circles. Therefore, the displacement rate on the outer circumference of the gears at the time of rotation (the displacement amount on the outer circumference per unit time) is not constant.
When images, carried by respective the photoreceptor drums, are sequentially superposed on a sheet of paper conveyed in the above-described laser printer, the respective images are misaligned due to the dislocation of the center of gear rotation. A solution is required so as to inhibit misalignment of images carried by the photoreceptor drums.
For this purpose, in the above-described laser printer, a phase reference point is predetermined for the respective gears based on the dislocation of the rotational center, and the phase differences between the adjacent drum gears and between the adjacent driving gears are set so as to be respectively constant.
SUMMARY
However, in the above-described laser printer, when the photoreceptor unit is removed and the drum gears and the driving gears are disengaged, the drum gears and the driving gears, especially in the upstream side of the removal direction, sometimes interfere with each other and are unintentionally rotated. As a result, a problem is caused wherein the phase differences between the adjacent drum gears and between the adjacent driving gears are changed.
One aspect of the present invention preferably provides a technique wherein, when an image carrier unit having a plurality of image carriers respectively carrying images is removed, image carrier gears, connected to rotational shafts of the image carriers, and driving gears, which transmit driving force to the image carrier gears, are inhibited from interfering from each other.
In one aspect of the present invention, an image forming apparatus includes an image carrier unit, a unit containing portion, a plurality of driving gears, and a disengagement unit. The image carrier unit includes a plurality of image carriers that is integrally disposed in the image carrier unit, respectively carries images, and respectively has rotational shafts. The image carrier unit further includes a plurality of image carrier gears connected to the rotational shafts. The plurality of image carrier gears transmits driving force to the plurality of image carriers so as to rotate the plurality of image carriers. The unit containing portion removably contains the image carrier unit. The plurality of driving gears is disposed in the unit containing portion, and respectively corresponds to the plurality of image carrier gears. Each of the plurality of driving gears is engaged with one of the plurality of image carrier gears that corresponds thereto so as to transmit driving force to the plurality of image carrier gears from a driving source. The disengagement unit disengages all the plurality of image carrier gears and the plurality of driving gears, and allows the image carrier unit to be removed outside of the unit containing portion.
In the image forming apparatus configured as above, the image carrier unit may become removal when all the image carrier gears and the driving gears are disengaged by the disengagement unit.
Therefore, the image carrier gears and the driving gears do not interfere with each other when the image carrier unit is removed.
In another aspect of the present invention, an image carrier unit includes a plurality of image carriers, a housing, a plurality of image carrier gears, and guided members. The plurality of image carriers respectively carries images, and has rotational shafts. The housing integrally supports the plurality of image carriers such that the plurality of image carriers are aligned along one direction and the rotational shafts are disposed in parallel to one another. The plurality of image carrier gears is respectively connected to the rotational shafts, and respectively engaged with a plurality of driving gears disposed in a unit containing portion of an image forming apparatus so as to transmit driving force for rotating the plurality of image carriers from a driving source to the plurality of image carriers via the plurality of driving gears. The guided members are guided by guide members disposed in the unit containing portion along a centerline direction directed from a rotational center of one of the plurality of driving gears to a rotational center of one of the plurality of image carrier gears that corresponds to the one of the plurality of drive gears.
The image carrier unit configured as above may be moved in the centerline direction by the guided members being guided by the guide members.
Therefore, by the above-described image carrier unit, the image carrier gears and the driving gears may be disengaged without the teeth of these gears interfering with each other.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described below, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view showing an exterior appearance of a printer according to a first embodiment of the present invention;
FIG. 2 is a perspective view showing the exterior appearance of the printer and an image forming unit in which the image forming unit is removed outside of the printer;
FIG. 3 is a perspective view showing an exterior appearance of a drum unit from which all development cartridges are removed;
FIG. 4 is a cross sectional view showing an internal structure of the printer in which the image forming unit is installed;
FIG. 5 is a schematic view showing a structure of a drive mechanism for driving various parts of the image forming unit as installed in a body frame of the printer, and a removal mechanism for removing the image forming unit from the body frame;
FIGS. 6A and 6B are explanatory views illustrating a removal operation for removing the image forming unit from the body frame;
FIGS. 7A and 7B are explanatory views illustrating the removal operation for removing the image forming unit from the body frame;
FIG. 8 is an explanatory view showing an engagement between a drum gear and an inner gear of the printer;
FIG. 9 is a schematic view showing a structure of a disengagement mechanism of a printer according to a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
First Embodiment
<External Structure of Printer 100 in First Embodiment>
In the following, when the disposition order of a plurality of constituents is indicated, the start point of the order is set in the front side of a printer 100 . That is, the constituent disposed in the moot front side of the printer 100 is referred to as the first one among the plurality of constituents.
As shown in FIG. 1 , a body 110 of the printer 100 includes a body casing 111 and a body frame 112 contained inside of the body casing 111 .
The body casing 111 is made of synthetic resin, and formed approximately in a rectangular parallelepiped shape. On a top surface 111 A of the body casing 111 , a paper discharge tray 111 B is formed. The paper discharge tray 111 B is downwardly inclined from the front side of the body casing 111 toward the rear side thereof. A paper discharge opening 111 C is disposed in an upper portion of the body casing 111 above the rear end portion of the paper discharge tray 111 B. Paper is discharged through the paper discharge opening 111 C on to the paper discharge tray 111 B.
In a front side of the body casing 111 , a front opening 111 D is formed. A front cover 111 E is disposed in an openable/closable manner for closing the front opening 111 D. The lower end of the front cover 111 E is supported by the body casing 111 .
The body frame 112 is configured so as to support various members provided for an image forming operation inside of the body 110 . Driving sources and driving force transmission mechanisms are disposed inside of the body frame 112 for rotating and driving the various members.
The left inner wall and the right inner wall of the body frame 112 are respectively provided with guide rails 112 A. More specifically, the respective guide rails 112 A are disposed approximately horizontally from the front side of the printer 100 toward the rear side thereof.
In the body frame 112 , an image forming unit 120 is installed such that the image forming unit 120 can be removed in a direction (shown with Arrow S in the figure) from the rear side of the printer 100 toward the front side thereof. In other words, the rear side of the printer 100 corresponds to the upstream side of the removal direction of the image forming unit 120 , and the front side of the printer 100 corresponds to the downstream side of the removal direction.
<External Structure of Image Forming Unit 120 >
As shown in FIG. 2 , the image forming unit 120 includes a drum unit 130 , and four development cartridges 140 .
The drum unit 130 includes a frame forming approximately a quadrangular plane with a front beam 131 , a left supporting plate 132 , a right supporting plate 133 , and a rear beam 134 .
More specifically, the front beam 131 and the rear beam 134 , respectively provided in the front end side and in the rear end side of the drum unit 130 , are disposed in parallel to each other. To the left and right ends of the respective front beam 131 and the rear beam 134 , the left supporting plate 132 and the right supporting plate 133 are connected. In the inner side of the left supporting plate 132 , four left plates 135 are aligned along the left supporting plate 132 . In the inner side of the right supporting plate 133 , four right plates 136 are aligned along the right supporting plates 133 .
Between the left plates 135 and the right plates 136 , the above-described development cartridges 140 are aligned from the front side of the drum unit 130 toward the rear side thereof. The development cartridges 140 are respectively supported by the left plates 135 and the right plates 136 in an attachable/detachable manner.
In the upper end portions of the left supporting plate 132 and the right supporting plate 133 , flange portions 132 A and 133 A are respectively formed. The flange portions 132 A and 133 A are engaged with the above-described guide rails 122 A when the drum unit 130 is inserted into the body frame 112 .
In the upper portion on the respective outer walls of the left supporting plate 132 and the right supporting plate 133 (beneath the flange portions 132 A, 133 A), rollers 137 A, 137 B, and 137 C are rotatably supported. ( FIG. 2 shows only the rollers 137 A, 137 B, and 137 C provided on the left supporting plate 132 .)
More specifically, the rollers 137 A, 137 B, and 137 C are respectively disposed in the front end portion, the center portion, and the rear end portion in the upper portion of the left supporting plate 132 and the right supporting plate 133 . That is, the drum unit 130 is guided along the guide rails 112 A in the front-to-rear direction of the body frame 112 by the rollers 137 A, 137 B, and 137 C being rotated on the guide rails 112 A. The diameters of the rollers 137 A, 137 B, and 137 C are determined such that the diameters become larger in the order from the roller 137 A, 137 B, and 137 C.
On the respective outer walls of the left supporting plate 132 and the right supporting plate 133 , projection members 138 A and 138 B are disposed. ( FIG. 2 shows only the projection members 138 A and 138 B provided on the left supporting plate 132 .)
More specifically, the projection member 138 A is disposed below and behind the roller 137 A. The projection member 138 B is disposed below and anterior to the roller 137 C.
The drum unit 130 is provided with a front handle 131 A in the front surface of the front beam 131 . The drum unit 130 can be easily removed from the body frame 112 by a user pulling the front handle 131 A toward the front side of the body frame 112 .
The drum unit 130 is also provided with a rear handle 134 A in the upper end portion of the rear beam 134 . The drum unit 130 can be easily carried by a user holding the front handle 131 A and the rear handle 134 A.
As shown in FIG. 3 , the left supporting plate 132 of the drum unit 130 is provided with four coupling insertion holes 132 B along the disposition direction of the development cartridges 140 such that the respective coupling insertion holes 132 B face the respective development cartridges 140 .
Each of the left plates 135 is provided with a coupling exposure hole 135 B in a position so that the coupling exposure hole 135 B faces the coupling insertion hole 132 B.
The coupling insertions holes 132 B and the coupling exposure holes 135 B are provided for inserting driving shafts (not shown) disposed within the body frame 112 so as to apply driving force to coupling receiving gears (not shown) disposed in the development cartridges 140 .
On the respective inner walls of the left plates 135 and the right plates 136 , guide grooves 135 A, 136 A are formed for guiding the development cartridges 140 in the up-and-down direction.
In the bottom portion of the drum unit 130 , four drum portions 150 are disposed along the disposition direction of the development cartridges 140 (only first three drum portions 150 from the front side are shown in FIG. 3 ).
<Internal Structure of Printer 100 >
As shown in FIG. 4 , in the body 110 of the printer 100 , the image forming unit 120 is disposed in the center portion thereof, and the paper discharge unit 193 is disposed behind the image forming unit 120 .
The body 110 further includes a scanner unit 160 , a transfer unit 170 , and a feeder unit 180 . The scanner unit 160 is disposed above the image forming unit 120 . The transfer unit 170 is disposed below the image forming unit 120 . The feeder unit 180 is disposed below the transfer unit 170 .
<<Structure of Feeder Unit 180 >>
The feeder unit 180 includes a feeder case 181 , a feed roller 183 , a separation roller 184 , a separation pad 185 , and a paper dust removal roller 187 .
The feeder case 181 is formed in such a manner that sheets of paper P can be stacked inside thereof. In the feeder case 181 , a paper pressing plate 182 is disposed. A rear end portion 182 A of the paper pressing plate 182 is rotatably supported inside of the feeder case 181 . That is, in the feeder case 181 , a front end portion 182 B of the paper pressing plate 182 is swayed approximately in the up-and-down direction in the figure.
The feed roller 183 is made of synthetic rubber. The feed roller 183 is rotatably supported above the front end portion 182 B of the paper pressing plate 182 by the body frame 112 . The feed roller 183 is driven so as to rotate in the counterclockwise direction in the figure, and conveys a sheet of paper P, stacked on the top inside of the feeder case 181 , toward the front side of the feed roller 183 .
The separation roller 184 is made of synthetic rubber in the same manner as the feed roller 183 . The separation roller 184 is rotatably supported by the body frame 112 in the front side of the feed roller 183 . The separation roller 184 is driven so as to rotate in the same direction as the feed roller 183 , and conveys the sheet of paper P toward the front side thereof.
The separation pad 185 is disposed so as to face the separation roller 184 . A separation surface 185 A of the separation pad 185 facing the separation roller 184 is made of a material having a high friction coefficient, such as synthetic rubber, felt, and so on. Below the separation pad 185 , a separation pad biasing spring 186 is disposed. By the separation pad biasing spring 186 biasing the separation pad 185 toward the separation roller 184 , the separation roller 184 and the separation pad 185 are pressed against each other.
The paper dust removal roller 187 removes paper dust adhered to the sheet of paper P. The paper dust removal roller 187 is disposed above and in the front side of the separation roller 184 so as to face a pinch roller 188 , and rotatably supported by the body frame 112 .
<<Structure of Image Forming Unit 120 >>
In the image forming unit 120 , the four development cartridges 140 ( 140 Y, 140 M, 140 C, and 140 K) are aligned from the front side of the printer 100 toward the rear side thereof. Beneath the development cartridges 140 , the four drum portions 150 are aligned from the front side of the printer 100 toward the rear side thereof, so as to face the development cartridges 140 .
The four development cartridges 140 Y, 140 M, 140 C, and 140 K respectively contain toners (developers) in some colors different from one another, such as yellow, magenta, cyan, and black. Although the development cartridges 140 Y, 140 M, 140 C, and 140 K contain toners of different colors, the structures thereof are exactly the same.
More specifically, the development cartridges 140 respectively contain toners, which are developers for developing electrostatic latent images, in respective cartridge cases 141 . The development cartridges 140 respectively include agitators 142 , supply rollers 143 , development rollers 144 , and blades 145 .
The agitator 142 stirs a toner contained in the cartridge case 141 , and is rotatably supported by the cartridge case 141 .
The supply roller 143 is made of a sponge roller, and rotatably supported by the cartridge case 141 .
The development roller 144 is made of a rubber roller, and rotatably supported by the cartridge case 141 . The supply roller 143 and the development roller 144 are disposed such that the supply roller 143 and the development roller 144 face each other and the periphery surfaces thereof contact with each other. The supply roller 143 is driven so as to rotate in the counterclockwise direction in the figure, and supplies an electrically-charged toner to the periphery surface of the development roller 144 .
The blade 145 is disposed so as to abut on the periphery surface of the development roller 144 . The blade 145 adjusts the amount of the toner supplied on to the periphery surface of the development roller 144 , which is driven so as to rotate in the counterclockwise direction in the figure.
The four drum portions 150 are configured exactly in the same manner. The drum portions 150 respectively include photoreceptor drums 151 and scorotron chargers 152 .
The photoreceptor drum 151 has a photoreceptive layer, made of a photoconductor, on the periphery surface thereof. The photoreceptor drum 151 is disposed such that the periphery surface thereof faces the periphery surface of the development roller 144 in the development cartridge 140 .
The photoreceptor drum 151 is rotatably supported by the drum unit 130 , and driven so as to rotate in the clockwise direction in the figure by a drive mechanism to be described later. However, the direction of the rotational shafts 151 C of all the photoreceptor drums 151 is set to be perpendicular to the installation direction of the drum unit 130 in a horizontal plane (a direction perpendicular to the surface of the drawing). That is, all the rotational shafts 151 C are disposed in parallel to one another.
The scorotron charger 152 is constituted so as to uniformly charge the periphery surface of the photoreceptor drum 151 . The scrotron charger 152 is disposed above the photoreceptor drum 151 so as to face the periphery surface of the photoreceptor drum 151 .
<<Structure of Scanner Unit 160 >>
The scanner unit 160 is constituted 80 as to emit laser beam, generated based on image data, from a laser emission portion (not shown) on to the periphery surfaces of the photoreceptor drums 151 . Also the scanner unit 160 is constituted so as to scan laser beam emitted therefrom in the width direction of the printer 100 (the direction perpendicular to the surface of FIG. 4 ).
<<Structure of Transfer Unit 170 >>
The transfer unit 170 includes a belt driving roller 171 , a driven roller 172 , a conveyance belt 173 , four transfer rollers 174 , and a belt cleaner 175 .
The belt driving roller 171 is disposed below and behind the drum portion 150 facing the development cartridge 140 K disposed in the most rear side among the four development cartridges 140 . The belt driving roller 171 is rotatably supported by the body frame 112 .
The driven roller 172 is disposed below and in the front side of the drum portion 150 facing the development cartridge 140 Y disposed in the most front side among the four development cartridges 140 . The driven roller 172 is rotatably supported by the body frame 112 .
The conveyance belt 173 is an endless belt made of a resin film, such as conductive polycarbonate or polyimide, wherein conductive particles, such as carbon, are dispersed. The conveyance belt 173 runs between the belt driving roller 171 and the driven roller 172 .
The conveyance belt 173 is moved in the counterclockwise direction in the figure by the belt driving roller 171 being driven so as to rotate in the counterclockwise direction. The conveyance belt 173 conveys the sheet of paper P placed thereon along the disposition direction of the development cartridges 140 .
The transfer rollers 174 are respectively disposed beneath the respective photoreceptor drums 151 so as to face the photoreceptive drums 151 of the drum portions 150 with the conveyance belt 173 inbetween. The transfer rollers 174 are rotatably supported by the body frame 112 , and rotated corresponding to the conveyance belt 173 moving counterclockwise.
That is, each of the transfer rollers 174 holds the sheet of paper P by sandwiching the sheet of paper P with the photoreceptor drum 151 facing thereto, and transfers an image (a toner image) carried on the periphery surface of the photoreceptor drum 151 to the surface of the sheet of paper P. Furthermore, the transfer rollers 174 convey the sheet of paper P together with the photoreceptor drums 151 toward the rear side the printer 100 .
The belt cleaner 175 is disposed beneath the second transfer roller 174 among the four transfer rollers 174 . The belt cleaner 175 removes toner and paper dust adhered to the surface of the conveyance belt 173 by a pair of cleaning rollers 175 A, 175 B.
<<Structure of Paper Discharge Unit 193 >>
The paper discharge unit 193 includes a heat roller 193 A and a pressure roller 193 B.
The heat roller 193 A is constituted with a metal cylinder, having a surface treated with as mold release process, and a halogen lamp contained in the cylinder. The heat roller 193 A is rotatably supported by the body frame 112 .
The pressure roller 193 B is made of silicone rubber, and disposed so as to be pressed against the heat roller 193 A at predetermined pressure. The pressure roller 193 B is rotatably supported by the body frame 112 .
In the paper discharge unit 193 , when the heat roller 193 A is driven so as to rotate in the clockwise direction in the figure, the pressure roller 193 B is correspondingly rotated in the counterclockwise direction. The sheet of paper P, conveyed from the transfer unit 170 , is fed between the heat roller 193 A and the pressure roller 193 B, and conveyed behind the rollers 193 A and 193 B. As a result, a toner on the sheet of paper P melts and adheres (is fixed) to the sheet of paper P. Then, the sheet of paper P is conveyed toward the paper discharge opening 111 C.
The paper discharge unit 193 furthermore includes a conveyance roller 194 for conveying the sheet of paper P on which toner is adhered, and a pinch roller 195 . The conveyance roller 194 and the pinch roller 195 are disposed behind the heat roller 193 A and the pressure roller 193 B.
The conveyance roller 194 is rotatably supported by the body frame 112 .
The pinch roller 195 is disposed so as to face the conveyance roller 194 , and rotatably supported by the body frame 112 .
By the conveyance roller 194 being driven so as to rotate in the clockwise direction in the figure, the pinch roller 195 is correspondingly rotated in the counterclockwise direction in the figure. As a result, the sheet of paper P is conveyed toward the paper discharge opening 111 C.
The paper discharge unit 193 still further includes paper guides 196 A, 196 B disposed above the conveyance roller 194 and the pinch roller 195 , for guiding the sheet of paper P with a toner adhered thereon.
The paper guides 196 A and 196 B guide the sheet of paper P, conveyed by the conveyance roller 194 and the pinch roller 195 , toward the paper discharge opening 111 C.
The paper discharge unit 193 further includes a paper discharge roller 197 and a paper discharge driven roller 198 both disposed in the vicinity of the paper discharge opening 111 C.
The paper discharge roller 197 and the paper discharge driven roller 198 are disposed so as to face each other in the up-and-down direction in the figure, and respectively supported by the body frame 112 in a rotatable manner.
By the paper discharge roller 197 being driven so as to rotate in the counterclockwise direction in the figure, the paper discharge driven roller 198 is correspondingly rotated in the clockwise direction. As a result, the sheet of paper P is discharged outside of the body 110 from the paper discharge opening 111 C.
<<Structure of Drive Mechanism and Removal Mechanism>>
As shown in FIG. 5 , the left outer walls of respective development cartridges 140 are provided with a supply roller driving gear 143 A and a development roller driving gear 144 A. The supply roller driving gear 143 A is connected to the rotational shaft of the supply roller 143 . The development roller driving gear 144 A is connected to the rotational shaft of the development roller 144 .
The respective teeth of the supply roller driving gear 143 A and the development roller driving gear 144 A are engaged with the teeth of the above-described coupling receiving gear. When driving force is applied from the above-described driving shaft to the coupling receiving gear, the supply roller driving gear 143 A and the development roller driving gear 144 A are correspondingly rotated. In other words, the supply roller driving gear 143 A and the development roller driving gear 144 A transmit driving force applied from the above-described driving axis to the supply roller 143 and the development roller 144 .
Inside of the drum unit 130 , four drum gears 151 A are disposed so as to be respectively connected to the rotational shafts 151 C of the photoreceptor drums 151 . Phases of the respective drum gears 151 A, which indicate rotational angles thereof, are determined with respect to reference rotational positions thereof. The reference rotational positions are set based on the locations of the rotational centers of the respective drum gears 151 A. The rotational orientations of the respective drum gears 151 A are set such that phase differences between the first and second drum gears 151 A, between the second and third drum gears 151 A, and between the third and fourth drum gears 151 A are predetermined phase differences. The predetermined phase differences may be all the same, or be partly the same, or be different from each other.
The body frame 112 (not shown in FIG. 5 ) is provided with four body gears 113 , constituted with two-stage gears: an inner gear 113 A and an outer gear 113 B. The body gears 113 are disposed beneath the drum unfit 130 , and rotatably supported by the body frame 112 .
More specifically, the body gears 113 are disposed along the disposition direction of the drum gears 115 A. Each of the inner gears 113 A of the body gears 113 is engaged with the teeth of the drum gear 151 A disposed above and behind the inner gear 133 A. In other words, each of the drum gears 151 A is engaged with the inner gear 113 A disposed below and in the front side of the drum gear 151 A.
Phases of the respective body gears 113 , which indicate rotational angles thereof, are determined with respect to reference rotational positions thereof. The reference rotational positions are set based on the locations of the rotational centers of the respective body gears 113 . The rotational orientations of the respective body gears 113 are set such that phase differences between the first and second body gears 113 , between the second and third body gears 113 , and between the third and fourth body gears 113 are predetermined phase differences. The predetermined phase differences may be all the same, or be partly the same, or be different from each other.
The drum gears 151 A receive reaction force from the inner gears 113 A when the inner gears 113 A are rotated. The reaction force has a direction at a predetermined angle (pressure angle: 20° in the present embodiment) with respect to a tangent line passing through the contact point between the pitch circle of the drum gear 151 A and the pitch circle of the inner gear 113 A.
If the inner gear 113 A is disposed beneath the drum gear 151 A in the perpendicular direction, the reaction force is applied to the drum gear 151 A, which is directed toward 20° in the upper rear side with respect to the horizontal direction. As a result, the reaction force applied to the photoreceptor drum 151 lifts the photoreceptor drum 151 . Therefore, maintaining suitable nip pressure between the photoreceptor drum 151 and the transfer roller 174 becomes difficult.
In the present embodiment, the inner gear 113 A is disposed below and in the front side of the drum gear 151 A as described above. Therefore, the reaction force can be directed along the conveyance direction of the sheet of paper P, and suitable nip pressure can be maintained between the photoreceptor drum 151 and the transfer roller 174 .
Beneath the body gears 113 , four drive motors 114 are disposed for the respective body gears 113 . Motor gears 114 A are connected to the rotational shafts of the respective drive motors 114 . The teeth of the respective motor gears 114 A are engaged with the teeth of the outer gears 113 B of the corresponding body gears 113 .
That is, when the drive motors 114 are driven, the body gears 113 and the drum gears 151 A are correspondingly rotated and transmit the driving force, applied from the drive motors 114 , to the photoreceptor drums 151 .
On the respective guide rails 112 A, holes are respectively formed in the front side, in the center portion, and in the rear side. The rollers 137 A, 137 B, and 137 C are engaged with these holes.
The size of the respective holes in the front-to-rear direction is determined so as to be approximately equivalent to the diameter of the roller to be engaged therein. Therefore, when the rollers 137 A, 137 B, and 137 C are rotated on the guide rails 112 A, the rollers 137 B and 137 C do not become engaged with the hole for the roller 137 A. The roller 137 C likewise does not become engaged with the hole for the roller 137 B.
Beneath the respective guide rails 112 A, disengagement mechanisms 115 are disposed (only the disengagement mechanism 115 on the left side of the printer 100 is shown in FIG. 5 ) for disengaging all the drum gears 151 A and the inner gears 113 A.
More specifically, the respective disengagement mechanisms 115 include links 116 , cover support members 117 , operation gears 118 , and disengagement guides 119 A, 119 B.
The links 116 are made of a rod-shaped member, and supported by the body frame 112 so as to be movable in the front-to-rear direction.
The length of the links 116 is such that the links 116 extend between the vicinity of the front end portion of the body frame 112 and the vicinity of the rear end portion thereof.
In the front end portion of the respective links 116 , front bend portions 116 A are formed. The front bend portion 116 A is formed by the front end portion of the link 116 being bent downward and then bent backward. Teeth are provided on the bottom circumference of the front bend portion 116 A.
The links 116 are also respectively provided with front inclined portions 116 B in front of the projection member 138 A of the drum unit 130 installed in the body frame 112 . The front inclined portion 116 B is made with a portion of the link 116 extending from in the front side of the projection member 138 A to the position where the projection member 138 A is disposed. This portion of the link 116 is inclined downward so as to form the front inclined portion 116 B.
Furthermore, the links 116 are respectively provided with rear inclined portions 116 C in front of the projection member 138 B of the drum unit 130 installed in the body frame 112 . The rear inclined portion 116 C is made with the rear portion of the link 116 bent so as to be inclined upwardly toward the front side, and then bent such that the leading end of the rear end portion is directed toward the front side.
The cover support members 117 are formed in an arc shape, and disposed beneath the front bend portion 116 A of the link 116 .
The arcs of the respective cover support members 117 is directed toward the upper rear side, and provided with a plurality of teeth thereon. The front ends of the respective cover support members 117 are connected to the bottom portion of the front cover 111 E. The cover support members 117 are rotated on the support shaft 111 F of the front cover 111 E when the front cover 111 E is moved so as to open/close the front opening 111 D.
The operation gears 118 are rotatably supported by the body frame 112 between the cover support member 117 and the front bend portion 116 A of the link 116 . The teeth of the operation gears 118 are respectively engaged with the teeth of the cover support members 117 , and with the teeth of the front bend portions 116 A of the links 116 .
The disengagement mechanisms 119 A, 119 B are respectively disposed in the vicinity of the projection members 138 A, 138 B of the drum unit 130 installed in the body frame 112 .
More specifically, the disengagement mechanisms 119 A, 119 B are configured with a pair of plate members sandwiching the projection members 138 A and 138 B. The direction of the plate members is determined so as to be in parallel to the direction of the center line extending from the center of the rotation of the body gear 113 (the center of the rotation of the inner gear 113 A) to the center of the rotation of the drum gear 151 A.
That is, the disengagement guides 119 A, 119 B respectively guide the projection members 138 A, 138 B along the direction of the center line.
By the disengagement mechanisms 115 configured as above, the image forming unit 120 is removed from the body frame 112 as follows.
The following describes the removal operation for removing the image forming unit 120 from the body frame 112 with reference to FIGS. 6A , 6 B, 7 A and 7 B. It is to be noted that the front cover 111 E, the cover support member 117 , and the operation gear 118 are not shown in FIGS. 7A and 7B so as to simplify the description.
As shown in FIG. 6A , as a user starts opening the front cover 111 E, the cover support members 117 are rotated in the clockwise direction in the figure, and the operation gears 118 are rotated in the counterclockwise direction. Correspondingly, the links 116 are moved toward the rear side.
Then, as shown in FIG. 6B , as the user further opens the front cover 111 E, the links 116 are further moved toward the rear side. The front inclined portions 116 B are abutted, on the projection members 138 A. Simultaneously, the rear inclined portions 116 C are abutted on the projection members 138 B.
As shown in FIG. 7A , when the user completely opens the front cover 111 E, the links 116 are furthermore moved toward the rear side. The image forming unit 120 is guided by the disengagement guides 119 A, 119 B and lifted in the above-described centerline direction. As a result, all the drum gears 151 A and the inner gears 113 A are disengaged, and the rollers 137 A, 137 D, and 137 C are removed from the above-described holes provided with the guide rails 112 A.
Subsequently, as shown in FIG. 7B , when the user pulls the image forming unit 120 toward the front side, the rollers 137 A, 137 B, and 137 C are rotated on the guide rails 112 A. The image forming unit 120 is guided by the guide rails 112 A, and removed to the outside of the body frame 112 .
Even when the image forming unit 120 is removed and all the drum gears 151 A and the inner gears 113 A are disengaged, if the teeth of the drum gears 151 A and the inner gears 113 A come in contact, the phase differences between the adjacent drum gears 151 A and between the adjacent the body gears 113 become out of the predetermined phase differences.
Therefore, the inventor of the present invention calculated the minimum travel distance X for the disengagement mechanisms 116 to move the image forming unit 120 .
The calculation will be described below with reference to FIG. 8 .
Here, the pitch circle diameter of the drum gear 151 A (the diameter of the circle with dotted line in the drum gear 151 A) is represented as D 1 . The pitch circle diameter of the inner gear 113 A (the diameter of the circle with dotted line in the inner gear 113 A) is represented as D 2 .
The size of the module of the drum gear 151 A (the distance between the circle with the dotted line in the drum gear 151 A and the circle with the full line) and the size of the module of the inner gear 113 A (the distance between the dotted line in the inner gear 113 A and the circle with the full line) are determined to be equivalent, and represented as M.
The angle between the centerline direction and the direction perpendicular to the removal direction of the image forming unit 120 is θ.
With using the various parameters determined as above, the distance W 1 in the perpendicular direction, as shown in FIG. 8 , between the straight line, drawn from the center of the drum gear 151 A in parallel to the removal direction, and the dot-dash line, drawn from the center of the inner gear 113 A in parallel to the removal direction, is obtained from:
W 1=( D 1+ D 2)cos θ/2
The distance W 2 in the perpendicular direction between the straight line, drawn from the center of the drum gear 151 A in parallel to the removal direction, and the tangent line, drawn tangentially to the circumference of the inner gear 131 A in parallel to the removal direction, is obtained from:
W
2
=
W
1
-
{
(
D
2
/
2
)
+
M
}
=
[
{
(
D
1
+
D
2
)
cos
θ
/
2
}
-
{
(
D
2
/
2
)
+
M
}
]
The distance W 3 in the perpendicular direction between the above-described tangent line, drawn tangentially to the circumference of the inner gear 113 A, and the tangent line, drawn tangentially to the circumference of the drum gear 151 A in parallel to the removal direction, is obtained from:
W
3
=
(
D
1
/
2
)
+
M
-
W
2
=
{
(
D
1
+
D
2
+
4
M
)
-
(
D
1
+
D
2
)
cos
θ
}
/
2
Therefore, the minimum travel distance X is obtained from:
X
=
W
3
/
cos
θ
=
{
(
D
1
+
D
2
+
4
M
)
-
(
D
1
+
D
2
)
cos
θ
}
/
2
cos
θ
In the disengagement mechanisms 115 , the height of the inclination of the front inclined portion 116 B and the rear inclined portions 116 C, and the length of the disengagement guides 119 A, 119 B are determined such that the image forming unit 120 is moved for at least the minimum travel distance X.
<Effects of Printer 100 >
In the printer 100 according to the first embodiment, the image forming unit 120 becomes removable after all the dram gears 151 A and the inner gears 113 A are disengaged by the disengagement mechanisms 115 . Therefore, the dram gears 151 A and the body gears 113 do not interfere with each other when the image forming unit 120 is removed.
As a result, according to the printer 100 , the phase differences between the adjacent dram gears 151 A and between the adjacent body gears 113 can be inhibited from becoming out of the predetermined phase differences when the image forming unit 120 is removed.
Moreover, in the printer 100 according to the first embodiment, the dram gears 151 A and the inner gears 113 A are disengaged by moving the image forming unit 120 along the centerline direction. Therefore, the engagement can be performed without the teeth of the dram gears 151 A and the inner gears 113 A becoming in contact with each other. As a result, the phase differences can be reliably inhibited from becoming out of the predetermined phase differences. Additionally, the teeth of these gears can be inhibited from being worn away.
Furthermore, in the printer 100 according to the first embodiment, the disengagement mechanism 115 moves the image forming unit 120 at least for the above-described minimum travel distance X in the centerline direction. Therefore, once the disengagement of these gears is performed, the teeth of these gears do not contact with each other. As a result, the phase differences can be inhibited from becoming out of the predetermined phase differences, which may be caused by the teeth of these gears being in contact with each other when the image forming unit 120 is removed.
Still furthermore, in the printer 100 according to the first embodiment, the inner gears 113 A are disposed below and in front of the drum gears 151 A. Therefore, the angle, in which pressure is applied from the inner gears 113 A to the drum gears 151 A, conforms with the direction of conveyance of a sheet of paper P. As a result, in the printer 100 according to the present embodiment, suitable nip pressure can be maintained between the photoreceptor drum 151 and the transfer roller 174 .
Moreover, in the printer 100 according to the present embodiment, the projection members 138 A, 138 B of the drum unit 130 are guided by the disengagement guides 119 A, 119 B in the body frame 112 . Therefore, the image forming unit 120 can be reliably moved along the centerline direction.
In addition, the projection members 138 A, 138 B are provided respectively in the front side and rear side of the drum unit 130 , and the disengagement guides 119 A, 119 B are provided respectively in the front side and the rear side in the body frame 112 . Therefore, the image forming unit 120 can be stably moved along the centerline direction.
Moreover, in the printer 100 according to the present embodiment, guide rails 112 A are provided in the body frame 112 , and the rollers 137 A, 137 B, and 137 C, rotated on the guide rails 112 A, are provided in the drum unit 180 . Therefore, the image forming unit 120 can be stably removed outside of the body frame 112 .
Furthermore, in the printer 100 according to the present embodiment, all the drum gears 115 A and the inner gears 113 A are simultaneously disengaged. Therefore, the image forming unit 120 can be efficiently removed from the body frame 112 .
Additionally, in the printer 100 according to the present embodiment, all the drum gears 151 A and the inner gears 113 are disengaged at the same time when a user opens the front cover 111 E. Therefore, a user can remove the image forming unit 120 immediately after opening the front opening 111 D.
Second Embodiment
A printer 200 according to a second embodiment can be simply obtained by partially modifying the structure of the above-described printer 100 according to the first embodiment. Accordingly, the same reference numbers are used to components that are the same as in the printer 100 according to the first embodiment, and the descriptions thereof are not repeated here.
<Structure of Disengagement Mechanism>
The following describes the structure of the disengagement mechanism in the printer 200 with reference to FIG. 9 . It is to be noted that the front cover 111 E, the cover support member 117 , and the operation gears 118 are not shown in FIG. 9 , in order to simplify the description.
As shown in FIG. 9 , the printer 200 includes links 216 , instead of the links 116 of the printer 100 according to the first embodiment.
The links 216 are different from the links 116 in a way that the length thereof is shorter than the links 116 .
In the printer 200 configured as above, when the links 216 are pushed toward the rear side by a user opening the front cover 111 E, firstly, the front inclined portions 216 B of the links 216 are abutted on the projection members 138 A. Then, the front side of the image forming unit 120 is guided by the disengagement guide 119 A, and lifted in the centerline direction.
When the user further opens the front cover 111 E and thereby pushes the links 216 toward the rear side, the rear inclined portions 216 C are abutted on the projection members 138 B. Subsequently, the rear side of the image forming unit 120 is guided by the disengagement guides 119 B, and lifted in the above-described centerline direction.
Therefore, in the printer 200 , the drum gears 151 A and the inner gears 113 A are sequentially disengaged from the front side of the drum unit 130 .
<Effect of Printer 200 >
In the printer 200 according to the second embodiment, the drum gears 151 A and the inner gears 113 A are sequentially disengaged from the front side. Therefore, even if the image forming unit 120 is heavy, a large load is not applied on the link 216 at a time. As a result, a user can easily disengage these gears.
[Variation]
Although specific embodiments have been illustrated and described herein, it is to be understood that the above description is intended to be illustrative, and not restrictive. Combinations of the above embodiments and other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention includes any other applications in which the above structures are used. Accordingly, the scope of the invention should only be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
For example, the inner gears 113 A of the above described printers 100 and 200 are disposed below and in front of the drum gears 151 A. However, the inner gears 113 A can be disposed in an alternative position, such as below and behind the drum gears 151 A. | An image forming apparatus includes a disengagement unit that disengages all of plurality of image carrier gears and plurality of driving, gears, and allows an image carrier unit to be removed outside of an unit containing portion. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to apparatus and method for automatically uniting two discrete lengths of web such as woven or knitted fabrics.
Heretofore, numerous types of equipment and techniques have been employed for joining two discrete lengths of textile material such as woven and knitted fabrics, generally in order to provide an indeterminate length of material for passage through a particular piece of process equipment. A continuous operation obviates the necessity for a roll-by-roll batch operation which is time consuming, and also counter-productive as to efficient operation of state of art processing equipment. Typically, in conjunction with a material accumulator or system, or in an environment where interruption of a processing machine is not critical, operators have historically placed a trailing end of one length of material and a leading end of a next length of material in a juxtaposed arrangement and sewn thereacross to create an appropriate joining seam. Similarly, techniques have also involved the joining of the leading and trailing ends of discrete lengths of material by other means such as heat sealing, and the like.
In each type of joining technique noted above, it is necessary for an operator to first be aware of the time when the production of a seam is necessary, and secondly to be physically present at the machine in order to facilitate manufacture of the joining seam. While in certain circumstances large rolls of material are utilized with seams normally only required once in a relatively prolonged period of time, the arrangement is still problematical. For example, should the material being processed become damaged, it is then necessary for an operator, once learning of the damage, to physically appear at the machine and manipulate the material to repair or remove the damaged portion of the material and to create a further seam thereat.
Typically, a single operator is assigned to a plurality of the processing machines in attempts to minimize labor intensity of the operation. With such an arrangement, should more than one machine assigned to a single operator require seaming at or about the same time, obviously the operator cannot simultaneously handle both assignments at the same time. It then becomes necessary to bring in a further operator, or to shut down one of the machines until such time as a joining seam can be produced. Not only does the machine down time result in lost production, but additionally, judgment of the operator as to whether a particular defect in a fabric should be repaired may be influenced by the operative condition of other machines and/or the willingness of the particular operator to in fact, perform his assigned task.
The present invention overcomes the problems noted above, in that, though an operator is still necessary, a lesser number of operators should be required on a per machine basis, and also the physical presence of the operator at the machine is only required on a very limited basis. Operator presence is normally required to make a judgment as to the necessity of repair of a defect with manufacture of the seam being accomplished automatically. The present invention thus represents significant improvement over prior systems and is not believed to be anticipated or suggested thereby.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved apparatus for the joining of edges of indeterminate lengths of web materials.
Another object of the present invention is to provide an improved apparatus for the automatic formation of a seam between a trailing edge of one length of web material and a leading edge of a next length of web material.
Still further another object of the present invention is to provide an improved apparatus for the automatic seaming of ends of different rolls of textile material to join same.
Another object of the present invention is to provide an improved method for producing a seam between two lengths of web material.
Yet another object of the present invention is to provide an improved method for the seaming of a trailing edge of one roll of textile material to a leading edge of a next roll of textile material automatically and without operator presence.
Generally speaking, the apparatus according to the teachings of the present invention comprises means for supporting and unwinding an indeterminate length of a first roll of web material and for directing said material being unwound along a predetermined path of web travel; means for supporting a second roll of web material adjacent said path of travel of said web material being unwound and for maintaining a leading edge of web from said second roll at a predetermined disposition adjacent said path of travel; means for controlling the unwinding of said first web of material so that as said first web of material is being depleted, a trailing edge of same is located at a predetermined disposition relative to said leading edge of said second roll of material; means for placing said trailing web edge from said first roll of web material into contact with said leading web edge of said second roll of web material at said predetermined location and for maintaining said edges in mutual contact thereat; means for producing a seam across said leading and said trailing edges; and means for moving said second roll of material to the unwind location for said first roll of material, whereby said unwind operation may continue.
More specifically, the apparatus of the present invention includes two roll stations on an unwind stand with surface drive rolls defining a cradle therebetween in a lower portion of each station. The path of travel of the web of a first roll of material being unwound extends rearwardly, adjacent the second roll of material which is first located at a preparation station, and is to be moved to the unwind station once the first roll of material is totally unwound. A manual actuator means is provided for the surface drive rolls of the preparation station such that once a full roll of material is provided thereat, an operator may manually actuate the drive means adequate to rotate the roll being prepared until the leading web edge of same is located. The leading edge is then manually brought into contact atop a web holding means, preferably in the form of a plurality of brushes extending across the width of the web. Certain of the brushes have pins therein for securement of the web. The leading edge of web extends beyond the brushes and is laid atop a sewing support means. Thereafter, upper opposing brushes are moved down into contact with the upper surface of the leading web edge to hold same in place.
Once the trailing edge of the roll being unwound is adjacent and in front of a location where the leading edge of the next web is being maintained, certain of the web holding brushes move outwardly until the two web longitudinal edges are aligned. A web inserter means is then brought into contact with the trailing edge of the web and forces same between the upper and lower holding brushes, locating the trailing web edge atop the leading edge of the next roll. In inserting the trailing web edge, the insertion means deflects the upper brushes rearwardly whereby during retraction of the insertion means the upper bristles hold the trailing web edge in proper location atop the leading web edge. Sewing means may then automatically move across the width of the two webs and trim and sew the webs together forming a junction seam. After the seam is formed, the new roll is transferred from the preparation station to the unwind station, and the operational speed of the unwinding apparatus increases, pulling the joining seam from between the brushes and along the normal path of travel of the web.
The apparatus of the present invention likewise includes a means for removal of an empty tube from a previously unwound web roll. As previously mentioned, the roll is unwound in a cradle formed between two surface drive rolls located beneath same. Consequently upon complete unwinding of the roll, only the core or tube remains in the cradle which continues to rotate along with surface drive rolls. During the unwinding operation and while the roll of web material is supported in the cradle, an idler roll is maintained atop the roll of material to prevent the material roll from jumping out of the cradle, particularly when the diameter of the roll is small, and would otherwise bounce about the cradle. Located on an underside of a support for the top idler roll is a frictional surface, which when brought into contact of an upper surface of the remaining tube or core, causes the tube or core to cease rotation, at which point it is driven out of the cradle by the upstream surface drive roll and deposited on the floor beneath the machine. Thereafter the roll cradle in the preparation area is pivoted upwardly and forwardly and causes the new roll to roll into the area just vacated by the tube. Thereafter, the unwinding operation continues.
Apparatus according to the present invention may be further provided with a defect detection system which determines the location and magnitude of a structural defect in the web being handled. Once a defect is detected and removal is required, a microprocessor which is operatively associated with the machine determines the location of the defect downstream from the detection apparatus and automatically stops the unwind operation, reverses the drive means and returns the defect to a predetermined defect removal location adjacent and above the previously described seaming operation. The web insertion means previously utilized for insertion of a trailing end of web between the holding brushes has been raised to the defect removal means, preferably a second set of brushes. The web insertion means is then actuated to move into contact with a portion of the web where the defect is located and to force a loop of the web thereat between and beyond the second pair of holding brushes. In like fashion the automatic sewing machine is raised to the level of the second brush arrangement and automatically trims the web to remove the defect and forms a new seam thereat. Once the defect has been removed, unwind operation continues, pulling the new seam from between the holding brushes then back through the brushes and along the normal path of travel. Other means may be provided in conjunction with the second brush unit, if necessary, to pull further web material through the brushes.
Generally speaking, the improved method according to teachings of the present invention for automatically joining two rolls of web material comprises the steps of moving a web of material from a first roll located at a first station along a predetermined path for same; locating a second roll of web material at a second station and placing a leading edge of said second web adjacent said path of travel of said first web and securing said leading edge of said second web thereat; locating said trailing edge of said web at a predetermined location adjacent said securement means for said leading edge of web material from said second roll; automatically bringing said trailing edge web material into contact with said leading edge web material from said second roll; joining said leading and trailing edges of material to unite said second roll of material to said first roll of material; transferring said second roll of material to said first location; and moving said web from said second roll along said path.
More particularly, in performance of the method of the present invention, when the second roll of material is placed at the roll preparation area or second location, the operator manually actuates the drive means thereat to locate the leading edge of web, after which the leading web edge is manually brought into contact with a lower web holding means. The operator then enables automatic operation and predetermined sequences are carried out automatically. Thereafter, once the drive means for the first station is interrupted to locate the trailing web edge from the first roll adjacent the web edge holding means, certain of the lower web edge holding means then holding the leading web edge move outwardly to a point where longitudinal edges of the webs are aligned. An upper web holding means then moves downwardly into contact with the surface of said leading web edge, and web insertion means engages said trailing web edge and inserts same atop the leading web edge, between the edge holding means. Once the trailing and leading web edges are properly positioned, an automatic sewing head moves along a path across the width of the web automatically trimming the web and producing a junction seam thereat. Following production of the junction seam, the second roll of web material is then transferred to the roll unwind station, and a further roll of web material is placed in the roll preparation area to be joined to a trailing edge of same at the appropriate time. Also, the drive means for moving the web is reactuated and automatically pulls the joining seam from within the holding means.
The method of the present invention further includes the automatic removal of defects from a moving web comprising the steps of detecting a defect in the moving web, returning the noted defect to a predetermined location; inserting said defected web portion between web holding means, correcting the defect and moving the corrected web along an intended path of travel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of a relevant portion of an apparatus according to teachings of the present invention.
FIG. 2 is a side elevational view of web holding means according to teachings of the present invention illustrating a leading web edge in place.
FIG. 3 is an isometric view of a web holding means according to teachings of the present invention.
FIGS. 4, 5 and 6 are schematic illustrations of web holding means according to the present invention in a preferred embodiment, illustrating automatic insertion of a trailing web edge therein and the production of a joining seam between trailing and leading web edges.
FIGS. 7, 8 and 9 are side elevational schematic views of a second web holding means in a preferred embodiment according to teachings of the present invention illustrating insertion of a web loop therein for the removal of a detected defect.
FIGS. 10 and 11 are side elevational schematic illustrations of a relevant portion of the apparatus according to teachings of the present invention illustrating removal of an empty core from a roll unwind station and transfer of a full second roll from a preparation station to the unwind station.
FIG. 12 is an elevational view of a seaming portion of apparatus according to the present invention.
FIG. 13 is a side elevational schematic view of a sewing head for use producing seam according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Making reference to the Figures, preferred embodiments of the present invention will now be described in detail. FIG. 1 schematically illustrates relevant portions of apparatus according to teachings of the present invention wherein the first roll of materially generally indicated as 10 is located in a web unwind or first station generally indicated as 20 with the web W being unwound therefrom and following a predetermined path of travel to a further piece of processing equipment (not shown). In the sense of the present invention, drive means for forwarding web W beyond the relevant apparatus of the present invention is not illustrated, but may be any conventional drive means for a web, particularly a textile web.
As seen in FIG. 1, web roll 10 is supported on a pair of surface drive rolls 22, 24 with stabilizing idler rolls 23 and 25 located thereabove. Idler rolls 23 and 25 are provided primarily to ensure proper location of roll 10 within the unwind station 20, and once adequate web is unwound from roll 10, rolls 23 and 25 cease to contact the surface of the roll. As schematically illustrated, surface drive roll 22 is associated with a drive pulley P through a belt B or the like, with pulley P being associated with a drive means M. Though not shown, drive roll 22 is interconnected with drive roll 24 to afford a driving motion thereto. Roll 10 is wound around a particular core 12.
As also illustrated in FIG. 1, adjacent unwind station 20, and opposite ends of roll 10 (only one shown) are a pair of vertical standards 14 at opposite ends of roll 10 to assist in maintaining roll 10 at station 20. Further, an additional idler roll 26 is freely rotatably received on a pivoted support means 27, with idler roll 26 resting atop roll 10. Support 27 pivots in the direction of the double headed arrow and thus follows the reducing diameter of roll 10 downwardly to assist in maintaining roll 10 properly in contact with surface drive rolls 22 and 24. Also received on an underside of support 27 is a frictional surface 28, the purpose of which will be described hereinafter.
Web W moving from unwind station 20 moves upwardly and about an idler roll 30 that is received between two vertical standards 32 (only one shown). Idler roll 30 is associated with a chain drive (not shown) and is moved between an upper position as shown in phantom behind standard 32 and a lower roll transfer position as also shown in phantom. Web W then turns downwardly extending around idler rolls 34, 36, 38 and 39 thus defining a path of web travel through the relevant apparatus of the present invention. The path of travel is located adjacent a seam forming station generally indicated as 60 and upwardly therealong, continuing to a next processing unit or the like.
Located immediately adjacent unwind station 20 is a roll preparation station generally indicated as 40 where a new roll of material is deposited onto a cradle defined by bottom surface drive rolls 42 and 44 both of which are driven as is schematically illustrated in FIG. 1 by appropriate pulley drive means generally indicated as 45 powered by motor M' that is operatively connected to a foot pedal 46 or other manipulable switch. Drive rolls 42 and 44 are received for rotation on a framework 47 that is pivotally mounted about a drive shaft 48 for drive roll 44 or some other convenient location. Framework 47 has a roll plate 49 secured thereto which extends angularly outwardly therefrom, the purpose of which will be described hereinafter.
Seam forming station 60 includes a moveable carriage 86 which is received about a drive means generally 55, preferably a screw arrangement for up and down movement therealong. Carriage 86 is raised while a new roll 50 is loaded into preparation station 40 and is then lowered. Carriage 86 is connectable to a base 60' to which lower brushes 62, 64 and 66 are secured by way of locking member 87 and locking pair 87' (See FIG. 12). When disconnected, carriage 86 may be moved independently of base 60'. Likewise brush assembly 75 is moved downwardly by an air cylinder arrangement 79 for a purpose to be described (See FIG. 12).
With roll preparation station 40 empty, and seaming station 60 raised, an operator positions a new roll of material such as a fabric or the like in roll preparation station 40, atop the cradle defined by surface drive rolls 42 and 44. The operator may then depress the foot pedal 46 causing surface drive rolls 42 and 44 to rotate until the leading edge L of the web on roll 50 is located. Station 60 is then lowered and base 60' separated therefrom as noted above. The operator manually pulls the leading edge L into seam forming area 60 (See FIG. 2). Particularly, as is shown in FIGS. 2 and 3, leading edge L of the web W' is pulled beyond a series of brushes 62, 64 and 66 mounted on base 60', which collectively constitute a preferred lower web holding means, and likewise across a sewing support surface 70 with a terminal end of same draping therefrom (See FIGS. 2 and 21) As can be particularly seen in FIGS. 2 and 3, lower web holding brushes 62 and 64 are provided with a plurality of pins 63 which pierce and hold leading edge L of web W'. Brushes 62 and 64 are then located inwardly of their outermost location, shown in solid lines in FIG. 3. Once the second roll 50 of web material is in place and the leading edge L secured atop brushes 62 and 64, the operator depresses an enabling switch 90 which causes an upper web holding brushes 67 of web holding means 61 to move downwardly into contact with an upper surface of leading edge L of web W' (See FIG. 4).
After roll 10 has been unwound to a predetermined point, a sensor schematically indicated as a switch 100 located along a standard 14 is actuated which indicates that the roll 10 is nearly unwound. Actuation of switch 100 then provides input to a control mechanism 210 which reduces the speed of drive elements associated with the apparatus, such as the surface drive rolls 22 and 24 and downstream drive means (not shown) whereby the unwinding speed reduces. Thereafter, as the trailing edge T of web W leaves core 12, it passes about idler rolls 30, 34, 36, and 38 and comes to rest adjacent web holding means 61 (see FIG. 4) when control means 210 stops the operation. Brushes 62 and 64 then move outwardly to the position shown in FIG. 3 in phantom where a sensor schematically illustrated as 110 senses the presence of the outer longitudinal edge of trailing edge T and thereby brings longitudinal edges of leading edge L into alignment therewith.
Once longitudinal edges of leading edge L and trailing edge T are in alignment, a web insertion means generally indicated as 80 (see FIG. 4) is actuated and pivotally moves about a pivotal connection 81 into contact with trailing edge T and carries trailing edge T through its pivotal path of travel. Web insertion means 80 is illustrated as an elongated arm 82 having a web pusher finger 84 secured thereto and extending outwardly therefrom. As can be seen in FIGS. 4 and 5, pusher finger 84 moves into contact with bristles 67' of upper brush 67 deforming bristles 67' rearwardly (See FIG. 5). Web insertion means 80 then pivots in the opposite direction with bristles 67' engaging and retaining trailing edge T, whereby trailing edge T is properly located atop leading edge L within the web holding means 61.
Return of web insertion means 80 from within web holding means 61, actuates an automatic sewing head generally indicated as 88 which moves across sewing table 70 (See FIG. 13), trims the outer edges of both leading and trailing edges of webs W and W' respectively, and produces a joining seam therebetween. Once the sewing head 88 completes its path of travel across the width of the respective webs, framework 47 of roll preparation station 40 pivots about pivot point 48, raising surface drive roll 42 against roll 50, and lowers roll plate 49 into contact with plate support 49' (See FIG. 1). Roll 50 then rolls out of the cradle defined by drive rolls 42 and 44 and onto unwind station 20 where it engages idler rolls 25, 23 and self locates atop surface drive rolls 22 and 24.
As illustrated in FIG. 13, sewing head 88 is mounted for movement along a screw 91. Sewing motor 92 rotates a drive member 93 received about screw 91 which effects movement therealong while producing a joining seam. It is desirable to increase stitch density at a fabric selvage. Accordingly, when machine 88 reaches the web selvage area a further drive means generally 94 rotates screw 91 in a direction counter to movement of drive member 93, slowing down the speed of movement of sewing machine 88 thus creating the higher density.
After trailing edge T has passed over idler roll 30 located in its upper position, idler roll 30 is lowered to its lower position, residing beneath the level of roll plate 49 during the roll transfer operation. Thereafter, once roll 50 is located at unwind station 20, idler roll 30 is returned to its uppermost position carrying web W' from roll 50 therewith to redefine the unwind path of web travel.
As idler roll 30 reaches its uppermost position, a sensor schematically indicated as a switch 120 is engaged which signals the control means 210 to return the web drive means to full operational unwind speed. Roll 50 is then unwound.
After roll 50 is located at unwind station 20, framework 47 pivots in the opposite direction, raising plate 49 and lowering drive roll 42, such that drive rolls 42 and 44 resume a proper disposition for receiving yet a further roll of material to be united with the web on roll 50 once same is unwound. In this fashion, an automatic unwinding operation may continue indefinitely without operator influence except for positioning the new roll at roll preparation station 40, manually placing the leading edge L of a web W' within the web holding means 61, and actuating enabling switch 90.
The basic operation of the automatic web joining arrangement having been described above, a further embodiment or adaptation of same will now be described, making reference to FIGS. 1 and 7-9 and 12. As may be seen in FIG. 1, web W after exiting the seam joining area passes by a defect detection device 200 which could be represented by any particular defect detection device that will determine the existence of holes, tears, rips and the like in a moving web. Preferably, defect detection device 200 is of the type as described and claimed in co-pending application, Ser. No. 6,727,284 filed concurrently herewith and entitled APPARATUS AND METHOD FOR DETECTING DEFECTS IN A MOVING WEB, which is incorporated by reference herein. Particularly where a detector 200 determines that a defect has occurred in web W and with detector 200 operatively associated with a control means 210, preferably a microprocessor, once it has been determined that the defect exists, the microprocessor which is programmed for such will reverse the direction of flow of web W and return same to a defect correcting area or upper brush assembly generally indicated as 75 (See FIG. 12) that is located at seaming station 60. Defect correcting area 75 includes a web holding means generally indicated as 76, which preferably is a pair of opposing brushes 77 and 78 of the type discussed with respect to web holding means 61 with the exception that holding pins 63 are not included. Once a defect is detected, seaming station 60 moves downwardly and base 60' and brush assembly 75 are separated from carriage 86. Such separation orients web insertion means 80 for pivotal movement through brushes 77 and 78. With the defect located immediately adjacent defect correcting area 75, a loop of web W is forced between brushes 77 and 78 to reside atop a sewing table 70 as described for production of a joining seam. Automatic sewing machine 88 may then move therealong to trim the defect from web W and to produce a new joining seam thereat.
Once the defect has been removed and the seaming operation is completed, the control means 210 reverses the direction of web feed to its original direction which automatically withdraws the new seam from within the web holding means, and the web follows its normal path of travel.
As could be expected, depending upon the size defect detected in the web, the length of same could exceed the length of pusher finger 84 such that when pusher finger 84 positions the web loop between web holding brushes 77 and 78, a portion of the defect still remains outside of the trimming and sewing area. As is shown in FIG. 7, a pair of rolls 81' and 82' are shown in phantom, being located adjacent a terminal end of sewing plate 70. Utilizing the preferred detector system as mentioned above, the microprocessor is informed as to the location and magnitude of the defect. Armed with such information, the program for the microprocessor could incorporate a feature such that when the length of the defect exceeds a predetermined amount, i.e., more than can be inserted in loop form by web insertion element 80, rolls 81' and 82' may be actuated to operate for a predetermined period of time adequate to totally bring the defect beyond the path of the sewing head, such that the entire defect may be trimmed from the web and the new seam formed adjacent thereto.
It will be understood, of course, that while the form of the invention herein shown and described constitutes a preferred embodiment of the invention, it is not intended to illustrate all possible form of the invention. It will also be understood that the words used are words of description rather than of limitation and that various changes may be made without departing from the spirit and scope of the invention herein disclosed. | Two lengths of discrete web materials are automatically joined by suitable alignment and positioning of their respective leading and trailing web edges. Transverse movement of such edges is automatically controlled so that longitudinal margins of such edges are aligned, also. Once a first roll of material is emptied and its trailing edge is joined with a leading edge of a new roll of material, support structure for the new roll is pivoted so that the new roll is physically moved into the support and drive position previously occupied by the old roll. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to gas turbine engines and more particularly to stator vanes for use in engines having high turbine inlet temperatures.
2. Description of the Prior Art
The design and construction of gas turbine engines has always required precise engineering effort to ensure the structural integrity of the individual components. One particularly critical area for concern is the turbine nozzle which is formed of a plurality of vanes disposed across the flow path for the high temperature gases in the turbine. During operation of the engine, the flowing gases are redirected by the nozzle onto the rotor blades of a turbine wheel. The temperature of the gases at the inlet to the turbine normally exceeds the allowable temperature limit of the material from which the vanes are fabricated. Consequently, the vanes are cooled to prolong their service life by reducing the metal temperature of the vanes during operation.
Cooling air to the vanes is supplied by the compressor section of the engine. The air is flowed through various conduit means both inwardly and outwardly of the working medium gas path to the turbine section of the engine. A hollow cavity within the airfoil section of each vane receives the cooling air. Air entry ports at both ends of the hollow cavity are in communication with the conduit means. A typical vane utilized in cooled turbines is shown in U.S. Pat. application Ser. No. 531,632 entitled, "Cooled Turbine Vanes" by Leogrande et al, of common assignee herewith. In Leogrande et al an insert is disposed within a hollow cavity at the leading edge of a vane airfoil section. The insert is positioned to direct adequate quantities of cooling air to the leading edge of the airfoil section for film cooling.
Film cooling requires a precise but relatively low pressure differential across flow emitting holes. If the pressure drop is too high, the emitted flow penetrates the passing medium and is deflected downstream with the combustion gases without establishing a film layer on the airfoil surface. On the other hand, if the pressure drop is too small, the hot combustion gases penetrate the cooling air layer to cause destructive heating of the vane material. Because the pressure differential between the cooling air within the vane cavity and the working medium gases at the vane leading edge is relatively small, the amount of flow through each hole is highly sensitive to local pressure deviations within the cavity.
To implement uniform film cooling at the leading edge of the airfoil section, the local pressure deviations in the hollow cavity must be reduced or eliminated. Continuing efforts toward that end are being made.
SUMMARY OF THE INVENTION
A primary aim of the present invention is to provide a coolable vane having improved service life. In one aspect, an object is to eliminate the back flow of working medium gases into the vane cooling system. Apparatus capable of providing a nearly uniform flow of cooling air to the leading edge of each vane is sought. One goal in sustaining uniform flow is the establishment of a substantially uniform pressure differential across the leading edge of the vane between the working medium gases of the flow path and the cooling air of the vane cavity.
The present invention is predicated upon the recognition that the cross flow of cooling air from one end of a hollow vane cavity to the other creates local pressure deviations at the various film cooling holes of the leading edge. More specifically, under certain engine operating conditions the cooling air supplied to one end of the cavity overrides the air supplied to the opposing end. The velocity of the air entering the end of the dominant supply becomes excessive and aspiration of the hot working medium gases into the hollow cavity through the film cooling holes results.
According to the present invention a mid-span baffle is operatively disposed within the hollow cavity of a coolable turbine vane, having entry ports for cooling air at both the inner and outer ends of the vane, to prevent the cross flow of air from one end to the other.
A primary feature of the present invention is the mid-span position of the baffle. In one embodiment the baffle is suspended from a U-shaped insert which brackets the leading edge cooling holes. In the same embodiment the baffle loosely engages one or more corresponding openings in the U-shaped insert to position the baffle within the cavity without inhibiting the lateral deflection of the insert in response to pressure forces within the insert.
A principal advantage of the present invention is the prolonged service life obtainable through incorporation of the mid-span baffle. Local burning of the vane material is prevented by eliminating the aspiration of hot working medium gases into the cooling cavity. A reduction in the cooling air pressure required to ensure a positive flow of cooling air through the leading edge holes enables an improvement in overall engine efficiency.
The foregoing, and other objects, features and advantages of the present invention will become more apparent in the light of the following detailed description of the preferred embodiment thereof as shown in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified cross section view of a portion of a gas turbine engine showing a vane at the inlet to the turbine;
FIG. 2 is a sectional view of the turbine vane taken along the line 2--2 as shown in FIG. 1;
FIG. 3 is a partially broken away, perspective view of the vane shown in FIG. 2;
FIG. 4 is a sectional view of the turbine vane showing an alternate internal construction; and
FIG. 5 is a partially broken away, perspective view of the turbine vane shown in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The turbine section 10 of a typical gas turbine engine is shown in partial cross section in FIG. 1. A stator vane 12 and a rotor blade 14 are disposed across an annular flow path 16 for the working medium gases discharging from a combustion chamber 18 during operation of the engine. The stator vane shown is one of a row of vanes which are located at the same axial position within a flow path. Similarly, the turbine blade shown is one of a row of turbine blades disposed within the flow path immediately downstream of the vanes. Each vane has an outer diameter base 20 and an inner diameter base 22 which support an airfoil section 24 extending therebetween. Each vane is coolable and is adapted to receive relatively low temperature air flowing from an inner annulus 26 and an outer annulus 28 in the turbine section.
The FIG. 2 sectional view reveals, extending in a spanwise direction between the inner and outer bases of the airfoil section, a cavity 30 which receives cooling air from the inner and outer annuli. The airfoil section 24 has a leading edge 32 which faces in the upstream direction with respect to flow through the path 16 and has incorporated therein a plurality of leading edge cooling holes 34. A trailing edge 36 having one or more passages 38 faces in the downstream direction with respect to the direction or working medium flow. A pressure side 40 of the airfoil section has a plurality of pressure side cooling holes 42; a suction side 44 of the airfoil section has a plurality of suction side cooling holes 46. The cavity 30 is formed by a pressure wall 48 and a suction wall 50. An insert 52, which is substantially U-shaped, is disposed within the cavity and extends in the spanwise direction between the inner and outer bases. The insert has a pressure leg 54 and a suction leg 56 and is fabricated of a flexible material such as sheet metal. The flexible insert is deformable against the pressure and suction walls of the cavity in operative response to increased pressure within the insert. A baffle 58 is suspended between the suction leg and the pressure leg of the U-shaped insert at a mid-span position within the cavity. The baffle loosely engages the pressure leg of the insert in a manner radially supporting the baffle without inhibiting the deflection of the pressure and suction legs of the insert against the respective pressure and suction walls of the cavity during operation. As is shown in FIGS. 2 and 3, the baffle is welded to the suction leg of the insert; in alternate embodiments loose engagement means corresponding to that shown at the pressure leg of the insert may be effectively employed.
An alternate internal construction for the hollow vane 12 is shown in FIG. 4 wherein the hollow portion is comprised of a leading edge cavity 102 and a trailing edge cavity 104. A leading edge 106 faces in the upstream direction and has incorporated therein a plurality of leading edge cooling holes 108. A trailing edge 110 faces in the downstream direction and has incorporated therein a passage 112. Each vane has a pressure side 114 which includes a first plurality of pressure side cooling holes 116 extending from the leading edge cavity 102 to the annular flow path and a second plurality of pressure side cooling holes 118 extending from the trailing edge cavity 104 to the annular flow path. Each airfoil section further has a suction side 120 including a first plurality of suction side holes 122 extending between the leading edge cavity and the flow path and a second plurality of suction side cooling holes 124 extending between the trailing edge cavity 104 and the annular flow path.
The leading edge cavity 102 is bounded by a pressure wall 126 and a suction wall 130 which have correspondingly a pressure wall sealing rib 131 and a suction wall sealing rib 132 extending therefrom. The leading and trailing edge cavities are separated by a cross member 134. A leading edge insert 136 and a trailing edge insert 138 have substantially U-shaped contours and are disposed within the leading edge cavity and trailing edge cavity respectively. Each insert has a pressure leg 140 which opposes the pressure wall of the respective cavity and a suction leg 142 which opposes the suction wall of the respective cavity. Impingement cooling holes 144 penetrate the leading and trailing edge inserts.
A baffle 146 is suspended between the suction and pressure legs of the U-shaped insert in the leading edge cavity. In the embodiment shown the baffle has a plurality of tabs 148 which loosely engage corresponding apertures 150 in the leading edge insert so as to position the baffle at a mid-span location with respect to the airfoil. The loose engagement between the baffle and the insert allows radial support of the baffle without inhibiting lateral deflection of the insert pressure and suction legs in response to increased pressure within the insert.
During operation of the engine, cooling air is flowed to the inner annulus 26 and to the outer annulus 28. The pressure differentials between the air in the two annuli and the medium gases of the flow path 16 are dependent upon the frictional flow losses en route to the respective annuli and upon the pressure drop established across the combustion chamber. Under operating conditions wherein the pressure of the gases in one of the annuli is greater than that in the opposing annuli, a cross flow of cooling air through the cavity 30 of the vane 24 occurs in the direction of the annulus having lower pressure. In a cross flow condition, then, the entire supply of cooling air to the leading holes 34 flows from the annulus having the dominant supply. Furthermore, the volume of the air entering the cavity 30 is increased beyond that flowed through the holes 34 to include the amount of cross flow air discharged into the opposing annulus. Under such a condition the flow velocities of air through the cavity may become excessive and cause aspiration of the working medium gases through the holes 34 into the cavity 30.
The baffle 58 of the present invention is disposed at a mid-span location within the cavity 30. The baffle prevents the cross flow of cooling between the two opposing supply annuli to significantly decrease the possibility of aspiration through the holes 34. Although the baffle is shown at the approximate geometric center of the airfoil section, it may be desirable to locate the baffle radially inward or outward within the cavity 30. A change in the radial position of the baffle within the mid-span region is desirable where the pressure of the cooling air in one of the annuli is known to be greater than that in the other. In such a case the baffle is adjusted in the direction of the annuli having a lesser supply pressure and can be so relocated without permitting cross flow.
The elimination of the potential for cross flow has the beneficial effect of lowering the required pressure differential between the cooling air and the working medium gases of the flow path 16 which is necessary to ensure that aspiration does not occur. Inasmuch as the pressure differential required to prevent aspiration is functionally derived from the pressure drop across the combustion chamber, any decrease in the required differential enables a corresponding reduction in combustion chamber flow losses. An improvement in overall engine efficiency results.
An insert, such as the insert 52 of FIG. 2 or the insert 136 of FIG. 4, is disposed within the respective cavity 30 or 102 to isolate the film cooling holes of the leading edge from the remainder of the cavity. Isolation ensures a positive flow of cooling air through the holes to the medium flow path in a region of highest pressure and temperature. The insert 52, which has a substantially U-shaped contour, brackets the leading edge holes 38 and the pressure side cooling holes 42 of the airfoil section shown in FIG. 2. Although the pressure side cooling holes are not provided in some constructions, the holes are incorporated in the preferred embodiment shown to increase the thickness of the boundary layer of film cooling air along the pressure side of the airfoil. The pressure side holes are isolated along with the leading edge holes in order to take advantage of the controlled flow provided at the leading edge holes by the apparatus constructed in accordance with the present invention.
In response to increased pressure within the insert as cooling air is flowed thereto, the pressure leg 54 and the suction leg 56 of the insert are deflected within the cavity 30 against the pressure wall 58 and the suction wall 50 respectively. This lateral deflection is uninhibited by the mid-span baffle 58 which loosely engages the insert. In one embodiment the baffle is welded to the suction leg 56 of the insert and loosely engages the pressure leg 54 of the insert, although a baffle loosely engaging both legs of the insert is equally effective. It is important to note, however, that both the suction and pressure legs are not structurally tied to the baffle and free lateral deflection of the insert legs is permitted.
In the alternate embodiment shown in FIG. 5, the baffle has a plurality of tabs 148 which loosely engage corresponding apertures 150 of the leading edge insert 136. As in a prior discussed construction, the baffle may be fixedly attached to either the pressure leg or the suction leg of the inserts without departing from the concepts taught herein.
Although the invention has been described with respect to a preferred embodiment, it should be understood by those skilled in the art that various changes and omissions in the form and detail thereof may be made therein without departing from the spirit and the scope of the invention. | A stator vane capable of use in the high temperature environment of a gas turbine engine is disclosed. Various construction details implement vane cooling concepts which are designed to prolong the service life of the vane. An effective leading edge cooling system is built around the uniform flow of film cooling air over the exterior surface of the leading edge from a cavity within the airfoil section of the vane. | 5 |
FIELD OF THE INVENTION
This invention regards reactive polymers for the treatment of skin afflictions and particularly crosslinkable urethane polymers with film properties and applicable to various skin disorders, and also to healthy skin as transdermal drugs supports.
BACKGROUND OF THE INVENTION
It is known that various treatments of skin diseases or the like has been proposed and used over the years, mostly through topical application of linements, unguents or caustic agents such as nitric acid, chloracetic acid, salicylic acid, etc.
Moreover, for many years, the use of natural or synthetic polymers that have a relative affinity with skin tissues, have been employed as protective agents or as excipients and carriers for dermoreactive substances.
Prior products of external medical action, to be classified in the cathegory of liquid plasters for "spray" application, supply protection films, owing to evaporation of the solvent constituted to water or of water mixed with organic compatible solvents. Other similar products are mixed compositions of polymers and medicinal additives (emostatics, disinfectants, antibiotics; dermoprotectives). These prior products consist mostly of copolymers whose duration "in situ" after application, is of very few days, because of their sensitivity to water and perspiration. Their use is anyway suggested for the medication of wounds of small or medium dimensions, and the principal advantage of these materials is often limited to their easy use. Compounds belonging to this family have been also obtained with natural polymers of cellulosic kind, more or less chemically modified. Anyway, they are always products having a certain water sensitivity, that adhere to skin only through physical bonds.
In the literature of the field, it was mentioned also the use in exceptional cases of chemical unsaturated reactive substances, that, applied on serious wounds, with hemorrage danger, facilitate the arrest of the blood flow of wounds, due to a violent hemostatic action. These chemical substances are monomers of the cyanoacrylate family, that at skin contact, and by means of its humidity, polymerize, in that they are hydro-reactive products and chemically combined in correspondence to wounds.
Anyway, these products are not suitable for the normal epidermal and transdermal skin therapy, because of the absolute lack of elasticity and because of chemical toxicity, negative aspects that could be only accepted in drastic situations (serious wounds in war situations, mutilations, dangers of serious hemorrages).
Filmogenic polymers, endowed with hydrorepellent action, used in order to isolate recent wounds or sores, sensible to the soaking water effect, are recent introduction in the pharmaceutical field. Similar to the above mentioned polymers are for example alkylpolysiloxanes and other siliconic basis polymers that deposit upon skin through physical adhesion. They were used in the treatment of bedsores.
Of more recent vintage is the use of a polymer on the basis of animal collagen fibres, used alone or in combination in separate layers, with siliconic polymers, which always constitute the external protective layers.
SUMMARY OF THE INVENTION
It has been surprisingly discovered, and this is the object of the present invention, that certain urethane polymers, besides having superior mechanical and chemical characteristics, than the polymers known until now for analogous employments, present the properties of chemically binding to skin proteins, and more generally to bodily ones, showing a real therapeutical action on the alterations of animal skin, particularly human one. According to the present invention, the principal characteristics of polyurethanes are: dermoreactivity, that is the capacity of closely binding to skin through chemical reaction; elasticity very similar to that of skin; a good resistance to abrasion as well as a good resistance and impermeability to water.
These polymers, applied to skin as thin film, completely react with and remain bound to skin until the exchange of the horny layer and they protect the underlying derma in the reconstructive phase and accelerate the regeneration through stimulation of the damaged tissues. So, the resultant polymeric film has elasticity characteristics similar to those of skin, following contours and deformations, superior mechanical characteristics, good resistance to the soaking action of water and to the attack of substances of ordinary occasional use that can cause skin troubles, particularly if sensitive, such as detersives, certain cosmetics and others. It is usually waterproof having partial air-permeability but it is possible to modify the formulation to allow a greater ratio of air penetration, and consequently to improve the oxygenation of the deepest skin layers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
According to the present invention, dermoreactive polymers are constituted to two components that are combined by mixing them immediately before the application on to the skin surface to be treated, and by leaving the applied coating to react for a determined period of time specifically for the application in question. The resultant polymers have a very high molecular weight and are cross-linked with a three dimensional structure, being very resisting even to the most common organic solvents; they steadily adhere to the epidermis and remain thereon for a variable period of time, that ranges from few days to three weeks about, that is until the healthy skin layers entirely regenerate. Just then, during the separation of the horny layer, owing to regeneration, the polymer film is removed therewith, leaving the new and healthy skin surface.
The first component A is an oligomer, with hydroxylic, amidic or aminic chemical functions. The second component B is constituted of a monomer, mostly an oligomer with isocyanate reactive chemical functions. The resultant reaction principally reguards hydroxylic, aminic or amidic and isocyanate groups according to the schematic equations well-known in the chemistry.
Another kind of reaction is the one that happens between the isocyanate groups and water, present in the atmosphere leaving the skin damp or in the skin exudate, with formation of new aminic groups, and the liberation of carbon dioxide, helping in this way the cross linkable reactions.
The --NCO functions of isocyanates react even with aminic and amidic hydrogens of the polypeptidic chains constituting the skin organic tissues according to the following schematic equation: ##STR1##
This reaction has a fundamental importance, from the point of view of the present invention, because it determines the polymer adhesion to skin. The polymer's reaction with damaged epidermic layers or anyway with superficial tissues determines a gradual devitalization of unhealthy skin cells, so to facilitate the body's rejection mechanism and to stimulate the regeneration of healthy cells.
In order to effect exactly the polymer's application, according tot he present invention, it's necessary that the part to be treated is clean as possible from fatty substances and dry, so to facilitate the perfect adhesion and the sealing surface action of the polymer film. For this reason, in the cases of pathologies with the presence of damp surfaces, it's necessary to dry the skin with absorbent materials having a large absorption capacity. For the most difficult cases in this sense, it will be useful to employ a combination of components at rapid reaction, so that the polymer in formation quickly binds to the surface and so it acts as barrier and stops the humor flow.
The pathologic cases in which the product, according to the present invention, has given the most evident results, are the different kinds of eczema or of dermatitis of allergic-toxinic origin, funginic, bacteric or chemical origin; troubles such as rhagades, chilblains, bedsores, burn sores and burns in general.
Most cases, examined in practical experiments, regard afflictions of chronic character, where therapy of modern medicine and pharmacology did not succeed in curing the disease: these were cases where one had often to deal with cortisone treatments, in order to mitigate temporarily the disease inconvenience, but that as it's known, reduces the efficacy of the immunity system, and anyway does not succeed in healing. The application of this kind of polymer, instead, could provide an effective treatment.
In the choice of substances, used for therapeutic formulations, according to the present invention, it is preferred to use, if possible, natural products; anyway, in order to get more sophisticated characteristics to the finished product, substances of synthesis were also taken into consideration.
So, a classic formulation is on castor oil basis, chemically constituted, mostly by tryglycerid of castor fatty acid, that reacts through its hydroxylic groups with isocyanates of isocyanate polymer.
Also in this case as in the most considered ones, the formulation is constituted to two components to be mixed at the use moment, parts A having hydroxilic aminic or amidic functions, and B having isocyanate functions.
Component A can be formulated with synthesis products, obtained through reaction of polyvalent alcohols with mono or polycarboxylic acid, preferably of aliphatic or cycloaliphatic series. The product, synthesized through polycondensation, has a molecular weight preferably between 500 and 2000 and a medium-low viscosity, in order to allow a lowest use of organic solvents. This component A can also be obtained from natural oil, prereacted, with polyvalent alcohols with consequent formation of hydroxylated glycerid successively reacted with carboxylic acids. Natural oils, mostly taken into consideration for such aim, are the following: linseed, castor, soya, grape-stone, maize, safflower, sunflower, groundnut, fish, oiticia, tung, perilla, cotton-seeds, olive, almond, nut, hazel, coco-nut, palm oils, and other ones of vegetal or animal derivation, to be included into the chemical family of tryglycerids of fatty saturated and unsaturated acids.
As polyvalent alchols, there can be used glycols such as ethylenic, propylenic etc. and their polyoxyalkylenic derived polyalcohols such as glycerin, trimethylolpropane, penthaeritrithol, exanetriol, sorbitane, exoses, saccharose. Monovalent alcohols can be also used as modifying agents.
Monocarboxylic synthetic aliphatics or of natural origin can be used as carboxyilic acids such as fatty acid, bi- and polycarboxyilic ones, as succinic, adipic etc, phthalic, isophthalic, terephthalic, tetrahydrophthalic, exahydrophthalic, endomethylente-trahydrophthalic, hydroxyacids, aminoacids, or lattons can be also included into the formulation of component A.
Component A can be also constituted of a copolymer urethane hydroxylated, obtained through reaction of a polyvalent alcohol, eventually modified for esterification or copolymerization with a polyisocyanate.
Component A can be also a copolymer obtained from unsaturated monomers having OH alcoholic or OH phenolic groups, amidic or aminic such as residue functions.
Analogously, component A can be also a polyamide or polyesteramide, at preferably low molecular weight or a polyether obtained through condensation of polyvalent alcohol with alkylenics or with chloridrine or a polyamine with aminic secondary hydrogens, preferably sterically hindered.
Component A can be also constituted of lattons polymers.
As regards the formulation of components B, it's principally characterized by the presence of isocyanate radicals (--NCO). Among substances that have these requirements, are included isocyanates or oligomers, obtained through addition of polyalcohol with isocyanates such as isophorondiisocyanate, trimethylexamethylendiisocyanate, examethylendiisocyanae, dicycloexylmetandiisocyanate. Though less suitable, other substances of this kind, are addition products or aromathic isocyanate based oligomers such as toluendiisocyanate, diphenylmethandiisocyanate. As component B, there can be used allophanate trimers of aliphatic isocyanates or cycloaliphatic, above mentioned, and also isocyanurate trimers thereof, and allophanate or isocyanurate copolymers of isocyanates, or even mixtures of pure trimers of copolymers between themselves.
Since the essential characteristic for the determining of therapeutic properties of products, according to the present invention, is the presence of isocyanates groups, to which is attributed the capacity of chemically binding with skin proteins, component B can be also the unique component on condition that it has physical-mechanical characteristics, suitable to the task of skin-protection. Anyway, the formulation of the product with two components to be mixed at the application moment, offers more possibilities in modifying characteristics because it allows the addition of solvents as regulators of viscosity, of matting agents, dyes, permeability agents, auxiliary drugs at percutaneous action in A, that chemically is the stablest part.
Additives that belong to the formulation of component A, are really important because they help to improve the product performances. So, in order to fit the film opacity to the natural one of skin, and to satisfy aesthetic requirements, there can be used natural or synthetic waxes, microdisposed in opportune solvents or in microdust state; paraffins at selected melting point; dust organic matting agents such as polyethylene, polypropylene, polytetrafluorethylene or similar copolymers of silicic nature, or on carbonates basis, preferably of cacium and magnesium or aluminum hydroxide and oxide basis.
Solvents eventually used, are chosen among those that present the best chemical-physical compatibility for skin, and a volatility as high as possible, so as to remain as short a time as possible in contact with the treated part. Auxiliary drugs that can be used, must be selected among theinert ones in comparison with the isocyanate groups, in order to avoid interaction, and they must be used in active form free from functions that interfere in the reaction witht he polymer. Specially when the polymer is used for transdermal absorption of drugs there are employed as carriers substances having solvent function as triacetine (glycerine triacetate), dimethylsulfoxide, butyl stearate, ethyl or methyl linoleate, methylpyrrolidone, ethylcaprylate, or other superior esters or solvents suitable for treatment. As aeropermeability agents of applied film, there can be considered hydrophilic fibrous fillers or simplier idrosoluble polymers dissolved in organic solvent not reactive with isocyanates.
EXAMPLE 2
523 parts of decanediol, 404 parts of sebacic acid, and 0.4 parts of tin dibutildilaurate are reacted under the conditions of Example 1, until there is obtained a polyester having an acidity index=0.5 and hydroxilic number=135.
EXAMPLE 3
536 parts of polyethoxylated glycerin (molecular weight=268), 116 parts of fumaric acid, 138 parts of salicylic acid, and 1.5 parts of tin dibutyldilaurate are reacted under conditions of Example 1, to obtain a polyester having condensation point=99.9%.
EXAMPLE 4
890 parts of soya-bean oil, 140 parts of penthaeritrytol and 0.3 parts of stannous chloride are reacted at 325° C. with the formation of a monoglyceride. The obtained monoglyceride is reacted with 146 parts of adipic acid at 200° until a polyester is obtained having an acidity index=1 and hydroxilic number=98.
EXAMPLE 5
Example 4, is respeated with the difference that soya-bean oil is replaced witht he same quantity of dehydrated castor oil. A polyester having analogous characteristics is obtained.
EXAMPLE 6
900 parts of fish-oil (sardine oil) with 184 parts of glycerin and 1 part of tin dibutyldilaurate are reacted at 235° in order to obtain the oil monoglyceride. this is cooled at 50° and reacted with 420 parts of trimethylhexamethylenediisocyanate, until there is obtained a product having an isocyanic number=0, and hydroxylic number=75.
EXAMPLE 7
174 parts of 1,10 decanediol, 938 parts of castor oil and 222 parts of isophorondiisocyanate are reacted as in Example 6 to obtain a polymer having isocyanic number=0 and hydroxylic number=114.
EXAMPLE 8
158 parts of trimethylhexamethylenediamine, 280 parts of oleic acid and 300 parts of hydrossistearic acid are reacted at 200° C. so to obtain a polyamide having acidity index=1, hydroxylic number=80 and equivalent hydrogenamidic 350.
EXAMPLE 9
There are reacted 134 parts of trymethylolpropane and 1068 parts of propylene oxide in the presence of 0.03 parts of metallic sodium at 5 Atm pressure, and 140° C. temperature until there is obtained a polyester having an hydroxyl index 140. At the end of reaction, the polyether is neutralized with 0.3 parts of magnesium hydrogenphosphate, MG Mg(H 2 PO 4 ) 2 and is filtered so to obtain a limpid product.
EXAMPLE 10
The following starting compounds are used to prepare a prepolymer A:
______________________________________CASTOR OIL 938ADIPIC ACID 4381-10 DECANEDIOL 1741-6 HEXANEDIOL 236 1786______________________________________
In a reaction vessel suitable for effecting esterification the Castor oil, Adipic acid, 1-10 Decanediol and 1-6 Hexanediol are charged keeping the atmosphere of the reactor under nitrogen stream. The mixture is esterified by heating, mixing the ingredients to the temperature of 200° C. under conditions of azeotropic recycle, using toluene as carrier solvent. In this way, the chemical-reaction-water is extracted and separated continuously from toluene in a suitable phase separator. In the rectification column, the temperature of the vapors at head of column are controlled so as not to exceed 100°. The vapors of reactions are condensed in a water-cooled condenser. The reaction is continued until the complete extraction of the theoretical reaction water (108 g) and until the acidity value of the prepolymer is equal or less than 0.5 and the hydroxyl number equal to 92.
The product is distilled under vacuum of 10 TORR the toluene and cooled to 50° C. The produce so obtained can be better transformed in component A by adding catalysts like tin dibutyldilaurate (0.05-1 percent) alone or together with tertiary aliphatic amine as triethylamine (0.05-0.5 percent) and solvent like acetone in order to give at the final product a reacxtivity degree and flow more suitable to the specific application.
COMPONENT B
EXAMPLE 11
510 parts of 1,6 hexamethylenediisocyanate are reacted with 18 parts of water in conditions known per se, in order to obtain at the end of reaction a biuret structured polymer with a NCO content equal to 24% of an hexamethylenediisocyanate monomeric content less than 0.2%.
EXAMPLE 12
168 parts of 1,6 hexamethylenediisocyanate, 222 parts of isophorondiisocyanate, 210 parts of trimethylhexamethylenediisocyanate and 18 parts of water are reacted in conditions known per se, in order to obtain at the end of reaction a biuret structured polymer with a content at NCO functions equal to 20% and a content of monomeric diisocyanate less than 0.3%.
EXAMPLE 13
440 parts of isophorondiisocyanate and 210 parts of trimethylhexamethylenediisocyanate are reacted at the presence of 0.2 parts of sodium methylate under conditions known per se, in order to obtain an isocyanurate monomer, having a NCO content equal to 16.8 and a diisocyanate monomeric content less than 0.3%. The obtained polymer is diluted with anydrous ethyl acetate and the sodium ion is eliminated with 1.2 parts of orthocholorobensoyl chloride, and filtering on ultraanydrous paper.
EXAMPLE 14
Through addition reaction of 174 parts of 1,10 decanediol with 420 parts of trimethylhexamethylenediisocyanate in conditions known per se, there is obtained a product having a content of --NCO functions equal to 13.8% and free isocyanate monomeric content less than 0.3%.
EXAMPLE 15
212 parts of myristylamine are reacted using conditions known per se with 420 parts of trimethylhexamethylenediisocyanate and at the end of reaction, there is obtained a product having a percentage of --NCO functions equal to 12.6% and a free monomeric isocyanate less than 3.0%.
EXAMPLE 16
By reacting 420 parts of trimethylehexamethylenediisocyanate and 228 parts of diisobutylhexamethylenediamine under conditions known per se, at the end of reaction there is obtained a product having a percentage of --NCO functions equal to 12.3% and content of free monomeric isocyanate less than 0.2%.
The product obtained has been employed in the treatment of skin effections according to the present invention.
EXAMPLE 17
The following starting substances are used to prepare a prepolymer B:
______________________________________TRIMETHYLHEXAMETHYLENEDIISO- 210 parts/wtCYANATEHEXAMETHYLENEDIISOCYANATE 3361-10 DECANEDIOL 130DISTILLED WATER 9ETHYLENEGLYCOL-DIMETHYLETHER 670ACETONE 75 1430______________________________________
In the reaction vessel are charged trimethyl-hexamethylenediisocyanate and hexamethylenediisocyanate. The reactor is purged with anydrous nitrogen and heated to the temperature of 80° C.
There is prepared a solution mixing 1-10 decanediol-water-ethyleneglycol dimethylether and the above solution is added gradually in 8 hours keeping the temperature in the reactor at 80° C.
Solvent vapours of ethyleneglycol-dimethylether are condensed in a water cooled condenser and recycled in the reactor.
After completion of the addition of solution, the product is kept in the reactor always at 80° C. It is distilled by heating gradually at 100° C. recovering the solvent.
A vacuum at 10 Torr is applied to the reactor by keeping the temperature at 100° C., including between the reactor and the vacuum pump an extra condenser and recovery tank are precooled at -35° C. These conditions of vacuum are kept for 30 minutes. The vacuum is stopped and the atmosphere in the reactor is saturated with nitrogen.
The propolymer above obtained is treated in a thin-layer-evaporator continuously under vacuum of 0.1 TORR and with evaporator wall's temperature of 125° C. This treatment is done to reduce at the minimum value the content of free diisocyanate monomer. The prepolymer is cooled at 40° C. and diluted with anydrous acetone.
The final product contains reactive NCO groups in a percentage of 15.4% and a content of free diisocyanate monomers of 0.3%.
COMBINATIONS OF COMPONENT A+B
EXAMPLE 18
To 90 parts of polyester, obtained according to Example 1, are added 9.8 parts of ethylacetate, 0.1 parts of paraffin having melting point at 90° C., and 0.1 parts of tin octoate, in order to obtain a finished product corresponding to component A, according to the present invention. This component A is mixed at the moment of use with the biuret polymer obtained in Example 11 in a careful ratio included between 3:1 and 5:1 for the treatment of skin affections.
EXAMPLE 19
99 parts of the polymer obtained according to Example 9 and 1 part of tin dibutyldilaurate are combined at the application moment with the isocyanurate polymer obtained in Example 13 in a careful ratio varying between 1:1 and 3:1.
Formulations so obtained have been used in the treatment chronical eczema, lasting for 2-5 years and judged incurable because the cures, executed before on the basis of linaments and compounds, according to the modern pharmacology, did not give any tangible result, while cortisone medicines desultorily used, sometimes provided improvements, but the pathology successively appeared.
The application of the product, according to the example, provide the formulation of soft films, that keep themselves integral for a variable period of time, ranging from about 7 to 20 days, according to cases, showing large resistance to water and to wear and tear, particularly when applied to the hands. With the film separation, because of the renovation of the skin horny layer, good results were mostly obtained. In the few cases in which the result was not resolutive, a second treatment or eventually a third one, in the most difficult cases, determined the complete healing.
EXAMPLE 20
95.65 parts of anhydrocastor oil, 0.05 parts of tin dibutyldilaurate, 0.1 of paraffin at melting point 48° C., 2 parts of beta-carotlene, and 2 parts of powdered polyethylene having a maxima particle size of 50 micron, are combined at the application moment with a product obtained through trimerization of the trimethylhexamethylenediisocyanate (trimer allophanate), according to respective careful ratios included between 1:1 and 2.5:1 for the treatment of skin afflictions.
EXAMPLE 21
91 parts of the polymer obtained according to example 7, 10 parts of N-vinylpirrolydone, one part of benzoinethylether and 1 part of tin dibutyldilaurate are mixed at the application moment with the allophanate polymer, according to Example 11 in respective careful ratios included between 2:1 and 4:1 for the treatment of skin afflictions.
EXAMPLE 22
99 parts of the product obtained according to Example 6, 0.5 parts of cobaltous octoate, and 0.5 parts of calcium octoate, are combined at the application moment with the isocyanurate polymer according to example 12, preferably in the ratio of weight 2:1 respectively for the treatment of skin afflictions.
EXAMPLE 23
Combination of products according to Example 1 to 9 with products according to examples 10 to 15, are used for exzema cures, dermatitis, fungic afflictions, and bedsores with positive resolutive results, after 20 days from the starting of the treatment.
EXAMPLE 24
A combination of products, as pointed out at Example 18, was used in order to treat a mycosis form that manifested with whitish plaques on a patient's leg.
The combination was applied immediately after the A+B mixing, with a brush in order to cover completely the infested parts (about 150 cmq on the whole). After about 4-5 days the applied polymer film spontaneously peeled off, leaving a skin surface a little reddened. The polymers application was successively repeated and the resulting film polymer kept adhered to the skin for a much longer period of time and separated after about 15 days. At the end, the treated part was completely healed and there were no relapses.
EXAMPLE 25
A components combination according to what is described in Example 20, was applied to the left cheek-bone temporal part of a patient afflicted with skin-alteration of unsure diagnosis (psoriasis or lupus). 20 minutes after the application the patient already felt a beneficent sensation of moderate warmth at the site of application which replaced the burning sensation.
After 40 minutes, the cross-linked film was dry, with perfect elasticity which did not give any unpleasant sensation of superficial stretching. In the meantime, spasms due to superficial nervous contractions that, before the treatment, determined local microwounds, disappeared. The separation of the polymer film happened after about 20 days. There resulted immediately the suspension of ache, and the diminution of The red livid colouring. A second application was made and after another 15 days the polymer layer separated. The surface undulying skin was rose-coloured, typical of skin in a healing phase. At the end, there was executed a third application, to which the reconstitutive phase of skin followed. The doctor judged that the reconstituted skin presented an aspect really better than the one regarding analogous cases of healings, obtained with radiotherapic treatments, combined with applications of specific medicines.
With reference to this, it is very important to note that the soothing action in comparison with inflammatory manifestations, due to reactive polymers according to the present invention, suggests anti-histaminic properties in the treatment of the infection. In fact the isocyanate radicals chemically block and neutralize the histamine molecules that free themselves from tissues in concomitance with unhealthy phenomena, and bind to the aminic groups belonging to them.
EXAMPLE 26
A case of skin pathology, in which the formation of superficial chaps appeared, more properly of rhagades on the palmar surface and between the fingers and on the plantar feet part, was with a combination of products according to Example 18, and the condition was alleviated in short time. Immediately after the compound application, the classic rhagades burning disappeared; hands were kept with fingers wide apart and feet were kept free from the contact with foreign bodies for 30 minutes, until the getting of a fair degree of dessication. After 3 days, through the transparent polymer film, it could be already observed the complete wounds cicatrization.
EXAMPLE 27
Some products combination, according to Example 16, 18, 19, 20 and 22, were used for the treatment of hands and feet chilblains, with very good results, shown by neutralization of skin irritation, consequent to the particular pathology. After 15-20 days, the treatment was finished with perfect healing.
EXAMPLE 28
A compound combination as reported in Example 22 was used for the cure of bedsores at the sacral bodily part of an old sick woman.
Previously, the woman had been treated with frequent applications of siliconic products without any positive result, but with progressive extension of the wounded part.
The product application, according to the present invention, was executed after having well dried the part; the patient immediately felt a great benefit, so that she was able to lean on the part with more facility without feeling great pain; since previous siliconic applications partially compromised the film adhesion, according to invention it was necessary to repeat the application 5 days later.
The bettering was considerable, but because of the compromising of the part due to the previous treatment, it was necessary to apply a third treatment with products of the present invention, executed 15 days after the separation of the second polymer film. At the end there was obtained the perfect healing of the wounded part.
EXAMPLE 29
There is prepared a type of component A by mixing 60 parts of prepared product (as shown at Example 7), 0.2 parts of paraffin (melting point 50° C.), 20 parts of glycerine triacetate, 8 parts of glycerine trinitrate, 1 part of tin butyldilauate, 0.2 parts of triethylamine, 10 parts of ethyl caprylate and 2.6 parts of pryrogenic silica. The product, obtained in such a way, was thixotropic.
4 parts of this component A were combined, by mixing, with 1 part of component B, prepared as shown in example 10. This particular combination was spread, till the reaching of a thickness of 100 micron and a surface of 30 cmq, on the back of a patient subjected to therapy for angina pectoris. This treatment showed an efficacy protracted for 4 days, that is for all the time the film remained attached to skin. Therefore, it was not necessary to repeat the application every day as is often required when transdermal ointment is used. Besides, there was the advantage due to the possibility of doing the cleaning without removing the reserves in situ of medicament.
EXAMPLE 30
There was prepared a type of component A with 80 parts of product (according with Example 7), 0.5 parts of tin dibutyldilaurate and 18.5 parts of allyl acetylsalicylate. This preparation A was combined with component B in the ratio 3:1 (as shown in example 10). This product was spread till the reaching of a thickness of 500 microns and a surface of 50 cmq on the internal part of the right thigh of a subject suffering from rheumatism. The film remained attached for 5 days. During this period of time, the application showed efficacy in considerably reducing the pain of articulations and eliminating the typical rheumatoid shivering sensations.
EXAMPLE 31
There was prepared a type of component A with 98 parts of monodehydrated castor-oil (that is with a ricynoleic radical transformed into a conjugated linoleic radical by eliminating one water molecule), 0.1 parts of tin dibutyldilaurate and 1.9 parts of dimethylsulfoxide.
This component A was combined with component B in the ratio 3:1 (as shown in example 10). The combination was applied on burns sores having a surface of about 250 cmq on a patient's abdomen. Before the application, there was removed necrotized tissues and the part to be treated was hydienically prepared in order that it showed a low exudation. The applied product kept oily consistence for about 1 hour. After about 2 hours, the part kept in contact with air was almost dried. After 3 hours, a barrier film formed protecting the treated part. 15 days later, the gradual detachment of film together with the devitalized tissue surface occured. The surface burnt was free from sores. A further application was made and, 10 days later, after complete polymer film detachment, the skin epitelial tissue of the treated part was perfectly constituted and healed.
Though the present invention has been shown on the basis of some realized examples, it is obvious that variations and/or modifications will be able to be brought both to description and examples without departing from the spirit and going out the protective ambit of invention itself. | Reactive polymer coatings for the treatment of skin disorders, constituted of cross-linkable polyurethanes, that have film properties, and are suitable to be applied to the skin in need of treatment are generally constituted of two components to be mixed at the usemoment, so that the cross-linkage mostly happens through interaction with the proteic components of the treated skin-parts. These formulations are also good carriers for transdermal action drugs. | 2 |
TECHNICAL FIELD
[0001] The invention generally relates to the field of mobile telecommunication networks. In particular, the present invention relates to employing a Hybrid Automatic Repeat Request (HARQ) procedure within a radio receiver.
BACKGROUND
[0002] In modern wireless receivers of Long Term Evolution (LTE), Worldwide Interoperability for Microwave Access (WiMAX) or Wideband Code Division Multiple Access (WCDMA) telecommunication systems, the received radio signal constellations are processed into soft-bits, each representing a probability of a bit being digital “zero” or digital “one”. The signal constellations are associated with typical modulation schemes such as Quadrature Phase Shift Keying (QPSK), Quadrature Amplitude Modulation (QAM) 16 or QAM 64. Thereby, each QPSK constellation point produces 2 soft-bits, each QAM16 point constellation point produces 4 soft-bits and each QAM64 constellation point produces 6 soft-bits.
[0003] A decoder algorithm such as for instance a Turbo decoder or an Viterbi decoder is exploiting gain from redundancy coding. By using complex processing a decoder algorithm attempts to correctly reconstruct the (encoded) transmitted sequence with highest probability. If a whole data block is decoded correctly and a Cyclic Redundancy Check (CRC) has been passed, an Acknowledgement Information (ACK) is transmitted from the receiver back to the sender in order to inform the sender about a successful data block reception. Otherwise a Not Acknowledgement Information (NACK) is transmitted and, depending on the type of data traffic, the same data block is usually again transmitted from the sender to the receiver. This type of error-control method is called Hybrid Automatic Repeat Request (HARQ).
[0004] In particular in LTE, WiMAX and WCDMA telecommunication systems in case of a failed data block reception, retransmission usually follows. However, retransmission may not follow in certain types of data traffic such as for instance Voice over IP (VoIP) data traffic. Normally, if a retransmitted data block is identical to the previous at least partially unsuccessfully transmitted data block, the retransmitted data block would have similar probability for a correct reception as the original one (assuming (a) that fading effects were not affecting the channel quality and (b) that data blocks were being received independently, without being combined together). In order to additionally improve the chance of a successful data signal decoding in retransmission, various schemes may be used.
[0005] In standards employing the so called with HARQ “chase combining” method, the same bits are being retransmitted again but the least reliable bits (which were previously transmitted for example as bits 4 and 5 in QAM64) could be retransmitted at the most reliable bit positions 0 and 1 . Depending on possibly selected constellation re-arrangements also the “bit position 2 ” and the “bit position 3 ” could be used for a reliable bit transfer. For instance in WCDMA QAM16 and QAM64 a proper selected constellation re-arrangement may allow the decoder to collect more reliable information about all bits coded on a specific constellation point.
[0006] Another possibility for realizing an effective data block transfer for example in LTE, WCDMA and other telecommunication systems is the so called HARQ “incremental redundancy” method. Thereby, rather than repeating the same bits (although using a different constellation mapping), instead more redundancy or parity bits are being sent. Of course, the number of the additional redundancy or parity bits typically depends on used coding rate and on the used interleaving scheme. A Turbo encoder requires a coding rate of ⅓, which means that three output bits are produced per single input bit.
[0007] Known puncturing or interleaving schemes are used in order to select for radio transmission only a subset of the overall encoded bits. Thereby, the effective coding rate may be changed from originally ⅓ to a coding rate of for example ⅔. In retransmissions, different interleaving parameters are selected and different sets of parity bits would be transmitted. Adding more parity bits may mean effectively changing the coding rate from ⅔ of the original transmission down to a coding rate of for example ½ or ⅓ for the retransmission. Typically, interleaving schemes are designed in such a way to avoid the same bits being sent at the same least reliable bit positions.
[0008] Due to air interface latencies and various system delays, a typical receiver employing HARQ must be able to handle multiple data blocks: one data block just being received and the other data blocks whose transmission has previously been failed and which are waiting for retransmission. Typically 4 to 6 HARQ processes are deployed. This means that the progress of transmitting 4 to 6 data blocks must be tracked.
[0009] When a data block fails a CRC check, its soft-bits are stored in memory and will be combined with new soft-bits being associated with a retransmission. The reason why the old soft-bits are stored is because they also contain valuable information about bit probabilities, which, when being combined with retransmitted soft-bits, will significantly increase the likelihood of successful data block decoding after retransmission. That is why retransmitted data blocks usually have a higher probability for a successful decoding.
[0010] In latest 3GPP standards, faster modulation schemes up to QAM64, Multiple Input Multiple Output (MIMO), larger bandwidths and more parallel data codes were added. All of these measures result in an increased data block size and consequently significantly increase the HARQ memory buffer requirements, which significantly increase the overall system memory allocation and thus, the cost for a corresponding radio receiver.
[0011] EP 1 337 066 B1 discloses a HARQ retransmission method in a telecommunication system, wherein data packets consisting of identical or partly identical modulation symbols encoded with a forward error correction (FEC) technique prior to transmission are retransmitted based on a repeat request and are subsequently bit-level combined on the basis of soft-information values (soft-bits). The calculation of the soft-bits being input into an FEC decoder comprises the steps of (a) calculating and buffering the soft-information values of the Most Significant Bits (MSBs) of each retransmitted data packet, (b) combining, for matching modulation symbols, the current soft-information values of the MSBs with the buffered soft-information values of at least one of the previous received transmitted packets and (c) calculating the soft information for at least some of the remaining bits from the combined soft-information values of the MSBs. On the receiver side this known HARQ retransmission method reduces the buffer size requirements.
SUMMARY
[0012] It is an object of the invention to provide a HARQ that allows for reducing the size of the HARQ buffer.
[0013] This object is achieved by the independent claims. Advantageous embodiments are described in the dependent claims.
[0014] According to a first aspect of the invention a HARQ procedure is provided comprising (a) calculating first soft-information values being associated with a first reception of the data block, (b) storing the calculated first soft-information values in a first buffer and (c) calculating second soft-information values being associated with a second reception of the data block, wherein the second reception results from a retransmission of the data block following the first reception. The provided method further comprises (d) rate matching a first soft data block comprising the calculated and stored first soft-information values, (e) rate matching a second soft data block comprising the calculated second soft-information values, and (f) performing a decoding of the received data block based on both the rate matched first soft data block and the rate matched second soft data block. Both rate matched soft data blocks might be concatenated before being transmitted to a decoder.
[0015] The described received data block determining method is based on the idea to store the calculated soft-information values, in the following also being referred to as soft-bits, before the rate matching (e.g. directly after soft bit calculation), e.g. by coupling the data output of a soft-bit calculation unit with any soft bit storage or buffer. The soft-bit calculation unit might also be denominated a combiner unit and/or a combiner and soft-bit calculation unit. Compared to storing (at least partly) rate matched soft-information, the described method allows to provide a significantly smaller buffer, as less information needs to be stored for the Hybrid Automatic Hybrid Request (HARQ) procedure. Thus, the buffer memory size requirements for the receiver can be significantly reduced.
[0016] The described rate matching may be carried out separately with the first soft-information values respectively the first soft data block and the second soft-information values respectively the second soft data block. This means that the information content of the calculated and stored first soft-bits and the information content of the calculated second soft-bits are combined with each other not before the described soft data block combination has been carried out.
[0017] By contrast to known HARQ procedures, wherein in accordance with for instance the 3GPP Standard 25.212 the content of the soft-bits is stored in a so-called virtual IR buffer being assigned to the rate matching, according to the described invention the content of the calculated is stored in buffers before a rate matching has been started.
[0018] With rate matching the data block size is matched to the radio frame(s). Initially a data block size (in bits) is selected, then data encoder increases the effective bit rate (typically 3 times) and then bits are punctured in order to decrease the data frame size to match that of the radio frame. Combination of 3:1 encoding and puncturing determines the effective coding rate. With deinterleaving and rate matching the soft-bit order is changed and the data block is placed in a larger buffer, in particular in a HARQ buffer. It is mentioned that soft-bits in such a HARQ buffer are “uncompressed” which means that for instance, if a known turbo decoder is used, the coding rate is expanded to the original 3:1 encoded rate, before the respective soft-bits are input into the turbo decoder.
[0019] In this respect it is mentioned that the coding rate r is defined by the ratio between (a) the number N of real data bits and (b) the sum of the number K of redundancy or parity bits and the number N of real data bits (r=N/(N+K)). Therefore, a coding rate of “½” means that N=K. Correspondingly, a coding rate of “one” would mean that there are no redundancy bits at all (K=0). Further, a coding rate of “⅓”, which is used for instance for the already mentioned turbo encoding, means that N=K/2.
[0020] According to an embodiment of the invention the method further comprises concatenating the rate matched first soft data block with the rate matched second data block. Concatenating is to be understood as any generating any (resulting) data block comprising the information of both (input) data blocks, e.g. joining the data blocks together end by end such that the last symbol of the first data block adjoins the first symbol of the second data block, filling the concatenated block alternately with bits or symbols of both data blocks, or performing any suitable logical operation of both data block resulting in the concatenated data block. Thereby, determining the received data block comprises decoding the concatenated data block.
[0021] According to a further embodiment of the invention the method further comprises (a) performing a de-interleaving of the first soft-information values and (b) performing a de-interleaving of the second soft-information values. This means that soft-bit processing involves not only the above described rate matching but also a de-interleaving.
[0022] Generally speaking, with the described method the newly retransmitted soft-bits may be similarly processed (e.g. in a parallel process) with the former received and temporarily stored soft-bits. At the end, de-interleaved and rate matched soft-bits from previous and current transmission are added to the same buffer and sent to turbo decoder. This means that the soft-bit processing is accomplished by running a state machine comprising both a deinterleaver and rate matching unit two times. The buffer necessary for storing the rate matched information is thus only needed temporarily (i.e. for short time periods and can be released e.g. if after a first unsuccessful decoding attempt, a further transmission has to processed) and can be used for other processes otherwise. This means that many (e.g. 6 HARQ processes) can share one “big” buffer. Only the (compressed) soft bits need to be kept stored. This is in contrast with known HARQ soft-bit processing, where the soft bits are stored in a buffer after the rate matching has been started (and are kept stored in case of a further transmission process).
[0023] As described above, e.g. in case of a turbo encoder the soft-bits in such a buffer are “un-compressed” to a 3:1 encoding rate according to present standards. For instance, if a transmitted data block has a coding rate approaching 1 , for each 1000 received bits, 3000 bits will be allocated in HARQ buffer after rate matching. The original 1000 bits may be placed in various locations of the HARQ buffer (e.g. at locations 2 , 5 , 6 , 9 , 13 , 17 , 19 , . . . ) and the remaining positions will be filled with zeros. In subsequent retransmissions, if the above mentioned incremental redundancy scheme is used, those locations may be filled with additional parity or redundancy bits transmitted later. For example in retransmission, additional 1000 bits could be sent, for a total of 2000, changing effective coding rate from 1 to 0.5. Therefore instead of saving hypothetical 3000 bits after first transmission (which is the case in known HARQ procedures), only 1000 bits could be saved.
[0024] After retransmission, the original 1000 bits and the newly received 1000 bits would be effectively combined. An inherent part of the invention described in this document is therefore the algorithm which saves soft-bits immediately after the combiner and before de-interleaving and rate matching. During retransmission processing, the de-interleaver and rate matching algorithm will be run two (or more) times, i.e. to process saved soft-bits from the previous transmission(s) and processing newly calculated soft-bits from the recently received data block.
[0025] According to a further embodiment of the invention the method further comprises (a) receiving the data block at least three times and (b) apart from the last received data block one of the first and the second received data block is rejected and the other of the first and the second received data block is maintained. Thereby, the rejected data block has a lower reception quality than the maintained data block. This means that the weakest of the previous received data blocks but not the last received data block is rejected.
[0026] Generally speaking, only a selection of data block receptions is used for determining the received data block. With respect to the total number of data block receptions this selection comprises only a reduced number of data block receptions. Thereby, the memory requirements for carrying out the described HARQ method can be further reduced without significantly reducing the overall reception quality.
[0027] In order to achieve a reliable data block reception the best data block receptions may be used. The selection of the best data block reception may be carried out based on information about for instance a Signal to Noise Ration (SNR), a Signal to Interference and Noise Ratio (SINR) and/or a radio channel quality which was existent during the respective data block reception.
[0028] The selection of the best data block reception may also comprise simply to use the last data block receptions of a series of data block receptions. At this point it is noted that it may be the case that the quality of a retransmission is getting worse with further retransmissions. However, when combining such a worse retransmitted data block with a previously transmitted data block a correct data block determination might be accomplished. Specifically, if for instance a first data block has been received with a 10 dB signal, a second data block has been received with a 8.2 dB signal and a third data block has been received with a 8 dB signal, a combination of the first and the third received data block may yield a correct determination of the data block if a combination of the first and the second received data block has already been attempted but a correct data block determination has failed.
[0029] In this respect it is mentioned that the invention is not limited to a process involving one original data block transmission and exactly two data block retransmissions. The described data block determination could also be accomplished with only one data block re-transmission or with three ore even more data block re-transmissions. For instance if one original data block transmission and three data block re-transmissions are carried out one could store respectively process only three of the altogether four data block transmissions. Thereby, one could use the last transmitted respectively received data block and reject from the remaining three old received data block this data block, which has been received with the lowest reception quality.
[0030] According to a further embodiment of the invention the method further comprises (a) calculating further soft-information values being associated with a further reception of the data block, wherein with respect to the first reception of the data block the further reception of the data block results from a further previous transmission of the data block, (b) storing the calculated further soft-information values in a further buffer, and (c) rate matching a further soft data block comprising the calculated and stored further soft-information values. Thereby, the received data block is determined by decoding a combination of the rate matched first soft data block, the rate matched second soft data block and the rate matched further soft data block.
[0031] This may provide the advantage that soft-bit information from three or more at least partially successful data block receptions can be effectively used in order to determine the correct content of the received data block. The number of retransmissions and the associated calculated soft-information values being used for determining the received data block can be adapted to the used modulation and coding scheme and/or to the signal quality of the received radio signal. There is no principal limitation with respect to a maximal number of retransmissions which could be used.
[0032] Generally speaking, depending on memory or buffer availability and the data block size processed, a system designer may chose how many data blocks with previous retransmissions should be saved. Thereby, a flexible trade-off between system performance and memory utilization can be performed.
[0033] According to a further embodiment of the invention the method further comprises re-arranging the calculated and stored first soft-information values and/or re-arranging the calculated second soft-information values. Thereby, the order or the sequence of the respective soft-bits is changed. This may be also called a constellation re-arrangement.
[0034] The described constellation re-arrangement may provide the advantage that the reliability of the data block determination can be improved if the above mentioned HARQ “chase combining” method is used. This means that the same bits are being retransmitted again but least reliable bits (which were previously transmitted for example in “bit positions 4 and 5 ” in QAM64) could be retransmitted at a more reliable positions such as for instance the most reliable “bit positions 0 and 1 ” or at the “bit positions 2 and 3 ”. Of course, this depends on the selected constellation re-arrangement. Thereby, the decoder may be allowed to collect more reliable information about all bits coded on a specific constellation point.
[0035] Depending on the selected modulation scheme different constellation rearrangements may be applied. The following tables 1 and 2 show different possible constellation re-arrangements for 16QAM and 64QAM:
[0000]
TABLE 1
Constellation re-arrangement for 16QAM
constellation
version
parameter b
Output bit sequence
Operation
0
v p,k v p,k+1 v p,k+2 v p,k+3
None
1
v p,k+2 v p,k+3 v p,k v p,k+1
Swapping
Most Significant Bits (MSB)
with
Least Significant Bits (LSB)
2
v p,k v p,k+1 v p,k+2 v p,k+3
Inversion of the logical values
of LSBs
3
v p,k+2 v p,k+3 v p,k v p,k+1
Swapping MSBs with LSBs
and inversion of logical values
of LSBs
[0000]
TABLE 2
Constellation re-arrangement for 64QAM
constellation
version
parameter b
Output bit sequence
Operation
0
v p,k v p,k+1 v p,k+2 v p,k+3 v p,k+4 v p,k+5
None
1
v p,k+4 v p,k+5 v p,k+2 v p,k+3 v p,k v p,k+1
Swapping MSBs and
LSBs. Inversion of
Middle Significant Bits
2
v p,k+2 v p,k+3 v p,k+4 v p,k+5 v p,k v p,k+1
Left circular shift of pair
of Significant Bits.
Inversion of MSBs
3
v p,k v p,k+1 v p,k+2 v p,k+3 v p,k+4 v p,k+5
Inversion of MSBs
[0036] It is pointed out that in case more than one retransmission of the data block is employed the described constellation re-arrangement could of course also be applied with the further soft-information values.
[0037] According to a further embodiment of the invention the method further comprises discarding a selection of calculated first soft-information values before storing the calculated first soft-information values in the first buffer. According to this embodiment only certain soft-bits may be saved while other soft-bits are rejected. This is advantageous because in higher order modulations schemes such as QAM16 and QAM64 not all soft-bits have equivalent quality (reliability). The receiver designer could choose any percentage of soft-bits to be saved. For example in QAM64, all most reliable bits (bit positions 0 and 1 ) and some of the medium-reliable bits (bit positions 2 and 3 ) could be saved. Thereby, the percentage of saved soft-bits may depend on memory and performance trade-off considerations. This means that the savings could be configurable.
[0038] In other words, irrespective of the HARQ scheme used, certain soft-bits are more reliable (and thus, of higher quality) than others. Therefore, by performing a suitable constellation re-arrangement during retransmissions, different sets of encoded/mapped bits are getting the chance to be transmitted at the most valuable (and most reliable) bit positions 0 and 1 . Since the most reliable bit positions depend on the selected modulation scheme it is always possible to identify which bits were sent at the most reliable positions. Therefore, only those bits may be saved in the respective HARQ buffer(s). During decoding a retransmitted data block only those selected most-reliable soft-bits from the previous transmission may be combined with the soft-bits received during retransmission. The remaining bits, which are usually a proportion of middle and/or least reliable bits from the previous transmission may be replaced by zeros.
[0039] It is pointed out that the described discarding procedure could also be carried out with the at least one further soft-information values. By discarding the at least reliable soft-bits the buffer size requirements could be further reduced.
[0040] It is further mentioned that retransmission and additional redundancy provided by it may result in approximately 3 dB of effective coding gain. Currently the worst case scenario from the HARQ buffer memory requirement perspective is when blocks are very large (QAM64, coding rate>0.9, large data blocks). Such transport formats are only possible in good conditions (high geometry, very low or zero relative speed between sender and receiver). In those circumstances, as much as 3 dB extra gain is not needed, because the radio channel link won't change that much between retransmission in order to lose 3 dB in signal quality. As a consequence it should be possible to reduce the number of soft-bits saving for retransmission in circumstances where trans-port formats are large.
[0041] In fast fading cases, where fading may result in a few dB drop in signal quality, usually more redundancy would be needed for retransmission to pass. However, fading channels practically always use smaller blocks, with lower coding rates. Therefore HARQ buffer requirement will be smaller and all soft-bits could be saved within available HARQ memory. As a consequence, selective dynamic discarding of certain soft-bits is easily feasible without performance loss.
[0042] According to a further embodiment of the invention the method further comprises inserting a zero value at a bit position, from which a selected calculated first soft-information value has been discarded. This may provide the advantage that even when certain comparatively unreliable soft-bits have been discarded the encoder can operate with unmodified data block formats.
[0043] According to a further embodiment of the invention the amount of discarded first soft-information values depends on a currently available buffer size and/or on a currently requested system performance. This may provide the advantage that the percentage of discarded soft-bits can be adapted appropriately to the current operational state of the receiver which is carrying out the described method. Thereby, a flexible trade-off between system performance and memory utilization may be accomplished.
[0044] According to a further embodiment of the invention the method further comprises reducing a resolution of the stored first soft-information values. This may be advantageous in particular when only certain more reliable soft-bits are saved in the first buffer and the less reliable soft-bits are discarded as described above.
[0045] Specifically, assuming that only certain more reliable QAM64/QAM16 soft-bits would be saved, their soft-bit values would be mostly large (due to their high reliability) and typically limited to max/min values due to quantization limitation. In that scenario it would be possible to reduce the bit-width (quantization) of the stored soft-bits. Depending on the resolution of the original soft-bits a saving of 50% could be possible with minimal performance loss.
[0046] In this respect it is pointed out that if only selected more reliable soft-bits are stored, their values will be large as they will be very reliable. Due to numerical representation and limited resolution, high percentage of those will be saturated to max/min numerical values. Therefore, reduction in their bit-width resolution will only slightly reduce information carried by those soft-bits, while allowing for, for example, a 50% memory size reduction.
[0047] For instance in a 4-bit representation, a majority of the most reliable soft-bits would concentrate around +7 and −7. It is therefore possible to reduce the resolution of the saved soft-bits. For example, their resolution could be changed from 4-bits down to 2-bits and their values rounded to +7, +2, −2, −7 levels. This would provide additional 50% buffer size saving with little or no performance loss.
[0048] It is mentioned that the described first soft-information values resolution reduction is of course also applicable for the above described further soft-information values, which are associated with the further reception of the data block.
[0049] It is further mentioned that even in QPSK, wherein the reliability of soft bits is uniform, it could still make sense to introduce a resolution reduction because thereby is could be possible to store more past retransmissions within a limited buffer size.
[0050] According to a further aspect of the invention there is provided a radio receiver arrangement for determining a received data block by employing a Hybrid Automatic Hybrid Request procedure. The provided radio receiver arrangement comprises (a) a calculation unit for calculating first soft-information values being associated with a first reception of the data block and for calculating second soft-information values being associated with a second reception of the data block, wherein the second reception results from a retransmission of the data block following the first reception. The provided radio receiver arrangement further comprises (b) a first buffer for storing the calculated first soft-information values, (c) a first rate matching unit for rate matching a first data block comprising the calculated and stored first soft-information values, and (d) a second rate matching unit for rate matching a second data block comprising the calculated first soft-information values. Further, the provided radio receiver arrangement comprises (e) a decoding unit for determining the received data block by decoding a combination of the rate matched first soft data block and the rate matched second soft data block.
[0051] Also the described radio receiver is based on the idea that calculated soft-information values or simply soft-bits can be stored directly at the output of a of the calculation unit. This means that the first buffer is located close to the combiner and the soft-information values are stored before the de-interleaving and, if applicable, a rate matching is carried out.
[0052] Compared to storing the calculated soft-information values after or within the first rate matching unit, the described method may provide the advantage that a much smaller amount of soft-bit information will need to be stored. Therefore, the memory size requirements for the first buffer can be significantly reduced.
[0053] The described radio receiver may be realized in any receiving network element of a telecommunication network. Specifically, the described radio receiver may be realized in a base station or in a relay node, which, in an upstream radio transmission, are receiving data blocks from a user equipment. Further, the described radio receiver may be realized in a user equipment, which in an downstream radio transmission scenario is receiving data blocks from a serving base station or a serving relay node.
[0054] According to an embodiment of the invention the calculation unit is further adapted for calculating further soft-information values being associated with a further reception of the data block, wherein with respect to the first reception of the data block the further reception of the data block results from a further previous transmission of the data block. Thereby, the radio receiver further comprises a further buffer for storing calculated further soft-information values and a further rate matching unit for rate matching a further soft data block comprising the calculated and stored further soft-information values. Further, the decoding unit is adapted for determining the received data block by decoding a combination of the rate matched first soft data block, the rate matched second soft data block and the rate matched further soft data block.
[0055] The described radio receiver may allow for employing the calculated soft-bit information from three or more at least partially successful data block receptions in order to determine the correct content of the received data block. Thereby, the reliability of a data block determination may be effectively enhanced.
[0056] The number of retransmissions and the associated calculated soft-information values being used for determining the received data block can be adapted to the currently used modulation and coding scheme and/or to the signal quality of the received radio signal. There is no principal limitation with respect to a maximal number of retransmissions which could be used.
[0057] According to a further aspect of the invention there is provided a radio communication system comprising (a) a radio transmitter for transmitting an encoded data block and (b) a radio receiver arrangement as described above for receiving the encoded data block and for determining the received data block by employing a Hybrid Automatic Hybrid Request procedure.
[0058] According to a further aspect of the invention there is provided a computer-readable medium on which there is stored a computer program for determining a received data block by employing a Hybrid Automatic Hybrid Request procedure. The computer program, when being executed by a data processor, is adapted for controlling or for carrying out the above described method for determining a received data block by employing a Hybrid Automatic Repeat Request procedure.
[0059] The computer-readable medium may be readable by a computer or a processor. The computer-readable medium may be, for example but not limited to, an electric, magnetic, optical, infrared or semiconductor system, device or transmission medium. The computer-readable medium may include at least one of the following media: a computer-distributable medium, a program storage medium, a record medium, a computer-readable memory, a random access memory, an erasable programmable read-only memory, a computer-readable software distribution package, a computer-readable signal, a computer-readable telecommunications signal, computer-readable printed matter, and a computer-readable compressed software package.
[0060] According to a further aspect of the invention there is provided a program element for determining a received data block by employing a Hybrid Automatic Hybrid Request procedure. The program element, when being executed by a data processor, is adapted for controlling or for carrying out the above described method for determining a received data block by employing a Hybrid Automatic Repeat Request procedure.
[0061] The program element may be implemented as a computer readable instruction code in any suitable programming language, such as, for example, JAVA, C++, and may be stored on a computer-readable medium (removable disk, volatile or non-volatile memory, embedded memory/processor, etc.). The instruction code is operable to program a computer or any other programmable device to carry out the intended functions. The program element may be available from a network, such as the World Wide Web, from which it may be downloaded.
[0062] The invention may be realized by means of a computer program respectively software. However, the invention may also be realized by means of one or more specific electronic circuits respectively hardware. Furthermore, the invention may also be realized in a hybrid form, i.e. in a combination of software modules and hardware modules.
[0063] It has to be noted that embodiments of the invention have been described with reference to different subject matters. In particular, some embodiments have been described with reference to method type claims whereas other embodiments have been described with reference to apparatus type claims. However, a person skilled in the art will gather from the above and the following description that, unless other notified, in addition to any combination of features belonging to one type of subject matter also any combination between features relating to different subject matters, in particular between features of the method type claims and features of the apparatus type claims is considered as to be disclosed with this document.
[0064] The aspects defined above and further aspects of the present invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to the examples of embodiment. The invention will be described in more detail hereinafter with reference to examples of embodiment but to which the invention is not limited.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 shows a block diagram of a radio receiver arrangement in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0066] The illustration in the drawing is schematically. In different drawings, similar or identical elements may be provided with the same reference signs.
[0067] FIG. 1 shows a schematic block diagram of a radio receiver arrangement 100 . The radio receiver arrangement 100 may be implemented in a base station of a cellular telecommunication network for receiving uplink data from a user equipment. The radio receiver arrangement 100 may also be implemented in a user equipment receiving downlink data from a base station or from a relay node of a cellular telecommunication network.
[0068] The radio receiver arrangement 100 comprises a soft-bit calculation unit 110 , which during operation of the radio receiver arrangement 100 receives digital data from receiver specific equipment comprising an antenna, a radio frequency unit, an receiver, an equalizer etc. For each data block, which has been received, the unit 110 processes soft-information values (=soft-bits) each representing a probability of a bit being digital “zero” or digital “one”. This is done for each received data block. If in accordance with the basic principles of Automatic Repeat Request (ARQ) or Hybrid Automatic Repeat Request (HARQ) one and the same data block is received more than one time, the soft-bit calculation unit 110 performs this soft-bit processing for each received data block, i.e. for the originally by the respective radio transmitter transmitted data block and for each re-transmitted data block. Since a request for retransmission takes some time in order to be completed, soft-bits being assigned to different data blocks may be handled in parallel. In case of one or more requested re-transmissions the data block handling is accomplished in an interleaved manner. This means that soft-bits having been generated from original and retransmitted different data blocks are processed in an interleaving manner.
[0069] It is pointed out that in FIG. 1 only the soft-bit processing is shown, which is associated with one and the same received data block. Specifically, the soft-bit processing is shown, which is associated with (a) a currently received and for the second time re-transmitted data block, (b) a previously received and for the first time re-transmitted data block and (c) a more previously received and originally transmitted data block. As can be seen from FIG. 1 , within the radio receiver arrangement 100 (a) the soft-bits being associated with the currently received data block are processed in a first processing branch 110 , (b) the soft-bits being associated with the previously received data block are processed in a second processing branch 120 and (c) the soft-bits being associated with the more previously received data block are processed in a third processing branch 120 .
[0070] It is mentioned that the invention described in this document is not limited to the processing of exactly the soft-bits being obtained from three data blocks, which are associated with different transmissions of one and the same data block. The described data block determination could also be accomplished with only one data block re-transmission or with three ore even more data block re-transmissions. The latter is indicated with the dashed line on the right side of FIG. 1 .
[0071] In particular in high-order modulations, due to Grey-coding and mapping scheme which is used, certain soft-bits are much more reliable (and therefore valuable for the decoder) than the remaining ones. Out of four coded bits 0123 (per QAM16 constellation point) or six coded bits 012345 (per QAM64 constellation point), bits 01 are the most reliable and have the highest mean soft-bit amplitudes. The remaining bits have lower mean soft-bit amplitudes and therefore a lower decoding value.
[0072] FIG. 2 presents how QAM16 constellation de-mapping (process of producing soft-bits) is done. In that FIGURE, “i” and “q” represent mapping range of digital “ones”. Out of four encoded QAM16 bits (per single point), “i1” and “q1” are the most reliable ones (also known as bits number “0” and “1”). Soft-bits “i2” and “q2” are less reliable and are known as bits “2” and “3”. It is mentioned that in QAM64, constellation is even denser with more points and additional, least reliable bits “4” and “5” are produced.
[0073] Accordingly, it is possible to discard certain soft-bits before continuing the further soft-bit processing without or with only marginally reducing the reliability of the finally determined data block. Of course, if certain soft-bits are discarded, then it should be those of lowest reliability.
[0074] Based on these considerations the radio receiver arrangement 100 depicted in FIG. 1 is provided with a soft-bit discarding unit 106 which according to the embodiment described here discards the least reliable soft bits. Thereby, the percentage of soft-bits discarded may depend on system architecture and/or on the transport format i.e. the currently used modulation and coding scheme. In this respect it is mentioned that a dynamic discarding of certain soft-bits is only possible if a multiple-pass de-interleaving and a rate-matching processing is implemented, otherwise, in a decompressed HARQ buffer, it is not know which soft-bits are more reliable.
[0075] Put in other words, the soft-bit discarding unit 106 may also be denominated a reliable bits selector, which discards the less reliable soft-bits from the output of the soft-bit calculation unit 104 . In case of 16QAM, these could be the soft-bits i 1 q 1 as mentioned before. In case of 64QAM, these could be the first 2 or 3 or 4 soft-bits.
[0076] It is mentioned that when using a Quadrature Phase Shift Keying (QPSK) modulation scheme all soft-bits typically have the same reliability. However, also in this case a discarding of soft-bits may be carried out which however may be not as effective as a specific discard of only little reliable soft-bits.
[0077] After the optional soft-bit discarding the remaining soft-bits obtained from the original and more previously received data block are stored in a delay buffer 131 . Accordingly, the soft-bits which have been processed from the first retransmitted data block are stored in a delay buffer 121 .
[0078] Before further processing the intermittent soft-bits stored in the delay buffer 121 and 131 a zero insertion is performed with the zero inserting unit 122 and the zero inserting unit 132 , respectively. As can be seen from FIG. 1 , the zero inserting unit 122 , which is connected to the delay buffer 121 , is assigned to the second processing branch 120 . Accordingly, the zero inserting unit 132 , which is connected to the delay buffer 131 , is assigned to the third processing branch 130 .
[0079] Descriptive speaking, the zero inserting units 122 and 132 perform the reverse function of the soft-bit discarding unit 106 . When reading from the delay buffer 121 or 131 , the respective zero inserting units 122 , 132 insert “zero” bits in place of those soft-bits that were discarded by the soft-bit discarding unit 106 .
[0080] In the following the further processing of the various soft-bits, which are associated with the altogether three data block transmissions, is described:
[0081] The soft-bits which have been calculated based on the currently received and for the second time re-transmitted data block are fed to a constellation rearrangement unit 114 . Accordingly, the soft-bits which have been calculated based on the previously received and for the first time re-transmitted data block (after an appropriate soft-bit discarding and a complementary zero insertion) are fed to a constellation rearrangement unit 124 . Just as well the soft-bits which have been calculated based on the more previously received and originally transmitted data block (also after an appropriate soft-bit discarding and a complementary zero insertion) are fed to a constellation rearrangement unit 134 .
[0082] With the various constellation rearrangement units 114 , 124 and 134 the order or the sequence of the respective soft-bits is changed. Thereby, as has already been mentioned above, a downstream arranged decoder may be allowed to collect more reliable information about all bits coded on a specific constellation point.
[0083] For the sake of conciseness the following soft-bit processing is only described with respect to the first processing branch 110 . However, it is explicitly pointed out that according to the embodiment described here the soft-bit processing being associated with the second processing branch 120 and the third processing branch 130 is the same.
[0084] The further soft-bit processing comprises a de-interleaving which is carried out in de-interleaving units 116 , 126 and 136 . According to the embodiment described here the de-interleaving is accomplished in the context of High Speed Downlink Packet Access (HSDPCH).
[0085] After performing the de-interleaving a rate matching is carried out with then de-interleaved code blocks provided by the de-interleaving units 116 , 126 and 136 . The rate matching is carried out with the rate matching units 118 , 128 and 138 . Thereby, the number of encoded bits being included in one code block is adapted to the currently available data transport capacity. The transport capacity on air is a function in particular of the bandwidth, the modulation scheme and/or the presence and absence of control information.
[0086] It is mentioned that in accordance with the 3GPP standard specification 25.212 each of the rate matching units 118 , 128 , 138 may also be provided with a virtual buffer, which would also be capable of temporarily storing soft-bits. However, by contrast to the temporal soft-bit buffering in the delay buffers 121 and 131 , a temporal storage in the virtual buffer would require much more storage capacity because of the already performed rate matching, which typically significantly increases the number of bits.
[0087] After having successfully performed the rate matching for the soft-bits being assigned to the various processing branches 110 , 120 and 130 the respective sequences of soft-bits are concatenated in a physical channel concatenation unit 150 . The resulting concatenated soft-bits are then fed to a decoder, which according to the embodiment described here is a known turbo decoder 152 . Thereafter, the resulting decoded data are fed to a code block concatenation and bit scrambling unit 154 . A code block being output from the code block concatenation and bit scrambling unit 154 is passed to a Cyclic Redundancy Checking (CRC) unit 156 . If a corresponding CRC check being performed in this CRC unit 156 is successful, the output of the CRC unit 156 , which is the output of the entire radio receiver arrangement 100 , represents the determined received data block.
[0088] At this point it is mentioned that the described invention is of course not limited for a soft-bit processing employing a turbo decoder. Of course also other decoders such as for instance a Viterbi decoder could used.
[0089] Modifications and other embodiments of the disclosed invention will come to mind to one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of this disclosure. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
LIST OF REFERENCE SIGNS
[0000]
100 radio receiver arrangement
104 Soft-Bit calculation unit
106 Soft-Bit discarding unit
110 first processing branch
114 Constellation rearrangement unit
116 De-interleaving unit
118 Rate matching unit
120 second processing branch
121 delay buffer
122 Zero inserting unit
124 Constellation rearrangement unit
126 De-interleaving unit
128 Rate matching unit
130 third processing branch
131 delay buffer
132 Zero inserting unit
134 Constellation rearrangement unit
136 De-interleaving unit
138 Rate matching unit
150 Physical channel concatenation unit
152 Turbo decoder
154 Code Block concatenation and Bit scrambling unit
156 Cyclic Redundancy Checking unit | It is described a method for determining a received data block by employing a Hybrid Automatic Repeat Request procedure. The described method comprises calculating ( 104 ) first soft-information values being associated with a first reception of the data block, storing the calculated first soft-information values in a first buffer ( 121 ), and calculating ( 104 ) second soft-information values being associated with a second reception of the data block, wherein the second reception results from a retransmission of the data block following the first reception. The described method further comprises rate matching ( 128 ) a first soft data block comprising the calculated and stored first soft-information values, rate matching ( 118 ) a second soft data block comprising the calculated second soft-information values, and decoding ( 152 ) a combination of the rate matched first soft data block and the rate matched second soft data block. It is further described a radio receiver arrangement, a computer-readable medium and a program element, which are all adapted for carrying out and/or for controlling the described received data block determination method. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 12/869,479 filed on Aug. 26, 2010, which claims the benefit of U.S. Provisional Patent Application No. 61/237,572 entitled “METHODS AND APPARATUS FOR MANIPULATING AND DRIVING CASING,” filed Aug. 27, 2009, the disclosure of which is incorporated herein in its entirety by this reference.
TECHNICAL FIELD
[0002] Embodiments of the present invention relate to manipulating casing for subterranean well bores. More particularly, embodiments of the present invention relate to methods and apparatus for gripping and rotating casing by the interior thereof from the earth's surface, which methods and apparatus may be employed to drill or ream with casing.
BACKGROUND
[0003] It is known in the art of subterranean drilling to use a so-called “top drive” to connect a section, also known as a “joint,” of well bore casing above a drilling rig floor to the upper end of a casing string substantially disposed in the well bore. Such casing strings, commonly termed “surface casing,” may be set into the well bore as much as 3,000 feet (914.4 meters), and typically about 1,500 feet (457.2 meters), from the surface.
[0004] Examples of methods and apparatus for making casing joint connections to a casing string are disclosed in U.S. Pat. Nos. 6,742,584 and 7,137,454, the disclosure of each of which patents is incorporated herein by this reference.
[0005] It is known in the art of subterranean drilling to drill and ream with casing, using a drilling or reaming shoe including a cutting structure thereon to drill a well bore, or to ream an existing well bore to a larger diameter, to remove irregularities in the well bore, or both. It would be highly desirable for the subterranean drilling industry to employ a top drive to apply weight on the casing in combination with casing rotation to drill or ream with casing using a drilling or reaming device at the distal end of the casing string.
BRIEF SUMMARY
[0006] In one embodiment, the present invention comprises a casing assembly having a longitudinal passage therethrough in communication with a plurality of circumferentially spaced, radially movable pistons and extending to at least one outlet of the lower end of the assembly, a plurality of selectively mechanically actuable, radially movable slips, a plurality of spring-biased friction blocks longitudinally spaced from the slips, a downward-facing packer cup positioned between the slips and the at least one outlet, and a tapered stabilizer guide below the downward-facing packer cup.
[0007] In another embodiment, the present invention comprises a method of manipulating casing comprising inserting an assembly into an upper end of a casing joint, gripping the casing joint by an interior thereof with the assembly responsive to longitudinal movement of one portion of the assembly with respect to another portion of the assembly, pumping drilling fluid through the assembly to cause the assembly to grip the interior of the casing joint responsive to hydraulic pressure of the drilling fluid, preventing drilling fluid from exiting the upper end of the casing joint, and rotating the casing joint.
[0008] Another embodiment comprises a method of driving casing, including engaging an uppermost casing joint of a casing string having a device with a cutting structure thereon at a lower end thereof substantially only on an interior of the uppermost casing joint, rotating the casing string by application of torque to the interior of the uppermost casing joint and applying weight to the casing string during rotation thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is a partial sectional elevation of a casing drive assembly according to an embodiment of the present invention.
[0010] FIG. 1B is a detail view of FIG. 1A showing a hydraulic anchor of the casing drive assembly.
[0011] FIG. 1C is a detail view FIG. 1A showing a mechanical spacing spear of the casing drive assembly.
[0012] FIG. 1D is a detail view of FIG. 1A showing a cup type packer and a tapered stabilizer of the casing drive assembly.
[0013] FIG. 2 is a schematic of a casing drive assembly, such as shown in FIG. 1A , disposed within a casing joint of a casing string above another casing joint.
DETAILED DESCRIPTION
[0014] The illustrations presented herein are not actual views of any particular drilling system, assembly, or device, but are merely idealized representations which are employed to describe embodiments of the present invention.
[0015] While embodiments of the present invention are described herein with respect to manipulation of, and drilling with, casing, it is also contemplated that an appropriately sized drive assembly may be used to engage, rotate, and apply weight for drilling with any suitable tubular goods having sufficient longitudinal compressive and torsional (shear) strength to withstand application of longitudinal force and torque for drilling. Accordingly, as used herein, the term “casing” means and includes not only convention casing joints but also liner joints, drill pipe joints, and drill collar joints. In addition, multiple-joint assemblies, termed “stands,” of any and all of the foregoing tubular goods may be used with, and manipulated by, embodiments of the apparatus of the present invention.
[0016] As used herein, the terms “upper,” “lower,” “above,” and “below,” are used for the sake of clarity in a relative sense as an embodiment of the casing drive assembly is oriented during use to manipulate and drive a casing joint or string.
[0017] Referring to FIG. 1A of the drawings, an embodiment of a casing drive assembly 10 according to the present invention comprises, from an upper to a lower end thereof, a hydraulic anchor 100 , a mechanical casing spear 200 , a cup type packer 300 , and a tapered stabilizer 400 .
[0018] As shown in FIG. 1B , the hydraulic anchor 100 comprises a housing 102 having a circumferential stop collar 106 about the upper end thereof for limiting insertion of the casing drive assembly 10 into a casing joint. The housing 102 includes a longitudinal passage 104 extending therethrough from top to bottom, in communication with lateral passages 108 extending to the interiors of spring-loaded, inwardly biased pistons 110 in two longitudinally separated groups, each group comprising a plurality of pistons 110 (in this instance, four) equally circumferentially spaced in pockets 112 in the housing 102 . Seals (not shown) enable fluid-tight movement of the pistons 110 in the pockets 112 responsive to a drilling fluid pressure within the longitudinal passage 104 . The pistons 110 comprise gripping structures 114 on exterior surfaces 116 thereof, as is conventional in the art. Such gripping structures 114 may comprise, by way of non-limiting example, machined teeth, crushed tungsten carbide, tungsten carbide inserts in the form of bricks, buttons or discs, superabrasive elements such as natural or polycrystalline diamond, or a combination thereof. In one embodiment, gripping structures comprise carbide inserts configured with teeth.
[0019] Secured to the lower end of the hydraulic anchor 100 is the casing spear 200 , which may be configured substantially as a Baker Oil Tools (Tri-State) Type “D” Casing Spear. As shown in FIG. 1C , the casing spear 200 comprises a mandrel 202 having a longitudinal passage 204 extending therethrough and in communication with the longitudinal passage 104 of the hydraulic anchor 100 . An outer housing 206 is longitudinally slidably and rotationally disposed over the mandrel 202 , longitudinal movement of the outer housing 206 being constrained by engagement of a lug 208 protruding radially from the mandrel 202 through a J-slot 210 having a longitudinally extending segment L and a laterally extending segment LA, the lug 208 extending through the wall of outer housing 206 . A plurality of slips 212 is disposed in a like plurality of slots 214 extending through the outer housing 206 . The slips 212 include lips 216 at longitudinally upper and lower ends thereof to retain the slips 212 within the slots 214 . The interior of the slips 212 comprise a plurality of stepped wedge elements 218 having concave, partial frustoconical radially inner surfaces 220 . The outer surfaces 222 of the slips 212 comprise gripping structures 224 , as is conventional in the art. Such gripping structures 224 may comprise, by way of non-limiting example, machined teeth, crushed tungsten carbide, tungsten carbide inserts in the form of bricks, buttons or discs, superabrasive elements such as natural or polycrystalline diamond, or a combination thereof. In one embodiment, gripping structures comprise tungsten carbide inserts in the form of buttons having four projecting, pyramidal points. Two longitudinally extending groups of eight to ten buttons per slip 212 may be employed.
[0020] Inner surfaces 220 of stepped wedge elements 218 are sized and configured to cooperate with stepped convex, frustoconical wedge surfaces 226 on an exterior surface of the mandrel 202 to move the slips 212 radially outwardly responsive to upward movement of the mandrel 202 within the outer housing 206 . A plurality of circumferentially spaced stabilizer friction blocks 228 are radially outwardly biased by springs 230 and are disposed within slots 232 in outer housing 206 and retained therein against the outward spring biased by lips 234 at upper and lower ends of the stabilizer friction blocks 228 . A lower housing 236 is secured to the lower end of the mandrel 202 .
[0021] Secured to the lower housing 236 of the casing spear 200 at the lower end thereof is a packer mandrel 302 of the cup-type packer 300 , as shown in FIG. 1D , the cup-type packer 300 having a longitudinal passage 304 therethrough in communication with the longitudinal passage 204 of casing spear 200 . A downward-facing, elastomeric, wire mesh-reinforced annular packer cup 308 is disposed over the upper mandrel 302 and retained thereon between an annular support wedge 310 abutting a downward-facing annular shoulder 312 and the upper end of a guide sleeve 314 , from which an annular, radially projecting casing guide 316 projects. The casing guide 316 comprises frustoconical upper and lower surfaces 318 , 320 longitudinally separated by a cylindrical guide surface 322 , circumferentially spaced, longitudinally extending slots 324 communicating between the upper and lower surfaces 318 , 320 .
[0022] As further shown in FIG. 1D , the tapered stabilizer 400 is secured at its upper end 402 to the lower end of the packer mandrel 302 , and includes a longitudinal passage 404 in communication with the longitudinal passage 304 of the cup-type packer 300 . The longitudinal passage 404 extends to, and communicates with, outlet slots 406 extending through an outer surface of a frustoconical, tapered stabilizer guide 408 terminating at a nose 410 .
[0023] In use, and with reference to drawing FIGS. 1A , 1 B, 1 C, 1 D and 2 , wherein a casing joint 500 is shown disposed above another casing joint 502 , a single joint of casing 500 is picked up using the rig elevators, as is conventional, and stabbed up into an existing casing joint 502 (if a casing string has already been started). The casing drive assembly 10 is made up with and suspended from a top drive via a slack joint, and lowered by the top drive into the bore of the casing joint 500 from the top thereof. The elevators stay latched and ride down the casing joint 500 during this operation. Once the casing drive assembly 10 has entered casing joint 500 sufficiently so that stop collar 104 arrests further travel of casing drive assembly 10 into the casing joint 500 , casing joint 500 is rotated to engage casing joint 502 . The casing joint 500 may be run up with the rig tongs or casing drive assembly 10 may be used to transmit rotation to the casing joint 500 once it is fully engaged with casing joint 500 , after engagement with the interior of casing joint 500 , as described below. The tapered stabilizer guide 408 , the casing guide 316 and the spring-biased friction blocks 228 aid insertion and centering of the casing drive assembly 10 into and within the casing joint.
[0024] If the casing joint 500 is the first joint in the casing string, a cutting structure, such as a drilling or reaming device, is made up with the lower end thereof prior to insertion of casing drive assembly 10 . Non-limiting examples of such devices are, for drilling, the EZ Case™ casing bit and, for reaming, the EZ Ream™ shoe. Otherwise, such a device 504 is already secured to the distal end of the lowermost casing joint in the casing string. To initially engage the casing drive assembly 10 with the interior of casing joint 500 , the casing spear 200 is manipulated, as by right-hand (clockwise, looking downward) rotation of the casing drive assembly 10 to move the lug 208 within the laterally extending segment LA of the J-slot 210 and align the lug 208 with the longitudinal segment L of the J-slot 210 , followed by application of an upward force to the casing drive assembly 10 . The spring-biased friction blocks 228 provide sufficient, initial frictional drag against the interior of the casing joint 500 to maintain the outer housing 206 of the casing spear 200 stationary within the casing joint 500 until the gripping structures 224 on the outer surfaces 222 of the slips 212 engage the interior of the casing joint 500 as the stepped convex, frustoconical wedges surfaces 226 of the mandrel 202 move upwardly with respect to the stepped wedge elements 218 on the interior surfaces 220 of the slips 212 and force the slips 212 radially outwardly to securely grip the interior of the casing joint.
[0025] The engaged casing joint 500 is then lifted using the top drive to permit slips of a holding device at the rig floor, commonly termed a “spider,” which are employed to suspend the existing casing string below the rig floor, as is conventional.
[0026] The rig pump may then be engaged and circulation of drilling fluid established through the casing drive assembly 10 through the longitudinal passages 104 , 204 , 304 and 404 and out into the interior of the casing joint 500 through the outlet slots 406 . Upward circulation of drilling fluid within the casing joint 500 is precluded by the packer cup 308 , which expands against and seals with the interior of the casing joint 500 under drilling fluid pressure, a prompt and fluid-tight seal being facilitated by the presence of the slots 324 of the casing guide 316 . Drilling fluid pressure is increased until sufficient pressure is observed to cause the pistons 110 of the hydraulic anchor 100 to grip the interior of the casing joint 500 .
[0027] The casing drive assembly 10 , with the casing joint 500 secured thereto by the hydraulic anchor pistons 110 , is then rotated by the top drive to rotate the casing joint 500 and any others therebelow (if any) in the casing string, the top drive also providing weight, and drilling or reaming commences. Notably, both torque and weight are applied to the casing joint 500 via engagement of the casing drive assembly 10 substantially only with the interior of the casing joint 500 .
[0028] The rig elevators remain attached as the casing joint 500 descends until a point just above the rig floor, where they can be reached and released for picking up the next casing joint. When the upper end of the casing joint 500 , engaged by the casing drive assembly 10 , approaches the rig floor, the slips of the spider are then employed to grip the casing joint 500 , drilling fluid circulation ceases, releasing the pistons 110 of the hydraulic anchor 100 from the casing joint under their inward spring-loading, the casing drive assembly 10 is lowered sufficiently to release the slips 210 of the casing spear 200 from the casing joint and rotated slightly to the left (counterclockwise, looking downward) to maintain the release of the slips 212 , and the casing drive assembly 10 is withdrawn from the casing joint 500 for subsequent insertion into another casing joint picked up by the rig elevators, the above-described process then being repeated.
[0029] A significant advantage of the use of a casing drive assembly according to an embodiment of the present invention is reduced casing thread wear, due to the lack of a threaded connection between the casing drive assembly and the casing joint engaged thereby.
[0030] While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention only be limited in terms of the appended claims and their legal equivalents. | An apparatus and methods for manipulating and driving casing. The apparatus includes mechanically responsive elements for gripping an interior of a casing joint, and hydraulically responsive elements for gripping an interior of the casing joint responsive to pressure of drilling fluid flowing through the apparatus. One method comprises manipulating a casing joint by mechanically gripping an interior thereof, hydraulically gripping the interior of the casing joint responsive to drilling fluid pressure, and rotating the casing joint. Another method comprises driving casing by applying weight and torque thereto through engagement with an interior thereof. | 4 |
ORIGIN
The invention described herewith was made in the performance of work under a NASA contract and is subject to the provisions of Section 305 of the National Aeronautics and Space Act of 1958, Public Law 85-568 (72 Stat. 435; 42 U.S.C. 2457).
BACKGROUND OF THE INVENTION
1. Field of the Invention
High temperature insulating materials which are suitable, for example, as reusable reentry heat shield for orbiting vehicles.
2. Description of the Prior Art
The development of a reusable space vehicle has created a need for a reusable surface insulating material. The characteristics required by such a material include mechanical strength and high strain to failure, as well as resistance to devitrification or crystallization at high temperature which would render the insulation inferior for reuse.
Conventionally, the high temperature insulations of the art have been formed by bonding ceramic fibers with inorganic binders. Aluminosilicate and silica fibers have been taught as appropriate for use in such composites (U.S. Pat. Nos. 3,077,413 and 3,752,683). The fibers, however, are always interspersed in a matrix of binder, usually an inorganic oxide such as colloidal silica. The use of a binder matrix limits the potential of the individual fibers in the resultant insulation to a fraction of their possible strength or strain to failure. The present invention is unique in that it dispenses with the binder matrix which the prior art considers necessary; the present materials are composed of fibers only.
The production of an acceptable insulation composed of fibers alone is even more of a surprise to the art in light of the fibers which are used to produce this new invention, one of which being the highly sensitive, high purity silica fibers. Since small amounts of impurities, it has been taught, can cause undesirable divitrification in such fibers, it could reasonably have been inferred from these teachings that the other fiber ingredient of this invention, aluminoborosilicate fibers, would act as such an impurity and cause devitrification of the silica fibers. This has now been shown not to be the case.
SUMMARY OF THE INVENTION
It has now been discovered that refractory composite insulation can be produced from two fibers: aluminoborosilicate and silica fibers. This two-fiber composite has more desirable properties than the conventional rigid insulations containing fibers, because each fiber imparts to the composite its desirable characteristics unencumbered by the binders required by the prior art. This advance in the art has resulted from the discovery that boron oxide, present in aluminoborosilicate fibers or as a separate ingredient, serves to stabilize the sensitive, high purity silica fibers at high temperatures. In the present composites, the fiber components are used at weight ratios of 1:19 to 19:1, and boron oxide constitutes from 0.5 to 30% by weight of the total fiber weight.
DETAILED DESCRIPTION OF THE INVENTION
The fibrous refractory composite insulation of the present invention is composed of two different fibers. In one embodiment of the invention these fibers are aluminoborosilicate and silica. Each of these fibers serves an important function in producing the desirable characteristics of the resultant insulation. Silica fiber is highly reactive and when of high purity is resistant to the devitrification which would limit the long term high temperature life time of the resultant insulation. This fiber may be viewed as providing a matrix for the more refractory aluminoborosilicate fiber which cannot easily be made into a rigidized form by itself. The aluminoborosilicate fibers do not soften or sinter significantly at temperatures lower than 1370° C. and therefore provide a higher temperature capability than an all silica insulation would provide. The boron oxide ingredient of the aluminoborosilicate fiber is in fact a stabilizer which prevents devitrification of the sensitive silicate fibers upon firing during the production of the insulation.
The two-fiber composite provides low density insulation which exhibits thermal expansion and thermal conductivity properties comparable to those of prior art insulations, while possessing improved strength, strain to failure, and temperature capabilities.
The insulation of the present invention can be made with varying ratios of the weights of aluminoborosilicate and silica fibers. This ratio is controlled to maximize the desired characteristics of the composite while minimizing the undesirable characteristics. Thus, addition of aluminoborosilicate fibers yields a desired increase in the temperature capabilities of the resultant insulation. At the same time, however, undesirable increases in thermal conductivity and thermal expansion coefficient also occur. With these considerations in mind, the weight ratios of the fibers can be varied within the range of 1:19 to 19:1, with a most satisfactory balance of properties being achieved at ratios between about 1:9 and 2:3. Optimum insulation for the current purposes of the inventors has been obtained with a dry weight ratio of about 4:1 silica fibers to aluminoborosilicate fibers (containing about 14% boron oxide).
Suitable forms of raw materials are available commercially. Silica fibers, at least 99.6% pure, are manufactured by Johns Manville and marketed as Microquartz 108 fibers. These fibers have an average diameter of 1.7 microns. Aluminoborosilicate fibers produced by the 3-M Company and known as AB-312, contain 62%±2.0% Al 2 O 3 , 14+2.0% B 2 O 3 and 24±2.0% SiO 2 . They may be obtained in average diameters ranging from 3 to 12 microns. Acceptable insulation may be made from aluminoborosilicate fibers ranging in diameters from 3 to 12 microns and silica fibers ranging in diameter from 1 to 6 microns.
Boron oxide, it has been pointed out earlier, is the essential ingredient of the present composites which prevents the devitrification that silica fibers would be expected to undergo at high temperatures in the presence of "impurities" such as aluminosilicate fibers. The oxide is generally added in a quantity ranging from 0.5 to 30% of the total weight of fibers, with a range of 1 to 6% being preferred for reentry shield applications. It has been found further that the boron oxide can be added to aluminosilicate fibers, with or without prefiring before the silica fibers are added, or that the oxide can be added in the form of aluminoborosilicate fibers, i.e., already fully integrated within the structure of said fibers. When aluminoborosilicate fibers are used, additional free boron oxide may be added to the composite mix, due respect being accorded to the overall content limitations already recited.
The optical properties of composite insulating tiles made from the above materials may be modified by inclusion of a small quantity of finely divided, preferably less than 300 mesh, impregnant or opacifying substance. These materials, which must be refractory in nature, include various oxides, e.g., chromium and cobalt oxides, silicon carbide, and the like. While up to 3% of opacifier may be added to the composite mix, some of it is lost during processing by washing, so that the quantity that ultimately remains in the finished tile is substantially lower than what was originally added. This however is not a matter of importance.
The basic procedure that has been devised to prepare the composites of the invention may be described as follows. The high purity silica fibers are first washed and dispersed in hydrochloric acid and/or deionized water. The ratio of washing solution to fiber is between 30 to 150 parts liquid (pH 3 to 4) to 1 part fiber. Washing for 2 to 4 hours generally removes the surface chemical contamination and nonfibrous material (shot) which would contribute to silica fiber devitrification. After washing, the fibers are rinsed 3 times at approximately the same liquid to fiber ratio for 10 to 15 minutes with deionized water. The pH is then about 6. Excess water is drained off leaving a ratio of 5 to 10 parts water to 1 part fiber. During this wash and all following procedures, great care must be taken to avoid contaminating the silica fibers. The use of polyethylene or stainless steel utensils and deionized water aids in avoiding such contamination.
The washing procedure has little effect on the bulk chemical composition of the fiber. Its major function is the conditioning and dispersing of the silica fibers.
The aluminoborosilicate fibers are prepared by dispersing them in deionized water. They can be dispersed by mixing 10 to 40 parts water with 1 part fiber in a V-blender for 21/2 to 5 minutes. The time required is a function of the fiber length and diameter. In general, the larger the fiber, the more time required.
The dispersed silica fibers and dispersed aluminoborosilicate fibers are then combined. The pH which is probably acidic is adjusted to basic with ammonium hydroxide. The slurry is then mixed. A slurry containing 12 to 25 parts water to 1 part fiber is mixed to a uniform consistency in a V-blender in 5 to 20 minutes. The preferred mixing procedure uses 15 parts water to 1 part fiber in the slurry producing an acceptable mixture in about 20 minutes.
The slurry is poured into a mold for pressing into the desired shape. The water is withdrawn rapidly and the resulting felt is compressed at 10 to 20 psi. Rapid removal of the water is required to prevent the fibers from separating. If graded properties are desired in the resultant material, the slurry can be allowed to settle and the fibers to partially separate before the removal of the water.
The final density of the finished tile is determined in part by the amount of compression placed on the felt, varying the wet molded dimension in relation to the fiber content. The insulation of the present invention has been prepared in densities ranging from about 0.08 to 0.48 g/cc. It can, however, be prepared in higher densities.
After molding, the insulation tile is dried and fired by the following preferred procedure. The tile is first dried in an oven for 18 hours; the temperature, initially 38° C., is raised at a rate of 11° C. per hour to 104° C., held there for 4 hours, raised again at a rate of 11° C. per hour to 150° C., and held there for 4 hours. The tile is taken directly from the drying oven, placed in the firing furnace, and fired. A temperature rise rate of 220° C. per hour or less is required in order to avoid cracking and warping in the case of a 15 cm×15 cm×7.5 cm tile. For larger tiles, slower heating rates may be required. The maximum firing temperature may vary from 1260° C. to 1370° C. depending upon the fiber ratio used and the final density of the insulation that is desired.
The temperature rise rate is chosen to permit relatively uniform temperatures to be achieved throughout the tile during the process. A faster temperature rise rate causes nonuniform strength and density and could cause cracking. Longer or higher temperature firing results in higher shrinkage and related greater resistance to subsequent shrinkage, as well as a shorter lifetime to devitrification. The maximum firing temperature is dependent upon the fiber ratio used and the density of the composite desired. The firing time and maximum temperature are selected to allow sufficient shrinkage to achieve stabilization while not allowing any devitrification.
After firing, the tiles are machined to obtain the desired final dimensions. Only about 0.5 cm of the material must be machined off.
The procedure used to prepare fibrous refractory composite insulation may be varied through a rather broad range with satisfactory results. In one variation, the silica or aluminoborosilicate fibers may be borated and prefired prior to use. This process is used to improve the morphological stability and physical properties of the resultant insulation.
The following examples are provided to illustrate the invention by describing various embodiments, including its best mode as presently conceived. All proportions used are expressed on a weight basis unless otherwise noted.
EXAMPLE 1
A tile having a density of 0.32 g/cc, and opacified with silicon carbide was produced according to the present invention, with 825 grams of silica fibers, 175 grams aluminoborosilicate fiber (average diameter - 11 μm length - 0.32 cm), 35 grams 1200 grit silicon carbide, 10 milliliters hydrochloric acid, 5 milliliters ammonium hydroxide and deionized water. The aluminoborosilicate fibers contained about 14% boron oxide.
The silica fibers were washed as in Example 2.
The aluminoborosilicate fibers were placed in a 7,570 ml capacity stainless steel double shell blender with 5,000 grams deionized water and mixed using the intensifier bar for 21/2 minutes to disperse the fiber.
The washed silica fibers, dispersed aluminoborosilicate fibers, and silicon carbide were placed in a 28.31 liter stainless steel double shell V-blender. Deionized water was added to bring the total weight to 15,000 grams. The ammonium hydroxide (5 ml) was added to adjust the slurry to basic before mixing. The slurry was mixed, degassed, transferred to a mold and pressed into a billet as in Example 2.
The billet was dried and fired as in Example 2, and then machined to 17 cm×17 cm×7.5 in accordance with normal machining practices.
A comparison of the crucial properties of the resultant tile was a silica fiber--colloidal silica matrix composite of the art made substantially according to Example III of the U.S. Pat. No. 3,952,083 to a density of 0.32 g/cc, yielded the following data:
______________________________________Tile: Present Invention Prior Art______________________________________Strain to failure 0.5% 0.2-0.3%Modulus of rupture 6.04 × 10.sup.6 N/M 1.67 × 10.sup.6 N/MTemperature capability 1540° C. 1480° C.______________________________________
EXAMPLE 2
In contrast to the tile of Example 1, another tile was prepared from the following ingredients and in the manner described below, which as shall be demonstrated is unsuitable for the purpose intended. The principal difference between the tile of this example and that of Example 1 is that no boron oxide was used here, either as part of the aluminosilicate fibers or in addition to said fibers.
The materials used were the following: 150 grams aluminosilicate fibers (AS-32, manufactured by 3-M Company containing 80% Al 2 O 3 and 20% SiO 2 ), 1000 grams of silica fibers (Microquartz 108), 35 grams of 1200 grit silicon carbide, 10 ml of hydrochloric acid, 5 ml of ammonium hydroxide, and deionized water.
The silica fibers were placed in a polyethylene container in 32 liters of deionized water. Hydrochloric acid (10 ml) was added to bring the pH to 3. Pure nitrogen was bubbled through the mixture to agitate the fiber and assist washing. Agitation was continued for two hours. The acidic water was then drained off, fresh deionized water added and the mixture again agitated with pure nitrogen for 15 minutes. The rinsing process was repeated 2 more times which brought the pH to about 6.0.
The aluminosilicate fibers were placed in a 7,570 ml capacity stainless steel double shell blender with 5,000 grams of deionized water and mixed using the intensifier bar for 21/2 minutes to disperse the fiber.
The washed silica fibers, dispersed aluminosilicate fibers, and silicon carbide were placed in a 28.31 liter stainless steel double shell V-blender. Deionized water was added to bring the total weight to 18,000 grams. Ammonium hydroxide (5 ml) was added to adjust the slurry to basic before mixing. The slurry was then mixed with the intensifier bar running for 20 minutes, removed from the V-blender and degassed, transferred into a mold, and pressed into a 21.6 cm×21.6 cm×10 cm billet. The top and bottom of the mold were perforated and covered with a 16 mesh aluminum screen to allow the excess water to flow out.
The billet was dried in an oven for 18 hours beginning at 38° C., increased at 11° C. per hour to 104° C., held for four hours at 104° C., increased at 11° C. per hour to 150° C. and held four hours at 150° C. After drying the billet was transferred to the firing furnace. The furnace temperature was increased at a rate of 220° C. per hour to the firing temperature, 1315° C., where it was held for 11/2 hours. After firing the temperature was decreased at a rate of 220° C. per hour to 980° C. where the furnace was turned off, then allowed to cool to room temperature. The fired tile showed cracks on one side and a 2% devitrification. After subsequent treatment at 1370° C. for 4 hours the tile had devitrified 87%.
EXAMPLE 3
The usefulness of boron oxide in the two-fiber composites of this invention can be further demonstrated by the following preparations.
In one run, an experimental mixture was made containing 25% aluminosilicate fibers (Fiberfrax H, manufactured by the Carborundum Company, containing 62% Al 2 O 3 and 38% SiO 2 ) and 75% pure silica fibers (Microquartz 108). The mixture was ground with mortar and pestle and then fired at 1400° C. for 5 hours. The resulting product underwent 48% devitrification. When the aluminosilicate fibers were prefired with boron oxide (85% and 15% respectively) at 1100° C. for 90 minutes and then mixed with the silica fibers and fired as above, the product exhibited no devitrification.
EXAMPLE 4
An acceptable 17 cm×17 cm×7.5 cm tile having a density of 0.11 g/cc was produced using 600 grams of silica fibers, 90 grams of aluminoborosilicate fibers (average diameter--11 μm, 0.64 cm long), 10 ml of hydrochloric acid, 5 ml of ammonium hydroxide, and deionized water.
The silica fibers were washed in accordance with the procedure of Example 2. The aluminoborosilicate fibers were dispersed in a 7,570 ml V-blender with 3000 grams of deionized water for 5 minutes. The washed silica fibers, dispersed aluminoborosilicate fibers, and ammonium hydroxide were mixed, with enough deionized water to bring the total weight to 9,000 grams, in a 28.31 liter V-blender for 10 minutes with the intensifier bar running. The slurry was removed from the V-blender, degassed, molded and the resulting billet dried as in Example 2. The billet was then transferred to the firing furnace. The furnace temperature was increased at a rate of 220° C. per hour to the firing temperature, 1260° C., where it was held for 5 hours. After firing, the temperature was decreased at a rate of 220° C. per hour to 980° C., at which point the furnace was turned off and allowed to cool to room temperature. The billet was machined to 17 cm×17 cm×7.5 in accordance with usual machining practices.
EXAMPLE 5
An acceptable 17 cm×17 cm×7.5 cm tile with yet greater stability toward devitrification than the tile of Example 1, having a density of 0.32 g/cc, and opacified with silicon carbide was produced using 825 grams of silica fibers, 175 grams aluminoborosilicate fibers (average diameter--11 μm, 0.64 cm long), 35 grams of 1200 grit silicon carbide, 10 ml of hydrochloric acid, 5 ml of ammonium hydroxide, 56.8 grams of boron oxide, and deionized water.
The silica fibers were washed in accordance with the procedure of Example 2. The boron oxide was dissolved in 4,000 grams of deionized water (concentration--1.42% boron oxide). The aluminoborosilicate fibers were placed in a stainless steel basket and dipped into the boron oxide solution (the aluminoborosilicate fibers absorbed 7 times their own weight of the boron oxide solution). The fibers with absorbed boron oxide were then dried at 104° C. for 4 hours and calcined at 1100° C. for 1 hour. The "borated" fibers were then placed in a 7,570 ml capacity stainless steel V-blender with 5,000 grams of deionized water and mixed using the intensifier bar for 21/2 minutes to disperse the fiber. The washed silica fibers, dispersed "borated" aluminoborosilicate fibers, silicon carbide, and ammonium hydroxide were mixed with enough deionized water to bring the total weight to 15,000 grams, in a one cubic foot V-blender for 20 minutes with the intensifier bar running. The slurry was removed from the V-blender, degassed, molded, dried, fired, and machined as in Example 1.
EXAMPLE 6
An acceptable 17 cm×17 cm×7.5 tile with graded properties, having a density of 0.32 g/cc, and opacified with silicon carbide, was produced using 825 grams of silica fibers, 175 grams of aluminoborosilicate fibers (average diameter--11 μm, 0.64 cm long), 35 grams of 1200 grit silicon carbide, 10 ml of hydrochloric acid, 5 ml of ammonium hydroxide, and deionized water.
The silica fibers were washed in accordance with the procedure of Example 2. The aluminoborosilicate fibers were dispersed in a 7,570 ml V-blender with 5000 grams of deionized water for 5 minutes. The washed silica fibers, dispersed aluminoborosilicate fibers, silicon carbide and ammonium hydroxide were mixed with enough deionized water to bring the total weight to 25,000 grams, in a 28.31 liter V-blender for 15 minutes with the intensifier bar running. The slurry was removed from the V-blender, degassed, molded, dried, fired and machined in accordance with the procedure of Example 1.
The resulting tile is relatively richer in silica at the top and aluminoborosilicate at the bottom.
EXAMPLE 7
A 17.5 cm×17.5 cm×9 cm tile with a temperature capability greater than that of the tile of Example 1, having a density of 0.24 g/cc, and opacified with silicon carbide, was produced using 750 grams of aluminoborosilicate fibers (diameter--1 to 3 μm), 250 grams of silica fibers, 35 grams of silicon carbide, 5 ml of ammonium hydroxide, and deionized water. The silica fibers were dispersed in a 7,570 ml V-blender with 5,000 grams of deionized water for 5 minutes.
The dispersed silica fibers, aluminoborosilicate fibers, silicon carbide, and ammonium hydroxide were mixed with enough deionized water to bring the total weight to 18,000 grams, in a 28.31 liters V-blender for 7 minutes with the intensifier bar running. The slurry was removed from the V-blender, degassed, molded, and dried as in Example 2. In the furnace, the temperature was increased at a rate of 220° C. per hour to the firing temperature, 1370° C. where it was held for 11/2 hours. After firing, the temperature was decreased at a rate of 220° C. per hour to 980° C., at which point the furnace was turned off and allowed to cool to room temperature. The billet was machined to 17.5 cm×17.5 cm×9 cm in accordance with the usual machining practices.
Although the products of this invention have been prepared in a manner which renders them particularly useful for space vehicle heat shields, it should be understood that materials of this type may be used in any high temperature insulation application for which their particular combination of properties qualify them. It should also be understood that many variations in composition and process can be carried out by the man skilled in the art without departing from the spirit and the scope of the invention as stated by the following claims. | A refractory composite insulating material prepared from silica fibers and aluminosilicate fibers in a weight ratio ranging from 1:19 to 19:1, and about 0.5 to 30% boron oxide, based on the total fiber weight. The aluminosilicate fiber and boron oxide requirements may be satisfied by using aluminoborosilicate fibers and, in such instances, additional free boron oxide may be incorporated in the mix up to the 30% limit. Small quanitites of refractory opacifiers, such as silicon carbide, may be also added. The composites just described are characterized by the absence of a nonfibrous matrix. | 2 |
RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] The invention relates to vehicle seats, particularly seats for automobiles and light trucks, but is also applicable to heavy vehicles or aircraft. The seats of this invention will provide increased occupant protection in the event of a rollover accident, or other situations requiring repositioning of the head/chest. Rollover accidents occur relatively slowly compared to other accidents, such as front, side, or rear impacts. Thus rollover accidents can utilize additional design techniques to achieve occupant protection. Rollover occupant protection system design involves the integration of a number of components in the vehicle, all of which must be compatible with each other. One element of the vehicle available to vehicle designers in developing effective rollover occupant protection system designs is the seat with integral restraint. One element of the vehicle that is particularly hazardous to restrained occupants is the intruding roof. This invention moves the occupant's head and chest away from the vehicle roof automatically during a rollover.
[0005] It has been known in the art for some time, recognized by the inventors for almost ten years, that an important tool available to designers of occupant safety in a rollover, along with, for example, stronger roof structures, better occupant packaging, more effective restraint systems, active or passive rollbars and other available technology, is to dynamically move the occupant away from the roof before the roof crushes. In large vehicles such as semi-truck cabs, there is room to move the entire seat straight down a large distance away from the roof, and several approaches for this problem have been proposed. In co-pending application, Ser. No. 10/807,325, by the same inventor, three concepts for accomplishing rollover protection in light passenger vehicles with power (electric) integrated seats (all-belts to seats) are identified: dynamically tilt the seat back rearward in order to effectively move the occupant's head away from the roof and rearward in the vehicle, reorienting the torso-head/neck complex to a more advantageous position and orientation; compress the seat back and seat cushion to be smaller than their normal dimensions to increase headroom in conjunction with rollover actuated pretensioning seatbelts; and, under certain circumstances move the seat cushion forward or rearward or laterally to better position the occupant relative to the roof structure and/or to allow for the downward deployment of the seat back in restricted compartment space conditions. However, many vehicle seats do not have powered adjustment for reclining. The current invention addresses rollover safety for seats without power reclining capability.
[0006] Although solutions to some of the concepts have been previously proposed, none have been implemented in light vehicles to date. As described in co-pending application, Ser. No. 10/807,325, the existing solutions are not compatible with power adjustable seats. However even for non-powered seats, previously proposed solutions are not, in fact, practical, because they do not address characteristics of real manual seat designs either.
[0007] The reclining mechanism on almost all manual seats includes a ratchet, gear, or scissor type positioning mechanism, where a mechanical stop is engaged in a detent. This stop is manually moved by a lever or other release mechanism. The seat is moved to the desired position, and then the stop is re-engaged in different detent, holding the seat in the desired position. In addition, many seats have stops that limit the reclining motion. Both the limiting stops and adjustment stops, typically, should be strong mechanically. Existing solutions for rollover protection that rely on reclining the seat back to move the occupant away from the roof do not address the issue of the recliner adjustment or limiting stops, and therefore cannot be implemented in conventional seat designs.
BRIEF SUMMARY OF THE INVENTION
[0008] The invention is a seat for a vehicle, the seat having a seat back and a seat cushion. The seat includes means for manual adjustment of the seat reclining position, including a mechanism which locks the seat in the desired reclining position. The invention includes a first actuator, which reclines the seat, a second actuator which unlocks the reclining mechanism (and mechanisms/actuators etc for subsequent control of the seat in terms of how far rearward it can go, and mechanisms/actuators/sensors to prevent the return of the seat back towards a more upright position), and a rollover sensor. In response to a signal from the rollover sensor indicating the vehicle is in a rollover condition, the reclining actuator and the unlocking actuator are engaged, such that the seat is rapidly reclined rearward. Further embodiments of the invention also include occupant sensing for additional control of the seat motion.
[0009] In another embodiment of the invention, the seat may have a recline position stop, and an actuator to move the stop (or remove the stop allowing a subsequent stop to become effective). In response to a signal from the rollover sensor indicating the vehicle is in a rollover condition the recline position stop is removed by the actuator, such that the seat can be reclined beyond the normal stop position. In some vehicle seats, a stop may be introduced to prevent the seat from reclining past the required position.
[0010] The actuators may have any combination of pyrotechnic pistons, motors, or spring loaded designs. The spring loaded actuator includes a spring, and a solenoid, pyro, or motor, which drives a release mechanism, such that in normal vehicle operation the spring is held in an extended or compressed position by the mechanism. In response to a signal from the rollover sensor, the mechanism is removed from the spring, freeing the spring to retract or compress. One such mechanism may be a pin.
[0011] The preferred seat of the invention also includes an integrated safety belt, with a pre-tensioner. The pre-tensioner is triggered in response to a signal from the roll-over sensor.
[0012] In another embodiment, the seat is held in the reclined position after the operation of the actuators in response to the rollover signal. In one version of this embodiment, the seat is held in the reclined position by re-engagement of the unlocking mechanism. The unlocking mechanism may be re-engaged by an additional actuator, which re-engages the mechanism, the additional actuator triggered by a timer that is set to a time sufficient to allow for the seat to recline. The actuator may also be triggered from a measurement of the seat's position, for instance by rotary encoder. Or the locking mechanism may be re-engaged by the release of the mechanism by the second actuator, after a time sufficient for the seat to recline. Alternatively, the seat may be held in the reclined position by the operation of another actuator which inserts a restraining device to secure the seat in the reclined position. In a further embodiment the motion of the seat past a trip point engages a stop, which is released to swing or move into position when the seat reaches the desired position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The detailed description of how to make and use the invention will be facilitated by referring to the accompanying drawings.
[0014] FIG. 1 depicts the major elements of a generic vehicle seat suitable for practice of the invention.
[0015] FIG. 2 depicts the major element of another exemplary seat design
[0016] FIG. 3 shows the elements of the invention for the first exemplary seat.
[0017] FIG. 4 illustrates the elements of the invention for the second exemplary seat.
[0018] FIG. 5 shows possible implementations of the actuators, particularly the spring loaded type.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIG. 1 , the seat consists of a back, 1 , and a cushion 2 . A manual reclining mechanism is shown is schematic form. A row or some other arrangement of detents or stop positions is shown at 3 . The seat back rotates about pivot point, 5 . 3 is connected to the seat back through pivotal member 4 , constructed such that motion of the member in the forward/reverse direction causes the seat back 1 to rotate about the pivot point 5 . A spring 8 is attached rigidly to the seat frame 9 on one end and to the member 4 on the other. When the locking mechanism 6 is released, the spring pushes the member rearward, causing the seat back to rotate forward. The passenger uses his weight to recline the seat backward against the spring 8 , and re-engages the locking mechanism when the seat is in the desired position. In addition some seat designs may have a stop 7 , which either intentionally, or non-intentionally limits the range of the recline motion. Another example of a manual reclining seat is shown in FIG. 2 . In this case, the spring 8 pushes up to cause rotation about the pivot point 5 . The locking mechanism consists of a lever on the side of the seat that attaches a cable 10 , which pulls a retainer away from the detent member 3 . It is to be understood that a wide range of manual reclining mechanisms exist. Some may have the lever on the seat back, at the rotation point, or other positions. The locking mechanism as well may take different forms. The exact design of the seat is not critical to the invention, as the invention is compatible with many seat designs. The nature of the stop, if one exists is also not critical. A skilled designer of such seats will understand how to apply the invention to a particular seat design from this disclosure. In addition, for seats with manual reclining, but other adjustments of the powered type, all of the features of co-pending application Ser. No. 10/807,325 may be practiced for the powered portions, while the current invention is practiced for the reclining motion.
[0020] Referring to FIG. 3 , the elements of the invention are added to the seat. An actuator, 11 is connected to the locking mechanism 6 and 3 . Another actuator 12 is configured to recline the seat. An optional actuator 13 is configured to move the stop 7 . FIG. 4 shows the elements 11 , 12 , and 13 arranged for the second exemplary seat design. It is to be understood that the locking mechanisms in manual reclining seats can be very strong, and must be released before a seat can be reclined by an actuator. It may be desirable to remove spring 8 's resistance to reclining motion as well. This could be accomplished by removing one or both surfaces that spring 8 act against, either by actuator or simply blowing the action surface with a charge. Alternatively, the spring itself could be blown or rendered ineffective by pyro or chemical means.
[0021] The invention requires a rollover sensor in the vehicle, which may or may not be integrated with the seat. Rollover sensor designs exist in the art, which are suitable for use with the invention. For purposes of implementing the invention, a particular rollover detector sensor may be used as long as the sensor is capable of discriminating between normal operation, and a wide enough range of roll conditions to ensure that a signal indicating immediate rollover will not be generated other than during a real rollover event.
[0022] Referring to FIG. 3 , in response to the rollover sensor signal, actuator 11 engages, releasing the locking mechanism. Actuator 12 engages, in such a way, or at such a time, that it is not pulling against the locking mechanism, i.e. time phased such that 11 is adequately engaged. Actuator 12 causes the seat to recline. The Figure shows a seat where just the back reclines, but it is understood that in some seats both the back and cushion rotate. The result is that the seat reclines rapidly, moving the occupant's head and chest away from the roof, and critically, the locking mechanism is released, allowing for reclining to take place. Optionally, if desirable, any limiting stop 7 may also be moved, actuator 13 , allowing for more than normal reclining in the event of a rollover. For some vehicles, a stop 7 may be inserted to prevent excess reclining.
[0023] The invention is best implemented in combination with a seat belt, integrated with the seat. The seat belt should have at least one pretensioner, known in the art, which is also triggered by the rollover signal.
[0024] Referring to FIG. 5 , variety of actuators may be employed at 11 , 12 , and 13 . For example, pyrotechnic pistons are used in automotive applications in similar applications such as seat belt pretensioners. In this application, the rollover signal triggers the pyro charge, which drives the piston shaft. The shaft could be connected to the locking mechanism 6 and 3 , reclining mechanism, 4 , and stop 7 in the invention. Slow burn pyro devices would be preferable for this application, since large masses are being moved, including the occupant. Therefore the reclining motion should not be too fast. Rollover events take place slow enough that there is time to recline at an occupant safe rate. Also, a motor drive actuator could also be employed at any of 11 , 12 , or 13 .
[0025] Another actuator mechanism contemplated by the inventors is shown in FIG. 5 . A suitably strong spring 14 is held pinned in the extended (or compressed) position by a solenoid device 15 . Motor or pyro actuators could also be employed at 15 . The spring may be attached, for example, to the reclining members 4 . The solenoid is actuated by the rollover signal, removing the restraining mechanism, such as a pin, freeing the spring, thereby accomplishing the desired motions. The case where the spring is held extended is shown in the figure, but the spring held compressed is also contemplated by the invention. Any combination of spring, motor, or pyro actuators may be used for any of the actuators described in the invention, as well as other suitable actuators within the scope of the invention.
[0026] Depending on the type of actuator used and the design of the seat, the invention may require additional features to work properly. Some seat/vehicle designs have no rear limit to the reclining motion, allowing for seats to recline to a fully flat or even beyond-flat position. This position is not ideal from a safety standpoint during a rollover accident. Therefore for this type of situation, a stop needs to be inserted to limit the range of reclining motion during a rollover condition. The insertion of the limiting stop may be accomplished by another actuator. Alternatively, the stop may be configured such that when the seat reaches the desired position, the movement of the seat past that point releases the stop to engage. One example would be to insert a pin(s) into a hole(s) in the seat frame when the seat reached the desired position. Another example of such a mechanism would be a bar on a spring loaded pivot configured such that when a part of the seat frame with an opening slides past the bar, the bar pivots into the opening, restraining the seat at that point in the reclining motion. Stops of this type would require that they lock into place when deployed. A variety of stop designs and suitable actuators, including those already described, will be obvious to skilled designers for particular seat/vehicle configurations.
[0027] Depending on the type of reclining mechanism used, provision may be required to keep the seat in the reclining position once reclined. As stated above, most reclining seats are configured such that the reclining spring 8 rotates the seat forward when the locking mechanism is released. The reclining actuator once engaged, may not be strong enough to overcome the spring, and any other forces, such as crash accelerations, once the reclining motion is over. For instance, pyro pistons may have insufficient reverse resistance once the charge is blown. One approach to keeping the seat reclined is to simply re-engage the locking mechanism once the seat is reclined. Many recliner locking mechanisms are spring loaded such that when the operator releases the handle, the mechanism re-locks. The locking mechanism release actuator may be set up with a timer such that the lock is released after a time sufficient for the seat to recline. Alternatively, the seat rotation may be measured with a rotary encoder or other electronic means connected to a circuit, which re-engages the lock at the appropriate position. An actuator of the solenoid type is particularly amenable to a timer or measured position approach, since the solenoid is turned on and off by control signals. For actuators of the pyro type, whose operation cannot be reversed as with the solenoid type, another actuator may be employed to re-engage the locking mechanism. Not all recliner lock mechanisms designs will reliably re-engage however when released. For these cases, another actuator may be used to insert a reverse motion stop once the reclining motion is complete. This stop would have the opposite effect as the motion-limiting stop described above. Or the restraining systems above that deploy when the seat reaches a certain position would be equally effective at keeping the seat reclined as limiting the amount of recline. Again, many different designs would suggest themselves to a skilled designer.
[0028] As vehicle protection becomes more sophisticated, smart safety systems will become prevalent that measure the presence of occupants as well as their size and weight, along with monitoring the type of accident the vehicle is undergoing. The safety systems of the present invention are well suited to such smart systems. For instance depending on the size and weight of an occupant, the smart system may determine that a limiting stop is or is not appropriate. Similarly, a limiting stop may be deployed on a front seat if the rear seat is occupied, but otherwise not deploy to allow more motion. Thus the invention also contemplates situations where when, and if, the safety systems are deployed is controlled by the smart system. Thus the rollover sensor signal will alert the system controller to the rollover event, but the safety device control signals will originate from the controller, which will decide which systems to deploy, how much to deploy them, and the time phasing of the deployment. | This invention is vehicle seat, which provides enhanced occupant protection in the event of a vehicle rollover. The seat includes a rollover sensor and mechanisms compatible with manual reclining seats. These mechanisms allow for rapid reclining of the seat during a rollover, by unlocking the reclining mechanism and automatically reclining the seat | 1 |
BACKGROUND
Conventional integrated circuits or modules may have multiple processors or die mounted to a single module. The module is connected to a power source and, therefore, has a limited amount of power that may be drawn from the power supply. The power drawn from the power supply is divided between the die. For example, if the module has two die and 100 watts is available to the module, each die may be limited to using 50 watts.
Situations arise wherein one of the die may be relatively idle and another die may be required to perform extensive processing, which requires an increase in the operating frequency of the die. The increased operating frequency, in turn, requires that the die draw more power. In the example described above, the active die will be limited to 50 watts, which limits the operating frequency of the die. Although the total power consumed by the second die may be less than 50 watts and the power consumed by the module may be less than the 100 watts available from the power supply. Thus, potential performance from the available, but unused, power may go unexploited with a simple, fixed division of power as described above.
SUMMARY
Devices and methods for managing power on a module are disclosed herein. In one embodiment, a module comprises a first die; a second die; and a power manager. The power manager monitors the power requirements of the first die and the second die and allocates power to the first die and the second die based on the power requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an embodiment of a module having two processors and a power manager.
FIG. 2 is an embodiment of a method for allocating power between the two processors of FIG. 1 .
DETAILED DESCRIPTION
Referring to FIG. 1 , the devices and methods described herein serve to manage the power available to die located on a module 100 . The die could be any devices or circuits. However, in the embodiments described herein, the die are processors. In the embodiment of FIG. 1 , there are two processors that are referred to individually as the first processor 106 and the second processor 108 . Included in the module 100 is a power manager 110 . It is noted that the power manager 110 may be firmware, an embedded controller or the like that communicates with the processors 106 , 108 . In other embodiments, the power manager 110 may be software or code that is executed on one or both processors 106 , 108 . It is noted that other devices may be located on the module 100 ; however, in order to simplify the drawings, they have not been included.
The module 100 includes two nodes, a first node 112 and a second node 114 , located on the ends of a segment 116 of the module 100 . The segment 116 conducts power to the processors 106 , 108 . In some embodiments, the resistance of the segment 116 is known. Voltages are measured at the first node 112 and the second node 114 . Therefore, the current drawn by the module 100 by way of the node 112 may be readily calculated.
A power supply 130 is connectable to the module 100 at the node 112 . The amount of current being drawn from the power supply 130 may be measured by way of the difference in voltage at the nodes 112 and 114 divided by the resistance of the segment 116 . The power supply 130 may be able to only supply a limited amount of power or current to the module 100 . Thus, the available power needs to be allocated between the two processors 106 , 108 , which is described in detail below.
As described in greater detail below, the power consumption of a processor is proportional to the frequency at which the processor operates. Thus, a processor operating at a high frequency consumes more power than when it operates at a low frequency. The devices and methods described herein serve to optimize the performance of the processors 106 , 108 by allocating power in such a way as to enable both processors 106 , 108 to operate at the highest frequencies possible.
Conventional modules simply divide the power between the die or processors on a circuit. Other modules fix the power allocation between the die, which does not provide for changes in the power allocation. This allocation of power does not provide for one die or processor to draw more power when other die or processors are inactive and not drawing their power allocations. The devices and methods described herein overcome this problem by allocating power among die depending on the required current draw of the die.
The power manager 110 serves to allocate power between the processors 106 , 108 . The amount of power used by a processor is proportional to the frequency at which the processor operates. A processor operating at a high frequency draws more power than when it operates at a low frequency. High frequency operation is required in order for a processor to quickly execute instructions. Likewise, when the processor executes fewer instructions or is idle, its operating frequency is reduced.
In conventional modules, the power allocated to each die or processor is fixed. For example, each processor may be allocated fifty percent of the available power regardless of the frequency at which the processors are operating. This leads to situations wherein a first processor may be idle and not using all of its allocation of power. A second processor may be executing a plurality of instructions and may be able to increase the execution speed by increasing its operating frequency. Because of the fixed power allocation, the second processor is unable to increase its operating frequency beyond the frequency corresponding to the fixed power allocation.
The methods and devices described herein overcome the above-described problems associated with fixed power allocations. In summary, the processors 106 , 108 indicate their processing requirements to the power manager 110 , which monitors the power consumption of the entire module 100 . The power manager 110 may then enable the processors 106 , 108 to change their operating frequencies depending on the available power. As an example, the total power available to the module 100 may be one hundred watts. The power manager 110 may, by default, allocate fifty watts to each processor. At one point, the first processor 106 may be relatively idle and may only use thirty watts during this idle period. Accordingly, the first processor 106 is operating at its optimal performance using only thirty watts. The second processor 108 may be executing a lot of code and may be operating at the frequency limit for its fifty watt allocation. Accordingly, the second processor 108 is not operating optimally, but it could operate optimally if it could increase its operating frequency. In order to increase the operating frequency of the second processor 108 , the power manager 110 may allocate power that would otherwise be used by the first processor 106 to the second processor 108 . The second processor 108 may then increase its frequency to correspond to the increased available power.
The operating frequency of the first processor 106 is then limited because some of its power has been allocated to the second processor 108 . Should the first processor 106 need to increase its operating frequency, it will have to do so by way of the power manager 110 . For example, the first processor 106 may send a signal or the like to the power manager 110 indicating that it needs to increase its operating frequency and, thus, needs to use more power. The power manager 110 may then instruct the second processor 108 to reduce its power consumption or operating frequency so that power may be allocated to the first processor 106 . The power allocation will shift between the processors 106 , 108 until both processors are operating at the same fraction of optimal performance. This fraction of optimal performance is sometimes referred to as optimability. It is noted that optimal performance is achieved when a processor is able to operate with the need to increase its operating frequency.
With regard to the previous example, the first processor 106 may be operating at one hundred percent of optimal performance even when it only uses thirty watts of power consumption because there is no need to run faster. The second processor 108 will be operating at less than one hundred percent performance even when it consumes fifty watts because it has a very active application running. It becomes the job of the power manager to balance the performance of both processors 106 , 108 by allocating power between the processors 106 , 108 until their performances equal. This will result in active processors receiving more power and running at higher frequencies than inactive processors.
Performance optimality can be calculated in different ways. In one embodiment, performance optimality is calculated by dividing the desired operating frequency of a processor by the actual operating frequency of the processor. The desired frequency could be up to one hundred percent of the maximum frequency the processor can achieve. It is likely that the power consumed by a processor operating at maximum frequency would be considerably larger than one half of the power available to the module 100 . Thus, if both processors 106 , 108 want to achieve maximum frequency due to a high workload, they will both be limited to the same fraction of that maximum. Their performance optimality will be less than one hundred percent each, but the performance optimality may be the same for both processors 106 , 108 .
Similarly if the first processor 106 is idle and the second processor 108 wants to operate at its maximum frequency, the second processor 108 will receive power from the power manager 110 until that maximum frequency is achieved. In this situation, the performance optimality of both processors is equal to 1.0 or one hundred percent.
It should be noted that other power allocation defaults may be assigned to the processors 106 , 108 . For example, if both processors 106 , 108 are required to operate at high frequencies, the power manager 110 may allocate power on a fixed allocations, such as sixty percent to one processor and forty percent to the other processor depending on what is performance optimal. It should also be noted that his approach makes the power management independent of the exact power used by each processor. Sometimes manufacturing differences will result in the same processor design consuming significantly different power for the same workload and frequency. By only communicating performance optimality (not power) to the power manager, these manufacturing differences are normalized out A flow chart 200 illustrating an embodiment of a method of allocating power between the two processors 106 , 108 is shown in FIG. 2 . At block 202 , the socket power is determined. This is the power that is available to the module 100 by way of the power supply 130 . At decision block 204 a determination is made as to whether the first processor 106 is operating at its optimal frequency.
If the first processor 106 is operating at optimal performance, processing proceeds to block 208 . Block 208 sends an indication to the power manager 110 that the first processor 106 is operating optimally. In other words, the first processor 106 does not need to increase its operating frequency and, thus, does not need to consume more power. Processing proceeds to block 210 where the power consumption of the first processor 106 is noted to the power manager 110 . This enables to the power manager 110 to reallocate power if necessary.
Referring again to decision block 204 , if the decision of decision block 204 is negative, processing proceeds to decision block 212 . Decision block 212 determines if there is power available to be allocated to the second processor 208 . If power is available, processing proceeds to block 214 where the power allocation to the first processor 106 is increased. This situation may occur when the second processor 108 is not operating at a high frequency and, thus, is not consuming a high amount of power. At block 216 , the increased power allotment to the first processor 106 is noted, which serves to track the power allocation between the processors 106 , 108 .
If the outcome of decision block 212 is negative, meaning that no more power is available for the first processor 106 , processing proceeds to block 220 . The negative result of block 212 indicates that, according to the power manager 110 , there is no available power from the power source 110 and the second processor 108 is using all of its allocated power.
Processing then proceeds to decision block 224 where a determination is made as to whether the second processor 108 has been allocated more power than the first processor 108 . If both processors 106 , 108 need to increase their performance, the power manager 110 may allocate equal power to both processors. If the decision of block 224 indicates that the second processor 108 has not been allocated more power than the first processor 106 , no further action is taken.
If the decision of decision block 224 indicates that the second processor 108 has been allocated more power than the first processor 106 , processing proceeds to block 226 . Block 226 decreases the power allocated to the second processor 108 in order to transfer the power to the first processor 106 . This reallocation of power may continue until both the first processor 106 and the second processor 108 have been allocated the same amount of power.
It is noted that if the processors 106 , 108 have been allocated the same amount of power and the first processor 106 still needs power, the request for more power from the first processor 106 may stay in the power manager 110 . The power manager 110 may continuously query the second processor 108 to determine if it may operate at a reduced frequency, which requires less power. If so, the power manager 110 may reduce the power allocation to the second processor 110 and allocate the power to the first processor 106 .
As set forth above, the devices and methods described herein serve to efficiently allocate the available power between die on a module. The result increases the operating frequency of a die on the module without diminishing the performance of other die located on the module. | Devices and methods for managing power on a module are disclosed herein. In one embodiment, a module comprises a first die; a second die; and a power manager. The power manager monitors the power requirements of the first die and the second die and allocates power to the first die and the second die based on the power requirements. | 6 |
FIELD OF THE INVENTION
The invention relates to an inductive component with a coil body which features a coil space delimited by an exterior flange and a winding tube, which features contact strips molded onto the exterior flange, and which has contact elements and wire guide slots which progress into the contact strips.
BACKGROUND
A coil of this nature is essentially known from European Patent Specification EP 0 594 031. These inductive components, primarily in the form of coils or repeaters, also featuring subdivided coil spaces, must satisfy elevated demands for surge voltage resistance and creep resistance. During the assembly of circuit boards with other electronic components, voltages of 200 V or more can occur between the coils. Consequently, it is necessary to wrap the coil body in such a way that buckling and bending stress exerted on the coil wire is as low as possible and that the coil itself is as uniform as possible. A uniform coil structure can also be necessary to satisfy electrical specifications for inductance. The relevant standards, such as EN60950 which applies to telecommunications applications and calls for creep resistance, must be observed in the respective specific applications of such coils or repeaters.
The coil ends, which must be connected to the contact elements, can be guided in the contact strips through wire guide slots. In practice, the first and each successive coil is attached to the inner surface of the flange with adhesive tape (barrier tape) and separated from the respective adjacent coil, so as to ensure creep resistance between the core and the first coil, on the one hand, and among the coils themselves, on the other hand. However, tension is exerted on the first coil and/or the inner coils as soon as the second coil and each ensuing coil is applied during production of the inductive component.
SUMMARY
Therefore, the object of the invention is to specify an inductive component of the type mentioned initially, but with improved properties.
In the invention, this object is solved by the features of claim 1 . Embodiments of the invention are characterized in subclaims.
An advantage of the invention is that the segment of the wire of the first coil that progresses away from the winding tube and toward the contact elements and/or the take-up pins of the contact elements has no or only minor frictional contact with the second or higher coil, thus resulting in lower tensile stress on the coil wire. This applies analogously to the ensuing coils, i.e., to the second coil when the third is applied, etc., if more than two coils are provided. The greatest advantage, however, arises with the first, innermost coil, because the distance between it and the contact strip is greatest.
Another advantage comprises the fact that the accuracy of the coiling process is increased during production of the component.
Advantageously, the barrier tape can be easily and securely applied laterally to the inside of an exterior flange because the coiling wire in this region is, for the most part, disposed in the wire guide slot and is at best only slightly disposed on the inside of the exterior flange.
Another advantage of the invention comprises the fact that, due to the progression of the terminal portion of the coil wire within the wire guide slots, the homogeneity of the layer structure of the coils is significantly improved, especially in higher coil layers. This makes it possible to design the inductive component as a surface-mountable component and, due to the homogeneous coil structure, to automate the configuration process (pick and place). At the same time, the coiling process of the inductive component can be managed in an accurately controlled manner.
An advantage of the invention comprises the fact that, because of the low buckling and bending stress exerted on the coil wire in the connection zones and because of the fact that the wire is guided through the wire guide slots, the surge voltage resistance and creep resistance of the component are improved.
In the following, the invention is explained in greater detail on the basis of four figures, in which identical elements are identified with the same reference numbers. Shown are in
DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically, an exploded view of a coil body according to the invention,
FIG. 2, a section through the coil body perpendicular to the axis of the winding tube,
FIG. 3, another schematic exploded view of the coil body according to the invention,
FIG. 4, schematic cross-sections of various forms of wire guide slots, and
FIG. 5, a schematic view through a terminal portion of the coil wire
DETAILED DESCRIPTION
A surface-mountable inductive element is depicted in the exemplary embodiment of FIG. 1 . According to FIG. 1, in which elements of the component, in the interest of symmetry and to improve comprehensibility, reference numbers are provided on only one side of the winding tube. An exploded view of the component is depicted as viewed from below, i.e., the view of the base to be attached to a circuit board at a later point. The inductive component is, in particular, a coil or a repeater, and can also comprise subdivisions of the coil space.
The coil body 10 features a coil space, which, in the exemplary embodiment, is not subdivided. The coil space is defined by a winding tube 11 , which, in the exemplary embodiment, is virtually ellipsoid, although it can also possess a different cross-sectional shape, such as circular. The coil space and/or the winding tube is laterally delimited by exterior flanges 12 a , 12 b . Contact strips 13 a , 13 b are molded in one piece to the exterior flanges 12 a , 12 b . Each of the contact strips contains contact elements which, in the exemplary embodiment, are rod-shaped and, at one end, are connected to the ends of the coils by take-up pins 14 ′ a to 14 ′ h and, at the other end, can be connected to corresponding contact surfaces through circuit board pins 14 a to 14 h , such as on a printed circuit board.
Of course, the contact strips can also have other forms of connecting elements, such as those known in the art for surface-mountable components. The geometry of the electric connecting elements of the coil body is largely independent of the design of the wire guide slots.
The parts of the contact elements protruding from the underside of the contact strips, the circuit board pins, are shaped such that the connecting contact portions of the contact elements are bent and flattened. The flattened undersides of the circuit board pins are disposed to be coplanar, so that the component can be easily placed onto a printed circuit board and soldered. In the exemplary embodiment, these areas are disposed in a plane that progresses in parallel to the axis A (see FIG. 2) of the winding tube.
To facilitate bonding of the coil, the contact elements are guided within the contact strips such that a second of each contact element, the take-up pin, protrudes laterally from the coil body. These ends of the contact elements, which are provided for coil bonding purposes, are also disposed essentially in a plane parallel to the axis of the winding tube. This embodiment of the contact elements also offers the opportunity to gain access to the coil connections, even if the component is soldered to a circuit board. However, the component can also be designed with push-through contact elements or other geometric configurations of the contact elements.
On each side of the coil space, several wire guide slots are disposed between the contact elements. In the exemplary embodiment, the wire guide slots 15 , 16 and 17 between the contact elements 14 a to 14 d —or corresponding wire guide slots on the other side of the coil space—are disposed on the undersides of the contact strips at right angles to the longitudinal axis of the contact strips of the coil body.
The wire guide slots, which initially progress within the contact strips essentially in parallel to the axis A of the winding tube, then bend in the direction of the coil space and the winding tube. “In the direction of” signifies that the depth of the respective wire guide slot is reduced toward the winding tube, and finally turns to zero on the inside of the exterior flange. In the exemplary embodiment, the bending point is so far from the inner edge of the contact strips or the inside of the exterior flange as to result in a slanted area, which can completely enclose the coil wire disposed therein without requiring that the wire be bent excessively at the bending point of the wire guide slot.
Instead of a comparatively strong bend, as shown in FIG. 1 and illustrated again schematically in FIG. 4 a as a step through a contact strip, other geometric forms of the progression of the wire guide slot on the side facing the inside of the exterior flanges can be provided. The cross-section of the wire guide slot in FIG. 4 b is continuously bent or curved, while FIG. 4 c shows a continuous diagonal of the cross-section relative to the axis of the winding tube 11 . In FIG. 4 c , the exterior flange 12 is thickened in the area of the transition to the contact strip 13 at the level of the wire guide slot, identified by reference number 24 . The geometric dimensions are designed so as to ensure that there are no sharp edges that could damage the insulation of the wire coil to be applied.
In FIG. 1, the slanted segment 18 and 20 of each wire guide slot —or corresponding areas on the other side of the coil space—, as is evident in FIG. 2 or FIG. 4, feeds into the inside of the respective exterior flange in proximity to the winding tube 11 , while the corresponding segments 19 of the central wire guide slot feed into the coil space while still in the area of the contact strip (see FIG. 2 ). This means that, since a rectangular cross-section of the wire guide slot was selected in the exemplary embodiment, the wire guide slots feed into the exterior region of the coil body with one corner contacting or immediately adjacent to the winding tube, e.g., at a distance from it of less than the width of one slot. Other cross-sections and courses of the wire guide slots are possible, such as a trapezoid or oval cross-section. Moreover, the external wire guide slots 15 , 17 must not be symmetrical to the wire guide slot 16 . Only the centrally disposed wire guide slot 16 feeds with essentially its entire cross-sectional width into the winding tube. This also means that the inside surfaces of the exterior wire guide slots can connect to the winding tube tangentially at best or that they are advantageously oriented toward the winding tube. If necessary, the longitudinal direction of the areas 18 and 20 can, instead of being parallel to the axis A of the winding tube, progress at an angle to it or, in extreme cases, directly toward it.
The necessary number of wire guide slots depends on the number of contact elements and, at each contact strip, is reduced by one relative to the contact elements.
According to the invention, the slanted areas 18 and 20 of the wire guide slots no longer progress exclusively in the contact strips, but at least partially in the exterior flanges. To prevent excessive weakening of the material of the exterior flanges in the area of the wire guide slots progressing in the direction of the winding tube, it can be provided that the exterior flanges are additionally reinforced, at least in the area outside the coil space, as schematically in FIG. 3 and FIG. 4 c . In this case, the exterior flanges feature, in the area of transition to the contact strips, a base reinforcement 23 , 24 that tapers in the direction of the axis of the winding tube. This reinforcement also makes it possible to essentially guarantee greater stability between the exterior flanges and the contact strips. In small components, this has a positive impact on the coplanar relationship between the contact element connection areas and the circuit board. Conversely, this significantly reduces the risk of a predetermined breaking point between the exterior flange and the contact strip.
Due to the slanted design of the wire guide slots in the inside portion of the exterior flanges, it is possible to already connect the connecting portion of the lowest coil with the take-up pins, even if soldering has not yet taken place. In this case, the wire connecting portion is disposed essentially within the wire guide slot reaches the coil space almost directly at the winding tube, such that it is at best only slightly disposed on the exterior flanges at right angles to the coiling direction. This is indicated schematically in FIG. 5, wherein coils W 1 and W 2 are provided, each fastened to the exterior flange 12 with barrier tape B 1 or B 2 and insulated against one another with an insulating layer I 1 .
Because the wire connector for the coil W 1 is essentially disposed in the wire guide slot, the second or ensuing coils can exert no or only reduced tension on the lowermost coil W 1 , thereby producing the additional effect of removing stress on the wire connector. This also makes it possible to provide the coils with a highly homogeneous structure, since the wire connectors do not cause any significant bulges in the coil part. As a result of this homogeneous coil, it becomes possible to make a surface-mountable component “pick-and-place”-able, i.e., to enable this component to be picked up by a suction gripper and placed onto the circuit board.
Depending on whether the slanted portions of the wire guide slots are disposed closer to the center or the outer zones of the coil space, these slanted or ramp-shaped portions 18 , 19 , 20 have different lengths and different angles of incline, since this is the only means of ensuring that the slanted portions can run into the respective inside of the exterior flange in proximity to the winding tube.
The figures also depict undercuts 21 a , 21 b in the contact strips, to which, for example, a lid to be placed over the component can be secured. The lid is preferably made from an elastic material and features indentations along the edges of its rim which can engage the undercuts 21 .
In the exemplary embodiment, pins 22 a , 22 b are also provided on the contact strips on the undersides of the inductive component, with said pins being used to help position the component on the circuit board. This, however, is a purely optional embodiment, since the component is also serviceable without the pins. | An inductive component includes a coil body having an exterior flange and a winding tube, a contact strip on the exterior flange, the contact strip having contact elements, and a wire guide slot formed into the contact strip. In a first region, the wire guide slot is substantially perpendicular to the exterior flange. In a second region, the wire guide slot is angled toward the winding tube relative to the first region. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 13/507,051, filed May 31, 2012, which is incorporated herein by reference.
[0002] This application is also related to U.S. patent application Ser. No. 12/925,354 filed Oct. 19, 2010 which claims the benefit of and priority to U.S. Provisional Application Ser. No. 61/281,314 filed Nov. 16, 2009 under 35 U.S.C, §§119, 120, 363, 365, and 37 C.F.R. §1.55 and §1.78 each of which is incorporated herein by this reference. This application is also related to U.S. patent application Ser. No. 13/385,486 filed Feb. 22, 2012, and incorporated herein by this reference.
FIELD OF THE INVENTION
[0003] The subject invention relates to vehicle underbody blast effects and ballistic damage mitigation.
BACKGROUND OF THE INVENTION
[0004] Mines and improvised explosive devices (IEDs) can damage vehicles and injure or kill vehicle occupants. Some work has been carried out to detect and disable mines and IEDs. Other engineering concerns tailoring vehicles to be more resistant to the blast of a mine or IED. Examples include the V-hull of the MRAP and STRYKER vehicles designed to deflect away a part of the explosive forces originating below the vehicle. See for example, published U.S. Patent Application Nos. 2011/0169240 and 2011/0148147, incorporated herein by this reference.
[0005] There is a limit, though, to how much of the explosive blast can be deflected. And, some vehicles cannot be engineered to include a V-hull. Still other vehicles cannot be equipped with heavy armor. The military HMMWV vehicle, for example, is and must remain configured to quickly traverse difficult terrain.
SUMMARY OF THE INVENTION
[0006] In examples of this invention, a lightweight effective blast shield is designed for use as a vehicle (e.g., underbody) design or as an attachment kit for blast mitigation due to a land mine or IED explosion. The shield is designed to partially deflect away the pressure wave of a blast and/or absorb a significant part of the blast energy by use of mechanisms and a phase changing material. Structures herein may be used to absorb impulses, energy, and/or blasts may be protected in the same way.
[0007] The invention features a blast mitigation method of forming a body of solid material which transitions from a solid state to a viscous fluid state when stressed which attaches to the body of the undercarriage of a vehicle. The material of the body transitions from a solid state to a viscous fluid state when an explosion occurs proximate the body and absorbs at least some energy from the explosion mitigating its impact on the vehicle. Further included may be the step of disposing a plunger plate with blades extending outwardly therefrom adjacent the body and oriented such that the blades are adjacent the body. The method may further include adding, to the undercarriage of the vehicle, a second body and disposing a plunger plate between the bodies.
[0008] Further featured is a method of equipping a vehicle with a blast shield, the method including placing a body of damping material proximate a vehicle undercarriage, the body of damping material transitioning from a solid state to a viscous fluid state when stressed, positioning a plunger plate with outwardly extending blades proximate the body of damping material with the plunger plate blades adjacent said body of damping material, and securing the combination of the body of damping material and plunger plate to the vehicle undercarriage for blast protection. If the vehicle includes an installed hull plate, the body of damping material and plunger plate can be secured to the vehicle hull plate. In another method, the vehicle hull plate is removed. Then, the body of damping material is sandwiched between a blast shield hull plate and the plunger plate and this combination of the blast shield hull plate, body of damping material, and plunger plate is secured to the vehicle undercarriage in place of the vehicle hull plate.
[0009] The subject invention, however. in other embodiments, need not achieve all these objectives and the claims hereof should not be limited to structures or methods capable of achieving these objectives.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] Other objects, features and advantages will occur to those skilled in the art from the following description of a preferred embodiment and the accompanying drawings, in which:
[0011] FIG. 1 is a schematic three dimensional view showing the undercarriage of a military vehicle equipped or fitted with a blast shield in accordance with an example of the invention;
[0012] FIG. 2 is a schematic exploded front view showing the primary components associated with one example of a blast shield of the invention;
[0013] FIG. 3 is a schematic cross sectional view of the shield of FIG. 1 positioned under a vehicle hull using a frame in accordance with examples of the invention;
[0014] FIG. 4 is a schematic exploded three dimensional front view showing another example of a blast shield in accordance with the invention;
[0015] FIG. 5 is a schematic three dimensional top view showing a plunger plate in accordance with examples of the invention;
[0016] FIG. 6 is a schematic exploded three dimensional view showing another example of a blast shield in accordance with the invention;
[0017] FIGS. 7-8 are schematic views of truncated V-hull blast shields;
[0018] FIG. 9 is a schematic three dimensional view showing the undercarriage of a particular military vehicle;
[0019] FIG. 10 is a schematic exploded view of an example of a blast shield in accordance with the invention which may be used with the vehicle shown in FIG. 9 and/or other vehicles;
[0020] FIG. 11 is a schematic exploded view of an example of a side mount blast shield similar in construction to the blast shield of FIG. 10 ;
[0021] FIG. 12 is a schematic exploded view showing another configuration of a blast shield in accordance with the invention;
[0022] FIG. 13 is a schematic exploded view showing the underside of the blast shield hull plate of FIG. 12 ;
[0023] FIG. 14 is a schematic exploded view showing a side mounted version of the blast shield of FIGS. 12 and 13 ;
[0024] FIG. 15 is a schematic exploded view showing another example of a blast shield in accordance with the invention; and
[0025] FIG. 16 is a schematic exploded view of an example of a V-hull blast shield.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Aside from the preferred embodiment or embodiments disclosed below, this invention is capable of other embodiments and of being practiced or being carried out in various ways. Thus, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Moreover, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.
[0027] FIG. 1 shows military vehicle 12 equipped with shield 14 including, in this particular example, frame 16 bolted to the undercarriage “hull” of the vehicle. FIG. 2 shows one version (without the frame) where vehicle hull or a hull plate is depicted at 18 . First body 20 abuts hull 18 and here is a slab of ultra high molecular weight polyethylene (UHIVIW-PE) material which transitions from a solid state to a viscous fluid state when sufficiently stressed. First body 20 could, in other embodiments, include plies of UHMW-PE material and/or be divided into sections. A plunger plate 22 may be provided and is preferably made of metal with concentric blades 24 a - 24 d abutting the bottom surface of slab 20 in this design. The concentric blades 24 a - 24 d may be configured in square, rectangular, circular, and elliptic or any other geometric pattern on the plunger plate 22 . The blades could be adjacent: e.g., touching or closely spaced to slab 20 or even partially within body 20 . Other extruded sections may also be used. See also FIG. 5 . Second body 25 , FIGS. 2-3 may be also included, in this example, abutting the bottom of plate 22 . Body 25 may be a one to three inch thick slab of UHMW-PE material which transitions from a solid state to a viscous fluid state when stressed. Or, body 25 could be a metal plate or a so-called “hard plate”. Such a kit could include blast shield hull plate 18 to replace an existing factory installed hull plate or the various layer(s) could be fastened to the existing vehicle hull plate.
[0028] When vehicle 12 , FIG. 1 equipped with such an undercarriage shield drives over a mine or IED which explodes, body 25 . FIG. 2 primarily functions to absorb energy from the blast caused by soil impacting the body which in response transitions from a solid state to a viscous fluid state. The UHMW-PE material will blister, crack, and shred and become heavily embedded with soil.
[0029] The combination of plunger plate 22 and body 20 functions to absorb the blast energy as the blades 24 are driven into body 20 and it changes from a solid to a viscous fluid state locally near the blades in response due to the pressure of the blast. Plate 22 may deform slightly and the blades of plate 22 will embed in body 20 and cut or partially cut into body 20 .
[0030] FIG. 3 shows the completed assembly of all components shown in FIG. 2 . When a critical stress magnitude is reached, the UHMW-PE material in bodies 20 and 25 undergoes a phase transition from a solid to a viscous fluid state. This phase transition occurs at or above a critical compressive stress magnitude. Upon impact, plunger blades 24 a - 24 d penetrate into UHMW-PE slab 20 . With an increasing impact force magnitude, the UHMW-PE material undergoes a phase transition at or above the critical stress. As the UHMW-PE material ahead of and adjacent to the plunger blades transitions into a viscous fluid state, the resisting force on the plunger blades drops sharply to a lower value. The plunger blades then continue to move through the material with a gradual further rise in force magnitude until a significant amount of the impact energy is absorbed.
[0031] Considering the complete assembly of the blast/impact mitigation shield fitted to the underbody of a vehicle, schematically shown in FIG. 3 , the physics of the blast effects mitigation my be explained as follows.
[0032] When a land-mine or and TED buried at certain depth in soil is detonated under a vehicle, first the mass of soil above the mine or IED strikes the bottom surface of the UHMW-PE body 25 with extremely high velocity. This extremely high momentum of soil is almost immediately reduced to a much smaller magnitude as the soil mass impinges on the UHMW-PE body 25 . The resulting normal force is of such high magnitude that in all areas of soil impingements the critical stress required for phase transition of UHMW-PE is crossed. The soil mass gets embedded into the phase transitioned viscous material of the UHMW-PE body and in this process a part of the blast energy is absorbed by the body 25 . The ejected soil and the blast pressure, whose magnitude depends on the explosive charge mass contained within the mine/IED and also the standoff, applies an extremely high impact force on the base of plunger plate 22 , which then forces most of the plunger blades to penetrate into the UHMW-PE body 20 . The resulting stress magnitudes in the UHMW-PE material in front of and surrounding the blades exceed the critical compressive stress magnitude for phase transition of UHMW-PE material. The blades of plunger plate 22 therefore penetrate into the locally transformed viscous material of UHMW-PE body 20 , which is supported against the application of normal force by the hull or the armor plate 18 of the vehicle. The work done in this process of plunger plate 22 displacement against the resistance offered to penetration of blades by the UHMW-PE body 20 is quite significant and this accounts for a large amount of blast energy absorption/dissipation. The remaining blast energy would cause the vehicle to be thrown up in the air. The height of throw depends on the remaining energy available following significant amount of energy absorbed by the blast/impact mitigation shield.
[0033] The blast/impact mitigation shield therefore reduces the net vertical upward force experienced by the vehicle and its occupants. This results in relatively lower magnitude of vertical acceleration, which can be designed to remain within a certain tolerance level for a specific threat of blast impulse.
[0034] The reduction in upward vertical acceleration of a vehicle fitted with a blast/impact mitigation shield following an underbody mine/IED blast can also be explained considering the rate of change of momentum. While a vehicle with only an armor plate used as underbody hull experiences a huge change in momentum within an extremely short time interval, the same vehicle, if fitted with a blast/impact mitigation shield, will take considerably longer time interval for the change of momentum due to the work done by the plunger plate 22 on the UHMW-PE body 20 . The force magnitude being proportional to the rate of change of momentum will be smaller for the latter case and so also the magnitude of vertical acceleration.
[0035] The preferred phase change material has an extremely high heat of fusion (145-195 J/g), and thus it requires significant amount of energy to transition it from a solid to a non-flowing viscous liquid state. In so doing, a significant amount of impact energy is dissipated. A material exhibiting a heat of fusion of greater than 190 J/g and a molecular weight of greater than 3.5 million is preferred. But, a heat of fusion greater than about 120 Joules per gram (J/g) may be acceptable. The percent crystallinity should preferably be greater than 10.
[0036] The molecular weight, specific heat of fusion and percent crystallinity of the UHMW-PE material stated above are preferred values. However, other polymer materials such as high density polyethylene (HDPE) and other polyethylene exhibiting similar phase transition behavior above a certain critical compression stress, but having smaller values of the above physical parameters can be used for this application.
[0037] In the example of FIG. 4 . second body 25 of FIG. 2 is not used. Instead, plate 22 abuts body 20 and body 20 abuts the hull or an armor plate under the vehicle 18 . Again, a frame may be used. In one test of this configuration, conducted using a blast test fixture weighing 17,500 pounds, three one inch thick plies of UHMW-PE material were placed between a one-quarter inch simulated hull plate 18 and plunger plate 22 as shown in FIG. 5 . 7.27 lbs. of composition C4 explosive 8″ in diameter and 2 ¼″ tall in a 24″ diameter cylinder was buried with 4″ of soil (50% sand, 50% clay, 12% moisture content). The standoff between plate 22 and the soil was 15.25 inches.
[0038] Upon detonation of the C4 explosive, blades 24 a - 24 d cut thorough the first layer of body 20 but only partially embedded in the second layer of body 20 . The third layer was unaffected. One-half inch thick metal plunger plate 22 was permanently deformed 1.3″ and hull 18 was deformed 2.9″.
[0039] FIG. 6 shows an option where plunger plate 22 abuts hull 18 and blades of plate 22 face the top of UHMW-PE body 20 . Another stiff plate may be used below the UHMW-PE body 20 (not shown in FIG. 6 ).
[0040] In still another example, under carriage shield 14 , FIG. 1 is one or more plies and/or one or more sections of UHMW-PE or similar material without a plunger plate. Frame 16 is also optional.
[0041] Six 1″ layers were bolted to a ¾″ thick rolled homogeneous armor (RHA) steel test “hull” and tested as in the example above. At a 9.25″ standoff, the hull plate was permanently deformed by 2 ⅞″. The bottom most layer of UHMW-PE material was blistered, cracked, and shredded (heavily soil embedded). The second layer of UHMW-PE material was only marginally affected and was intact, somewhat discolored since it was somewhat exposed to this soil blast. The third through sixth layers of UHMW-PE material were unaffected. With a 15.25″ standoff using four layers of 1″ thick UHMW PE material, the hull plate deformed by 4″. The lowest most UHMW-PE layer was intact but imbedded with soil. The second through fourth layers were unaffected.
[0042] Examples of the invention provide a new type of blast or impact energy absorption that utilize a novel design and unique elastic-plastic deformation behavior of ultra high molecular weight (UHMW) polyethylene or similar materials. They unexpectedly exhibit rapid absorption of kinetic energy and reduce blast force magnitude through an energy absorption process and in causing slight delay in the rate of change of momentum during an impact or blast event. The UHMW-PE material undergoes a reverse phase transition back to solid state when the stress level drops below the critical value following the impact or blast event. It dissipates the absorbed energy by way of expansion through solidification and also in doing work by partially pushing back the plunger or plunger blades. See also U.S. application Ser. No. 13/385,486 file Feb. 22, 2012 incorporated herein by this reference.
[0043] Featured is a blast mitigation shield comprising damping material in a solid state and which transitions from a solid to a viscous fluid state when stressed in compression above a critical stress, for example due to a blast event. A plunger plate includes blades positioned in or adjacent to the damping material to be driven into the damping material when impacted by a blast event transitioning the damping material to a viscous fluid state absorbing the impact. In other examples, the system described herein is configured as a drop platform. The “hull” described herein is thus the primary surface of the drop platform.
[0044] Blast or impact shields in accordance with the examples of the invention include one or more bodies of damping material in a solid state and which transition from a solid to a viscous fluid state when stressed in compression. Examples of the material include ultra high molecular weight polyethylene, high density polyethylene (HDPE), and equivalents thereof. A constraining frame is optional. If used, the plunger plate may include extended blades which may terminate in pointed knife portions positioned at or closely adjacent to the damping material. When the plunger plate is impacted by a blast event or an impact event, the blades are driven into the damping material transitioning it locally near the blades from a solid to a viscous fluid state absorbing the energy of the blast or the impact through work done by the plunger blades. For an airdrop platform, the damping material and/or plunger blades may be secured to the bottom of a drop platform, and/or distributed as narrow strips along the perimeter of the bottom surface.
[0045] The blast/impact mitigation shield can be designed for a vehicle having flat bottom hull as schematically shown in FIG. 1 and also for a vehicle having a “V-shaped” hull or a “double V-shaped hull”. FIGS. 7 and 8 schematically show examples of a vehicle underbody truncated V-hull 18 ′ and corresponding truncated V-shaped blast/impact mitigation shield design. The blast/impact mitigation shield can be designed and configured to meet the same objective of blast effect mitigation.
[0046] FIG. 9 depicts a “Mine Resistant Ambush Protected” (MRAP) vehicle with existing hull plate 18 . At the factory or in the field, the blast shield may be attached to hull plate 18 or, alternatively, hull plate 18 could be removed and the blast shield, typically including a replacement blast shield hull plate, could be fastened to the vehicle undercarriage in place of the factory provided hull plate. In other designs, the blast shield extends along most of the undercarriage of the vehicle. In still other designs, the blast shield is disposed inside the vehicle, on the vehicle floor or deck for example.
[0047] FIG. 10 shows a truncated-V configured blast shield assembly including ⅜″ steel plunger plate 30 with blades 32 (1 ½″ tall and 3/16″ thick). In other designs, the blades are post-like structures, pyramid shaped, for example. In this example, UHMW-PE body 34 is divided into sections 34 a, 34 b, 34 c and 34 d 1 ¾″ to 2″ thick to conform to the contours of both plunger plate 30 and hull plate 36 . Each section could include multiple plies. In other examples, a monolith sheet or sheets are used and they are shaped to conform to plunger plate 30 . In this particular example, hull plate 36 is also a truncated-V shaped metal plate ⅜″ thick with stiffener members 38 a and 38 b. UHMW-PE strips 40 a and 40 b reside on the top of hull plate 36 . Typically, fasteners are used to secure plunger plate 30 to both UHMW-PE body 34 and hull plate 36 . Hull plate 36 then includes bolting rails 37 a and 37 b for mounting the sandwich assembly to the bottom of the vehicle or even to the existing factory installed hull plate, armor, or the like. Plunger plate 30 in this particular embodiment utilizes both longitudinal and transverse blades in the pattern shown which penetrate body section 34 a - 34 d. The longitudinal and transverse blades also act to stiffen blast plate 30 and transfer the blast forces over a greater effective area for larger penetration of the UHMW-PE 34 a - 34 d to maximize the absorption of energy.
[0048] In other examples, hull plate 36 and plunger plate 30 have a V-shaped, or flat, or conforming shape to fit a particular vehicle undercarriage.
[0049] FIG. 10 shows a bottom mount configuration while FIG. 11 shows a side mount configuration where plunger plate 30 now includes side plates 50 a and 50 b and hull plate 36 includes corresponding side plates 52 a and 52 b. Hull plate side plates 52 a and 52 b can be fastened to the vehicle undercarriage.
[0050] FIGS. 12-13 show a design where plunger plate blades 32 ′ are formed of metal angle or triangle shaped members. UHMW-PE body 34 ′ has sections 34 a′, 34 b′, 34 c′ and 34 d′ (3 inches thick) with grooves 60 formed in the underside thereof corresponding to blades 32 ′ of plunger plate 30 ′ so the blades thereof are received in the grooves of the UHMW-PE body. This design enables a thinner overall assembly with a thicker body of blast absorbing material resulting in a greater standoff between the blast shield and the ground.
[0051] Hull plate 36 may also include blades 62 on its underside (like a plunger plate) and the top of body 34 ′ may now include grooves 64 receiving blades 62 therein. Blades 62 may also be triangular shaped steel members. Hull plate 36 ′ may further include stiffening member 66 . UHMW-PE strips 40 a and 40 b may also be provided as before. The grooves 64 on the top of body 34 ′ are offset from the grooves 60 on the bottom of body 34 ′. As before, the angled blades 32 ′ and 62 may penetrate and entrap the phase transitioned material of body 34 ′ between the hull and blast plates and partly absorb the energy released by a blast.
[0052] FIG. 14 shows a side mount version of the design of FIGS. 12-13 wherein plunger plate 30 ″ includes side plates 70 a and 70 b and hull plate 36 ″ includes side plates 72 a and 72 b. In some designs, plunger plate 30 ″ includes blades and/or hull plate 36 ″ includes blades. Depending on the specific design, absorbing body 34 ′ may include top and/or bottom grooves.
[0053] FIG. 15 shows another possible design with plunger plate 30 ″″ having blades 32 ″, UHMW-PE body sections 34 a″ - 34 d″, 0.25 inch hull plate 36 ″, and strips 40 a and 40 b. Here, the bottom of body sections 34 ″ may be smooth. Grooves 64 ′ in the top surface of the body sections correspond to blades (e.g., blade 62 ) extending downwardly from the bottom of hull plate 36 ′″. It is also possible for body sections 34 ″ to have grooves on the bottom surface thereof receiving the blades of plunger plate 30 ″. A side mount version of this design is also possible. FIG. 16 shows a V-hull design with plunger plate 30 iv , body section 34 a′″ and 34 b′″, and hull plate 36 iv .
[0054] Thus, although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments.
[0055] In addition, any amendment presented during the prosecution of the patent application for this patent is not a disclaimer of any claim element presented in the application as filed: those skilled in the art cannot reasonably be expected to draft a claim that would literally encompass all possible equivalents, many equivalents will be unforeseeable at the time of the amendment and are beyond a fair interpretation of what is to be surrendered (if anything), the rationale underlying the amendment may bear no more than a tangential relation to many equivalents, and/or there are many other reasons the applicant can not be expected to describe certain insubstantial substitutes for any claim element amended.
[0056] Other embodiments will occur to those skilled in the art and are within the following claims. | A blast mitigation method includes forming a body of solid material which transitions from a solid state to a non-flowing viscous fluid state when stressed which attaching it to the body of the undercarriage of a vehicle. The material of the body transitions from a solid state to a viscous fluid, state when an explosion occurs, is proximate the body and it absorbs at least some energy from the explosion mitigating impact on the vehicle. A plunger plate with blades extending outwardly therefrom is coupled to the body and oriented such that the blades are adjacent the body. | 5 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority from pending provisional patent application No. 61/139,503 filed Dec. 19, 2008, the disclosure of which is incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention is directed to a screw connector for earth-moving equipment and the like adapted to secure components of the equipment to each other with a screw-nut connection that remains operable in environments involving earth, dirt, abrasives and the like.
Earth-moving equipment, such as power-driven shovels, loaders, scoops, dippers and the like, typically has a bucket, the earth-digging front end of which is normally defined by a generally U-shaped heavy-duty lip that is suitably fastened to the bucket. The lip includes a plurality of digging teeth which project from a front edge of the lip as well as wear plates which line interior surfaces of the lip to protect it from being worn down by earth, coal and the like into which the lip is pushed during earth-moving maneuvers. The teeth mounted to the lip are subject to much wear and require frequent replacement. To accommodate such replacements without requiring undue labor, the teeth are typically removably attached to an adaptor which in turn is secured to the lip.
In the past, wear plates lining the inside of the lip were welded onto the lip so as to not obstruct the rearward movement of earth and the like over the lip into the bucket while preventing the lip per se from being worn down by earth moving across it. Replacing welded-on wear plates from the lip is labor-intensive. First, the welds securing the plates to the lip must be removed and ground down so that a new wear plate can be installed. Next, the plates must be positioned on the lip and then welded onto the lip to securely mount them thereon. This task has to be repeated each time a wear plate must be replaced.
SUMMARY OF THE INVENTION
To overcome disadvantages of prior art power-driven earth-moving equipment connectors for components attached to lips, buckets and the like of the equipment, the present invention provides a unique screw connection defined by a screw cooperating with an appropriately shaped nut. The screw of the connection typically has a tapered shank and a head for rotating the shank about its axis and for engaging a component of an earth moving equipment that is to be attached to another component of the equipment. The screw further has a thread that extends over less than one full rotation or circumference of the screw, that is, that extends over less than 360° and that preferably extends over no more than about a three-quarter turn (270°) of the screw. The thread cross-section tapers over its circumferential length and has a maximum cross-section at a point in the vicinity of the head of the screw. The smallest cross-section of the thread is at the other end of the thread. The nut cooperating with the threaded shaft has a complementary, tapered thread that is configured to receive the tapered thread on the shaft of the screw.
To connect the screw and the nut to each other, typically with one or more components between them, the screw is aligned with the corresponding bore in the nut and rotated three-quarters of a turn. At the beginning of the turn, the relatively small end of the thread at the end of the screw shank remote from the head is loosely received in the much wider thread of the nut. As a result, there is ample space between the threads on the screw shank and in the nut hole through which sand, abrasives and other materials that might become lodged between the opposing threads and interfere with properly securing the screw to the nut can readily drop downwardly and away from the threads so that the screw can be fully rotated through the designated, e.g. three-quarter, turn, thereby firmly securing the parts between the nut and the screw head to each other.
To signal to the operator when the screw has been fully inserted into the nut, e.g. by rotating it through the required three-quarters of a turn, the screw and the nut are preferably provided with visual indicators that signal to the operator whether the required turn of the screw has been completed. For example, the screw may be provided with a laterally extending pin that engages a stop or the like on the nut. Other arrangements for determining the completion of the required turn can of course be used.
Should replacement of one of the parts of the components secured by the screw connection be required, the operator engages the screw head, rotates it in the opening direction, and then withdraws the screw from the threaded nut hole to enable replacement of the part or parts in question. As soon as the screw and the nut have been slightly moved in the opening direction, the threads on them become separated and contaminants that may be present between the opposing threads cannot interfere with fully opening the connection.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a screw and a cooperating nut constructed in accordance with the present invention and provided with respective threads that extend over less than the entire circumference of the screw and the hole and which have cooperating cross-sections that taper from the vicinity of the screw head towards the other end;
FIG. 2 is a perspective view of a screw constructed in accordance with the present invention and to better illustrate the extent and configuration of the thread;
FIG. 3 is a schematic representation of the cross-section of the thread on the screw shown in FIGS. 1 and 2 and shows that the cross-section of the thread is largest in the vicinity of the screw head and is smallest at the thread;
FIG. 4 is a perspective, schematic view of a lip for attachment to a bucket, a shovel and loader or the like and illustrates how wear plates are secured to the lip between tooth supporting adaptors with the improved screw connection of the present invention;
FIG. 5 is a perspective, exploded, side elevational view of portions of a lip, the shroud, the wear plate and the bolts and nuts used to secure them to each other;
FIG. 6 is a cross-sectional view showing the parts illustrated in FIG. 5 in their assembled condition;
FIG. 7 is a perspective view of a screw retainer collar used in connection with the nut and screw illustrated in FIGS. 6 and 7 ;
FIG. 8 is an underneath view of an adapter and an earth digging tooth attached thereto in accordance with the present invention;
FIG. 9 is a side elevational view taken on line 9 of FIG. 8 ;
FIG. 10 is an exploded, perspective view of a connector constructed in accordance with the present invention that is particularly adapted for securing digging teeth to adapters;
FIGS. 11-13 are fragmentary, cross-sectional views which are taken on lines 10 - 10 , 11 - 11 and 12 - 12 , respectively, of FIG. 9 ;
FIG. 14 is a plan view of another embodiment of the present invention and illustrates a tooth secured to an adapter with a horizontally oriented bolt; and
FIGS. 15 and 16 are fragmentary, cross-sectional views which are taken on lines 15 - 15 and 16 - 16 of FIG. 14 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-3 , a screw connection 2 constructed in accordance with the present invention has a screw or threaded bolt 4 and a cooperating nut 6 . Screw 4 has a screw head 8 at its “upper end” and a shaft 10 that extends coaxially away from the head in a “downward” direction, as illustrated in FIG. 1 . The shaft is preferably slightly tapered in a downward direction (away from the screw head) and includes a smooth lower portion 12 and an upper portion 14 over which a three-quarter turn (270°) thread 16 extends from the vicinity of the screw head 8 , e.g. beginning at about and preferably slightly below the lower end of the screw head 8 and extending downwardly at the selected helix angle.
The cross-section of thread 16 and in particular its height is largest at its uppermost end 19 (in the vicinity of the screw head). It gradually and linearly decreases in a downward direction to a thread end point 17 that is typically slightly rounded. FIG. 3 schematically illustrates along a straight line the decreasing cross-section (and therewith also the decreasing axial extent) of the thread from its uppermost point 19 to its lowermost end point 17 . In the preferred embodiment, the periphery of thread 16 also includes a slight downward taper in the axial direction of the shaft 10 , typically at the same angle as the taper of the shaft, although this taper can be dispensed with if desired.
Nut 6 may have a variety of exterior dimensions and configurations to suit particular applications. The nut illustrated in FIG. 1 has a straight portion 18 joined by a semicircular portion 20 and defines a through hole 22 including a thread 24 that is complementarily shaped to thread 16 on screw 8 so that the screw can be threadably received by the thread in nut 6 .
To connect screw 8 to nut 6 , shaft 12 of the screw is axially aligned with hole 22 in base 6 and is then axially advanced through the hole until thread 16 on the screw engages thread 24 on the nut. Rotation of the screw relative to the nut is continued through the entire arc over which the threads extend, in the presently preferred embodiment over an arc of about 270°. To facilitate turning of the screw, screw head 8 includes a non-circular socket, for example a square socket 26 that extends in the axial direction. Other socket configurations or other means for rotating the screw, such as a conventional hexagonal head, for example, can be used.
To signal the operator that he has or has not completed the required three-quarter turn of the screw to firmly engage it with the nut, the screw may be provided with a pin or the like (not shown) which engages an appropriately placed stop in the nut (not shown), or vice versa. So long as the pin does not engage the stop, the operator knows that the screw has not been completely turned, and when the pin is engaged with the stop, the operator is signaled that the required three-quarter turn has been completed and no further turning of the screw is possible.
Due to the decreasing cross-section of thread 16 on screw 8 , there will be play between it and the corresponding thread 24 in nut hole 22 through which loose sand, dirt and the like, if any, can escape to prevent contaminants that may otherwise lodge between the cooperating threads from preventing a complete closure of the screw relative to the nut. Similarly, if, after a period of use, the screw connection 2 must be loosened, a very slight rotational movement of screw 8 relative to nut 6 disengages and separates the thread flanks of the screw and from the thread flanks in the nut. As a result, any contaminants that might have become lodged underneath screw head 8 and/or between the threads during normal use of the thread connection of the present invention are immediately freed and can drop out of the way. Any contaminants that might remain on the threads do not interfere with the opening of the screw because a slight turn of the screw relative to the base immediately separates the thread flanks. As a result, the contaminants no longer are an obstacle to the complete separation of the screw from the nut.
Referring to FIGS. 4-6 , details of connecting various components such as wear plates and shrouds are illustrated in greater detail.
A lip 30 of a power-driven shovel, loader and the like that has a horizontal portion 32 and a front edge 35 . A shroud 40 positioned between adjacent teeth is placed over the front edge of the lip. It has an aperture 58 through which the elongated shaft 10 of a screw 4 constructed as previously described (and shown in FIGS. 1 and 2 ) extends. Aperture 58 is aligned with a corresponding, preferably slightly tapered aperture 60 located proximate front edge 35 of the lip, as is shown in FIG. 6 . The top of aperture 60 has an enlarged recess 62 which receives a nut 6 as shown in FIG. 1 . By virtue of its configuration, nut 6 is non-rotatable inside recess 62 . The shroud has upper and lower legs 64 , 66 and a blind hole 68 in the lower leg that is aligned with hole 58 in the upper leg of the shroud.
After nut 6 has been placed inside recess 62 and the shroud has been placed over the front edge 35 of the lip, screw 4 is lowered through aperture 58 until its thread 16 engages the corresponding thread in nut 6 . Following turning of the screw through three-quarters of a turn, the screw is firmly anchored to the upper leg 66 of the shroud, its elongated shaft 10 is in firm engagement with the aperture 60 in the lip, and a lowermost end 70 of the screw extends into the blind hole in the lower leg 64 of the shroud. With screw 4 firmly tightened against nut 6 as shown in FIG. 10 , the shroud is fully secured to the lip and prevented from becoming loose (unless the screw is turned open) because the screw, including screw head 8 , are completely disposed inside bores 58 , 60 and 68 and are locked in place by the shroud until the screw is loosened.
Still referring to FIGS. 4-6 , a wear plate 42 is secured to the horizontal portion 32 of the lip by initially forming an enlarged diameter, blind circular depression 72 . A retainer 74 , shown in FIG. 7 , is welded in place inside the circular depression so that an upper surface 73 of the retainer is substantially flush with the horizontal surface 32 of the lip. The retainer extends over less than 360° to define an access 77 to a central opening 76 into which a screw 78 (shown in FIG. 6 ) can be inserted. The screw has an enlarged diameter head 80 and a shaft 82 , including a thread 84 constructed as described above and illustrated in FIGS. 1-3 . The diameter of shaft 82 and thread 84 is slightly less than the diameter of opening 76 in retainer 74 so that the screw can be slidably inserted by slipping its head 80 beneath the retainer until its shaft engages the walls of the opening defined by the retainer. The length of shaft 82 is selected so that an end surface 86 of the shaft is substantially flush with the upper surface of wear plate 42 .
A nut 88 that cooperates with screw 78 is welded into a hole 90 in the wear plate that is to be attached to the plate. Nut 88 has a tapered thread as described above in connection with FIGS. 1-3 .
To attach the wear plate to the lip, screws 78 are slipped beneath retainers 74 in the circular openings 72 in the lip so that their heads 8 are rotatably and removably retained beneath retainer 74 as seen in FIG. 6 . The wear plate is placed onto the lip so that its nuts 88 are in substantial alignment with screws 78 in the lip, and a turning tool (not shown) is inserted into sockets 90 in the nuts to turn the nuts through the preferred angle of about 270° until a stop mechanism, constructed as described above, engages which signals the operator that the screw-nut connection has been completed and the wear plate has been firmly secured to the screw and therewith the lip.
FIG. 4 illustrates an entire lip 30 that is to be attached to a bucket or the like for moving earth and other materials (not shown). The lip has a generally U-shaped configuration and includes a horizontal portion 32 joined by upstanding lateral arms 34 at respective ends of the horizontal portion. A front edge 35 of the lip mounts a number of spaced-apart adaptors 36 to which digging teeth 38 are movably attached.
As previously described, shrouds 40 are located between adjacent teeth and arranged along the front edge of the lip. Shrouds are frequently also installed on the two forwardly facing surfaces of lateral arms 34 .
Wear plates 42 are arranged on the top surface of horizontal portion 32 of the lip. For this purpose, the lip has embedded openings 44 defined by depressions 72 and opening 77 on retainer 74 through which screws 78 including their heads 80 and shafts 82 can be slidably inserted so that, thereafter, the screw cannot be pulled upwardly.
The hole pattern 52 in the wear plates corresponds to that of embedded openings 44 in the horizontal portion of the lip. Nuts 88 welded to the wear plates have tapered threads extending preferably over about three-quarters of their respective circumferences, as described above in connection with FIGS. 1-3 . The nuts in the wear plates are aligned with screws 78 projecting through retainers in the lip, and the screws are tightened three-quarters of a turn until the pin on one of the nuts (not shown) and the screws and the cooperating stop (not shown) on the other one engage each other. This signals that the screw connection has been satisfactorily completed. When desired or otherwise needed, the wear plates applied to the lip can have other configurations; for example, a single wear plate can extend over the entire length and/or width of the lip.
When it is time to replace the wear plates, or only those wear plates which exhibit excessive wear, the respective screws thereof are loosened and withdrawn to disengage the wear plates from the screws, the worn wear plates are replaced with fresh ones, and the fresh wear plates are again secured to the horizontal portions 32 of the lip as described above. The loosening of the screws typically lifts the wear plates off the underlying lip surface, which facilitates the removal of the plates.
The entire process of replacing the wear plates only takes minutes as compared to the time-consuming removal of welded-on wear plates and their replacement with fresh wear plates, which must also be welded on as required in the prior art. Significant cost savings are thereby attained.
Wear pads 56 applied to the exterior and/or interior surfaces of upright lip arms 34 can be applied to the side arms in the same manner as wear plates 42 described in the preceding paragraphs.
In a preferred embodiment of the invention, the teeth 38 shown in FIG. 4 are attached to adapters 36 in an analogous manner with a screw and a nut (not separately numbered in FIG. 4 ) constructed and arranged analogously to the manner in which the shrouds are attached to the lip.
Preferably, the releasable connection between a tooth 38 and an adapter 36 employs a version of the bolt of the present invention which, in addition to the above-discussed thread of a decreasing axial height, includes a resilient member between the head 8 of the bolt and its shank 10 which biases the shank into a mating bore, as is further described below.
Referring to FIG. 10 , the “axially resilient” bolt 90 , like bolt 4 described above, has a bolt head 8 and a preferably tapered shank 8 ′, although the shank could be of a cylindrical cross-section for a given application.
Head 8 of bolt 90 is defined by an enlarged diameter, upper section 92 from which a cylindrical shaft 94 depends downwardly. Shaft 94 is dimensioned so that it slidably fits into a hole 96 in shank 10 to allow shaft 94 , and therewith head 8 , to move axially and rotationally relative to the shank. Shaft 94 includes a recess 98 along a portion of its lower periphery which is spaced from the lower end of the shaft and which has a circumferential extent that equals the circumferential extent of helical screw thread 100 . The axial length of recess 98 is selected so that head 8 can axially move relative to shank 10 over a desired distance that is selected to generate a desired force in the axial direction before and while the thread formation is tightened.
The helical thread 100 on the enlarged portion of head 8 extends over no more than 360° and, preferably, extends over an arc substantially less, for example an arc in the range between about 120° and 180°. A hole 101 extends across the diameter of enlarged head portion 92 so that one end of the hole is in substantial alignment with a lowermost end 102 of the thread and preferably immediately adjacent to the end of the thread. Although not clearly shown in FIG. 10 , thread 100 has a decreasing axial height as shown in FIG. 3 . A metal cap 104 with a rounded end is slipped into the hole so that its rounded end protrudes past the opening of the hole at the lower end 102 of the thread. The hole (not shown) includes an internal recess that engages an end flange 106 of the cap to retain the cap inside the hole and prevent it from being pushed out of the other end. When installed, as further described below, a resilient member, such as a plug 108 made of an elastomeric material, such as plastic or rubber, or a compression spring (not shown), has a shaft portion 110 that extends into the interior of cap 104 . Rubber plug 108 includes an enlarged head which engages the surface of the bore into which shank 10 extends to keep it compressed, thereby urging the rounded end of the metal cap past the lower end 102 of the thread into a stop hole (not shown in FIG. 10 ) for releasably locking the bolt in place. For turning the bolt, head 108 is preferably provided with a connection, such as a square protrusion 112 (or hole, shown in FIG. 1 ), for turning the bolt with a wrench or the like.
Disposed between the upper end of shank 10 and the lower end of enlarged head portion 92 is a resilient member, for example a ring 114 constructed of a resilient material, such as rubber or plastic. In a preferred embodiment, relatively thin metal washers 116 are disposed between the respective ends of the ring and the opposing surfaces of shank 10 and enlarged head portion 92 .
Axially resilient bolt 90 is assembled by initially placing an elastomeric ring 114 and washer 116 combination onto shaft 94 of head 12 , and thereafter shaft 94 is inserted into hole 96 in the shank until recess 98 in the shaft of the head is axially positioned so that it overlies an aperture in shank 10 through which a locking pin 118 can be inserted. Upon insertion of the locking pin, its inner end projects into recess 98 , thereby limiting axial movements between head 8 and shank 10 to the vertical height of the recess and circumferential or pivotal movements to the circumferential arc of the recess.
Referring to FIGS. 8-13 , in one preferred embodiment of the invention, axially resilient bolt 90 is installed between an adapter 36 and a tooth 38 in an upright position. The adapter has a nose 120 that extends into and is snugly received in a rearwardly open cavity 122 inside tooth 38 . The adapter-tooth assembly has upwardly and downwardly facing surfaces generally indicated by reference numeral 124 , 126 which slopingly converge in a forward direction as shown in FIG. 9 , and the assembly has generally upright sides 128 as seen in FIG. 8 .
Although the bolt 90 can be installed at any place across the width of upper and lower surfaces 126 , in the presently preferred embodiment of the invention a bore 130 that receives the axially resilient bolt 90 is arranged in the vicinity of one of the two upright sides 128 of the adapter-tooth assembly 36 , 38 , as seen in FIG. 8 . Bore 130 is tapered, that is, it converges in an upward direction as seen in FIG. 9 , and the larger, lower end of the bore is an open end 132 to provide access to the bore from the exterior. The other end of the bore may be blind, as shown in FIG. 9 , or open (not shown in FIGS. 8-13 ).
The lower end 132 of bore 130 opens into a downwardly open, enlarged recess 134 , the approximate forward half of which is a continuation of bore 130 , and the aft portion of which extends rearwardly past the bore, as can be seen in FIG. 9 . A helical groove 136 , which is complementary to helical thread 100 on bolt 92 , is arranged in the adapter wall defining bore 130 so that at least an upper end 138 of the groove is located within recess 134 . At the lower end, helical groove 136 terminates in a stop hole 140 , dimensioned to receive metal cap 104 when bolt 90 is installed. The lower end of the helical groove may be located partially or wholly inside bore 130 or within recess 134 .
To secure tooth 38 to adapter 36 , the cavity 122 of the tooth is slipped over nose 120 of the adapter and pushed rearwardly to the maximum extent possible, at which point both define bore 130 , as is further described below. Thereafter the axially resilient bolt 90 is inserted into bore 130 until the tapered shank 8 ′ of the bolt engages the correspondingly tapered surfaces of bore 130 . Next the operator pushes downwardly on head 8 of the bolt to compress elastomeric ring 114 until the lower end 102 of helical thread 100 becomes aligned with the upper end of helical groove 138 in recess 134 of the adapter. Upon alignment, the operator turns head 8 , for example with a wrench engaging the square drive projection 112 at the top of bolt head 8 . Due to the compression of the resilient ring, an additional axial force, generated as head 8 is turned, reaches a maximum when the head has been turned over the full arc of the thread thereon, at which point resilient plug 108 pushes metal cap 104 into stop hole 140 in the adapter to thereby lock the bolt in place. Any possible force that might be encountered between the tooth and the adapter with bolt 90 secured in place cannot dislodge the bolt, and the firm and secure connection between the tooth and the adapter established by the bolt is maintained. In this context, it is noted that since the respective ends of bolt 90 are within the surrounding bore and are not directly accessible from the exterior, no encountered exterior force can cause the bolt to rotate and end cap 104 remains in place in stop hole 140 .
When it is time to replace tooth 38 on adapter 36 , the operator engages the actuator 112 at the top of head 92 with a wrench and turns it in the opposite, opening direction. To permit this, the stop hole engaging end of cap 104 is rounded, as shown, or otherwise tapered (not shown), so that, upon the application of a sufficient torque onto the bolt head, cap 104 is pushed out of and becomes disengaged from the stop hole, thereby enabling further rotational movement of the bolt until its thread 100 becomes disengaged from helical groove 136 in the adapter and can be removed.
In a preferred embodiment of the invention, bore 130 is divided into three axially extending sections. A lowermost bore section 142 and an uppermost bore section 144 are defined by full, 360° through bores 142 , 144 , respectively, as is illustrated in FIGS. 11 and 13 .
A center section 150 of the bore is jointly defined by a rounded, approximately semicircular recess 152 formed into adapter 36 and a similar, at least partially circular cutout 154 formed in a rearwardly extending flange 156 of the tooth, a rearward end 158 of which is received in a recess 160 in the adapter as seen in FIG. 12 .
For stability, the opposite side of tooth 38 has a similar, rearwardly extending flange 156 that is snugly received in a recess (not shown) in the adapter.
Tooth 38 and adapter 36 are assembled by pushing them together as far as permitted to substantially align sections 142 , 144 , 150 of bore 130 , and the axially resilient bolt 90 is inserted into aperture 130 as far as possible. Thereafter, an axial force is applied to bolt head 8 until thread 100 becomes aligned with the thread receiving groove in the adapter. Bolt head 92 is then turned over the arc of its thread 100 , which further presses the shank into tapered bore 130 . The thus inserted bolt maintains the nose and the adapter locked to each other because the bolt and the opposing surfaces of the adapter and the tooth overlap and become immovably secured to each other until bolt 90 is loosened again as above described.
Referring to FIGS. 14-16 , in another preferred embodiment of the present invention, the axially resilient bolt 90 is placed between adapter 36 and tooth 38 in a horizontal orientation and is located at the upper portion of the resulting assembly, that is, above adapter nose 120 that extends into the rearwardly open cavity 122 in the tooth.
In this embodiment, tapered bore 130 is defined by overlapping sections of the adapter and the tooth. The adapter defines a downwardly extending, generally horizontal, semicircular groove 162 , an aft end of which terminates in an enlarged, rearwardly extending recess 164 in the adapter. The depression extends substantially over the full length of the bore.
Tooth 38 includes a relatively wide, rearwardly extending flange 166 which, on its underside, includes a boss 168 , the inside of which defines an at least partially circular, downwardly open groove 170 that is aligned with groove 162 in the adapter to thereby define bore 130 between them in which bolt 92 is received.
To fully assemble adapter 36 and tooth 38 in the embodiment shown in FIGS. 14-16 , the tooth is slipped over nose 120 of the adapter as far rearwardly as possible, at which point the semicircular grooves 162 and 170 in the adapter and the tooth, respectively, are in substantial alignment with each other. Bolt 90 is then inserted into bore 130 , the elastomeric ring 114 between the head and the shank of the bolt is compressed until the helical thread 100 on the bolt becomes aligned with helical groove 136 , and the bolt is rotated over the arc of its helical thread until metal cap 104 becomes aligned and is pushed into stop hole 140 by rubber plug 108 , the head of which is engaged by the surface of bore 130 against which it rests. When cap 104 becomes aligned with the stop opening, the cap is driven into the opening, thereby fixing the bolt relative to the nut and the adapter and preventing the two from becoming separated from each other until the bolt is forcibly withdrawn as was described above.
As is true for the earlier discussed embodiment, tooth 36 includes another rearwardly extending flange 166 located on the underside (not shown in FIGS. 14-16 ) of the adapter.
A particular benefit of this embodiment of the invention is that by placing bolt 90 in a horizontal position at the upper side of the adapter-tooth assembly, the bolt becomes a force transmitting member which transmits forces applied to the tooth to the adapter, thereby reducing the stresses to which other parts of the adapter are exposed. | A connector for earth-moving equipment subjected to contact with earth, abrasive materials and the like has a nut with a body and a hole extending through the body. A bolt with a shank adapted to extend into the hole has an enlarged head at one end of the shank. Cooperating thread formations are defined on the shank and in the hole. The thread formations have cooperating matching cross-sections that decrease from a vicinity of the head of the screw towards the other end of the screw and that extend over a circumference of less than 360° and typically of no more than 270°. The connector is adapted to connect various components, including teeth and adapters, to each other and to lips at the front end of earth moving buckets and the like. | 4 |
FIELD OF THE INVENTION
[0001] The invention is related to a blend of an ultrafine kaolin and a substantially poor film forming latex, and the use thereof.
BACKGROUND OF THE INVENTION
[0002] High gloss (for example, >65%) attainment in paper coatings typically involves the use of plastic pigments which may be solid or hollow in form. The plastic pigments are “non film forming”, i.e., do not coalesce under ambient temperature and those encountered during the drying and finishing (calendaring or super calendaring) of coated paper. Hollow sphere plastic pigment (HSPP) has a core-shell morphology wherein the core is filled with water. During the paper coating drying process, the water in the void may diffuse through the shell and leave air voids. Due to the difference in refractive index between air and surrounding polymer shell, light is effectively scattered, contributing to coating opacity. The use of HSPP in paper coatings lead to improvements in gloss, brightness, and opacity and are considered to be more effective than solid plastic pigment (See, U.S. Pat. No. 6,410,158). In addition, print performance is often improved as a result of elevated sheet gloss, smoothness and opacity. The degree to which the sheet properties are improved is dependent on the particle size and void volume of the HSPP, other mineral pigments used, and the type and amount of finishing utilized. HSPP is used in the range of 2 to 20% by dry weight of pigment depending on the level of gloss desired. The remainder of the pigment portion of the coating is typically made up of inorganic materials such as kaolin, ground calcium carbonate (GCC), talc (minerals), titanium dioxide or precipitated calcium carbonate. The particle size of HSPP is typically in the range of 0.1 to 1.0 micrometers, and the particles are suspended in an aqueous phase and supplied at approximately 25-30% solids by weight.
[0003] Because HSPP is a significantly expensive pigment compared with typical mineral pigments used in paper coatings (at least 10 times more expensive than kaolin on a dry basis) and also more expensive than solid latexes (at least 25% more expensive on dry basis), paper manufacturers are always looking for more economically suitable alternatives, It would therefore be an advancement in the art to develop a suitable replacement for HSPP.
SUMMARY OF THE INVENTION
[0004] This invention is directed to a paper coating or binding formulation, comprising an aqueous emulsion which comprises a copolymer derived from one or more monomers, and an ultra fine kaolin pigment. In certain embodiments, this invention is directed to a blend of high T g latex (substantially non-film forming) and ultrafine kaolin.
[0005] This invention is also directed to a paper comprising a fiber matrix and a coating or binding composition comprising an aqueous emulsion which comprises a copolymer deviced from one or more monomers, and an ultrafine kaolin pigment.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0006] This invention relates to synergistic use of a high glass transition temperature (“T g ”) latex and an ultrafine kaolin to replace the HSPP in a coating color formulation, without any adverse impact on runnability and coated sheet properties.
[0007] The ultrafine kaolin of this invention has at least 55% of the particles by weight less than 0.3 μm (as measured by the X-ray sedimentation technique using Sedigraph 5100) and finer particle size. In an embodiment, 55% of the particles are by weight less than 0.3 μm. In another embodiment, 70% of the particles are by weight less than 0.3 μm, as it is well known that decreasing the particle size of the pigment improves gloss. However, decreasing particle size also leads to decrease in hiding provided by the coating or sheet opacity and this can potentially be overcome by using bulking chemicals such as polyamine. Ultrafine particle size kaolin pigments, used for their gloss contribution, have been shown to be suitable extenders for HSPP.
[0008] The present invention shows that fine particle size kaolin pigments or solid plastic pigments, used for their gloss qualities, may be suitable extenders for HSPP. However, complete replacement of HSPP is possible primarily with using a relatively T g solid latex (T g >30 deg C.) in combination with an ultrafine kaolin. The high T g latex is substantially non-film forming under the process conditions encountered to obtain finished paper and paperboard coatings such as application, metering, drying and calendaring of the coating. The high T g latex is derived from one or more monomers to provide a T g of >30 deg C. The latex (also referred to as aqueous copolymer emulsion) is synthetically prepared by polymerizing the monomers using free-radical aqueous emulsion polymerization.
[0009] Monomers suitable for use in the paper coating or binding formulation can generally be ethylenically unsaturated monomers including, for example, styrene, butadiene, vinyl acetate, carboxylic acids, (meth)acrylic acid esters, (meth)acrylamide, and (meth)acrylonitrile. For example, suitable monomers can include vinylaromatic compounds (e.g., styrene, α-methylstyrene, o-chlorostyrene, and vinyltoluenes); butadiene (i.e.,1,2-butadiene); conjugated dienes (e.g., 1,3-butadiene and isoprene); α,β-monoethylenically unsaturated mono- and dicarboxylic acids or anhydrides thereof (e.g., acrylic acid, methacrylic acid, crotonic acid, dimethacrylic acid, ethylacrylic acid, allylacetic acid, vinylacetic acid maleic acid, fumaric acid, itaconic acid, mesaconic acid, methylenemalonic acid, citraconic acid, maleic anhydride, itaconic anhydride, and methylmalonic anhydride); esters of α,β-monoethylenically unsaturated mono- and dicarboxylic acids having 3 to 6 carbon atoms with alkanols having 1 to 12 carbon atoms (e.g., esters of acrylic acid, methacrylic acid, maleic acid, fumaric acid, or itaconic acid, with C1-C12, C1-C8, or C1-C4 alkanols such as ethyl, n-butyl, isobutyl and 2-ethylhexyl acrylates and methacrylates, dimethyl maleate and n-butyl maleate); acrylamides and alkyl-substituted acrylamides (e.g., (meth)acrylamide, N-tert-butylacrylamide, and N-methyl(meth)acrylamide); (meth)acrylonitrile; vinyl and vinylidene halides (e.g., vinyl chloride and vinylidene chloride); vinyl esters of C1-C18 mono- or dicarboxylic acids (e.g., vinyl acetate, vinyl propionate, vinyl n-butyrate, vinyl laurate and vinyl stearate); C1-C4 hydroxyalkyl esters of C3-C6 mono- or dicarboxylic acids, especially of acrylic acid, methacrylic acid or maleic acid, or their derivatives alkoxylated with from 2 to 50 moles of ethylene oxide, propylene oxide, butylene oxide or mixtures thereof, or esters of these acids with C1-C18 alcohols alkoxylated with from 2 to 50 mol of ethylene oxide, propylene oxide, butylene oxide or mixtures thereof (e.g., hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, and methylpolyglycol acrylate); and monomers containing glycidyl groups (e.g., glycidyl methacrylate).
[0010] Additional monomers suitable for use in the paper coating or binding formulation can include linear 1-olefins, branched-chain 1-olefins or cyclic olefins (e.g., ethene, propene, butene, isobutene, pentene, cyclopentene, hexene, and cyclohexene); vinyl and allyl alkyl ethers having 1 to 40 carbon atoms in the alkyl radical, wherein the alkyl radical can possibly carry further substituents such as a hydroxyl group, an amino or dialkylamino group, or one or more alkoxylated groups (e.g., methyl vinyl ether, ethyl vinyl ether, propyl vinyl ether, isobutyl vinyl ether, 2-ethylhexyl vinyl ether, vinyl cyclohexyl ether, vinyl 4-hydroxybutyl ether, decyl vinyl ether, dodecyl vinyl ether, octadecyl vinyl ether, 2-(diethylamino)ethyl vinyl ether, 2-(di-n-butylamino)ethyl vinyl ether, methyldiglycol vinyl ether, and the corresponding allyl ethers); sulfo-functional monomers (e.g., allylsulfonic acid, methallylsulfonic acid, styrenesulfonate, vinylsulfonic acid, allyloxybenzenesulfonic acid, 2-acrylamido-2-methylpropanesulfonic acid, and their corresponding alkali metal or ammonium salts, sulfopropyl acrylate and sulfopropyl methacrylate); vinylphosphonic acid, dimethyl vinylphosphonate, and other phosphorus monomers; alkylaminoalkyl (meth)acrylates or alkylaminoalkyl(meth)acrylamides or quaternization products thereof (e.g., 2-(N,N-dimethylamino)ethyl (meth)acrylate, 3-(N,N-dimethylamino)propyl (meth)acrylate, 2-(N,N,N-trimethylammonium)ethyl (meth)acrylate chloride, 2-dimethylaminoethyl(meth)acrylamide, 3-dimethylaminopropyl(meth)acrylamide, and 3-trimethylammoniumpropyl(meth)acrylamide chloride); allyl esters of C1-030 monocarboxylic acids; N-Vinyl compounds (e.g., N-vinylformamide, N-vinyl-N-methylformamide, N-vinylpyrrolidone, N-vinylimidazole, 1-vinyl-2-methylimidazole, 1-vinyl-2-methylimidazoline, N-vinylcaprolactam, vinylcarbazole, 2-vinylpyridine, and 4-vinylpyridine); monomers containing 1,3-diketo groups (e.g., acetoacetoxyethyl(meth)acrylate or diacetonacrylamide; monomers containing urea groups (e.g., ureidoethyl (meth)acrylate, acrylamidoglycolic acid, and methacrylamidoglycolate methyl ether); and monomers containing silyl groups (e.g., trimethoxysilylpropyl methacrylate).
[0011] Suitable monomers can also include one or more crosslinkers such as N-alkylolamides of α,β-monoethylenically unsaturated carboxylic acids having 3 to 10 carbon atoms and esters thereof with alcohols having 1 to 4 carbon atoms (e.g., N-methylolacrylamide and N-methylolmethacrylamide); glyoxal based crosslinkers; monomers containing two vinyl radicals; monomers containing two vinylidene radicals; and monomers containing two alkenyl radicals. Exemplary crosslinking monomers can include diesters of dihydric alcohols with α,β-monoethylenically unsaturated monocarboxylic acids, of which in turn acrylic acid and methacrylic acid can be employed. Examples of such monomers containing two non-conjugated ethylenically unsaturated double bonds can include alkylene glycol diacrylates and dimethacrylates, such as ethylene glycol diacrylate, 1,3-butylene glycol diacrylate, 1,4-butylene glycol diacrylate and propylene glycol diacrylate, divinylbenzene, vinyl methacrylate, vinyl acrylate, allyl methacrylate, allyl acrylate, diallyl maleate, diallyl fumarate and methylenebisacrylamide. in some embodiments, the crosslinking monomers can include alkylene glycol diacrylates and dimethacrylates, and/or divinylbenzene. The crosslinking monomers when used in the copolymer can be present in an amount of from 0.2 to 5 phm and are considered part of the total amount of monomers used in the copolymer.
[0012] In addition to the crosslinking monomers, small amounts (e.g., from 0.01 to 4 phm) of molecular weight regulators, such as tert-dodecyl mercaptan, can be used. Such regulators can be added to the polymerization zone in a mixture with the monomers to be polymerized and are considered part of the total amount of monomers used in the copolymer.
[0013] In some embodiments, the monomers can include styrene, α-methylstyrene, (meth)acrylic acid, itaconic acid, maleic acid, fumaric acid, crotonic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, Cert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, vinyl acetate, butadiene, (meth)acrylamide, (meth)acrylonitrile, hydroxyethyl (meth)acrylate and glycidyl (meth)acrylate.
[0014] The copolymer can be a pure acrylic copolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, or a vinyl acrylic copolymer.
[0015] In some embodiments, the copolymer can be a pure acrylic copolymer derived from one or more monomers chosen from (meth)acrylic acid, (meth)acrylic acid esters, (meth)acrylamide, and (meth)acrylonitrile. In some embodiments, the copolymer can include from 71 to 99.5 phm of at least one (meth)acrylic acid ester, from 0 to 6 phm of itaconic acid and/or meth(acrylic) acid, from 0 to 3 phm of at least one (meth)acrylamide, from 0 to 20 phm of at least one (meth)acrylonitrile, and from 0 to 5 phm of vinyl triethoxysilane.
[0016] In some embodiments, the copolymer can be a copolymer of methyl methacrylate (“MMA”) and n-butyl acrylate (“BA”). In some embodiments, the copolymer can include from 25 to 85 phm of MMA, from 20 to 65 phm of BA, from 0 to 6 phm of itaconic and/or (meth)acrylic acid, from 0 to 3 phm of at least one (meth)acrylamide, from 0 to 20 phm of at least one (meth)acrylonitrile, and from 0 to 5 phm of vinyl triethoxysilane.
[0017] In some embodiments, the copolymer can be a copolymer of MMA and 2-ethyl hexyl acrylate (“2-EHA”). In some embodiments, the copolymer can include from 25 to 85 phm of MMA, from 20 to 65 phm of 2-EHA, from 0 to 6 phm of itaconic and/or (meth)acrylic acid, from 0 to 3 phm of at least one (meth)acrylamide, from 0 to 20 phm of at least one (meth)acrylonitrile, and from 0 to 5 phm of vinyl triethoxysilane.
[0018] In some embodiments, the copolymer can be a copolymer of 2-EHA and BA. In some embodiments, the copolymer can include from 20 to 65 phm of 2-EHA, from 20 to 65 phm of BA, from 0 to 6 phm of itaconic and/or (meth)acrylic acid, from 0 to 3 phm of at least one (meth)acrylamide, from 0 to 20 phm of at least one (meth)acrylonitrile, and from 0 to 5 phm of vinyl triethoxysilane.
[0019] In some embodiments, the copolymer can be a styrene acrylic copolymer derived from monomers including styrene, (meth)acrylic acid, (meth)acrylic acid esters, (meth)acrylamide, (meth)acrylonitrile, and mixtures thereof. For example, the styrene acrylic copolymer can include styrene and at least one of (meth)acrylic acid, itaconic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, (meth)acrylamide, (meth)acrylonitrile, and hydroxyethyl (meth)acrylate. The styrene acrylic copolymer can include from 24 to 87 phm of (meth)acrylates, from 18 to 81 phm of styrene, from 0 to 2 phm of (meth)acrylamide, and from 0 to 20 phm of (meth)acrylonitrile. The styrene acrylic copolymer can also include from 0 to 3 phm of one or more crosslinking monomers as described above such as alkylene glycol diacrylates and dimethacrylates.
[0020] In some embodiments, the copolymer can be a styrene butadiene copolymer derived from monomers including styrene, butadiene, (meth)acrylamide, (meth)acrylonitrile, itaconic acid and (meth)acrylic acid. The styrene butadiene copolymer can include from 25 to 95 phm of styrene, from 15 to 90 phm of butadiene, from 0 to 6 phm of itaconic and/or (meth)acrylic acid, from 0 to 2 phm of (meth)acrylamide, and from 0 to 20 phm of (meth)acrylonitrile. The styrene butadiene copolymer can also include from 0 to 3 phm of one or more crosslinking monomers as described above such as divinylbenzene.
[0021] In some embodiments, the copolymer can be a vinyl acrylic copolymer derived from monomers including vinyl acetate, (meth)acrylic acid, (meth)acrylic acid esters, (meth)acrylamide, (meth)acrylonitrile, and mixtures thereof. For example, the vinyl acrylic copolymer can include vinyl acetate and at least one of (meth)acrylic acid, itaconic acid, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, (meth)acrylamide, (meth)acrylonitrile, and hydroxyethyl (meth)acrylate. The vinyl acrylic copolymer can include from 24 to 87 phm of (meth)acrylates, from 18 to 81 phm of vinyl acetate, from 0 to 2 phm of (meth)acrylamide, and from 0 to 20 phm of (meth)acrylonitrile. The vinyl acrylic copolymer can also include from 0 to 3 phm of one or more crosslinking monomers as described above such as alkylene glycol diacrylates and dimethacrylates.
[0022] The monomers and the amounts that the monomers are used to form the copolymer are selected to provide a T g of the copolymer >30 deg C. to faciliate gloss development and outside of the typical Tg range of −10 deg C. to 25 deg C. of a copolymer that serves as a binder in the paper coating. The choice of the monomers used in the copolymer may also be driven by economic concerns, for example, to decrease the cost of producing the paper coating or binding formulation. The choice of the monomers may also be driven by the characteristics of the monomers and the requirements of the end applications, for example, to resist water and/or light.
[0023] The product designated as Styronal ND811 (BASF Corporation), is a carboxylated styrene/butadiene copolymer dispersion useful as a gloss additive for paper and paperboard coatings. It has a solids content of about 50% (allows for improved coating color solids over hollow sphere plastic pigment and thus lower coating drying costs) and a T g of 56° C. On its own it is unlikely to match the gloss imparted by the HSPP (see, U.S. Pat. No. 6,410,158; Example 2).
[0024] Surprisingly, as the following examples show, replacement of hollow sphere plastic pigment by a combination of the nanosized kaolin pigment and the high T g latex is possible and would provide a substantial economic advantage to the paper mill without impact on their existing infrastructure. The ultrafine kaolin replaces the standard kaolin and the high T g latex replaces the plastic pigment in the formulation or the blend of ultrafine kaolin and high T 9 latex can be used.
EXAMPLE 1
[0025] Styronal ND 811 by itself does not provide the gloss achieved with the hollow sphere plastic pigment.
[0026] Table 1 shows the formulation with the hollow sphere plastic pigment was subjected to one change - replacement of the pigment (Sample 4) with the high T 9 latex Styronal ND811 (Sample 7).
[0000]
TABLE 1
Coating Formulation
Sample #
4
7
High Bright # 1 Kaolin
40
40
GCC
60
60
Dispersant
0.19
0.19
SB Latex
9.0
9.0
Starch
7.0
7.0
Calcium stearate
1.0
1.0
Hollow sphere PP
5.0
Styronal ND 811
5.0
[0027] The formulation was made at 59% solids and pH 8.0. It was applied to LWC groundwood basepaper using the Modern Metalcraft coater. The coated paper was dried, cut into sheets and calendared (2 nips, 250 F roll temperature and 500 pli pressure) to target gloss of 65% using standard procedures known to the skilled artisan.
[0000]
TABLE 2
Formulation viscosity and the coated paper properties.
Sample #
4
7
Sample Description
HSPP
ND811
Brookfield Viscosity (cps) 20 rpm
7400
5500
Brookfield Viscosity (cps) 100 rpm
2480
1814
Hercules Viscosity
58
43
AA-GWR (g/m 2 ) (2 atm, 2 min.)
45
48
Sheet Gloss 75° (%)
63
61
IGT Dry Pick (ft/min)
134
138
[0028] Clearly, the ND811 does not achieve the gloss target.
EXAMPLE 2
[0029] Table 3 shows that an ultrafine kaolin product, M07-1061, when used as a replacement of the #1 High Brightness kaolin pigment, leads to a significant decrease (2 parts from 5 parts) in the plastic pigment while achieving the gloss target under the same calendaring conditions. The formulation and the coating color viscosity, solids and target coat weight and gloss are shown in Table 3.
[0000]
TABLE 3
Coating Formulation CO2007-0238
Sample #
1
5
High bright # 1 Kaolin
40
M07-1061
40
GCC
60
60
Dispersant
0.2
0.2
SB Latex
9.5
9.5
Starch
6.5
6.5
Calcium Stearate
1.0
1.0
Sphere PP
5.0
2.0
Solids as is (%)
59
59
pH as is
8.0
8.0
Vicsocty 1000-1400 # 6 spindle (rpm)
100
100
[0030] The coating color was applied to base paper using the Modern Metalcraft coater. The coated paper was dried, cut into sheets and calendared to target gloss of 65% using standard procedures. Table 4 shows the coated paper properties.
[0000]
TABLE 4
Paper Properties
Sample #
1
5
Sample Key
# 1 Kaolin
M07-1061
Sample Description
HSPP - 5 parts
HSPP - 2 parts
Sheet Gloss 75° (%)
66
66
Brightness (%)
77.2
77.0
IGT Dry Pick (ft/min)
142
130
[0031] The substitution of the product designated as M07-1061 for the #1 High Brightness kaolin pigment and decrease in plastic pigment content to 2 parts from 5 parts resulted in same gloss without loss in sheet brightness.
EXAMPLE 3
[0032] Example 3 shows that the combination of the BASF products designated as ND811 (latex) and M07-1061 (kaolin) would replace the plastic pigment completely with improvement in sheet gloss and without loss in coating strength.
[0000]
TABLE 5
Coating Formulations
Sample
E
F
G
High Bright #
40
1 Kaolin
M07-1061
40
40
GCC
60
60
60
Dispersant
0.2
0.2
0.2
SB Latex
9.5
9.5
9.5
Starch
6.5
6.5
6.5
Calcium
1.0
1.0
1.0
stearate
Hollow sphere
5.0
PP
Styronal ND
4.0
3.0
811
Viscosity
1000-1400 # 6
1000-1400 # 6
1000-1400 # 6
spindle 100 rpm
spindle 100 rpm
spindle 100 rpm
Coat weight
6.4
6.4
6.4
Gloss Target
65
65
65
[0000]
TABLE 6
Paper Test Results
Sample Key
HS PP
M07-1061
M07-1061
Sample Description
5 parts
4.0 parts
3.0 parts
ND 811
ND 811
Brookfield Viscosity
5120
4780
4720
(cps) 20 rpm
Brookfield Viscosity
1640
1524
1520
(cps) 100 rpm
Hercules Viscosity
40.5
29.2
29.2
Apparent at Peak
(cps)
AA-GWR (g/m 2 ) (2
49.1
68.6
81.2
atm, 2 min.)
Sheet Gloss 75° (%)
63
68
67
IGT Dry Pick (ft/min)
363
361
383
[0033] Table 6 shows significant improvement in gloss using the combination of M07-1061 without adverse impact on coating strength. Also, as observed in previous examples, the rheology of the coating color was improved and the water retention of all the coatings still remained excellent with the replacement of the plastic pigment.
EXAMPLE 4
[0034] Example 4 shows again that a combination of BASF products designated as ND811 and M07-1061 would eliminate the plastic pigment with improvement in performance over just the ND811 or just the M07-1061. The formulation and the coating color characteristics are shown in Table 8.
[0000]
TABLE 8
Sample
1
2
3
4
High bright # 1 Kaolin
38
38
M07-1061
38
38
GCC
40
40
40
40
Calcined Kaolin
14
14
14
14
HSPP
4
ND 811
6
3
Starch
4
4
4
4
XSB Latex Binder
12
12
11
11
Dispersant, Thickener, Cross linker and lubricant same amount in both
formulations
Solids as is (%)
59
59
59
59
pH as is
8.5
8.5
8.5
8.5
[0035] The coating color was applied to basepaper using the Modern Metalcraft coater. The coated paper was dried, cut into sheets and calendared to target gloss of 70% using standard procedures. Table 9 shows the coated paper properties.
[0000]
TABLE 9
Paper Properties
Sample #
1
2
3
4
Sample Key
# 1 Kaolin
#1 Kaolin
Only
M07-1061
with HSPP
with ND811
M07-1061
at ND-811
Sheet Gloss 75° (%)
71
71
67
71
Brightness (%)
79
79
79.6
79.4
Opacity (%)
88.3
87.5
87.7
87.9
Print Gloss 75° (%)
83
79
78
81
[0036] The substitution of HSPP with just the ND811 maintains the sheet gloss and the sheet brightness but opacity decreased significantly by 0.8 points and the print gloss decreases by 4 points. On the other hand, substitution of the #1 grade kaolin with an ultrafine kaolin and taking out HSPP leads to decrease in gloss by 4 points and print gloss decrease by 5 points. However, the use of both ND811 and the ultrafine kaolin leads to equal gross, better sheet brightness, marginally lower sheet opacity and print gloss.
[0037] In certain embodiments, the monomers and kaolin pigment are added individually or in combination as a blend to the coating or binding formulation.
[0038] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims. | This invention is directed to a paper coating or binding formulation, comprising an aqueous emulsion which comprises a copolymer derived from one or more monomers, and an ultra fine kaolin pigment. In certain embodiments, this invention is directed to a blend of high T9 latex (substantially non-film forming) and ultrafine kaolin. This invention is also directed to a paper comprising a fiber matrix and a coating or binding composition comprising an aqueous emulsion which comprises a copolymer deviced from one or more monomers, and an ultrafine kaolin pigment. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application Ser. No. 09/535,880, which was filed Mar. 28, 2000.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to fishing lures and, more particularly, but not by way of limitation, to a fishing lure that is particularly designed to take advantage of each sense used by fish to hunt for food (i.e., vibration detection, hearing, smell, and sight) without sacrifice of one principle for another.
[0004] 2. Description of the Related Art
[0005] Fish generally prefer live or freshly killed food. As a result, they have become adapted to utilize their senses of vibration detection, hearing, smell, and sight to focus their hunts toward live foodstuffs. Capitalizing on this knowledge, many sporting goods manufacturers have proposed fishing lure designs in which an element of the lure is adapted to provide a vibration, a sound, a smell or a look that simulates live food. For example, many if not most lures incorporate a vibration effect, wherein the lure wobbles, to resemble a vital organism, as it is pulled through the water. Similarly, other lures have been formed in shapes that resemble baitfish, crawfish, worms or other components of a normal fish diet. Likewise, manufacturers have incorporated sound and smell into their designs as means for initially attracting fishes' attention. Particularly, lures include steel shot or other rattles within for making noises as the lure is vibrated through the water, and/or aromatic liquid fish attractants are applied to the exterior of the lure or are injected into cavities within the lure just prior to deployment.
[0006] Unfortunately, one element of the lure design must often be traded for effective implementation of another. For example, most lures look nothing like ordinary fish foodstuff. This failure to fully capitalize on one of the fish's senses, however, is not due to its unimportance. Rather, it is generally because the shape of the lure is most often dictated by the fluid dynamics involved in making the lure vibrate as it is pulled through the water, which is necessary for simulating vitality as well as for operating any internal rattle. As a further frustration atop the sacrificed look, it turns out that the generation of motion in this manner also suffers the drawback of requiring the fish to act immediately. If the fish hesitates to strike, the lure will be pulled out of reach and, usually, out of mind. The foregoing also applies to the employment of fish attractant in that the lure ejects the fish attractant as it is pulled through the water, which results in the fish attractant attracting fish to a location already vacated by the lure.
[0007] As a result of this deficiency, lures have been developed to incorporate an internal vibration mechanism generally consisting of an electrically operated motor for driving an eccentrically weighted shaft. Operation of the motor causes the lure to wobble according to the eccentric weight on the motor's shaft, obviating the need to draw the lure through the water to achieve the jerking motion that might be expected of a small bait fish or the like. Unfortunately, the internal vibration mechanisms of previous designs were inefficient and bulky, which rapidly depleted battery power and, worse, resulted in extremely heavy lures unable to float. The lures thus sank to or at least very near the bottom, which rendered them largely ineffective in attracting fish.
[0008] With the deficiencies of the related art in mind, it is therefore a primary object of the present invention to improve over the related art by providing a fishing lure adapted to play to each sense used by hunting fish, without necessity for sacrifice of one principle for another. The fishing lure is therefore capable of producing vibration and sound and dispersing fish attractant without the necessity of pulling the lure through the water. Further, the fishing lure resembles common live foodstuffs fed upon by fish. Finally, it is another object of the present invention to provide a fishing lure that either floats or is capable of diving before returning to the surface.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, a fishing lure includes a body, a cartridge suitable for insertion into the body and adapted to house a vibration producing assembly, and a removable head securable to the body. The body includes a chamber for receiving the cartridge therein. The fishing lure further includes an attractant delivery system and a noise making device. The body, removable head, cartridge, and vibration producing assembly are sufficiently lightweight so as to enable the body and attached removable head to float at or near the surface of a surrounding body of water. The body and the removable head are shaped to resemble fish foodstuff. The removable head is configured to either facilitate diving or maintain a desired level as the fishing lure is pulled through surrounding water.
[0010] The vibration producing assembly imparts vibrations to the body and includes a battery and an electric motor. The cartridge includes a compartment that contains the electric motor and a chamber that receives the battery therein. The electric motor includes a shaft having an eccentric weight attached thereto, which is positioned on the shaft off the central axis of the fishing lure. The vibration producing assembly further includes a first terminal connected to the electric motor and disposed in the chamber for engagement with the battery and a return line terminating in a second terminal attached to the cartridge. The removable head includes a contact plate that engages the battery and the second terminal, thereby facilitating the delivery of power from the battery to the electric motor.
[0011] The attractant delivery system dispenses fish attractant responsive to the vibrations imparted to the body by the vibration producing assembly. The attractant delivery system includes a length of tubing positioned adjacent the body. The length of tubing includes an aperture for receiving fish attractant and an outlet therefrom for dispensing fish attractant responsive to the vibrations imparted to the body by the vibration producing assembly. The length of tubing attaches to the body to resemble a dorsal fin of a baitfish.
[0012] The noise making device, which is preferably a bell, produces sound responsive to the vibrations imparted to the body by the vibration producing assembly. The body includes a compartment housing the noise making device therein.
[0013] A method of catching fish includes inserting into a fishing lure a cartridge adapted to house a vibration producing assembly; activating the vibration producing assembly, thereby imparting vibrations to the fishing lure; and casting the fishing lure into a body of water. The method of catching fish further includes delivering fish attractant into the water from an attractant delivery system operated responsive to the vibrations imparted to the fishing lure. The method of catching fish still further includes producing sound using a noise making device disposed in the fishing lure and operated responsive to the vibrations imparted to the fishing lure.
[0014] Finally, many other features, objects and advantages of the present invention will be apparent to those of ordinary skill in the relevant arts, especially in light of the foregoing discussions and the following drawings, exemplary detailed description, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Although the scope of the present invention is much broader than any particular embodiment, a detailed description of the preferred embodiment follows together with illustrative figures, wherein like reference numerals refer to like components, and wherein:
[0016] [0016]FIG. 1 illustrates, in a perspective view, a first preferred embodiment of the fishing lure of the present invention;
[0017] [0017]FIG. 2 illustrates, in a cut away side view, the fishing lure of FIG. 1;
[0018] [0018]FIG. 3 illustrates, in a cut away side view, a cartridge of the fishing lure of FIG. 1;
[0019] [0019]FIG. 4 illustrates, in a cut away side view, a removable head of the fishing lure of FIG. 1; and
[0020] [0020]FIG. 5 illustrates, in a side view, a second preferred embodiment of the fishing lure of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Although those of ordinary skill in the art will readily recognize many alternative embodiments, especially in light of the illustrations provided herein, this detailed description is exemplary of the preferred embodiment of the present invention, the scope of which is limited only by the claims appended hereto.
[0022] Referring now to FIGS. 1 - 4 , the lure 10 of this first preferred embodiment is shown to generally comprise a body 11 with a removable head 27 . The body 11 generally comprises a hull 12 , which includes a bulkhead 13 and a chamber wall 22 . The hull 12 of the body 11 preferably comprises two halves that are secured together to form the hull 12 using any suitable means, such as friction or an adhesive. However, those of ordinary skill in the art will recognize many techniques to form the hull 12 . The body 11 , in this first embodiment, is shaped to resemble a small bait-type fish. Nevertheless, those of ordinary skill in the art will readily recognize that the body 11 may comprise any shape and particularly any shape similar to fish foodstuff, such as frogs, grasshoppers and certain other insects, worms, and the like. Consequently, the lure 10 resembles typical fish foodstuff to capitalize on fishes' sense of sight. As will be better understood further herein, the lure 10 resembles typical fish foodstuff without sacrificing the other fish attraction aspects of vibration detection, hearing, and smell.
[0023] As shown particularly in FIGS. 2 and 3, the bulkhead 13 and the chamber wall 22 define a chamber 24 that removably receives a cartridge 18 therein. The chamber wall 22 includes protrusions 22 A and 22 B that frictionally engage the cartridge 18 to aid in preventing movement of the cartridge 18 about the chamber 24 . The cartridge 18 provides a housing for a vibration producing assembly 14 , which generally comprises an electric motor 15 and a battery 19 . The cartridge 18 defines a compartment 20 that receives the motor 15 therein. The compartment includes bulkheads 20 A and B that secure the motor 15 within the cartridge 18 . Likewise, the cartridge 18 defines a chamber 25 that receives the battery 19 , which is secured therein by the removable head 27 . The vibration producing assembly 14 further comprises a terminal 23 A connected to the motor 15 , which serves as the positive input, and a return line 23 B connected to the motor 15 and terminating in terminal 23 C. As will be better understood further herein, the vibration producing assembly 14 is particularly adapted to take advantage of a fish's sense of vibration detection.
[0024] The electric motor 15 comprises a shaft 16 having an eccentric weight 17 attached thereto. The eccentric weight 17 preferably attaches to the shaft 16 off the central axis of the lure 10 . Thus, as the motor 15 rotates the eccentric weight 17 via the shaft 16 , the eccentric weight 17 causes the lure 10 to wobble or vibrate, thereby resulting in the lure 10 imparting vibrations into the surrounding water that are detectable by fish. Consequently, the lure 10 capitalizes on fishes' sense of vibration detection in an improved manner in that the lure 10 produces detectable vibrations without the necessity of the lure 10 being pulled through the water, thereby drawing fish to the exact location of the lure.
[0025] As shown particularly in FIGS. 1 - 4 , the removable head 27 in this first preferred embodiment defines a cavity 42 and includes a curved surface 40 . The curved surface 40 of the removable head 27 permits the lure 10 to perform dives when it is desirable to pull the lure 10 through the water before returning to a normal floating level. Particularly, water flowing over the curved surface 40 drives the lure 10 downward followed by the lure 10 returning to a normal floating level, thereby providing the lure 10 with motion that simulates certain live fish foodstuff. The removable head 27 , in this first embodiment, is shaped to resemble a head of a small bait-type fish. Nevertheless, those of ordinary skill in the art will readily recognize that the removable head 27 may comprise any head shaped similar to fish foodstuff, such as frogs, grasshoppers and certain other insects, worms, and the like.
[0026] The removable head 27 further includes threads 43 that engage threads 28 of the hull 12 to permit removable attachment of the removable head 27 to the body 11 as well as an O-ring 44 that prevents water leakage into the chamber 25 . Eye-hooks 41 A and B attach to the nose and the upper portion of the removable head 27 , respectively, using any suitable means, such as integral formation therewith during a molding process, to allow securing of the lure 10 to a fishing line.
[0027] The removable head 27 still further includes a contact plate 45 attached at its rear using any suitable means, such as integral formation therewith during a molding process for the removable head 27 . The contact plate 45 forms a terminal for the vibration producing assembly 14 . The contact plate 45 further maintains the battery 19 engaged with the terminal 23 A when the removable head 27 is completely engaged with the body 11 . As such, the positive terminal 21 A of the battery 19 engages the terminal 23 A, and the contact plate 45 engages the negative terminal 21 B. In addition, the contact plate 45 engages the terminal 23 C of the return line 23 B. Accordingly, a complete circuit is formed that allows the battery 19 to provide power to the electric motor 15 . As long as the removable head 27 is secured to the body 11 , the electric motor 15 operates to impart vibrations into the surrounding water that are detectable by fish. Although this first embodiment discloses a removable head 27 , those of ordinary skill in the art will readily recognize that the lure 10 may include a removable tail section that operates in place of the removable head 27 .
[0028] The inclusion of the cartridge 18 in the lure 10 provides the advantage of allowing replacement of the motor 15 . Damage to a fishing lure motor ruins the lure and results in the necessity of a costly replacement of the entire lure. However, in the event of damage to the motor 15 , the cartridge 18 is removed and replaced with a new one, thus allowing continued use of the body 11 and the removable head 27 . Furthermore, a single cartridge 18 may service multiple lures, thus eliminating the necessity of purchasing multiple more expensive lures.
[0029] As also shown in FIG. 2, the body 11 includes a compartment 31 having a noise making device therein, which according to this first preferred embodiment, is a bell 30 . Those of ordinary skill in the art, however, will recognize many substantially equivalent embodiments for the noise making device. It should be noted, however, that the bell embodiment shown in FIG. 2 is preferred for its light weight and propensity to make noise as a consequence of the vibrations imparted to the lure 10 through the rotation of the eccentric weight 17 . Consequently, the lure 10 capitalizes on fishes' sense of hearing in an improved manner in that the lure 10 produces detectable sounds without the necessity of the lure 10 being pulled through the water, thereby drawing fish to the exact location of the lure 10 .
[0030] Finally, as particularly shown in FIGS. 1 and 2, the lure 10 of this first embodiment also comprises a unique attractant delivery system 32 . The attractant delivery system 32 generally comprises a length of tubing 33 attached to the body 11 and configured to resemble the dorsal fin of a small bait-type fish. Nevertheless, those of ordinary skill in the art will readily recognize that the tubing 33 may comprise any shape and particularly any shape related to a body part of fish foodstuff, such as frogs, grasshoppers and certain other insects, worms, and the like. The tubing 33 is attached to the body 11 using any suitable means, such as integral formation therewith during a molding process for the body 11 .
[0031] The tubing 33 includes an aperture 34 positioned towards its front and an outlet 35 therefrom positioned at the rear of the tubing 33 . Fish attractant is delivered into the tubing 33 at the aperture 34 using a bottle including a tube sized to fit within the aperture 34 . The fish attractant remains within the tubing 33 and does not readily exit the outlet 35 due to capillary action within the tubing 33 . However, upon engagement of the motor 15 and the rotation of the eccentric weight 17 , the vibrations imparted to the lure 10 overcome the capillary action within the tubing 33 , thereby facilitating a controlled release of the fish attractant into the surrounding water. Consequently, the lure 10 capitalizes on fishes' sense of smell in an improved manner in that the lure 10 releases fish attractant without the necessity of the lure 10 being pulled through the water, thereby drawing fish to the exact location of the lure 10 . Although not critical for successful use of the lure 10 , it has been found that the use of a red colored attractant contributes to the success of the lure 10 by giving the appearance of wounded fish foodstuff.
[0032] As particularly shown in FIG. 5, a lure 100 of the second preferred embodiment is identical to and includes each feature of the lure 10 of the first preferred embodiment, except a removable head 50 has been substituted for the removable head 27 . The removable head 50 is identical to and includes each feature of the removable head 27 , except the curved surface 40 of the removable head 27 has been eliminated. As such, the removable head 50 does not facilitate diving of the lure 100 when it is desirable to pull the lure 10 through the water. Water flows evenly around the removable head 50 , resulting in the lure 100 traveling straight at a desired floating level, thereby providing the lure 100 with motion that simulates certain live fish foodstuff. The removable head 50 , in this second embodiment, is shaped to resemble a head of a small bait-type fish. Nevertheless, those of ordinary skill in the art will readily recognize that the removable head 50 may comprise any head shaped similar to fish foodstuff, such as frogs, grasshoppers and certain other insects, worms, and the like. Although this second embodiment discloses a removable head 50 , those of ordinary skill in the art will readily recognize that the lure 10 may include a removable tail section that operates in place of the removable head 27 .
[0033] The weight of lures 10 and 100 is of extreme importance in their designs. Particularly, the lures 10 and 100 must float at or very near the surface of surrounding water to be effective in attracting fish. Consequently, the lures 10 and 100 are constructed from light weight materials, and, more importantly, the motor 15 must be sufficiently small and light weight that it allows the lures 10 and 100 to float at or very near the surface of surrounding water. Furthermore, the motor 15 must draw minimal current from the battery 19 , which conserves the charge on the battery 19 and prevents the battery 19 from adding weight to lures 10 and 100 that would prevent the lures 10 and 100 from floating at or very near the surface of surrounding water.
[0034] It should be understood that the weight of the lures 10 and 100 may be adjusted by manipulating the weight of the removable heads 27 and 50 through filling of their respective cavities with additional material. As such, the lure 10 may be constructed to float at the surface of the surrounding water, just below the surface of the surrounding water, or even deeper depending upon the type of fish desired for attraction. Furthermore, as previously described, the removable head 27 is designed to permit diving of the lure 10 when it is desirable to pull the lure 10 through the surrounding water before returning to float at or very near the surface of the surrounding water. Alternatively, the removable head 50 is designed to maintain lure 10 floating at or very near the surface of the surrounding water when it is desirable to pull the lure 10 through the surrounding water.
[0035] While the foregoing description is exemplary of the preferred embodiment of the present invention, those of ordinary skill in the relevant arts will recognize the many variations, alterations, modifications, substitutions and the like as are readily possible, especially in light of this description, the accompanying drawings and claims drawn thereto. For example, various eyehooks 36 and treble hooks 37 may be provided according to the size and type of fish to be attracted by the lure 10 . In any case, because the scope of the present invention is much broader than any particular embodiment, the foregoing detailed description should not be construed as a limitation of the scope of the present invention, which is limited only by the claims appended hereto. | A fishing lure includes a body, a cartridge suitable for insertion into the body, and a removable head securable to the body. The removable head is configured to either facilitate diving or maintain a desired level as the fishing lure is pulled through surrounding water. The cartridge is adapted to house a vibration producing assembly that imparts vibrations to the body. The fishing lure further includes an attractant delivery system and a noise making device. The vibration producing assembly is further sufficiently lightweight so as to enable the body and attached removable head to float at or near the surface of a surrounding body of water. The attractant delivery system dispenses fish attractant responsive to the vibrations imparted to the body by the vibration producing assembly. The noise making device produces sound responsive to the vibrations imparted to the body by the vibration producing assembly. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of an earlier filing date from U.S. Provisional Application Ser. No. 60/225,460 filed Aug. 15, 2000 which is fully incorporated herein by reference.
BACKGROUND
1. Field
The disclosure relates to oilfield downhole operations. More particularly, the disclosure relates to a self-lubricating swage device for expanding a tubular in a wellbore.
2. Prior Art
As is well known to those of skill in the art, expandable tubulars such as reformable deformed junctions have been known to the oilfield art. One will recognize the benefit of the exemplary deformed junction in that the junction is easily transported through the casing of a cased wellbore or through an open hole wellbore to its final destination at a junction between a primary and lateral borehole. Once the junction is properly positioned it is reformed into a Y-shaped junction to assist in completing the wellbore. In the fully reformed condition of the junction, the outer dimensions are generally greater than the ID of the casing or open hole. Thus of course it would be rather difficult to install the junction in its undeformed condition. Many methods have been used to expand tubulars or reform a deformed junction in the borehole. One of the prior art methods has been to employ a swaging device. Swaging devices generally comprise a conical or frustoconical hardened member having an outside diameter (OD) as large as possible while being passable through the wellbore casing or the open hole. This swage is urged to travel through a tubular or previously positioned deformed junction whereby the tubular or junction is reformed into an operational position. Where the tubular or junction is located in a vertical or near vertical wellbore, setdown weight alone often is sufficient to generate the approximately 100,000 pounds of force required to expand the tubular or reform the junction. Where the tubular or deformed junction is being placed in a highly deviated wellbore or a horizontal wellbore however, setdown weight might not be sufficient to force the swage device through the junction. In this event, one of skill in the art will recognize the hydraulic procedure alternative to setdown weight which includes an expansion joint located above the swage device, a drill tube anchor located above the expansion joint and a ball seat located below the expansion joint such that by dropping a ball, pressure can be applied to the tubing string whereby the expansion joint is forced to expand downhole which urges the swage device through the tubular or junction. Expansion joints are well known in the art, as are anchors and ball seats.
One of the problems encountered in swaging any tubular in a wellbore is the high frictional resistance that results from the contact between the swage and the contacted surface. Oftentimes the cross-sectional shape of the pipe is elliptical and not round. Swaging such a cross-sectional shape generates extremely high contact forces, which can cause galling and tearing of either or both of the swage and the pipe, which can in turn increase the force required to push the swage through the tubular.
Traditional methods of reducing friction include the use of conventional lubricants. In the application at hand, the use of conventional lubricants is limited because the lubricant must be applied to the surfaces immediately before the swage contacts the junction or the pipe. The biggest drawback to this type of application is the cost of placing the lubricant into a position where it can be utilized. Furthermore, since conventional lubricants typically have an adverse effect on cement used in the vicinity within the wellbore, such lubricants must be removed from the area before the cementing operation is commenced. There is a high cost associated with removing the lubricant prior to the application of the cement. Although a multitude of downhole lubricants and friction reducers are commercially available, hole depths and pipe configurations almost always render their use uneconomical.
Similar drawbacks are experienced during the removal of the prior art swaging devices. The obstacles encountered with respect to lubrication to force the swaging devices into a wellbore are the same as the obstacles encountered in the removal of the swaging devices from the wellbore. The metal (or other material) of the tubulars being expanded generally has a certain amount of resilience such that after the swage device has been forced through the tubular to expand it, the tubular itself will rebound to a smaller ID than the OD of the swage device by several thousandths of an inch. Because of the rebound, nearly as much lifting force is required on the swage device to remove it from the wellbore as is needed to initially urge the swage through the tubular. In the absence of any type of lubrication, this lifting force can be as much as 100,000 pounds. Although a drilling rig can easily pull ten times this weight, in a highly deviated or horizontal wellbore, the friction created on the curvature of the well can be high enough to absorb all of the force imparted at the surface and leave none available for the swage. Thus the tool is stuck. The amount of force necessary to pull the swage through the newly expanded and unlubricated tubular can also be sufficient to damage other well tools or tubulars. Such damage can of course cost significant sums of money to repair and require significant time both to diagnose and to repair.
SUMMARY
The self-lubricating swage avoids the above drawbacks by creating a self-lubricating single or two-part swage device. The single part device comprises a lubricious material associated with the swage. The two-part device comprises a primary swaging tool and second expansion device positioned ahead of the primary swaging tool for expanding a tubular in a wellbore. For simplicity, the second expansion device is termed a “nose swage”. It will be understood that this term is not known to the applicants hereof to have any specific meaning in the art and is selected for use only to describe what is taught herein and the equivalents thereof. The self-lubricating nose swage can be utilized with any type of primary swaging tool. The primary swaging tool is supported on a mandrel, and the nose swage member is supported on an end of the mandrel. The nose swage member may be fabricated of a first lubricious solid material, which is preferably a smearable material such as bronze. Alternatively, the nose swage may be constructed primarily of a different first material and coated with a layer of lubricious material. Additionally or alternatively, the nose swage may contain a plurality of grooves disposed therein, which may be filled with a second lubricious material such as polytetrafluoroethylene. The self-lubricating swage device of the present invention is employable in place of a conventional swage, the function of which being fully assimilated.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several FIGURES:
FIG. 1 is a side view of the swage in a swaging position;
FIG. 1A is a side view of the nose swage, which has disposed within it a plurality of spiral grooves for accommodating a lubricious material;
FIG. 2 is a side view of the device wherein the swage cup has been moved to a second position, which is the retrieving position;
FIG. 3 is a cross section view of a second embodiment; and
FIG. 4 is a side view of an alternative embodiment with a helical groove thereon for receiving a lubricious material.
FIG. 1B is a side view of the nose swage which has disposed within it a plurality of longitudinal grooves for accommodating a lubricious material;
FIG. 1C is a side view of the nose swage which has disposed within it a plurality of concentric grooves for accommodating a lubricious material.
FIG. 4A is a side view of an alternate embodiment having longitudinal grooves for accommodating a lubricious material.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a self-lubricating swaging device is shown generally at 10 . Swaging device 10 comprises a forward surface or nose swage shown generally at 12 and a primary swaging tool shown generally at 14 .
Nose swage 12 is a tool of a cup-like structure having a head surface 16 , a cavity opposing head surface 16 , and an outer side surface 18 that defines a frustoconical shape of nose swage 12 . A box thread 20 is provided for threadedly attaching nose swage 12 to a pin thread 23 on a mandrel 22 . Nose swage 12 is locked into place on mandrel 22 by at least one setscrew 24 , which is received in a groove 26 on mandrel 22 .
One purpose of nose swage 12 is to act as a pre-expanding swage to begin the expansion process of a tubular. As swaging device 10 is forced through a hole (not shown) of the tubular (the inside surface of which is illustrated schematically in phantom lines) the outer side surface 18 of nose swage 12 begins to expand the tubular through contact with an inside surface 28 (shown in phantom lines) of the tubular. As nose swage 12 is pushed farther into the tubular, outer side surface 18 further pushes away inside surface 28 of the tubular to expand the tubular.
Another purpose of nose swage 12 is as a lubricator. To this end nose swage 12 is fabricated from a smearable low friction bearing material such as bronze (or coated in such material to a sufficient thickness to provide the needed lubrication, which is preferably about one quarter of an inch or greater thickness). As swaging device 10 is forced through the tubular, the contact force between outer side surface 18 of nose swage 12 and inside surface 28 of the tubular causes the material of nose swage 12 to smear onto inside surface 28 . If swaging device 10 is being forced through a non-circular hole, the material of nose swage 12 smears off primarily onto inside surface 28 at the point of contact between outer side surface 18 and inside surface 28 .
In an alternate embodiment, as shown in FIG. 1A, nose swage 12 , still being composed of the smearable material, further contains a plurality of grooves 21 disposed therein. Grooves 21 may extend concentrically ( 21 A) around nose swage 12 , or they may extend from head surface 16 toward primary swaging tool 14 either longitudinally ( 21 B) across outer side surface 18 or in a spiral configuration (illustrated as 21 C). Grooves 21 are packed with a lubricant (not shown), which is typically a thin film bonded lubricant, such as polytetrafluoroethylene, molybdenum disulfide, graphite, or a similar material. When nose swage 12 contacts inside surface 28 and the surface of nose swage 12 is smeared away, the lubricant is also smeared onto inside surface 28 to further facilitate the sliding of swaging device 10 through the junction. If, on the other hand, nose swage 12 is fabricated of a non-smearable material, then grooves 21 may be packed with a smearable material, such as bronze, or a thin film bonded lubricant, such as polytetrafluoroethylene, molybdenum disulfide, graphite, or a similar material. It will be appreciated that the point of the nose swage is to effectively apply the lubricious material to the ID of the tubular being expanded. The nose swage may be constructed of any material that supports that purpose. This includes metals, plastics, etc.
In another embodiment, nose swage 12 is not used but rather the primary swage 14 is provided with a groove pattern (illustrated as 21 a in FIG. 4) or a lubricious coating on a surface thereof (not shown). The materials may be any of those disclosed hereinabove or similar acting materials. In FIG. 4, the primary swage with a helical pattern of grooves ( 25 A) thereon is illustrated In FIG. 4A a longitudinal pattern of grooves 25 B is illustrated.
Referring back to FIG. 1, primary swaging tool 14 is shown mounted on mandrel 22 by a threaded connection 30 and a plurality of setscrews 32 . Each setscrew 32 is received in a groove 34 , the combination of which with threaded connection 30 prevents movement of a support 36 . Support 36 is preferably a frustoconical annular element of a single piece, although multiple pieces could be used to achieve the desired result. Support 36 is provided with at least one port 38 , the outlet of which is positioned uphole of a point of contact of swaging device 10 with inside surface 28 of the junction being deformed. Preferably, several ports 38 are positioned on support 36 . Port 38 also intersects an upper bore 40 extending axially through support 36 , of which there are preferably several configured within support 36 . Upper bore 40 is open to an annular space 42 . As should be understood, there may be several bores 40 opening into annular space 42 .
Support 36 is shown in FIG. 1 supporting a swage cup 44 and thereby preventing the deflection of swage cup 44 toward mandrel 22 . Swage cup 44 extends outwardly from a swage cup base 46 . A lower bore 48 extends axially through swage cup base 46 , opens on the downhole end of swage cup base 46 , and is configured to receive well fluid (not shown) downhole of a contact area 50 of swage cup 44 . Lower bore 48 extends to an uphole end that communicates with annular space 42 . Annular space 42 ensures communication between lower bore 48 and upper bore 40 thus effecting through passage of well fluids from below the contact point 50 of swage cup 44 with inside surface 28 (which forms a metal-to-metal seal) to port 38 above contact point 50 . By this provision, a hydraulic lock is avoided under swage cup 44 , which would otherwise prevent movement of swaging device 10 through the tubular. If provision for fluid flow-through was not provided, it might become more difficult to move swaging device 10 through the junction since overcoming a hydraulic lock would be extremely difficult without an outlet for fluid pressure.
Swage cup 44 and swage cup base 46 are located on mandrel 22 by shear screws 52 only. Swage cup 44 and swage cup base 46 are preferably fabricated so as to be a single annular component that is slideable along mandrel 22 . Therefore, a means of holding swage cup 44 and swage cup base 46 in the swaging position on support 36 is needed. One embodiment of such means is shear screws 52 that are received in groove 54 . It will be recognized by one of ordinary skill in the art that since shear screws 52 are the only means in this embodiment which hold swage cup 44 and swage cup base 46 in place, swage cup 44 and swage cup base 46 may rotate 360° around mandrel 22 relatively freely. The significance of annular space 42 then is to ensure that lower bore 48 is in fluid communication with upper bore 40 no matter what orientation the swage cup 44 and swage cup base 46 have relative to support 36 .
In the condition shown in FIG. 1, one of ordinary skill in the art should appreciate that swaging device 10 being forced through a tubular will quite effectively expand the tubular similarly to prior art swages. Once the expansion is complete and it is desirable to remove the swaging tool from the wellbore, an upward pull is necessary. The configuration of the tool as it is being pulled up the wellbore is shown in FIG. 2 . Referring now to FIG. 2, upon pulling swaging device 10 in the upward direction point 56 of swage cup 28 will contact the inside diameter (not shown) of the tubular due to the resilience of the tubular as discussed hereinbefore. The pressure on point 56 will tend to prevent swage cup 44 from moving uphole. This force is translated through swage cup base 46 to shear screws 52 (or other retaining arrangement) that will then shear under that force (or release in some other way). One of skill in the art will recognize that the particular amount of force required to shear the screws is engineerable in advance and should be matched to an appropriate amount of force to indicate that withdrawal of swaging device 10 is desired. Upon shearing of screws 52 , swage cup base 46 and swage cup 44 move downhole until swage cup base 46 is in contact with a swage stop 58 . It should be briefly noted at this point that swage stop 58 is connected to mandrel 22 via a regular thread 60 and a plurality of setscrews 62 . Swage stop 58 further includes an o-ring 64 to seal swage stop 58 against mandrel 22 .
Upon shifting swage cup 44 and swage cup base 46 downhole into contact with swage stop 58 , a gap 66 is formed between swage cup 44 and support 36 . Because of gap 66 , continued pulling on swaging device 10 causes swage cup 44 to deflect toward mandrel 22 to a degree that is sufficient to allow it to slide through the junction. A desired mount of deflection to achieve the stated result is several thousandths of an inch. Gap 66 may be anywhere from several thousandths of an inch to a larger gap. The deflection of swage cup 44 will merely be what is necessary for it to move through the junction at a significantly reduced force as it is being withdrawn from the wellbore.
Referring now to FIG. 3, a second embodiment of the invention is shown generally at 110 . The general mode of operation remains but the way in which it is carried out is slightly different. Since each of the components of this embodiment is slightly different than each of the counterparts in the first described embodiment, the components of the new embodiment are numbered in multiples of one hundred.
At the downhole end of swaging device 110 , a self-lubricating nose swage 112 is threadedly attached to a mandrel 122 at a thread 120 and is locked in place by at least one setscrew 124 , which is received in a groove 126 . Nose swage 112 , in addition to acting as a pre-forming swage to open tight tubulars, prevents a shear ring (release ring) 142 from falling off the end of mandrel 122 after a shear screw (or other release) 150 is sheared.
In the operational condition, with shear screw 150 intact, the space between the uphole end of nose swage 112 and downhole end of shear ring 142 is preferably sufficient to allow full shearing of shear screw 150 by displacement of shear ring 142 in the downhole direction before the noted surfaces interengage. This prevents a partial shearing condition which may impede performance to some degree although should not completely prevent swaging device 110 from performing.
Mandrel 122 supports the swaging device and, through its movement, activates the same. In the running position (shown), a swage ring support 136 is in position to support a swage ring 144 . Both swage ring support 136 and swage ring 144 in this embodiment “float” on mandrel 122 (i.e., swage ring support 136 and swage ring 144 are not attached to mandrel 122 ). At the uphole end, swage ring support 136 is prevented from moving further uphole by a retaining ring 137 . Retaining ring 137 is threadedly connected to mandrel 122 by a thread 130 and is prevented from moving on thread 130 by at least one setscrew 132 , which is received in a groove 134 . In a preferred embodiment, mandrel 122 is “turned down” from a shoulder 141 to be positioned even with the uphole end of retaining ring 137 and extending to the downhole end of swaging device 110 . This provides more annular area between the mandrel surface and the borehole or junction so that thicker swage components may be used. The “turn down” from shoulder 141 also provides extra stability to retaining ring 137 .
Swage ring support 136 abuts retaining ring 137 at an interface 139 and includes a fluid bypass 138 . Support for swage ring 144 is along an interface 145 . As a unit, swage ring support 136 and swage ring 144 function as they did in the previous embodiment and indeed as do those of the prior art to expand a tubular. It is with the recovery of swaging device 110 that its unique construction is evident and beneficial. It should be noted that swage ring 144 includes at least one fluid bypass conduit 147 that communicates with an annulus 149 .
Located downhole of swage ring 144 is shear ring 142 . Swage ring 144 is abutted against shear ring 142 at an interface 143 . Shear ring 142 is prevented from longitudinal movement on mandrel 122 by a plurality of shear screws 150 , which engage a groove 151 on mandrel 122 . Shear ring 142 , in conjunction with retaining ring 137 , maintains swage ring support 136 and swage ring 144 in the operative running and reforming position. It should be noted that slots 153 are provided on both the uphole and downhole sides of shear ring 142 in a preferred embodiment to allow for fluid bypass. While only the uphole end of shear ring 142 requires slots 153 to allow fluid bypass, placing slots 153 on both ends assures that fluid bypass will occur even in the event that swaging device 110 is assembled backwards.
Once swaging device 110 has been forced through the tubular being expanded, it is normally withdrawn or pulled uphole. In the event that swaging device 110 encounters significant resistance, the features disclosed herein will be set in motion. Since both swage ring support 136 and swage ring 144 are not connected to mandrel 122 , resistance provided by the deformed junction is translated directly to shear screw 150 . At a predetermined amount of force, shear screw 150 will shear and allow mandrel 122 to move uphole. At this point, shear screw 150 has sheared, but swage ring support 136 has not been moved relative to swage ring 144 . Thus, the frictional engagement therebetween is rendered independent and not cumulative with respect to the amount of force necessary to shear screw 150 . Upon movement of mandrel 122 uphole, a snap ring 164 impacts a shoulder 166 on swage ring support 136 and will move snap ring 164 out of its support position under swage ring 144 . This, as in the previous embodiment, allows swage ring 144 to flex, thereby allowing retrieval of swaging device 110 . In practice, the disengagement of swage ring support 136 with swage ring 144 is assisted by a jarring action that normally results from the sudden shear of screw 150 . It should be noted, however, that a straight pull on swaging device 110 would also dislodge swage ring support 136 from swage ring 144 . The jamming action is a likely mode of operation; however, it is not a required mode of operation. Overcoming the friction generated by the flexible swage ring 144 being urged into contact with swage ring support 136 by the junction is all that is necessary. After shearing, swage ring 144 and shear ring 142 will rest on nose swage 112 while support shoulder 166 will rest on snap ring 164 . In this condition, support for swage ring 144 is not available and swage ring 144 is free to flex, thereby allowing swaging device 110 to be recovered from the junction. Commonly, the flexing that will occur is into a slight oval shape.
It should be appreciated that in both embodiments of the invention the shear release or other release mechanism may not be used in all conditions. The swaging device 10 may pull through the junction without needing to be flexible. Because the tools of each embodiment incorporate the invention, swaging device 10 of either embodiment is retrieved whether or not swaging device 10 gets stuck in the junction. If swaging device 10 does get stuck, shear screw(s) 52 will shear on continued pickup of swaging device 10 and swaging device 10 will operate as hereinbefore described.
While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation. | A self-lubricating swage expands tubulars and includes a primary swaging tool supported on a mandrel that has a lubricious capacity or a primary swaging tool supported on a mandrel and a nose swage member supported on an end of the mandrel. In the latter the nose swage member is fabricated of, is coated with or otherwise includes and applies a lubricious material that smears onto a surface coming into contact with the nose swage member. The smearing of the lubricious material facilitates the sliding of the swaging member as it contacts the inner walls of the tubular. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved manual implement, and more particularly to a hand tool comprised of a novel handle and a combination blade, blade support and handle socket with an integral implement fulcrum, which efficiently translates a minimum of physical effort on the part of the user into superior torque and lever forces for effectively loosening, excavating, lifting and relocating a load of material.
2. Discussion of the Prior Art
From farms to factories, from mines to the city, applications for shovels, spades and similar hand tools abound, and one of the most frequent and basic uses of such an implement is in a garden.
Gardening is a greatly favored, widely practiced and highly profitable pastime. In urban areas, however, space is at a premium, and garden plots tend to be small. Since it is not feasible to employ machinery, and noise and pollution factors must be considered, various hand tools have always been used to accomplish the necessary gardening chores. The greatest time and effort consuming task of gardening, and possibly the most dreaded, is tilling. The hard physical exertion required just to cultivate the smallest plot is fatiguing, debilitating and can even be injurious, since such exertion places serious and sometimes unacceptable strain on the heart, the spine, the muscles, and other parts of the body. A yound and healthy person finds it to be a backbreaking job, and an elderly or infirm person may have no chance of performing this task at all.
Many implements and accessories have been developed in an attempt to overcome or at least ease the hard physical labor required to wield a shovel, but these fall far short of their goal. The greatest inherent disadvantage in known tools is their inability to translate the efforts of the user into effective action by the implement so that minimal action and force by the user accomplishes the loosening, excavation and relocating operations of blade load in the most efficient manner possible with the least degree of strain and fatigue.
Tools which have specifically addressed this problem include those disclosed in U.S. Pat. No. 738,057 to O'Connor, U.S. Pat. No. 2,716,538 to Arrowood and U.S. Pat. No. 3,436,111 to England. O'Connor teaches a fulcrum attachment for shovels which allows the shovel handle to act as a lever on the blade to loosen ground, but the device of O'Connor does nothing to alleviate the bending, lifting or physical stress on the user, and only makes loosening the soil easier. Arrowood discloses a soil loosening tool which is also used to remove weeds. Although it employs a lever and fulcrum configuration, it still necessitates bending by the user to upheave the loosened ground, as is shown in the drawings of the patent, and Arrowood makes no provision for excavating and relocating the loose soil. The hand tools of England also incorporate the fulcrum and lever principle for loosening ground, and yet do not provide for excavating and redepositing of the soil except by bending and lifting actions and the concomitant physical strain on the user.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a manual implement, comprised of an arcuate handle and a combination blade, blade support and handle socket with an integral implement fulcrum, which effectively accomplishes the operations of load loosening, excavating and relocating by efficient translation of a minimum physical effort by the user into the requisite mechanical forces and actions by the implement.
Another object of the present invention is to provide a hand tool which precludes the stooping, bending or lifting normally necessary to perform the various load handling steps, thereby vastly diminishing the physical exertion of the user.
It is also an object of the present invention to provide a manual implement which can be used by anyone, regardless of age or strength, with substantially the same results.
A further object of the present invention is to provide a highly efficient, compact and lightweight hand tool which is inexpensive and easy to manufacture and use.
Other objects within the scope of the invention will become apparent from the following specification, claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of the improved manual implement of the present invention;
FIG. 2 is a front elevational view of the combination blade, blade support and handle socket of the present invention;
FIG. 3 is an exploded elevational view of the handle with the combination blade, blade support and handle socket of the present invention;
FIG. 4 is a top perspective view of the combination blade, blade support and handle socket of the present invention, with the handle base in cross section; and
FIG. 5 is a rear elevational view of the combination blade, blade support and handle socket of the present invention.
FIG. 6 is a schematic illustration of a precut single blank of sheet material which forms the combination blade, blade support and handle socket means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the improved manual implement of the present invention is shown at FIG. 1 in utile assembly. The implement includes a handle (10) and an integral blade, blade support and handle socket, generally denoted at (12). Member (12) can be metal or plastic, depending upon the application for which it is intended. A single precut blank of suitable sheet material, such as soft steel or a thermoplastic, can be stamped or folded by any suitable means to form the combined member (12) and may then be otherwise treated or tempered to prepare it for end use.
Member (12) includes a main blade portion (14) with a blade tip (16). The blade shown in the figures is that of a shovel, but particularly configured blades can be formed for special applications or to handle materials of different weight, consistency and blade adherence. Centrally formed in blade (14) is an inverse wedge or V channel (18), the vertex of the V rearward of blade (14) with the edges of the channel sides integral with the blade face. V channel (18) commences upward in blade (14) substantially from blade midpoint. At the uppermost points of the side edges of V channel (18), which are approximately level with the top of the blade face, transition folds (20) commence. Transition folds (20) invert the sides of V channel (18), i.e., fold the sides back upon themselves. This reversal of the sides of V channel (18) at transition folds (20) terminates V channel (18) at blade top, and the angularly folded sides of V channel (18) form an inverted V channel (22) directly above and extending laterally rearwardly of V channel (18) and blade (14). Transition folds (20) terminate at the initial vertex point of inverted V channel (22), which is also the termination vertex point of V channel (18). Examples of angle dimensions may include an approximate 15 degrees off blade face to the vertex of V channel (18) proximate its commencement, and an approximate 26 degrees off V channel (18) vertex for transition folds (20).
The top of blade (14) at its outermost edges is folded rearwardly of blade face to form substantially downturned lips (24). Lips (24) continue along the top of blade (14) toward transition folds (20) in smooth angular transition to blade (14) from substantially downturned at the edges to approximate 90 degree angles off blade (14) at their juncture with commencement of transition folds (20). At the commencement points of folds (20), lips (24) curve at an approximately planar right angles to continue along the bottom edges of inverted V channel (22) as flanges (26), which are attached and substantially perpendicular to inverted V channel (22) along its length. The portions of blade top between lips (24) and transition folds (20) are foot-rests (28), which are intended for step-pushing blade (14) into material in the conventional manner. Inverted V channel (22) extends rearwardly of blade (14) for a distance equal to approximately 70% of total blade length, and terminates at handle socket front faces (30), which are intersecting angularly offset planes between the terminal edges of the sides of inverted V channel (22) and the front edges of socket side faces (32). Socket side faces (32) are positioned substantially parallel to each other by the angular offset of socket front faces (30) from inverted V channel (22), and are of a length slightly greater than the length of the handle base from front to rear. The rear bottom edges of socket side faces (32) are curved in a substantially 90 degree quadrant to form socket fulcrum arcs. When the socket fulcrum arcs are tangential with the rear edges of socket side faces (32), the faces extend rearwardly to form socket tabs (34). Tabs (34) are of a width equal to the distance between the rear points of tangent of the socket fulcrum arcs and the tops of socket side faces (32), and are of a length slightly greater than the handle base width. Tabs (34) are folded one over the other, the outermost tab forming the rear face of the handle socket.
At their initial contact point with socket side faces (32), flanges (26) curve through an arcuate quadrant portion to form flange fulcrum arcs complementary to the socket fulcrum arcs, and widen interiorly of socket side faces (32). At the socket fulcrum arc tangent points, the width portions of flanges (26) exterior of socket side faces (32) end in substantially planar edges, and the widened portions of flanges (26) interiorly of the socket side faces (32) extend to form flange tabs (36), which are of a width equal to the distance between socket side faces (32) and of a length equal to extend to the top of the socket rear face formed by overlapped socket tabs (34). Flange tabs (36) smoothly overlap interiorly of overlapped socket tabs (34), and the handle base is fastened in the rear of the socket through all four tabs (34, 36).
Handle (10) includes grip (38) at its top end, which is substantially oval in cross section, and the handle smoothly transits from substantially oval in diminished section at grip (34) along its length to substantially rectangular in increased section at handle base (40), the longer sides of the rectangle being the side faces of the handle base. The transition of handle (10) over its length is shown more fully at FIG. 3. Handle (10) may be of other shapes, or combinations of shapes. Two requirements in configuration of the handle cross section are that the handle be of sufficient dimensions to efficiently withstand the physical stresses at the socket when the handle is moved and the blade meets the resistance of the load to be lifted, which is translated through the blade and blade support to the socket and thus to the handle base, and the grip be easily grasped and held by the hand of the user. The upper portion of the handle is in diminished cross section because this corresponds with diminished stresses at that portion of the handle, while the base is of sufficiently larger section to effectively wield member (12).
An arc (42) is formed in handle (10) approximately one quarter of the total handle length from grip (38). Appropriate handle measurements are, by way of example, approximately 32" in length from base (40) to arc (42), and about 1' in length from the handle arc to grip (38), with an arc of approximately 128 degrees. While the overall length of the handle and degree of arc can vary, the detail proportions of the handle remain the same. The section of handle between grip (38) and handle arc (42) forms a torque shaft and lever portion, and the degree of arc extends that handle portion forward a distance substantially equal to the combined lengths of the blade support and socket. To accomplish this, the vertical axis of handle (10) off inverted V channel (22) would be 100 degrees in the case of the example proportions given above for handle length and handle arc degree.
From the bottom to the rear face of handle base (40) is a one quarter curve which forms the handle fulcrum arc, also seen in FIGS. 3 and 5, and which allows base (40) to precisely seat in the socket. Handle (10) is secured in the socket by fastening means (44) through each socket side face (32) substantially at the lowermost front corners of base (40), and through the tabs (34, 36) substantially at its uppermost central portion within the socket. The position of the socket side face fastenings prevents the tendency of base (40) to drive forward and rupture socket front faces (30) and inverted V channel (22), in addition to otherwise securing the handle within the socket. The rear fastening stabilizes the socket and secures it to itself by securing overlapped socket tabs (34) and flange tabs (36) overlapped therebeneath. This fastening also precludes the tendency of base (40) to drive downward or otherwise deform the socket, as well as further fastening the handle within the socket. Upon fastening base (40) in the socket, the implement is complete, and a smoothly integral implement fulcrum is provided.
In FIG. 2, the combination blade, blade support and handle socket is shown in elevation. A cover plate (46) is attached along the side edges of inverted V channel (22) and socket side faces (32) to thus close the bottom of the channel and socket from materials having high adherence, preventing them from compacting within the channel and the open bottom of the socket. Plate (46) extends perpendicularly beyond the side edges of inverted V channel (22) to form the flanges (26), with the flange ends proximate blade (14) attached to footrests (28). Plate (46) is attached to socket side faces (32) and includes a 90 degree curve to form the implement fulcrum arc, the flange portions exterior the socket ending as substantially planar surfaces. The distal portion of plate (46) extends to form socket rear face (48), which is attached to socket side faces (32) along their rear edges. Blade plate (50) is attached to V channel (18) at the channel edges on the blade and along transition fold lines (20) to close the blade face.
The view at FIG. 3 illustrates the implement of the present invention with an exploded view of the handle to show its cross section along various points of its length. Tabs (34, 36) are illustrated in overlapped relationship, and the handle base fulcrum arc is shown. The positions of insertion for fastening means (44) are also illustrated. Fastening means (44) may be any pin type fastener, such as screw-threaded devices, dowel pins, rivets, etc., with suitable characteristics for attachment of the handle without shearing or damage to the handle base or socket under normal use.
FIG. 4 illustrates a top perspective view of member (12) showing handle base (40) in cross section at the point where it enters the socket. Socket front faces (30) are angularly offset from the front face of handle base (40). Tabs (34, 36) are shown overlapped and fastened. The size of the socket and length/width of tabs (34, 36) are dependent upon blade size, since flanges (26) and inverted V channel (22) form the blade support and their size and length are also determined by blade size. Handle base (40) would be complementary in size to wield member (12); thus, a larger blade would entail a larger support and larger socket, and a larger handle base. The top view shows blade (14) substantially bowled and a point to tip (16). Blade (14) and tip (16) would alter from that shown if the blade were formed in a particular configuration for a specific application and, in that instance, V channel (18) might be partially visible in blade (14).
FIG. 5 shows a rear view of member (12) of the present invention in slight perspective elevation, illustrating the widening of flanges (26) interiorly of socket side faces (30), the fulcrum arc curve of handle base (40), and the transit of lips (24) from downturned at blade edge to right angle off blade (14) at transition folds (20). Footrests (28) are at a slight slope but nearly perpendicular to blade tip (16), so the slope is not great enough to allow the foot of the user to readily slide off. Lips (24) are downturned at the outermost edges of blade (14) and continue along the top of the blade face while simultaneously and smoothly turning upward, so they are at a substantially 90 degree angle to blade (14) as they reach blade top terminii, approximately parallel to the ends of the edges of inverted V channel (22) and commencement points of transition fold lines (20). Formation of downturned lips (24), smooth transition of footrests (28) to right angle off blade (14) at blade top terminii, and planar right curves into flanges (26) provide the necessary rigidity for inverted V channel (22), and a highly effective stabilization of compression forces between the implement fulcrum and blade under load.
FIG. 6 is an example of the precut single sheet material from which the integrally folded member is made. For the example of dimensions given above for the blade and handle, the angle of footrests (28) off inverted V channel (22) would be 80 degrees, thereby giving additional height to the outside top corners of blade (14) for downturned lips (24) to enhance the substantially perpendicular footrest angle off blade support. The angle of transition lines (20) between V channel (18) and inverted V channel (22) would be 41 degrees, causing the implement fulcrum to be lifted higher off grade in the fully formed member (12) when the blade is located and moved to depth, as well as allowing the handle to be thrust forward, away from the user, when secured into the socket formed in member (12).
In use, the blade tip is positioned rearwardly adjacent the material to be excavated. The user initially grips the handle arc with either hand and steps on either footrest. The relationship of the straight sides of the blade and the blade tip provide enhanced facility for entry of the blade into the material, in this case compacted soil. The blade cuts slightly forward of a straight downward direction, and the implement fulcrum arc is raised approximately 15 degrees above the plane of the footrest as the blade sinks into the ground to the desired depth, thus raising the implement fulcrum from grade approximately two to three inches when the blade is at depth. With the first hand grasping the handle arc, the user draws the handle backward and downward, thereby breaking loose the soil as backward/downward movement of the handle brings the initial point of the implement fulcrum down to engage grade. The downward thrust on the handle causes the implement fulcrum to indent at grade level and thus become a radially moving point of fulcrum, or a fixed heel, and tensions the implement fulcrum in grade to prevent fulcrum slippage. The designed angle of blade penetration into material is to be rearward of vertical by only such degree as affords sufficient adherence of material to blade.
With the second hand, the user then grips the torque shaft and lever portion of the handle between the grasped handle arc and the grip and continues backward/downward motion of the handle, which excavates the blade and its load without the user bending or lifting, and moves the point of fulcrum rearwardly along the arc curve. Releasing the handle arc, the user places the first hand on the grip and continues backward/downward handle movement. This latter step engages the rear point of arc of the implement fulcrum and raises the blade with its contents to a height equal to the length of the inverted V channel and handle socket with fulcrum radius above the excavation site, the blade substantially level with grade. At this point, for ease of the user, the handle end may be gripped with both hands or one hand may grip the other. The user then turns wrist and hand to either side to cause linear sideward movement of the blade, or can walk-pivot the blade between the points of the handle grip and fulcrum to a complete 180 degree turn if desired. However, a turn of the wrist and the stationary points of the implement fulcrum and the handle grip move that portion of the blade and blade support beyond the implement fulcrum in an exaggerated arc, and a flick or twist in either direction of wrist and hand strikes either side of the blade on grade at a desirable optimum distance from the site of excavation without necessitating lifting or throwing of blade load. This optimum set-aside distance of blade load, like the height of the blade off grade when fully excavated, is determined by the length of the inverted V channel and the socket with the radius of the implement fulcrum arc. The substantially straight edges of the formed blade combined with their angle off blade center insures that the sides of the blade strike grade along their entire length at the same instant, providing a maximum overturning and vacating of the load from the blade.
The torque and leverage provided by the implement of the present invention is mainly an efficient relationship between the length of the blade, the length of the inverted V channel support, the shape and radial length of the fulcrum, and the angle of the handle and the length of the handle to its arc. Many variations and modifications as to materials of construction and the dimensions stated above in describing the invention are possible, for which reason the embodiment herein is detailed mainly by relative proportions. The implement describes a compact line of mechanical forces, twice offset but nonetheless linear, which provides a straight lever action with one part of a handle which becomes a lever and torque shaft with another, and a highly efficient blade, blade support and handle socket member which integrates an implement fulcrum and provides effective translation of physical action into optimum mechanical reaction. The line of mechanical forces presented by the implement configuration also overcomes the stresses of linear compression and tension without the need for any additional attachments, braces, or other implements. The particular construction of the handle and of the combined blade, blade support, handle socket and integral fulcrum provide lateral strength and stability along all of its individual components, thereby imparting inherent superior strength to a lightweight and compact implement.
It can be seen from the description of the implement of the present application that the combination blade, blade support and socket member may be produced in a wide variation of sizes, shapes and attitudes for application to tasks involving many types of materials which may have differing weight, consistency and blade adherence. Although solving the problem of the physical exertion necessitated by the task of tilling is a major consideration to the spirit of the invention, the invention is by no means limited to that function. Any application requiring manual handling of load material such as by a conventional spade, shovel or similar implement is well within the scope of the present invention. | A manual implement comprises of a handle which incorporates a lever shaft in one portion and a torque and lever shaft in another, and a novel integral blade, blade support and handle socket. The implement presents a twice offset but linear line of mechanical forces which allows the user to loosen, excavate and relocate a load of material without the concomitant hard physical exertion normally necessary to accomplish these steps by efficiently translating a minimum amount of force and action by the user into effective mechanical force and action by the implement. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is based on Japanese Patent Application No. 2002-344342, filed on Nov. 27, 2002, and is based on and claims priority under 35 U.S.C. § 119 to Japanese Patent Application 2004-040357, filed on Feb. 17, 2004, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention generally relates to an embroidering system. More particularly, the present invention pertains to an embroidering system including plural embroidering machines.
BACKGROUND
With known embroidering systems including plural embroidering machines, an operator has to initialize each embroidering machine in order to operate all the embroidering machines simultaneously. For more efficient operation, for example, a known embroidering system described in Japanese Patent Laid-Open Publication No. H06-304372 operates a first embroidering machine simultaneous with the other embroidering machines by allowing the first embroidering machine to memorize the information including the embroidering data and by transferring the memorized information to the other embroidering machines.
Notwithstanding, with the construction of the known embroidering system described in Japanese Patent Laid-Open Publication No. H06-304372, although the operational efficiency is increased for simultaneously embroidering the identical embroider pattern with the plural embroidering machines because the information is transferred from the first embroidering machine to the other embroidering machines, it is not practical for embroidering plural embroidering patterns with the plural embroidering machines.
Further, with the construction of the known embroidering system described in Japanese Patent Laid-Open Publication No. H06-304372, the minor errors between the embroidering machines are inevitable and thus the embroidering cannot be completed simultaneously at all embroidering machines even if the plural embroidering machines are started to operate simultaneously. In other words, because the timing for the completion of the embroidering is different depending on the embroidering machines, the operational efficiency is declined. More particularly, in case at least one of the embroidering machines is still operated, the embroidered products cannot be removed simultaneously, which significantly declines the operational efficiency.
A need thus exists for an embroidering system which completes the embroidering approximately simultaneously when the embroidery is performed with the plural embroidering machines synchronously.
SUMMARY OF THE INVENTION
In light of the foregoing, the present invention provides an embroidering system which includes a central control device, and a plurality of embroidering machines. The plural embroidering machines are synchronously operated by a command from the central control device. The central control device individually adjusts embroidering speeds of the plural embroidering machines.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawings, wherein:
FIG. 1 shows a block diagram of an embroidering machine system according to a first embodiment of the present invention.
FIG. 2 shows a perspective view of an embroidering machine included in an embroidering system of FIG. 1 .
FIG. 3 is a flowchart showing the process for the preparation of the embroidering.
FIG. 4 is a flowchart showing the process for the embroidering.
FIG. 5 is a block diagram showing other control systems according to the embroidering system of FIG. 1 .
FIG. 6 is a graph used for explaining the operation of the other control systems shown in FIG. 5 .
DETAILED DESCRIPTION
One embodiment of the present invention will be explained with reference to the illustrations of the drawing figures as follows.
As shown in FIG. 1 , an embroidering machine system 10 includes a personal computer PC serving as a control device. The personal computer PC is connected to, for example, four embroidering machines EM. The four embroidering machines EM are simultaneously actuated by the embroidering data sent from the personal computer PC for forming a predetermined embroidering pattern with plural colors.
As shown in FIG. 2 , the embroidering machine EM includes an embroidery frame actuation device 6 for two-dimensionally actuating an embroidery frame 56 on a horizontal surface, a sewing mechanism 1 for actuating an embroidery needle provided over a needle piercing hole 60 in the upward and downward direction, and a needle selecting device 16 as described, for example, in Japanese Published Examined Application No. S53-43336 and Japanese Published Examined Application No. S55-8626.
With the construction of the first embodiment, because the needle selecting device 16 selectively sets one of needles 581 – 586 right above the needle piercing hole 60 , the thread threaded at the needle positioned right above the needle piercing hole 60 is used for the embroidering.
An embroidering machine arm is provided with a bobbin table 55 R and a bobbin table 55 L for holding thread bobbins on the left and right sides of the embroidering arm. Four bobbins are always held at each bobbin table 55 R, 55 L. Threads wound around six bobbins out of eight bobbins in total are selectively threaded at the needles 581 – 586 through a tension 61 , each hole of a thread guiding board 62 , and a hole of a thread take-up lever.
The embroidering machine EM includes a control portion having a CPU as a primary part. When the embroidering data is sent from the personal computer PC to the control portion via an interface, the embroidering pattern with plural colors is embroidered on a cloth set at the embroidering frame 56 by the embroidering machine EM.
The embroidery sewing information of the several kinds of the embroidering patterns, in other words, the embroidering data, is written in a first embroidery device provided in the personal computer PC. The embroidering patterns are specified with unique names (i.e., file names). The embroidering sewing information of the file name of each pattern includes small number of management data and large number of stitch data. The management data includes the data indicating a predetermined thread color Ci and the thread color selecting order. The stitch data includes control data and frame actuation amount data. The control data includes thread change command data, end command data (i.e., the command data for completion of the embroidering), or the like. The frame actuation amount data shows a predetermined actuation amount (i.e., an X-axis moving amount and a Y-axis moving amount) from the last embroidery frame position (i.e., the last embroidering frame position is defined at a position where the center of the frame is positioned right above the needle piercing hole 60 at start). The stitch data includes the frame actuation amount data in order by one stitch unit when the thread is not changed and the embroidery is not completed. The thread change command data is inserted at the timing of changing the thread. The timing of the completion of the embroidering, that is, the end of the stitch data, corresponds to the end command data. With the thread color, RGB code is adopted.
The personal computer PC includes a second memory device. The second memory device is provided with the information of needle numbers N 1 –N 6 provided at the six needles 581 – 586 of the embroidering machine EM and colors of the threads is supplied at the needles 581 – 586 as the pairs [Nj, Cj](j=1–6) via an input device such as a keyboard, a mouse, or the like in advance.
In order to produce the desired embroidering patterns with plural colors with the embroidering machines EM ( 1 – 4 ) by operating the embroidering machine system 10 , the operation is prepared in the following process as shown in FIG. 3 .
First, an image of the embroidering pattern with plural colors appears on a colored display. The pattern on the screen is shown with a line drawing showing threads with corresponding colors.
In order to replace the color for each thread, the operator selects the desired color from the color data chart displayed on the screen when clicking the corresponding line drawing. Thereafter, the content of the predetermined thread color Ci of the management data is amended to add the needle number Ni simultaneously in order to correspond to the selected color. In case the selected color is supplied at none of the needles, it is judged that the closest color is selected.
The embroidering data is transmitted from the personal computer PC to the CPU of the embroidering machine.
Each embroidering machine EM ( 1 – 4 ) individually includes an activation switch and a stop switch. The CPU of the personal computer PC always recognizes the state of the activation switch as the stop switch as an activation signal of the binary signal.
The operation and the embroidering process by the embroidering machine system 10 is explained, for example, taking the case that the activation switch of the embroidering machine EM ( 1 ) is ON as shown in FIG. 4 .
When the activation switch of the embroidering machine EM ( 1 ) is ON, the activation signal recognized by the CPU of the personal computer PC is switched from OFF to ON so that the CPU of the personal computer PC provides the command to the all embroidering machines EM ( 1 – 4 ) for requesting the response of the state confirmation signal. The embroidering machine EM which has completed the preparation operation responds to the CPU of the personal computer PC with the state confirmation status signal. In case at least one of the embroidering machines does not respond with the state confirmation status signal, the CPU of the persona computer PC indicates the relevant embroidering machine for urging the operator to prepare the operation of the embroidering machine. The CPU of the personal computer PC maintains the stopped state of the embroidering machine system 10 unless the preparation operation is completed for the embroidering machines which had not responded with the state confirmation status signal.
When the state confirmation status signal is responded from the all embroidering machines EM ( 1 – 4 ), the CPU of the personal computer PC actuates the all embroidering machines EM ( 1 – 4 ). Simultaneous with the response of the state confirmation status signal, the embroidery frame initial position coordinate signal is responded so that the CPU of the personal computer PC commands the embroidery frame to move to the initial position.
In case the stop switch of one of the embroidering machines is turned on to transmit the stop signal to the CPU of the personal computer PC or the error status signal is transmitted to the CPU of the personal computer PC from the embroidering machine having the error during the embroidering operation by the operation of the all embroidering machines EM ( 1 – 4 ), the CPU of the personal computer PC commands to stop the all embroidering machines EM ( 1 – 4 ).
In case at least one of the embroidering machines is stopped in accordance with the completion of the embroidering operation, the state of the other embroidering machines is maintained.
Each embroidering machine EM ( 1 – 4 ) includes a synchronous switch. For example, when the synchronous switch of the embroidering machine EM ( 2 ) is OFF, the command for requesting the response of the state confirmation signal is not provided from the CPU of the personal computer PC to the embroidering machine EM ( 2 ). In other words, the embroidering machine EM ( 1 ), the embroidering machine EM ( 3 ), and the embroidering machine EM ( 4 ) are synchronously actuated and the embroidering machine EM ( 2 ) is released from the synchronous actuation. Thus, the release of one of the embroidering machines, for example, the embroidering machine EM ( 2 ), from the synchronous actuation of the other embroidering machines, for example, the embroidering machine EM ( 1 ), the embroidering machine EM ( 3 ), and the embroidering machine EM ( 4 ) is advantageous for independently actuating the embroidering machine EM ( 2 ) and for actuating the other embroidering machines synchronously even when the embroidering machine EM ( 2 ) is out of order.
The switching between the synchronous operation and non-synchronous operation of the particular embroidering machine with the other embroidering machines may be set at the personal computer PC. The switching of the synchronous operation and the non-synchronous operation may be applied not only for the integral actuation but also for the particular operation (e.g., the start, the stop, the error stop, the initial setting of the frame position, or the like) and may be changed in accordance with the operational environment.
Although the foregoing processes are explained in case that the different embroidering patterns are embroidered with the embroidering machines EM ( 1 – 4 ), the same is applied when the embroidering machines EM ( 1 – 4 ) embroider the common pattern. In case the embroidering machines ( 1 – 4 ) embroider the common pattern at the embroidering system 10 , the particular problem is raised, which is immediately solved as explained with reference to FIG. 5 .
As shown in FIG. 5 , the embroidering machine EM includes a stitch detection means 600 ( 1 – 6 ). The stitch detection means 600 ( 1 ), 600 ( 2 ), 600 ( 3 ), 600 ( 4 ), 600 ( 5 ), 600 ( 6 ) transmit the pulse signal to the CPU of the personal computer PC every upward and downward reciprocation of the needle 581 , the needle 582 , the needle 583 , the needle 584 , the needle 585 , and the needle 586 respectively. Every time the pulse signal is transmitted to the CPU, a total stitch number counter adds by one. The value shown at the total stitch number counter corresponds to the stitch number for the embroidery from the start of the embroidering by the embroidering machine EM. The embroidering machine EM includes a speed sensor 620 and a timer 630 for detecting the rotational number of a common motor 610 for actuating the needle 581 , the needle 582 , the needle 583 , the needle 584 , the needle 585 , and the needle 586 . The speed sensor 620 always transmits the pulse signal showing the rotational number of the motor 610 to the CPU of the personal computer PC. In place of the plural stitch detection means, the rotational number of a sewing machine main shaft may be countered.
The stitch number is supposed to be always the same with the embroidering machines EM ( 1 – 6 ) in terms of the designing. However, the stitch number may be varied because of the manufacturing tolerance, or the like. With the embroidering machine system 10 , even if the stitch number is varied depending on the embroidering machine, the variations are detected immediately to amend the stitch number to be the identical within a predetermined time. More particularly, as shown in FIG. 6 , in case, for example, the embroidering machine EM ( 1 ) and the embroidering machine EM ( 2 ) are started simultaneously to have the stitch number d 1 of the embroidering machine EM ( 1 ) and the stitch number d 2 of the embroidering machine EM ( 2 ) the same up to a time t 1 but the stitch number d 2 assumes less than the stitch number d 1 at a time t 2 (i.e., for the explanatory purpose, the operation of the other embroidering machines is disregarded), the CPU commands to increase the rotational speed of the motor 610 ( 2 ) of the embroidering machine EM ( 2 ) (i.e., the embroidering speed of the embroidering machine EM( 2 )) within a predetermined time T so that the stitch number d 1 and the stitch number d 2 are equalized again (i.e., d 1 =d 2 ). Defining the embroidering speed of the embroidering machine EM ( 1 ) and the embroidering speed of the embroidering machine EM ( 2 ) as V 1 , V 2 respectively, the following formula is established.
V 2 = V 1 +( d 1 − d 2 )/ T
Thus, the CPU commands to increase the rotational speed of the motor 610 ( 2 ) of the embroidering machine EM ( 2 ) within the predetermined time T until the embroidering speed V 2 of the embroidering machine EM ( 2 ) attained from the formula is detected.
By performing the motor rotational number control every predetermined time, the stitch number d 1 of the embroidering machine EM ( 1 ) and the stitch number d 2 of the embroidering machine EM ( 2 ) can be maintained to be equalized, and thus the completion timing of the embroidering of the embroidering machine EM ( 1 ) and the embroidering machine EM ( 2 ) can be equalized.
According to the embroidering system of the embodiment, the efficient sewing operation can be achieved because the plural patterns or the single pattern can be synchronously embroidered with the plural embroidering machines. Further, the synchronous operation is always achieved because the other embroidering machines do not operate when one of the embroidering machines is not at the operation.
According to the embroidering system of the embodiment, the particular embroidering machine can be released from the synchronous actuation of the plural embroidering machines. This is advantageous for the individual actuation of the particular embroidering machine and the non-operation of the particular embroidering machine due to the failure.
According to the embroidering system of the embodiment, the embroidering by the plural embroidering machines actuated synchronously can be completed approximately simultaneously.
The principles, preferred embodiment and mode of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiment disclosed. Further, the embodiment described herein is to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby. | An embroidering system includes a central control device and a plurality of embroidering machines. The plural embroidering machines are synchronously operated by a command from the central control device. The central control device individually adjusts embroidering speeds of the plural embroidering machines. | 3 |
FIELD OF THE INVENTION
This invention relates to the preparation of reinforcing fibers, and more particularly to a mechanical method of converting a relatively inexpensive monofilament or unbranched form of fiber into a form having a high degree of fibrillation, so that the fiber becomes suitable for use as a reinforcing material for composite mixtures.
BACKGROUND
In the production of composite materials, for example friction materials for use as brake linings, clutch faces, and the like, fibrous materials are used to bind the composition together. The reinforcing fibers not only impart desirable characteristics to the final product, they also provide "green strength" during preforming of the composite wherein the composition mixture is preliminarily compacted or densified prior to final pressing and curing. (Pre-forming of compositions for friction materials is well known in the art, see for example Searfoss et al U.S. Pat. No. 4,150,011 and Gallagher et al U.S. Pat. No. 4,374,211, to which reference may be had for further background.)
For many years asbestos appeared to be the ideal reinforcing material for composite friction materials. It is inexpensive, extremely durable, and its fiber bundles can easily be "opened" to provide a fiber mass which displays a large surface area per unit weight. This in turn provides strong engagement with and binding of frictional compositions.
However, the controversy concerning the possible carcinogenic effect of asbestos prompted attempts to develop alternative materials. This has proven very difficult in practice. Many substitute materials have been suggested and tried, but very few of them have proven satisfactory in commercial practice. Two principal reasons for the lack of success have been the fact that other fibers have not, with few exceptions, provided anywhere near the preformability and reinforcing properties of asbestos fibers; and those which do are undesirably expensive. For example, the aramid synthetic fibers, such as those sold by DuPont under the trademark "Kevlar", are available in a so-called "pulp" form which has a high degree of fibrillation, but its high cost has hindered widespread use. On the other hand, fibers such as acrylic, nylon, fiberglass, wollastonite, steel, mineral fibers, ceramic fibers, cotton and polyester, are less expensive than Kevlar, but it has not been possible to provide them in forms with sufficient degrees of fibrillation to reinforce as effectively as Kevlar.
There has thus been a strong demand for a lower cost fiber which can be fibrillated to a degree equivalent to that of Kevlar pulp fiber. Extensive research programs have been undertaken to develop such an alternative, but so far without commercial utility and practicality.
PRIOR ART
American Cyanamid Company of Wayne, N.J. has advertised that its "Creslan T-98" brand acrylic fiber (a co-polymer of acrylonitrile and methyl methacrylate) can be refined to "split" the fibers longitudinally and form fibrils along the main filament, similar to cellulose, asbestos and Kevlar. However, so far as is known to me, all attempts to refine this acrylic material to fibrillate it have demonstrated that the resulting material is not sufficiently opened or fibrillated to serve satisfactorily as a reinforcing material in composite friction material.
Morgan U.S. Pat. No. 3,068,527, assigned to DuPont, teaches a process of producing a fibrid slurry in which a polymer gel structure produced by an interfacial technique is violently agitated by a "Waring Blendor" or similar device. The interface polymerization is conducted between fast reacting organic condensation polymer-forming intermediates at an interface of controlled shape between two liquid faces. The gel, prior to drying, is torn or shredded by the blender and forms a fibrous slurry. The patent teaches that the gel structure is destroyed on drying of the interfacially formed structure, and that thereafter the final or formed structure will not form fibrils when beaten in the liquid suspension.
White U.S. Pat. No. 3,242,035, assigned to DuPont, teaches a method wherein polyamide and other materials are fibrillated by passing a film-like strip of material through a zone of high turbulence provided by a high velocity jet of air. The turbulence ruptures the film to form a multifibrous continuous network of fibrils.
Lauterbach U.S. Pat. No. 4,477,526, also assigned to DuPont, teaches a method wherein continuous filament aromatic polyamide yarns are stretch-broken under high tension while being sharply deflected in a lateral direction by a mechanical means. The broken ends of the fibers are highly fibrillated, to provide a brush-like appearance at the end of the fiber.
Wrassman U.S. Pat. No. 4,501,047 discloses a process in which agglomerates of Kevlar and other fibers are separated into discrete fibers by resilient contact with a series of blades which have pick-like or pointed tips. The process is performed in a continuous airstream that carries the separated fibers to an outlet.
So-called "refiners" are well known for treating fibers to give them some of the properties needed for the manufacture of pulp or paper. In these devices, the fibers or particles are suspended in water and subjected to a shearing or cutting action under pressure, usually between a cone and plug or between disks. Refining is usually a continuous operation; a beater, which is a machine fitted with a bed-plate and a roll, is usually used for batch operations. By way of example, such devices are produced by Bolton-Emerson Inc. of Lawrence, Mass., and Beloit Corp. of Pittsfield, Mass.
"Beating and Refining-Equipment", an article by Donald W. Danforth of Bolton-Emerson, Inc., contains a summary of techniques and equipment for treating fibers for the manufacture of paper and paperboard.
"ISO Standards Handbook 23 - Paper Board and Pulps", 1984, briefly describes "refiners" and "beaters" for the treatment of fibrous materials.
Unsuccessful Efforts to Fibrillate Staple Fibers
The initial attempts to use a commercially available acrylic staple fiber made by BASF were unsuccessful inasmuch as preforms could not be produced; the preformed composite was not sufficiently durable to enable it to be transferred from the preforming mold to the mold wherein final pressing is carried out. Efforts to overcome this problem by crimping and dry grinding in an attrition mill were unsuccessful. A minor degree of fibrillation was eventually achieved, but it was inadequate for preforming friction materials.
The previously-identified Creslan T-98 acrylic fiber produced by American Cyanamid contains included water which presumably would make it easier to fibrillate. I approached several commercial refiner manufacturers with a view to fibrillating this material, in the hope that it might be refined in a manner similar to paper making fibers. Attempts were made to fibrillate it in several different types of refiners and beaters, including commercial refining machines made by Beloit and Bolton-Emerson, already identified.
The comparative degree of fibrillation achieved by a specific process can be effectively observed by examining the fibers under magnification of 100x or more, with a scanning electron microscope. Some fibers which appear to be fibrillated when examined by the unaided eye, can be seen under such magnification to be only poorly fibrillated or even degraded. (As used herein "fibrillated" means that much smaller diameter branches or fibrils are split longitudinally from the main larger diameter stem or trunk; the fibrils are long and tangled but most remain attached to the trunk at one end.) A more pragmatic test of the degree of fibrillation is to incorporate the fiber in a friction composite and observe the degree of green strength it imparts to a pre-form.
As shown hereinafter, no useful fibrillation could be achieved for many materials, and even the preferred form of fibers used in this invention could not be effectively fibrillated in commercial refiners, but only by the new method I have discovered.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with this invention, filamentary fibers having no or only a low degree of fibrillation are converted into a fibrillated, highly branched fibers which have a physical structure similar to Kevlar pulp, by exposing the formed (as opposed to newly reacted or gel-state) unfibrillated fiber to intensive agitation by sharp edged spinning blades, while suspended in a liquid, such as water, to which the fibers are inert. The blades can be mixing or chopping blades and establish a vortex with turbulent flow such that the suspension repeatedly passes across the individual blades so that the long sharp knife edges of the blades hit the fibers. The fiber mass is thereafter separated from the liquid and dried.
Especially good results are obtained if the starting fiber is an acrylic fiber which is a copolymer of acrylonitrile and methyl methacrylate, having an entrained water content of about 50%, such as the "Creslan T-98" fiber. On a bench scale, fibrillation can be accomplished by using a chopper/mixer of the type sold by Osterizer Division of Sunbeam Corp., Milwaukee, Wis. under the "Osterizer" trademark (cf. their U.S. Pat. No. 2,530,455). Other useful small scale size mixers/choppers are made by Waring Products Division of Dynamics Corporation of America, New Hartford, Conn., and by General Electric.
It is important to point out that exposing the fiber to the action of such blades in air does not achieve a degree of fibrillation which is useful for reinforcing composite materials; the fiber must be suspended in liquid and turbulently recirculated across the blades for effective results. Moreover, even under liquid immersion, an unusually long time may be required. For example, a conventional household "Osterizer" requires about 20 minutes at high speed to fibrillate about 2 grams of acrylic fiber, even at the highest speed setting ("liquify").
DESCRIPTION OF THE DRAWINGS
The invention can best be further explained and described by reference to the accompanying drawings, in which:
FIGS. 1-8 and 10-13 are scanning electron microscope photographs of various types of fibers, as purchased or after processing in various devices. The actual magnification of each picture can be calculated from the printed dimension in microns (μm) which corresponds to the width of the rectangle printed within the border of the photograph.
Specifically,
FIG. 1 shows commercial Kevlar staple (unfibrillated) fiber;
FIG. 2 shows commercial Kevlar pulp fiber,
FIG. 3 shows the unsatisfactory mass obtained by treating Creslan T-98 type of acrylic fiber in a Beloit "high consistency" commercial refiner;
FIG. 4 shows the unsatisfactory results when the same type of fiber is processed in a Bolton-Emerson tornado type of commercial pulper;
FIG. 5 shows the unsatisfactory results obtained when the same type of acrylic fiber is processed in a Clafflin-type refiner;
FIG. 6 shows the same type of fiber as processed by American Cyanamid to improve its fibrillation;
FIG. 7 shows the lack of fibrillation of the same type of fiber after treatment in accordance with Wrassman U.S. Pat. No. 4,501,047;
FIG. 8 shows "A513" brand acrylic fibers as processed by BASF;
FIG. 9 is a diagrammatic illustration of apparatus for use in the preferred method of carrying out the invention on a small scale;
FIG. 10 shows commercial Creslan T-98 brand acrylic staple fibers, before processing;
FIG. 11 shows Creslan T-98 acrylic fiber after processing in accordance with the preferred method of practicing the invention, and illustrates the high degree of fibrillation thereby achieved;
FIG. 12 shows Kevlar staple fiber which has been processed in accordance with the invention and illustrates the high degree of fibrillation achieved; and
FIG. 13 shows nylon flock fiber processed in an Osterizer mixer-blender and illustrates the unsatisfactory fibrillation achieved.
DETAILED DESCRIPTION
The difference between unfibrillated and highly fibrillated forms of the same basic polymer ("Kevlar" brand aramid) is apparent from comparison of FIGS. 1 and 2. So-called Kevlar "staple", shown in FIG. 1, is essentially monofilamentary and unbranched; the fibers are essentially parallel, unentangled, and have no fibrils branching from them. Fiber surface area is relatively low per unit weight. This fiber imparts little green strength to a preform of a composite friction material, and is unsatisfactory in pre-forming. In contrast, FIG. 2 shows the so-called "pulp" form of Kevlar (sold commercially by DuPont), which is very highly fibrillated and has tangled fibrils that generally remain attached at their ends to the larger trunk fibers. This form has a large surface area for its weight, and is highly suitable for use in reinforcing friction materials.
It was the object of this invention to develop a method whereby a staple form of starting material, less expensive than Kevlar, could be converted into a new form having a degree of fiberosity approaching that displayed by Kevlar pulp.
Attempts of previously identified refiner manufacturers to do this were carried out with acrylic fibers at my request, and were entirely unsuccessful. Electron microscope examination of Creslan T-98 acrylic staple as supplied shows that the fibers are unbranched (FIG. 10). When the material was processed in prior art refiners and beaters of several different types, the results were not nearly as good as the Kevlar pulp shown in FIG. 2. Prior to the discovery of the present method, no processing technique was found which achieved fiber characteristics like those of Kevlar, that is, long, thin, tangled, excelsior-like fibrils which remain attached to the trunk or stem fibers of diameter several times larger. For example, type T-98 acrylic fiber processed in a commercial "high consistency" refiner made by Beloit produced a rather coarse, dense, degraded form (FIG. 3) including pieces which appear to have been melted or fused. This material is unacceptable for use as a reinforcing agent in friction material. This is demonstrated by attempting to preform mixes using fiber processed by the above method; the results are unsatisfactory.
Again, when the same acrylic staple material was processed in a so-called "tornado" pulper, produced by Bolton-Emerson Company, the fibers merely kink or deform (FIG. 4); the fiber shows little more fibrillation than that of the staple starting material.
Still further, when the same starting material is processed in a Bolton-Emerson Clafflin-type refiner, the fibers were degraded with little formation of fibrils (FIG. 5).
Samples of Creslan T-98 supplied by American Cyanamid, double passed through a disc refiner, showed little fibrillation and even supposedly "fibrillated" material (FIG. 6) sampled by American Cyanamid, made later by them by an undisclosed method, displayed poor fiber characteristics. That material comprised matted felt-like masses of very fine fibers, largely disconnected from the trunk fibers. These unattached mats do not adequately "anchor" or tie together a composite.
Attempts to fibrillate this same type of acrylic fiber with other types of refiners, including valley beaters and Koller mills, all yielded an insufficient amount and type of fibrillation.
Nor did processing the acrylic fiber in a device of the type described in Wrassman U.S. Pat. No. 4,501,047, previously referred to, fibrillate it. As shown in FIG. 7, the staple fibers showed only a few fibrils, and they were short and fine. The material was "opened" as the patent indicates, but not fibrillated and was inadequate for preforming.
The result of an attempt by BASF to fibrillate its A513 brand of acrylic fiber is shown in FIG. 8. Again, the fibrillation is inadequate.
I therefore concluded that acrylic fiber cannot be pulped in available refiners, beaters, or other equipment representing the state of art for paper pulp manufacture.
Somewhat in desperation after a long series of fruitless attempts to fibrillate with commercial refiners and beaters, I finally made a test with a domestic "Osterizer" brand mixer/chopper which I had at my home. To my surprise, I discovered that acrylic fiber containing included water could be fibrillated to a very satisfactory degree, if immersed in liquid in this type of machine. This machine is, of course, a chopping, mixing and blending device, and its effect in fibrillating was therefore surprising, especially considering that commercial refiners were ineffective.
The objective of imparting a high degree of branching to monofilamentary or unbranched fibers would not seem to be served by working the fiber in a chopping or mixing type of device, which has knife-like cutting blades. Such a device would be expected to chop fibers transversely into shorter lengths, rather than to fibrillate them. Indeed, a chopping type of effect--i.e., cutting the fibers into shorter lengths--is all that results when nylon fiber is processed in a chopping type of device. The processed nylon fibers, shown in FIG. 13, were not fibrillated.
The best material for use in this method is acrylic fiber which contains 50% included water. (By "included water" is meant elongated pockets of water entrapped within the fiber itself, not merely surface wetness). Experimentation to date has shown that if a dry form of the fiber is used (a dry form is available, or the water can be removed by heating), the fibers do not adequately fibrillate under the present method. It is theorized that the water inclusions may establish longitudinally extending "zones of weakness", along which the fiber tends to split.
The preferred form of starting material, Creslan T-98 having a denier of 5.4, is shown enlarged in FIG. 10, and can visually be likened to the unbranched monofilamentary Kevlar staple shown in FIG. 1. The material is converted to a highly fibrillated form as shown in FIG. 11, by processing in accordance with the invention.
FIG. 9 shows the internal configuration of an "Osterizer" mixer-chopper which is presently preferred for carrying out the process on a small scale. This device has a vessel 20 presenting a processing chamber 21 of truncated conical shape. Four blades 22 extend at right angles to one another and are alternately curved up or down. Baffles in the form of ribs 24 are formed on the vessel wall, and project inwardly toward the paths of movement of the blades. This configuration creates a strong turbulent vortex action (designated by the arrows 23) whereby essentially all the fibers in the suspension are recirculated across the paths of movement of the blades. Each blade has a sharp cutting edge 25; this has been found to be important in contributing to fibrillation, because a blade having a dull edge, or merely a sharp tip, is ineffective. The lower blade tips project outwardly about 90% of the distance to the vessel wall, so that the clearance is only about 10% of the radius of the blades. The fibers are thereby closely confined and cannot escape passing downwardly between the blades as they are recirculated by the turbulent vortex action.
In the preferred practice of the method, as used to produce the fibers shown in FIG. 11, 750 ccs. water were placed into a 1.25 liter vessel. 2 grams of staple T-98, denier 5.4, fiber were suspended at a low blade speed setting and then agitated at the highest speed setting ("liquify") for 20 minutes. The blade speed (no load) at the highest speed setting is believed to be roughly 100 feet per second at blade tips 26.
It can be seen that some large stem or trunk fibers remain in the product shown in FIG. 11; possibly they might be further fibrillated by continued working, but the fibrillation shown is excellent. There is a surprising lack of fines and degraded or separated fibril bits; by and large the fibers form an entangled mass, not a collection of discrete pieces, and remain strongly attached to the large or stem fibers.
The similarity between the morphological properties of the fibrillated T-98 and Kevlar pulp was demonstrated by separately incorporating the fibers into standard composite test mixtures. Comparison of both the green strengths and cured product performances were made. The test mixture used was of the type shown in the Searfoss patent previously identified; separate batches containing 3.3% wt. of each fiber specified below were made. Mixing procedure was uniform for each batch. A preform of 100 g was made from each of the three batches, using a three bump cycle of 500 psi. Initial readings of hardness (durometer) and thickness were taken; two additional readings were taken over a 48 hour period.
______________________________________Results: DurometerFiber Values Thickness______________________________________A. Kevlar Pulp Initial 83,85,85,86 16-17 mm 24 hours 84,82,79,83 16-19 mm 48 hours 75,77,78,82 17-20 mmB. T98 fibrillated Initial 80,85,85,87,80 16-17 mm in accordance 24 hours 83,80,80,79 17-20 mm with invention 48 hours 76,80,75,73 17-20 mmC. T98 Acrylic Initial 68,70,74,75 20-25 mm staple 24 hours 60,74,72,66 20-27 mm 48 hours Unstable 22-28 mm______________________________________
The visually perceived integrity of the preform containing fibrillated T98 (Batch B) corresponded to that of the preform containing Kevlar pulp (Batch A). In contrast, an unacceptable degree of integrity resulted from the preform made with Batch C having the acrylic staple constituent. This infirm preform was also characterized by the lack of definite edges.
The test samples made from Kevlar pulp and fibrillated T98 were cured and then tested for impact resistance and frictional properties. Impact resistance was measured by a Dynatup drop weight impactor system manufactured by General Research Corp. Testing parameters of a 10.01 lb. hammer weight and a Charpy tup raised to a height of 1 inch were employed. Each of the cured pieces was subjected to the test five times.
______________________________________Results:Fiber Max. Load (lbs.)______________________________________Kevlar Pulp 718, 723, 748, 738, 734Fibrillated T98 739, 722, 724, 725, 717______________________________________
Utilizing the SAE J661a procedure, the friction ratings of the materials were determined:
______________________________________Fiber Friction Rating % Wear______________________________________Kevlar Pulp N-.40 (F) H-.37 (F) 4.4Fibrillated T98 N-.42 (F) H-.41 (F) 4.4______________________________________
The results indicated that the frictional properties and strength characteristics of the Kevlar pulp-based formulation were satisfactorily maintained when the fibrillated acrylic was used in place of the Kevlar pulp.
The method also works very well to fibrillate Kevlar staple, the similarly processed form of which is shown in FIG. 12.
Knowing now that fibrillation can be achieved by this method, it is straightforward and routine to test other fibers by this method to identify those which can similarly be fibrillated. Methods to determine adequacy of fibrillation include scanning electron microscope examination, and preforming.
Results to date establish that many other fibers do not respond satisfactorily to the present method. For example, FIG. 13 shows the results when nylon flock is treated; virtually no fibrillation is achieved.
The Osterizer is a small, domestic or bench scale size apparatus, and the rate of processing in it would be far too low for efficient commercial practice. However, it is contemplated that commercial production rates can be achieved by use of larger machines of similar design. | A method of mechanically converting unbranched fibers into highly branched or "fibrillated" fibers which are especially suitable for reinforcing composite materials such as brake linings. Unbranched starting fibers, immersed in water, are subjected to prolonged working in an intensive mixer or chopper having a very rapidly spinning blade with sharp knife edges, until extensive fiber branching occurs. Fibrillation can be achieved by this method even though conventional fiber "refining" techniques have no significant effect on the same starting material. | 3 |
FIELD OF THE INVENTION
The invention relates to a ladder platform comprising a plate including a peripheral edge extending from one side of the plate and placeable at its first end on a crosspiece of a ladder and comprising a suspension link supported on the second end of the plate and attachable to a crosspiece, of the ladder.
BACKGROUND OF THE INVENTION
Many designs for ladder platforms are known from the state of the art. These ladder platforms form a stepping platform, on which an operator can stand safely and comfortably during longer periods of time on the ladder.
Furthermore ladder platforms are known, which are only used to store articles or tools, for example a paint bucket or building parts to be installed.
The known ladder platforms forming a stepping platform have the disadvantage, that, when the platforms are used to store tools or other items, an edge preventing the falling off or rolling off of tools or articles does not exist. On the other hand, the known platforms created for storing articles are not stepping platforms, since the existing edge significantly interferes with the stepping movement.
The basic purpose of the invention is to produce a ladder platform of the above-mentioned type, which with a simple design and operatively safe maneuverability can be utilized both as a stepping platform and also as a storage platform.
SUMMARY OF THE INVENTION
The purpose of the invention is attained by a mounting element pivotal about an axis, which is parallel with respect to the plate, being supported on the first end of the plate, which mounting element can form-lockingly engage a crosspiece.
The inventive ladder platform is distinguished by a number of considerable advantages. The inventive plate has a peripheral edge at one side, so that the plate assumes the shape of a flat bowl or a cornered bowl. The other side of the inventive plate is completely flat, so that it is possible without obstacles to stand on the plate, without having to step on an edge. The flat design of the plate furthermore makes it possible in a particularly simple manner to coat the stepping surface of the plate in a suitable manner, for example with a layer for preventing slipping.
By supporting the plate by means of the mounting element, which can engage a crosspiece, it is possible in a simple and safe manner to turn the plate in order to one time arrange the completely smooth outside serving as the stepping side on top and another time, when the ladder platform is used for storage, have the edge of the plate point upwardly.
The possibility of the invention, that the mounting element can form-lockingly engage a crosspiece, assures at all times a safe mounting of the plate, thus preventing the plate from becoming loose from the web due to stress.
A favorable further development of the invention provides, that the mounting element includes two mounting plates which are each pivotally supported on the outside of the edge of the plate, and a web connecting the mounting plates, and that the mounting plates are each provided with a recess for receiving the crosspiece. The support of the mounting plates on the outside makes it possible to pivot these without obstacles relative to the plate in order to turn the plate in its arrangement. Since the two mounting plates are connected by means of a web, it is assured, that both mounting plates each simultaneously engage the crosspiece. Thus an incorrect arrangement of the inventive platform is impossible.
The recess in the mounting plates for mounting onto the crosspiece makes it possible in a particularly simple manner to find an association of the mounting plates or of the mounting element with the crosspiece and in particular to assure a form-locking connection.
Each mounting plate has in a particularly favorable design, which can be manufactured in a particularly simple manner, a U-shaped cross section. This permits a safe mounting on the crosspiece and guarantees a sufficient form-locking contact. Furthermore a first leg of the U-shaped cross section can have a locking projection directed toward the second leg, which locking projection is dimensioned such, that same, when the first leg rests on a side surface of the crosspiece, undercuts the crosspiece and prevents the mounting element from slipping off of the crosspiece.
To assure the crosspiece to be guided sufficiently into the inside of the U-shaped mounting plate profile, the second leg can have an incline. Since usually today's ladders have crosspieces having a rectangular or square cross section, it is thus possible in a particularly simple manner to guide the crosspieces into the recess of the mounting plate and have said crosspiece through a slight rotation form-lockingly engage said mounting plate, in particular the locking projection provided on the first leg.
The web connecting the two mounting plates is fastened preferably on the second leg of the U-shaped cross section or profile of the mounting plate in order to assure in this manner an adjustment or pivoting as large as possible of the mounting plate.
In order to guarantee a sufficient pivoting capability of the mounting plates relative to the plate or to the edge of the plate, the base area of the U-shaped cross section of each mounting plate each is supported in an advantageous manner pivotally on the edge of the plate. This has proven to be particularly favorable also in view of strength problems, since it is easily possible to suitably dimension the base area.
The web can, in a particularly advantageous embodiment of the invention, be biased away from the crosspiece by means of an elastic element. The initial bias assures, that the first leg and the locking projection rest at all times in a safe manner against the crosspiece. An incorrect operation is thereby not possible, since the operator, when moving the mounting plates onto the crosspiece, must automatically bring the elastic element into engagement with the crosspiece, so that thus the suitable initial biasing force is automatically produced.
It can thereby be advantageous to arrange the elastic element in the center area of the web, since the use of one single elastic element, for example a spring, can be sufficient in this embodiment.
The suspension link has in a further, particularly favorable development of the invention two parallel bars, which at one end are each supported pivotally about an axis parallel with respect to the pivot axis of the mounting element on the edge of the plate, with the other ends of the bars each being bent partly circularly and being connected by means of a diagonal trussing. It is possible with this design of the inventive suspension link to attach said suspension link to a crosspiece due to the partly circular bend, with the bar being able to be arranged embracing the crosspiece either from below or being able to be attached to the crosspiece such, that it embraces same from above. These different possibilities of attachment make it possible to attach the plate in many different positions to a ladder, without having to remove and turn over the suspension link. Furthermore it is not necessary according to the invention to provide additional attachment and support mechanisms which would be usable only for one purpose, either as a stepping platform or as a storage platform.
It can be furthermore advantageous to provide a recess on the edge of the plate facing the mounting element, by means of which recess the plate, when used as a stepping platform, can in addition form-lockingly engage the crosspiece.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereinafter in connection with one exemplary embodiment and the drawings.
In the drawings:
FIG. 1 is a simplified side view of the inventive ladder platform used as a stepping platform,
FIG. 2 a view similar to FIG. 1, in which the ladder platform is used as a storage shelf,
FIG. 3 is a top view of the inventive mounting element,
FIG. 4 is a cross-sectional view along the line IV--IV of FIG. 3,
FIG. 5 is a top view of a portion of the inventive ladder platform, and
FIG. 6 is a cross-sectional view of the portion of the ladder platform shown in FIG. 5.
DETAILED DESCRIPTION
FIGS. 1 and 2 illustrate a side view of an exemplary embodiment of the inventive ladder platform.
The ladder used in connection with the platform includes two parallel sidepieces 21, which, in the usual manner, can be constructed in the form of a rectangular profile. Crosspieces 4 are fastened in the usual manner to the sidepieces 21 which crosspieces, also in the usual manner, have a square profile.
The inventive ladder platform includes a plate 1, which is constructed, substantially square,. or rectangularly. An upstanding peripheral edge 2 is provided all around the plate extending from one surface of the plate, which edge can be constructed for example by bending areas of the plate 1. Thus the plate 1 forms with the edge 2, as is particularly shown in FIG. 2, a flat bowl.
A first end 3 of the plate is pivotally connected to a mounting element, which includes two mounting plates 8, which are supported laterally on the edge of the plate, namely on the outer side of the edge 2, in such a manner, that they are pivotal about an axis 7. The axis 7 is arranged substantially parallel with respect to the plane of the plate 1.
The two holding plates 8 have, as can be seen from FIGS. 1, 2 and 4, a U-shaped cross section, with one base area 15 of the U-shaped cross section being supported pivotally on the edge 2. A first leg 11 is provided with a locking projection 13 at its free end, with the first leg 11 and the locking projection 13 being dimensioned such, that, as shown in FIGS. 1 and 2, a square crosspiece profile of the crosspieces 4 can be form-lockingly embraced. A second leg, 12 forms together with the first leg 11 a recess 10 of the mounting plate 8, which is dimensioned such, that the crosspiece 4 can be guided into the recess 10 without jamming. The second leg 12 has for this purpose an incline 14 arranged on the free end of the second leg 12 and opposite the first leg 11. In order to prevent a jamming of the crosspieces 4 in a safe manner, a notch 22 can furthermore be provided at the transition from the second leg 12 to the base area 15, as this is shown in FIG. 4.
The two second legs 12 are connected through a web 9 illustrated in cross section in FIGS. 1, 2 and 4. The web 9 may also have a substantially U-shaped cross section.
To assure, that the first leg 11 and the locking projection 13 and also the base area 15 are in contact with the crosspiece, an elastic element 16 is provided, as this is illustrated in FIG. 3, in the center area of the web 9. Said elastic element 16 is constructed like a pressure spring, as is shown in FIGS. 1, 2 and 4. The elastic element 16 assures, that the second leg 12 of the respective mounting plate 8 is being pressed away from the crosspiece 4.
The edge 2 of the plate 1 has in the area of the first end 3 a recess 23, which is formed such, that the edge 2, in the arrangement of the plate 1 shown in FIG. 1, can engage form-lockingly the crosspiece 4 in order to guarantee an additional anchoring.
Furthermore, a suspension link 5 is supported on the second end 6 of the plate 1 opposite the mounting element on and the edge 2 of said plate 1, which suspension link 5 is pivotal about an axis 18, which is arranged parallel with respect to the axis 7. The second end 6 of the plate 1 is mounted in this manner. The suspension link 5 has two bars 17, which are parallel to one another and which are arched at their free ends 20 and are connected with one another through a diagonal trussing 19. The ends 20 of the bars 17 are designed such in their bend, that a partial embracing or enclosing of a crosspiece 4 is possible.
FIG. 1 shows an arrangement of the ladder platform of the invention, in which it serves as a stepping platform. The plate 1 points thereby upwardly, while the edge 2 is arranged downwardly. The suspension link 5 is attached to the upper crosspiece 4 in such a manner, that it at least partially embraces said upper crosspiece from above. Furthermore the recess 23 of the edge 2 is form-lockingly engaged with the lower crosspiece 4. The two mounting, plates 8 of the mounting element are moved over the lower crosspiece 4 and embrace said lower crosspiece form-lockingly such, that the elastic element 16 causes an abutment of the first leg 11, of the locking projection 13 and of the base area 15 against the respective sides of the lower crosspiece 4.
FIG. 2 shows an arrangement of the inventive ladder platform, in which same serves as a storage platform. The plate 1 is arranged such for this purpose, that the edge 2 projects upwardly. The suspension link 5 embraces an upper crosspiece 4 of the ladder, while the mounting plates 8 of the mounting element are in turn mounted on a lower crosspiece 4. The elastic element 16 also in this case causes an abutment of the first leg 11, of the locking projection 13 and of the base area 15 against the respective sides of the crosspiece 4.
FIG. 3 is a top view of the web 9 and of the two mounting plates 8 showing in particular the arrangement of the two mounting plates and of the elastic element 16.
FIG. 4 is a cross-sectional view along the line IV-IV of FIG. 3 particularly clearly showing hereby again the design of the mounting plates 8.
FIG. 5 is a top view of the plate 1, however, not showing the mounting plates 8 and the webs 9. Rather, the suspension link 5 is shown in detail. The ends 24 of the bars 17, which ends face the plate 1, are either guided received in recesses of the edge 2 of the plate 1 or are supported in additional bearing blocks not illustrated in detail. It is also possible to screw a screw 25 onto each free end of the ends 24 in order to prevent the bars 17 from slipping out of the edge 2.
FIG. 6 is a cross-sectional view of the arrangement shown in FIG. 5 with the suspension link 5 being shown shortened in particular with respect to the bars 17.
The inventive ladder platform for the first time created the possibility to construct with only one platform both a stepping platform and also a storage bowl. The invention makes it possible in a particularly simple manner to change from one to the other form of use. Furthermore the invention assures, that the ladder platform is at all times safely anchored to the ladder, without that the danger exists, that the ladder platform comes loose by itself during stress or while in operation. Furthermore it is particularly advantageous, that the inventive ladder platform has small dimensions, so that it can be stored space-savingly when not needed.
The invention is not limited to the illustrated exemplary embodiment, rather many possibilities for modifications result within the scope of the invention for the man skilled in the art. | Stepping platforms, like storage platforms suspendable on a ladder, are known from the state of the art. However, these are not variable in use and in particular cannot simultaneously meet both functions. The invention provides, that a suspension link is supported on one end of a plate with a peripheral edge, while a mounting element is provided on the other end, which mounting element can include two mounting plates, which are supported pivotally on the outside of the plate and include a recess into which a ladder crosspiece is receivable. The inventive ladder platform can be used as an accessory for all types of ladders. | 4 |
This is a continuation-in-part of my patent application Ser. No. 26,788, filed Apr. 3, 1979, entitled COMBINED CAMERA TRIPOD AND LUGGAGE CART UNIT, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to camera supports, such as tripods or unipods, and more particularly is directed to a collapsible cart and camera support unit in which the tripod or unipod forms part of a two-wheeled equipment carrying cart for transporting the tripod or the unipod on which the camera is mounted along with photographic equipment and accessories and/or other luggage.
2. Description of the Prior Art
Cameras, photographic equipment, supplies and accessories are usually carried in gadget bags which are placed on the ground while the photographers, both amateur and professional, do their work thereby subjecting such gadget bags to being forgotten, stolen, or at the very least, soiled or damaged. Tripods with their versatile yet bulky pan heads and operating handles are usually carried separately in collapsed condition. Together, the collapsed tripod and gadget bag present difficulty in carrying from place to place even when the tripod is strapped to the bag or when the latter has a sufficiently large interior capacity to accommodate the tripod. Photographers all share this long existing need for alleviating the inconvenience and burdensomeness of transporting their photographic equipment from place to place as well as a need for a platform on which the gadget bag may be placed while working.
Recent developments in video cameras and equipment for recording movies on video tape cassettes have created a present need for a light weight, relatively inexpensive and easily manipulatable two-wheel cart which will include a separable unipod to adjustably support the pan head of the video camera while photographing and also provide a platform support for the video cassette recorder enabling the camera and recorder to be wheeled from place to place as a unit.
A preferred embodiment of the invention is shown herein as a cart and camera support unit having a telescoping tripod leg construction wherein the inner tube section is positioned at the upper end of the leg and the outer tube forms the bottom ground engaging section so that the locking mechanism between the sections may be similar to that disclosed in my prior U.S. Pat. No. 3,259,407, granted July 5, 1966 and entitled Lock For Telescoping Tubes.
SUMMARY OF THE INVENTION
Among the objects of the invention is to satisfy the hereinbefore described needs by providing a two-wheeled cart capability to collapsible tripods of the various popular telescoping leg constructions and to unipods, which capability shall be accomplished by a simple, yet sturdy accessory which is relatively inexpensive to manufacture and easy to connect as an attachment to one of the legs of such tripod or to the unipod by the manufacturer, the retailer, or by the consumer. The cart accessory shall include a collapsible platform which, when extended in operative position, shall accommodate a photo-equipment, gadget bag, a video cassette recorder or luggage thereon while the tripod or unipod, with pan head and camera mounted thereon, is in a retracted and collapsed condition for transporting on the wheels in an inclined position as a cart and camera support unit. The extended platform provides two feet coacting with the wheels as a four point ground engaging support for the unit with the platform disposed horizontally when at rest and permitting the platform to serve as a supporting base for the unipod in its extended upstanding operative position. The platform, when not is use, shall be collapsible into a compact condition and be readily separable from the attached tripod or unipod leg, the two separated and collapsed components being sized to fit beneath aircraft passenger seats as carry-on articles.
The invention features the cart and camera support unit which combines a two-wheeled photo-equipment cart with any one of a variety of conventional collapsible camera tripods or unipods serving as the camera supports, each having a pan head provided with a manipulating and locking handle projecting therefrom. In reference to the tripod, the pan head is mounted on a base to which the telescoping length-adjustable legs are pivotally attached at the upper ends thereof for movement from a diverging operative position to a retracted parallel relation. The conventional ground engaging non-slip tip or cap of one of the tripod legs is replaced by a component of a connecting means acting between the two-wheeled cart and the tripod leg. The photo-equipment cart comprises an elongated transverse bar supported by the two wheels located at opposite ends thereof and on which bar are mounted a collapsible platform, a pair of symmetrically spaced upstanding stops as a rear luggage barrier, and the other component of the connecting means which is centrally located on the upfacing surface of the transverse bar to removably engage the first component for securing the cart to the tripod leg with the transverse bar disposed perpendicularly to the longitudinal axis of the leg. The collapsible platform comprises a pair of bars, each having one end pivotally mounted on the transverse bar spaced symmetrically on opposite sides of the connecting means and an opposite free end downturned to form a ground engaging foot. The platform is in extended operative position for supporting photo-equipment thereon when the bars are in parallel relation and perpendicular to the transverse bar wherein the feet cooperate with the two wheels as a four point support enabling the cart and tripod unit, when at rest, to carry the photo-equipment or other luggage on the platform and dispose the collapsed tripod in a vertical position. Elastic cord tie-downs are provided for removably retaining the equipment on the platform. The platform collapses by pivoting the free ends of the bars toward each other in overlapping relation against the transverse bar.
Another embodiment of the invention utilizes a unipod in place of the tripod leg in its separable attachment to the transverse bar so that the four point ground engaging support of the platform afforded by the two wheels and two feet provides a stable base for the unipod while serving as a vertical support for the pan head and camera while in operation.
A feature of the invention is the simplicity of the separable connection between the tripod or unipod leg and the cart. After the ground engaging non-slip cap is removed, the female component of the connecting means is readily force fitted into the bore of the tripod or unipod leg and locks in a concealed operative position enabling quick and easy attachment of the cart to the tripod or unipod and also removal therefrom, the cap being replaceable without disturbing the female component in its concealed position.
The handle of the camera pan head, when properly orientated, provides a convenient handle for wheeling the cart and camera support unit in a conventional, luggage cart, inclined position wherein the platform feet are raised out of ground contact. Strap means, located adjacent the non-slip caps, binds all three retracted tripod legs together while the cart unit is being wheeled.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cart and camera support unit constructed to embody the invention utilizing a tripod and pan head as the mounting for a camera and the tripod legs spread apart in operative position, a gadget bag being shown in broken lines positioned on the platform of the two-wheeled cart.
FIG. 2 is a perspective view of the unit shown in FIG. 1 but with the tripod in a fully collapsed condition and the unit being wheeled by the pan head handle, the platform having the gadget bag shown thereon in broken lines and secured in place by a pair of elastic cords.
FIG. 3 is a perspective view of the two-wheeled cart embodying the invention provided as an accessory, the platform bars being shown in full lines in extended operative position and in broken lines in collapsed position, the female component of the connecting means being shown engaging the male component prior to being press fitted into the bore of the tripod leg.
FIG. 4 is an enlarged perspective view of the female connecting means component shown in FIGS. 3 and 5 removed from the unit.
FIG. 5 is an enlarged sectional view taken on line 5--5 in FIG. 1 showing details of the connecting means between the tripod leg and the cart.
FIG. 6 is an enlarged sectional view taken on line 6--6 in FIG. 2 showing details of the mounting of the platform bars, the caster forks and the upstanding stops of the front barrier on the transverse bar of the cart.
FIG. 7 is a view similar to FIG. 3 but showing a modified cart construction.
FIG. 8 is a view similar to FIG. 5 but showing the connecting means of the cart shown in FIG. 7 mounted on a tripod leg wherein the inner tube section is positioned at the lower end of the leg.
FIG. 9 is a side elevational view of a cart and camera support unit embodying the invention but utilizing a unipod and pan head as the mounting for a video camera and the platform of the cart as a support for the video cassette recorder indicated in broken lines, the unipod, pan head and camera being shown in full lines in a fully retracted rest position and indicated in broken lines in an extended operative position.
FIG. 10 is a front elevational view of the unit shown in FIG. 9, the camera being removed from the pan head and the video cassette recorder being indicated in broken lines.
FIG. 11 is a sectional view taken on line 11--11 in FIG. 10, the platform bars being shown in full lines in extended operative position and indicated in collapsed position in broken lines.
FIG. 12 is an enlarged detail view of the releasable clamping mechanism between the lower outer and upper inner tube sections of the unipod with parts broken away to show interior structure, and
FIG. 13 is a side elevational view of the unit shown in FIG. 9 being wheeled by the pan head handle, the video cassette recorder being shown strapped in place.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings, 20 generally denotes a cart and tripod unit, constructed to embody the invention, seen in FIGS. 1, 2 and 5 to comprise the combination of a camera tripod 30 with a two-wheeled cart 21 shown in FIG. 3 as an add-on accessory.
Tripod 30 may be of any conventional construction seen to generally comprise a base 31 having a central bore through which vertical extension tube 32 extends, the latter mounting a conventional universally adjustable pan head 33 on the upper end thereof. Pan head 33 includes a radially extending handle 34 which, in the well understood manner, serves as a means for manually positioning camera C with respect to the vertical axis (azimuth) and a horizontal axis (inclination), namely, the axis for tilting camera C in the front to rear plane in which the longitudinal axis of handle 34 extends. Handle 34 also serves by axial rotation thereof to lock the pan head 33 with respect to the inclination axis and in some pan head constructions also locks the azimuth rotation. Pan head 33 may also include a camera mounting means 33a which pivots on a third axis extending perpendicularly to the other two axes providing for tilting camera C in the side to side plane and may have a separate handle (not shown) for this adjustability.
All three legs of tripod 30, shown in FIGS. 1 and 2, are similar in construction to those described in my hereinbefore mentioned patent and, for identification purposes, two of the legs are each designated numeral 35, while the third leg, to which cart 21 is attached, is designated numeral 36. Legs 35 and leg 36 are seen to comprise upper, inner tubes 35a and tube 36a and lower, outer tubes 35b and tube 36b, respectively. The upper ends of tubes 35a and tube 36a are pivotally attached to the periphery of base 31 and have projecting finger manipulating tabs 35c and tab 36c, respectively, for actuating the locking means between the inner and outer tubes as per my above mentioned patent. The bottom ends of outer tubes 35b are fitted with conventional ground engaging non-slip caps 37 while the latter is omitted or removed from outer tube 36b to accommodate the attachment of cart 21 in the manner hereinafter fully described.
As seen in FIG. 3, an elongated transverse bar 22 mounted on wheels 25 comprises the primary horizontal supporting member of cart 21 and also of cart and tripod unit 20 when tripod 30 is collapsed for transport. Wheels 25 may each be mounted in a caster fork 23, one located at each opposite end of transverse bar 22, for rotation on a fixed axis below and parallel to the longitudinal axis of bar 22. Each caster fork 23 and wheel 25 may be of any conventional construction and provided with a toe operated locking lever or brake 23a for wheel 25. Transverse bar 22 may terminate in downturned opposite ends 22a against each of which one of the caster forks 23 is mounted by suitable fastening means, such as, bolt 24 and nut 24a. Bolt 24 extends through aligned openings formed in the horizontal cross-piece of caster fork 23 and in transverse bar 22 adjacent downturned end 22a, the latter serving to fix the abutting caster fork 23 against rotation on bolt 24.
A pair of spaced bars 26, each having one end 26a pivotally secured by a suitable pivot pin 27 to transverse bar 22 inwardly of bolts 24, serves as a collapsible platform for cart 21. The other free end of each bar 26 is downturned to provide short vertical legs 26b which coact with wheels 25 as a four point support for the rest position of cart and tripod unit 20. Pivot pin 27, as seen in FIG. 6, may be of the quick assembly type fastener having a push-on cap-shaped speed nut 27a and utilizing a split spring washer 27b providing spring tension to the pivoted connection.
The separable connecting means between tripod leg 36 and cart 21 is shown in FIGS. 3, 4 and 5 to comprise a threaded male component mounted to upstand from the center of transverse bar 22 as by bolt 28a threaded through an opening in bar 22 and secured therein by a suitable bonding material, and a female component shown in FIG. 4 as tube connector 28 having a hub 28b formed with a threaded axial bore for receiving bolt 28a therein. Tube connector 28, being of a known construction, has a pair of concavo-convex spring washers between which hub 28b is sandwiched and which are formed with cutouts 28e providing spaced resilient grippers 28c having sharp peripheral edges 28d. When forced convex end first into the bore of lower tube 36b, engagement of the tubular wall by edges 28d prevent removal of and lock female component 28 in position.
Upstanding stops are provided on transverse bar 22 as a rear barrier for cooperating with leg 36 in preventing gadget bag G or other luggage placed on cart 21 from sliding off the platform when cart and tripod unit 20 is in a rearwardly inclined wheel transporting position. Such stops, as seen in FIGS. 1, 2, 3 and 6, are provided on transverse bar 22 as angle bars 29 secured by bolts 24 and having upstanding portions 29a aligned with the platform facing side of transverse bar 22.
Strap means is also provided to bind collapsed legs 35 to leg 36 when cart and tripod unit 20 is in the transport position shown in FIG. 2. To this end, openings 22b are formed in transverse bar 22 symmetrically spaced with respect to male component 28a for mounting a strap means in the form of short elastic cord 41. The latter extends between openings 22b with opposite end portions passing therethrough and being suitably anchored as by enlarged folded and stapled ends or knots 41a.
As seen in FIGS. 2 and 3, short vertical legs 26b and upstanding portions 29a may be formed with openings 26c and 29b, respectively, adjacent the free ends thereof for attaching the opposite ends of elastic retaining cords 40 which may be provided to pass over and secure gadget bag G or other luggage placed on cart 21, all in the well understood manner. One end of each cord 40 may be anchored to cart 21, as by the enlarged folded and stapled or knotted end 40a at opening 26c and the opposite end provided with a hook 40b for removably engaging opening 29b.
The practical utility and operation of cart and tripod unit 20 will now be apparent. The preparation of lower tube 36b of tripod 30 for its removable attachment to cart 21 after removal of cap 37 simply entails threading female component 28 onto the male component 28a with the convex side facing upward and the peripheral edges 28d of the lower grippers 28c spaced a short distance above the surface of transverse bar 22. Female component 28 is then forced into the open end of lower tube 36b until the latter snugly abuts transverse bar 22 and component 28 is locked in position completely within tube 36b as shown in FIG. 5. Thereafter, transverse bar 22 may be rotated to take up any slack and thereby complete the attachment. With transverse bar 22 secured to leg 36, lower tube 36b may be released for rotation with respect to upper tube 36a to dispose transverse bar 22 in the desired tangential relation with respect to tripod 30 as shown in FIG. 1.
Platform bars 26 are pivoted to their extended position against angle bars 29 which also serve as limiting means for the parallel alignment of bars 26 with each other in perpendicular relation to transverse bar 22.
Tripod 30 of unit 20 functions in substantially the conventional manner, but wheels 25, which replace a non-slip cap as the ground engaging means for leg 36, are locked by depressing the toe operated brake levers 23a to prevent any undesirable movement due to possible rolling of unlocked wheels 25. In this operative position of tripod 30, as seen in FIG. 1, the platform of carrier 21 is available for placing thereon gadget bag G or other articles while pictures are being taken. To move unit 20 to another picture taking position without collapsing tripod 30, legs 35 are simply folded against leg 36 and brake levers 23a released, freeing unit 20 for manipulation by handle 34 to roll on wheels 25 to the next picture taking position while gadget bag G remains in position on the platform.
Transformation of cart and tripod unit 20 from its tripod function shown in FIG. 1 to a luggage cart is readily accomplished by collapsing the tripod legs and securing legs 35 against leg 36 by short elastic cord 41 as shown in FIG. 2. Tripod handle 34 may then be orientated to project forwardly with respect to the cart 21 and slightly upwardly to serve as a convenient handle for manipulating unit 20 on wheels 25 in the inclined position as is clear from FIG. 2. Gadget bag G and/or other luggage may be secured in position on platform bars 26 by the pair of elastic cords 40, hooks 40b being removably secured to any convenient structure on tripod 30, such as, the radially extending pivot supports of legs 35 on base 31, or, as seen in FIG. 2, in openings 29a of angle bars 29.
It will also be clear that when not being pulled along by handle 34 on wheels 25 in the inclined position shown in FIG. 2, cart and tripod unit 20 may be at rest with tripod 30 extending vertically and platform bars 26 disposed horizontally whereby short vertical legs 26b engage the ground and cooperate with wheels 25 as a stable four point support.
To separate cart 21 from tripod 30 when the luggage carrier capability of the unit is no longer required or to provide a more compact arrangement of components, as for fitting beneath the seat of an aircraft as carry-on articles, platform bars 26 may first be pivoted toward each other to overlap and lie against transverse bar 22 in the collapsed position shown in broken lines in FIG. 3. Transverse bar 22 is then rotated with respect to the lower leg tube 36b in a counter-clockwise direction to unscrew bolt 28a from tube connector 28. Elastic cords 40 may then be neatly wrapped around transverse bar 22 and platform bars 26 in collapsed position, and hooks 40b engaged in openings 29a, thus providing the separated cart 21 in compact, portable form. For use of tripod 30 without reassembly with cart 21, a non-slip cap 37 may be slipped onto the bottom end of lower tube 36b without interference by tube connector 28, cap 37 being readily removable for reassembly of unit 20.
In keeping with the scope of the invention contemplating use of a wide variety of tripods and extendable leg constructions in combination with cart 21 as well as various modifications of the latter in achieving the hereinbefore described desired capabilities of cart and tripod unit 20, FIG. 8 shows a tripod leg 46 having an upper, outer tube 46a, a lower, inner tube 46b and a locking collar 46c therebetween, all of conventional construction. An example of a locking collar construction is shown in FIG. 12 and hereinafter described. While it is clearly understood that a female component of the separable connecting means such as connector 28 will function with lower, inner tube 46b of leg 46 in substantially the same manner as hereinbefore described with respect to lower, outer tube 36b of leg 36, FIG. 8 shows the female component as a plug 58 having a threaded axial bore for engaging male component, threaded bolt 58a. Plug 58 is secured in tube 46b by a set screw 46d which may also extend through belt 42, securing the latter to tube 46b. Belt 42, serving as an alternative to short elastic cord 41, may have a buckle (not shown) for releasably fastening the other two tripod legs to leg 46.
FIG. 7 shows a modified form of cart 51 comprising an elongated transverse bar 52 mounting wheels 55 in caster forks 53 provided with toe operated brakes 53a. Caster forks 53 are attached by bolts 54 and nuts 54a and are provided with suitable means for preventing relative rotation between caster forks 53 and transverse bar 52, for example, downturned ends of the latter similar to ends 22a of cart 21 (not shown), or roll pins 54b extending through aligned openings in transverse bar 52 and in the horizontal cross-piece of caster fork 53.
Spaced platform bars 56, which function in a manner similar to bars 26 of cart 21, are each pivoted at one end 56a thereof on a pivot pin 57 which may likewise be similar to pivot pin 27 of carrier 21. Each bar 56 has an opposite free end downturned as a short vertical leg 56b which may also have an opening 56c for anchoring an elastic retaining cord 40 thereto. Upstanding stops to serve as rear barrier means are provided as angle bars 59, being alternatively somewhat higher than comparable angle bars 29 of cart 21. Cart 51 also illustrates an alternative location for angle bar 59 wherein attachment ends 59a are mounted by pivot pins 57 on pivoted ends 56a of platform bars 56 and are fastened to pivot with the latter by roll pins 59c in the well understood manner so that upstanding bars 29 align with the platform facing side of transverse bar 52 when platform bars 56 are in the extended, operative position shown in FIG. 7. Openings 29b are formed at the upper ends of angle bars 59 for releasable engagement by hooks 40b of elastic cords 40.
Transverse bar 52 has bolt 58a secured to upstand from its center in the manner similar to bolt 28a of cart 21 thereby providing for separable assembly of cart 51 with a tripod leg fitted with a female component, such as, component 28 or 58.
The invention also contemplates the separable attachment of cart 21 or 51 to tripods having extendable legs of cross-section other than circular, such as, channel-shaped or triangular, by adapting to such legs female components of the connecting means comparable to self-locking tube connector 28 or a fitted plug retained by a set screw comparable to plug 58 or the like.
A cart and camera support unit particularly directed to video cameras and their recording equipment is shown in FIGS. 9 to 13, inclusive, as cart and unipod unit 60 comprising a two-wheeled cart 61 separably mounting unipod 70 herein shown to include a pair of telescoping tubes, namely, an outer, lower tube 75 and inner, upper tube 76. Video camera CC may be mounted on a conventional universally adjustable pan head 73 having handle 74, similar to pan head 33 and handle 34 of tripod 30, pan head 73 being attached to the upper end of tube 76. Any conventional means may be provided to releasably lock telescoping tubes 75 and 76 in relative adjusted positions. FIG. 12 illustrates a locking means seen to include a collar 77 internally threaded onto external threads terminating the upper end of outer tube 75 and a split ring 78, made of tough plastic material, such as nylon, located within collar 77 and surrounding the portion of inner tube 76 projecting from the upper end of outer tube 75. Split ring 78 has a bottom feathered edge adapted to extend between the tubes 75 and 76 and lock the two together as pressure is applied to the upper edge of ring 78 by the inwardly projecting flange 77a of collar 77 when the latter is threaded downwardly onto outer tube 75. A resilient ring 73a also surrounds inner tube 76 above collar 77 to damp any impact of pan head 73 against collar 77 due to uncontrolled or accidental retraction of unipod 70.
Cart 61 comprises elongated transverse bar 62 mounting beneath and at opposite ends thereof caster forks 63 with wheels 65, and mounting on the upfacing side of bar 62 a barrier assembly 69, a pair of spaced pivoted bars 66 providing the collapsible platform, and the male member 68a of the separable connecting means between cart 61 and unipod 70. Transverse bar 62 may be of solid construction similar to bar 52 of cart 51, or as seen in FIGS. 9 and 13 may be an extrusion to provide light weight and rigidity having a center bore substantially rectangular in cross-section and a longitudinal centralized slot on one surface, herein shown as the bottom surface, communicating with the center bore.
Each of the spaced bars 66 has one end 66a thereof pivotally secured to transverse bar 62 by a suitable pivot pin 67. The opposite free end of each bar 66 is downturned to provide vertical legs 66b which may terminate in plastic caps 66c for ground engagement and coaction with wheels 65 as the four point support for unit 60.
The separable connecting means between unipod 70 and cart 61 includes bolt 68a as the threaded male component attached to upstand from the center of transverse bar 62 in a manner similar to bolt 28a of transverse bar 22, and tube connector 68 as the female component secured in the bottom end of lower tube 75 in the same manner as connector 28 is secured in lower tube 36b of tripod leg 36.
Rear barrier assembly 69 includes a pair of angle bars 69a having upstanding portions 69b, the upper ends of which are connected by transverse member 69c, portions 69b and member 69c being located forwardly of transverse bar 62 and unipod 70, as seen in FIGS. 9, 11 and 13. Bolts 64 and nuts 64a serve to secure both the caster forks 63 and angle bars 69a to transverse bar 62, a lock washer 64b being provided on bolt 64 between caster fork 63 and bar 62 to prevent relative movement therebetween.
A suitable strap means is also provided for cart 61 to retain video recording equipment R or other luggage on the platform formed by spaced bars 66 and against rear barrier assembly 69. Such strap means may be elastic retaining cords similar to cords 40, or, as here shown, may be a two section luggage strap 80 of woven fabric webbing, each section being permanently attached at one end to vertical legs 66b by suitable rivets 80b, the other ends of the sections being releasably and adjustably secured together by a buckle 80a attached to one of the sections in the well understood manner.
Electric wiring between camera CC and equipment R, which usually connects to one or both components by removable terminal plugs, has been omitted from the drawings.
The operation of cart and unipod unit 60 will be clear from FIGS. 9 and 13, the weight of video recording equipment R on extended bars 66 contributing to the stability of unipod 70 and camera CC while the latter is in operation with the aid of handle 74. Unipod 70 is readily separated from cart 61 by unscrewing the connecting means components 68 and 68a, and bars 66 folded against transverse bar 62 in the same manner and for the same purpose as hereinbefore described for cart 21 and tripod 30. When unipod 70 is separated from cart 61, a non-slip ground engaging cap, similar to caps 37 of tripod 30 may be slipped onto the bottom end of outer tube 75 concealing tube connector 68 and completing unipod 70 for its usual intended use.
Cart and camera support units and the two-wheeled cart constructions for separably connecting to the bottom ends of one of the legs of conventional camera tripods or to unipods herein disclosed are seen to achieve the several objects of the invention and to be well adapted to meet conditions of practical use. As various possible embodiments might be made of this invention, and as various changes might be made in the disclosed units and cart constructions, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not in a limiting sense. | A two-wheeled collapsible cart comprises a transverse bar having one wheel mounted on a caster fork beneath each opposite end thereof, a pair of symmetrically spaced bars pivotally mounted on the transverse bar providing therewith a collapsible platform and a pair of upstanding barrier bars. The bottom end of a lowermost section of an extendable leg of a camera tripod or unipod from which the non-slip cap has been removed is fitted with an element of a separable connector which engages a companion element mounted on a midportion of the transverse bar. Each spaced pivoted bar terminates in a downturned foot which cooperates with the wheels as a four point ground engaging support for the platform and the mounted upstanding tripod or unipod when the bars are in extended position. The handle of a conventional pan head which adjustably supports the camera on the tripod or unipod also serves as a manipulative handle for the cart when the platform, carrying the camera equipment, is tilted from the four point ground engaging position for transport on the two wheels. A strap is located for encircling the three tripod legs for retention in closed parallel position when the legs are retracted. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to sewing machines.
A sewing machine is known from U.S. Pat. No. 1,242,403 which has a so-called skipping feed, which roughly performs a square movement. An upper feed means performing a movement of the same type is associated with this skipping feed. The skipping feed and the feed means are necessarily disengaged from the workpiece during the insertion of the needle thereinto and during looping during the upward movement of the needle. During this time a presser foot, resiliently displaceable against its drive, driven in the movement cycle and in the particular movement direction of the needle, is pressed from above against the workpiece, so that the latter is pressed against the throat plate or the base plate of the lower arm which surrounds it. Thus, in the vicinity of the stitching point, the workpiece is either fixed between the feed and the feed means or between the throat plate and the presser foot. The small-area construction of the presser foot is intended to ensure a relatively easy rotatability of the workpiece, in order to be able to follow major curves or angles of the seam to be produced.
German Patent Specification No. 399873 discloses a mending sewing machine, which does not have a feed dog. Its presser foot is in each case raised by the workpiece, when the needle has been removed therefrom and is engaged again when the needle is inserted. This enables the material to be moved, which is performed in a completely free manner by the operator and can be in a random direction.
SUMMARY OF THE INVENTION
The object of the invention is to provide a sewing machine which permits workpieces to be turned as easily as possible during sewing in order to follow complicated seam profiles easily.
Accordingly, the present invention provides a sewing machine comprising a feed dog for a workpiece to be sewn, said feed dog having a workpiece conveyor performing a skipping feed and adapted to be positioned beneath the workpiece, a presser foot fixed to a presser foot bar, at least one needle, an arm shaft for raising and lowering said needle and a lifting gear for raising the presser foot from the workpiece during the stitching cycle of said needle, said lifting gear being constructed in such a way that during the insertion of said needle during its downwardly directed movement and roughly until it reaches the bottom dead center thereof, the presser foot is raised from the workpiece.
The essence of the invention is that during the insertion of the needle, i.e. during the downward movement thereof from the instant of insertion to the bottom dead center, the workpiece is not subject to any contact pressures from above, apart from the minor compressive forces, caused by the friction between needle and workpiece during insertion and which are in fact desirable for ensuring a clean engagement of the workpiece on the throat plate in the stitch formation zone. During this time, the workpiece can be turned in a completely free manner, which makes matters much easier in the case of heavier materials, such as leather or heavy fabrics, e.g. canvas or the like. However, in the case of very soft materials, these measures ensure that the seam profile can be effected in sharply curved portions or even in corners, without causing distortion of the workpiece. Owing to the fact that turning takes place precisely around the inserted needle, a fine appearance of the seam profile is ensured, so that such measures can in particular be used when producing pot seams, i.e. seams which are visible from the outside, but also in general for producing form seams.
Preferably, the lifting gear has a cam plate drive which is arranged to be driven by said arm shaft and which is coupled to the presser foot bar by means of a transmission rod.
The lift by which the presser foot is raised from the workpiece is desirably adjustable. This measure is particularly advantageous for adapting to different compressibilities of the workpiece material. The position to which the presser foot can be raised from the workpiece may also be adjustable. This measure is appropriate to use for adapting to particularly thin or particularly thick workpieces.
According to a preferred embodiment the presser foot is constructed as a support for a rotating, intermittently drivable feed means. The feed means may comprise a timing belt. These measures are particularly advantageous for producing crinkle-free seams.
If it is to be ensured that with an otherwise manual guidance of the workpiece, the seam to be produced has a constant spacing with respect to the workpiece edge, a stop plate may be provided having a bearing edge facing the needle. The spacing between the needle and the bearing edge is desirably adjustable.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described, by way of example, with reference to the drawings, in which:
FIG. 1 is a rear view of one embodiment of a sewing machine according to the invention;
FIG. 2 is a side view of the sewing machine taken in the direction of the arrow II in FIG. 1;
FIG. 3 is a plan view of the base plate of the sewing machine base plate taken in the direction of the arrow III in FIG. 1;
FIG. 4 is a perspective view taken in the direction of the arrow IV in FIG. 1; and
FIGS. 5a to 5c show the stitch formation area of the sewing machine taken in the direction of the arrow V in FIG. 1 and showing different phases of the needle movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, a sewing machine 1 is provided on its top surface with a lower arm constructed as a base plate 2 and which is received in a workpiece supporting plate 3. A hollow upper arm 4, i.e. constructed in the form of a housing, is fixed to the base plate 2. An arm shaft 5 is mounted in rotary manner in said upper arm 4 and is provided at one end with a handwheel 6 and with its free end terminates in a not shown, conventional, crank gear, which is used for driving a needle bar 7 with a needle 8. A presser foot bar 9 is displaceably mounted in the upper arm 4 (FIG. 2) and to its lower end is secured a presser foot 10. The presser foot 10 is constructed with a guide roller 11 and a groove 12 for receiving a timing belt 13. The presser foot bar 9 is surrounded by a compression spring 14, one end of which is supported by means of a disk 15 on the upper arm 4, while the other end of which is supported on a bearing block 16, which is fixed by means of a setscrew 17 to the presser foot bar 9. To the bearing block 16 is hinged a tie rod 18, whose free end is held and guided in a rotary, adjustable manner in an oblong hole 20 of a lever 21 by means of an adjusting screw 19. This oblong hole fixture is used for adjusting the height of lift a of the presser foot 10 and consequently to bring about adaptability to different conpressibilities of the workpiece materials. The lever 21 is fixed to a shaft 22, which is rotatably mounted in the arm 4. One end of a lever 24 is adjustably fixed by means of a clamping connection 23 to the shaft 22, said lever having a recess 25 for receiving a roller 27 which is rotatably mounted on a bolt 26. The roller 27 is in contact with a cam disk 28 secured in angularly adjustable manner to the arm shaft 5. At its free end 29, i.e. at the end opposite to the clamping connecting 23, the lever 24 has a bearing surface 30. A one-way pneumatic cylinder 31 is secured by screws 32 to the upper arm 4 and has a piston rod 33 which projects into the upper arm 4 above the arm shaft 5 and which can co-operate with the bearing surface 30 of the lever 24. The above-described mechanism, which is in driving connection with the presser foot bar 9, forms a lifting gear H. Adjustment of the height a of the bearing block 16 on the presser foot bar 9 and/or a corresponding adjustment to the clamping connection 23, makes it possible to adapt the stroke length of the presser foot 10 to different workpiece thicknesses.
A shaft 36, extending parallel to the arm shaft 5, is pivotably mounted in bearings 34, 35 on the upper arm 4 (FIG. 1). One end of the shaft 36 projects into a not shown ratchet brake with laterally positioned bearings (Torrington type). Such constructions are, for example, known from U.S. Pat. No. 4,271,776. This ratchet brake is connected to a crank 37. Laterally of the bearing 35, the shaft 36 is axially fixed by means of an adjusting ring 38 and its other end, facing the presser foot 10, is connected in non-rotary manner with a gear wheel 39, around which passes the timing belt 13. A rocking lever 40 is pivotably mounted on the shaft 36, said lever being provided with a cap 41 covering the gear wheel 39 and a downwardly radially extending lever 42 (FIG. 2). The lower end of the lever 42 carries a guide member 44 for the timing belt 13 which is fixed to the lever 42 by means of a screw 43. One end of a guide lever 45 is fixed by a shoulder screw 46 to the lever 42 and its other end is secured to the presser foot bar 9.
Within the upper arm 4 is arranged a conventional stitch regulating gear 47, which is connected with a crank 49 by means of a tie rod 48. The crank 49 is mounted in non-rotary manner on a sliding shaft 52 which is mounted in bearings 50, 51 below the base plate 2, while a further crank 53 is fixed in non-rotary manner to the shaft 52. Cranks 53 and 37 are connected in driving manner by means of a tie rod 54. The sliding shaft 52 is provided with a feed fork 55, connected by means of a bolt (not shown) to a conveyor beam 56, which is supported by a crank (not shown) on an eccentric lug of a shaft (not shown) connected to the arm shaft 5 by means of a timing belt gear 57. In the vicinity of the needle 8, a feed dog 58 is arranged on the conveyor beam 56. A throat plate 62 having a recess 60 for the feed dog 58 and a stitch hole 61, is secured by means of screws 59 to the base plate 2. A stop plate 63 is adjustably fixed, by means of a screw 66 engaging in an elongated slot 65 in said stop plate 63, to the base plate 2, so that the distance between a bearing edge 64 of the stop plate 63 and the stitch hole 61 and consequently the distance from a seam to the workpiece edge is adjustable. In general, the bearing edge 64 is linear and runs parallel to the conveying direction of the feed dog 58. In addition, in the conveying direction, the bearing edge 64 extends on either side of a vertical line through the stitch hole 61, so that the workpiece edge can be guided in all cases tangentially to the bearing edge 64. The presser foot 70 and the feed dog 58 form a feeding device. As generally usual, the feed dog 58 performs a four-motion feed movement causing a skipping feed.
Operation takes place as follows. It is assumed that before the start of working, the needle 8 of the sewing machine is in its uppermost position and, due to the operation of the working cylinder 31, the presser foot 10 is in the raised position. The operation of the working cylinder 31, i.e. the extension of its piston rod 33, ensures, through the co-operation of said rod 33 with the bearing surface 30, that the lever 24 is pivoted around the shaft 22, so that simultaneously the lever 21 is rotated. The upward movement of the lever 21 is transmitted by means of the tie rod 18 to the bearing block 16, so that the presser foot bar 9 is raised against the force of the compression spring 14, so that the presser foot 10 is disengaged from the throat plate 62. During the upward movement of the presser foot bar 9, by means of the guide lever 45, the lever 42 and consequently the guide member 44 is pivoted away from the presser foot bar 9, so that the timing belt 13, constructed as the upper material displacement means, remains in the tensioned position. By operating the cylinder 31, the roller 27 is simultaneously moved out of the action area of the cam disk 28.
A workpiece W, which in FIG. 3 is shown in exemplified manner in the form of a shirt cuff, is placed in the initial position A on the base plate 2 of the sewing machine 1, the outer workpiece edge being engaged with the bearing edge 64 of the stop plate 63.
On operating a not shown starting button of a control means, initially the pneumatic working cylinder 31 is reversed, so that the presser foot 10 is lowered on to the workpiece W. On rotating the arm shaft 5, an oscillatory movement is produced in the stitch regulating gear 47, which causes an intermittent movement of the shaft 36 and consequently the timing belt 13, as the upper material displacement means, due to the ratchet brake located in the crank 37.
Simultaneously, the feed dog 58 performs a feed movement, so that the workpiece W is moved in the direction of arrow 67. As soon as the tip of the needle 8 stitches the workpiece W, cf. FIG. 5b, the cam disk 28 with its operating cam 28' runs on to the roller 27 of the lever 24, so that the latter is pivoted. By means of the lever 21, the presser foot bar 9 and consequently the presser foot 10 is raised by a small amount from the workpiece W, which corresponds to the height of lift a. Simultaneously, the feed dog 8 has assumed a position in which it is located below the bearing surface for the workpiece W, i.e. below the surface of the throat plate 62. As no frictional forces are now exerted by the timing belt 13, in the form of the upper material displacement means, or the feed dog 58 on the workpiece W, the latter can be easily turned or can be aligned with respect to the bearing edge 64 of the stop plate 63. During further stitch formation, the needle 8 performs its downward stroke into the lowermost position, i.e. down to bottom dead center, where it performs an upward movement, at the beginning of which the loop lifting movement necessary for stitch formation takes place. When, during its downward movement, the needle 8 reaches bottom dead center, the presser foot 10 is again lowered on to the workpiece W, due to the corresponding shaping of the operating cam 28' of the cam disk 28, so that during the formation of the thread loop (FIG. 5c), which is seized by hook G, the workpiece W is held firmly on the throat plate 62. The presser foot 10, which simultaneously carries a circulating material displacement means (timing belt 13), at this time simultaneously fulfils the function of a presser pad for the workpiece W. The needle 8 is moved further upwards during the further stitch formation cycle. When the needle 8 has left the workpiece W, the latter is again moved and the operation can be repeated to form another stitch.
The invention is not restricted to the above described embodiment but modifications and variations may be made without departing from the scope of the invention as defined by the appended claims. | A sewing machine with a workpiece feed comprises a feed dog positioned below the workpiece providing a four-motion feed movement. A presser foot is fixed to a presser foot bar and can be raised from the workpiece during the stitching cycle by a lifting gear to ensure turning of the workpiece. This makes it possible to follow complicated seam patterns. The lifting gear is constructed in such a way that the presser foot is raised from the workpiece while the needle perforates the material, during its downwardly directed movement approximately up to its bottom dead center position. | 3 |
INTRODUCTION
[0001] This invention was supported in part by funds from the U.S. government (NIH Grant No. AI40686) and the U.S. government may therefore have certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] Mononuclear phagocytes (monocytes and macrophages) are critical components of both innate and acquired immunity and are found in virtually every tissue of the body, including the central nervous system. Mononuclear phagocytes participate in both antibody dependent and independent cytotoxicity, phagocytosis and killing of bacteria, destruction of effete erythrocytes, presentation of antigens for T cell activation, and secretion of a wide variety of inflammatory cytokines.
[0003] The secretion of inflammatory cytokines, as well as mononuclear phagocyte effector functions, are greatly influenced by soluble mediators. For example, priming by interferon gamma (IFNγ) and exposure to lipopolysaccharide, tumor necrosis factor alpha (TNFα), interleukin-1 (IL-1), or granulocyte-macrophage colony stimulating factor (GM-CSF) can stimulate mononuclear phagocytes to secrete inflammatory cytokines such as TNFα, IL-1 and interleukin-6 (IL-6) (Auger, M. J. and J. A. Ross. 1992. In: The Macrophage: the natural Immune System , New York: Oxford University Press, pp. 1-74). Interleukin-10 (IL-10; originally known as cytokine synthesis inhibitory factor) has been shown to inhibit the expression of a wide range of inflammatory cytokines in vitro (Berkman, N. et al. 1995. J. Immunol. 155:4412-4418; de Waal Malefyt, R. et al. 1991. J. Exp. Med. 174:1209-1220) as well as in vivo (Chernoff, A. E. et al. 1995. J. Immunol. 154:5492-5499; van der Poll, T. et al. 1997. J. Immunol. 158:1971-1975). Glucocorticoids, interleukin-4 (IL-4) and interleukin-13 (IL13) have also been shown to down regulate the expression of inflammatory cytokines produced by mononuclear phagocytes. In addition to inhibiting the release of inflammatory cytokines, glucocorticoids have also been shown to upregulate the expression of CD163 on mononuclear phagocytes (Hogger, P. et al. 1998. Pharm. Res. 15:296-302; Hogger, P. et al. 1998. J. Immunol. 161:1883-1890; Wenzel, I. et al. 1996. Eur. J. Immunol. 26:2758-2763).
[0004] CD163 is a mononuclear phagocyte restricted antigen which is a member of the cysteine rich scavenger receptor family group B. Normal human macrophages stain brightly for CD163 and glucocorticoid treatment in vivo increases CD163 expression (Zwadlo-Klarwasser, G. et al. 1992. Int. Arch. Allergy Immunol. 97:178-180; Zwadlo-Klarwasser, G. et al. 1990. Int. Arch. Allergy Immunol. 91:175-180). It has been suggested that these CD163 bright macrophages may play a role in the resolution of inflammation as they are found in high numbers in inflamed tissues (Zwadlo, G. et al. 1987. Exp. Cell Biol. 55:295-304) and have been shown to release an incompletely characterized anti-inflammatory mediator (Zwadlo-Klarwasser, G. et al. 1995. Int. Arch. Allergy Immunol. 107:430-431).
[0005] One mononuclear phagocyte marker that bears a striking resemblance to CD163 is p155 (Morganelli, P. et al. 1988. J. Immunol. 140:2296-2304). Expression of this 134 kDa (non-reduced)/155 kDa (reduced) glycoprotein is restricted to mononuclear phagocytes and upregulated by glucocorticoid treatment. It has now been found that CD163 is identical to P155 and that this molecule could have activity as an anti-inflammatory molecule. Thus, this glycoprotein is believed to be useful as a biomarker for inflammation and inflammatory conditions and processes in humans.
[0006] A method has now been developed for detection of CD163 in human plasma. This method is useful in monitoring inflammation and inflammatory processes in humans.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to provide a method for detecting CD163 in a biological sample, preferably a plasma sample, which comprises contacting the biological sample with a CD163 capture antibody and a CD163 detection antibody, so that levels of CD163 in the biological sample can be quantified. The method of the present invention is particularly useful for monitoring the course of an inflammatory condition or process.
[0008] Another object of the present invention is to provide a composition for prevention and treatment of inflammation which comprises CD163. In one embodiment, the composition further comprises a glucocorticoid.
[0009] Another object of the present invention is to provide a method for reducing signs and symptoms of inflammation which comprises contacting cells or tissues with the CD163 molecule, either alone or in combination with a glucocorticoid.
[0010] Yet another object of the present invention is to provide a method for preventing or treating inflammation in an animal which comprises administering to an animal an effective amount of a composition comprising CD163 either alone or in combination with a glucocorticoid.
DETAILED DESCRIPTION OF THE INVENTION
[0011] CD163 is a glucocorticoid inducible member of the scavenger receptor cysteine rich family of proteins. It is known that CD163 is highly expressed on human macrophages but has been reported to be found on less than 50% of peripheral blood monocytes. It has now been found that, contrary to previous reports, more than 99% of all CD14 positive monocytes express CD163. It has also been found that IL-10, like glucocorticoids, induces higher CD163 expression on cultured human monocytes. Glucocorticoid-induced CD163 expression has also been examined and found to be due to an IL-10 independent mechanism since it was not inhibited by anti-IL-10 and was additive with IL-10 treatment. It has also been found that p155, a previously identified monocyte/macrophage marker of unknown function, is the same as CD163. The fact that CD163 is upregulated by potent anti-inflammatory mediators such as glucocorticoids and IL-10 indicates that CD163 may be an important anti-inflammatory molecule and a potential biomarker for inflammation and inflammatory conditions.
[0012] Previous studies using mAbs RM3/1, Ber-Mac3 and others had reported that only 0%-40% of circulating monocytes are positive for CD163 (Hogger, P. et al. 1998. Pharm. Res. 15:296-302; Hogger et al. 1998. J. Immunol. 161:1883-1890; Zwadlo, G. et al. 1987. Exp. Cell Biol. 55:295-304; Backe, E. et al. 1991. J. Clin. Path. 44:946-953 ; van den Heuvel, M. et al. 1999. J. Leuk. Biol. 66:858-866). However, previous studies with another antibody to p155, a molecule that has been shown to be identical to CD163, Mac 2-48, has consistently demonstrated that virtually all freshly isolated monocytes are positive for CD163. To address the possibility that sub-optimal detection of the lower affinity RM3/1 and Ber-Mac3 antibodies (previously used only with FITC labeled secondary antibodies) might account for this discrepancy, freshly isolated PBMCs were stained with FITC conjugated AML 2.23 (anti-CD14) and biotinylated RM3/1 or biotinylated Mac248, followed by detection with SAPE.
[0013] Although Mac2-48 staining was slightly higher, virtually all CD14 bright PBMCs were positive for both RM3/1 and Mac 2-48, while most CD14 dim or negative PBMCs were negative. When PBMCs were gated for CD14 bright cells, greater than 99% were positive for both RM3/1 and Mac 2-48, while the P3 control mAb detected less than 1% of the gated cells. Virtually identical results are obtained when highly purified monocytes were used in place of fresh PBMCS. These results indicate that CD163 is expressed on nearly all CD14-positive circulating monocytes.
[0014] To assess whether different cytokines could influence CD163 expression, freshly isolated PBMCs were cultured for 24 hours in the presence of various cytokines, 200 nM DEX (as a positive control for CD163 upregulation), or control media. The cells were then subjected to staining and flow cytometric analysis.
[0015] Treatment of PBMCs for 24 hours with IL-10 alone or the synthetic glucocorticoid DEX alone increased monocyte CD163 expression by approximately 4- and 7-fold, respectively (p<0.01). Combined DEX plus IL-10 treatment resulted in significantly higher CD163 expression than when monocytes were cultured with DEX only or IL-10 only, indicating an additive effect when glucocorticoid treatment was used in conjunction with IL-10 (p<0.01). None of the other cytokines tested had a statistically significant effect on monocyte CD163 expression at the concentrations used, and none significantly increased or decreased the DEX-induced upregulation of expression. The increased expression of CD163 by IL-10 and glucocorticoid treatment was also demonstrated by western blots of monocyte lysates. These data indicated that CD163 upregulation plays an important role in the anti-inflammatory actions of glucocorticoids.
[0016] In order to determine whether the increased expression of CD163 on monocytes is due to increased RNA and protein synthesis, northern blots were performed on monocyte lysates. Monocytes were treated for 8 hours with either IL-10, the glucocorticoid FP or control media. CD163 mRNA levels increased from undetectable to strong bands with the addition of IL-10 or FP. This indicated that the induction of CD163 by IL-10 or glucocorticoids is due, at least in part, to increased RNA and protein synthesis.
[0017] A dose-response relationship between IL-10 treatment and CD163 expression was established by culturing PBMCs for 24 hours in the presence of 0.1 to 100 ng/ml IL-10. The results were a sigmoidal dose response curve when levels of CD163 expression were related to IL-10 concentration. CD163 expression was increased approximately 3.5 fold by 10 and 100 ng/ml IL-10 treatment when compared to control (p<0.01).
[0018] It was possible that, in addition to direct effects on mononuclear phagocytes, DEX might upregulate CD163 expression indirectly by altering the amount of IL-10 produced by lymphocytes. In order to test this possibility, PBMCs were cultured with IL-10, DEX or control media in the presence or absence of a blocking anti-IL-10 IgG. Results showed that expression of CD163 was not significantly affected by the presence of anti-IL-10 in control or DEX treated cells. However, IL-10 upregulation of CD163 expression was inhibited by anti-IL-10 (p<0.01), where CD163 expression was reduced to near control levels. These findings indicate that DEX increased CD163 expression by an IL-10 independent mechanism.
[0019] In addition to testing the effects of cytokines in combination with glucocorticoids on levels of CD163, studies were performed to examine the effects of glucocorticoids in combination with lipopolysaccharide (LPS). Monocytes cultured with LPS alone had low levels of CD163 detected on their surface using an immunofluorescence technique for CD163 detection. Treatment of cells with DEX or IL-10 alone increased expression of CD163, as had been previously shown. However, when monocytes were cultured for 48 hours with DEX combined with LPS, their was a synergistic increase in CD163 expression, where the effect of DEX alone was increased by more than 2-fold when LPS treatment was added.
[0020] Additional in vitro studies with LPS showed that LPS induces shedding of monocyte surface CD163 within 2 hours, a result that was consistent with studies by others using the phorbol ester PMA. PMA has been shown to induce rapid shedding of surface CD163 from monocytes in culture, an effect that was blocked by protease inhibitors (Droste, A. Et al. 1999. Biochem. Biophys. Res. Commun. 256:110-113). Therefore, like PMA, LPS is capable of inducing CD163 shedding. LPS-induced shedding occurred even with monocytes that had been cultured for 48 hours in DEX and thus had 5- to 10-fold higher levels of surface CD163 than freshly isolated monocytes. In cells that had increased levels of CD163 due to treatment with glucocorticoids plus LPS, as reported above, the surface CD163 molecules are largely resistant to shedding induced by subsequent treatment with LPS, although they remained sensitive to PMA-induced shedding. This LPS-conferred resistance to subsequent LPS-induced shedding of CD163 is similar to reported endotoxin pre-conditioning for resistance to subsequent inflammatory insults.
[0021] The effect of the cytokine IL-10 was shown to be unique among the cytokines tested in that, like glucocorticoids, it augmented CD163 expression on freshly isolated mononuclear phagocytes. This increase in CD163 is thought to be a direct effect on monocytes, as studies using highly purified monocytes or the established human monocyte cell line THP-1 yielded results that were in agreement with those performed using PBMCs. In contrast, a number of other cytokines (including IL-4 and IL-13) did not upregulate CD163 expression at the concentrations tested. Even though IL-4, IL-10 and IL-13 have all been reported to inhibit monocyte production of inflammatory cytokines such as TNFA (Cosentino, G. et al. 1995. J. Immunol. 155:3145-3151; Joyce, D. A. et al. 1996. Cytokine 8:49-57; Joyce, D. A. et al. 1996 . J. Interferon Cytokine Res. 16:511-517), differential regulation of mononuclear phagocyte surface molecules by IL-10 and IL-4/IL-13 is not without precedent. For example, CD64, like CD163, is upregulated by IL-10, but not by IL-4 or IL-13 (de Waal Malefyt, R. et al. 1993. J. Immunol. 151:6370-6381; te Velde, A.A. et al. 1992. J. Immunol. 149:4048-4052).
[0022] When given in combination with DEX, IL-10 is the only cytokine tested that significantly increased CD163 expression over DEX treatment alone. Since the concentration of DEX used is >90% saturating for the glucocorticoid receptor and the dose of IL-10 used gives maximal CD163 induction, the additive effect of these treatments suggests that glucocorticoids and IL-10 influence CD163 expression by independent mechanisms. This conclusion is further supported by the finding that an anti-IL-10 antibody (which blocks the biological activity of IL-10) reduced the IL-10 induction of CD163 to control levels, but had no effect on the DEX induction of CD163. This demonstrates that the glucocorticoid effect is not dependent on elevated levels of extracellular IL-10 and does not upregulate CD163 expression by first increasing IL-10 synthesis and release.
[0023] The finding that either GM-CSF or IL-4 plus DEX does not enhance CD163 expression over DEX treatment alone contrasts with that of a recent report. While Van den Heuvel and colleagues (van den Heuvel, M. et al. 1999. J. Leuk. Biol. 66:858-866) found that neither GM-CSF nor IL-4 alone had any effect on CD163 expression, they detected a synergistic effect using either GM-CSF or IL-4 plus DEX. This disparity is likely due to differences in experimental procedures such as isolation technique, culture conditions and duration of stimulus. In the previous report, monocytes were purified by gradient centrifugation, lymphocyte resetting and monocyte adherence while the present studies used density centrifugation purified PBMCs. Furthermore, cells were treated for 24 hours, while in the previous study cells were treated for 2 days.
[0024] The dose response curve for the IL-10 effect on CD163 expression demonstrates a dynamic range of IL-10 concentrations that is from 0.1 ng/ml to 10 ng/ml. This is consistent with previous findings concerning the effect of IL-10 on a wide range of monocyte functions such as tissue. factor expression and associated procoagulant activity (Ernofsson, M. et al. 1996. Br. J. Haematol. 95:249-257; Ones, L. T. et al. 1996. Cytokine 8:822-827), as well as MIP-1α (Berkman, N. et al. 1995. J. Immunol. 155:4412-4418), metallo-proteinase (Lacraz, S. et al. 1992. J. Clin. Invest. 90:382-388) and TNF receptor (Hart, P. H. et al. 1996. J. Immunol. 157:3672-3680) expression.
[0025] The fact that CD163 is upregulated by potent anti-inflammatory mediators such as glucocorticoids and IL-10 indicates that this CD163 may be an important anti-inflammatory molecule. Further, these data provide support for the use of CD163 detection in biological samples, such as blood or plasma, as a means for detecting the presence of inflammation or inflammatory conditions in patients.
[0026] In order to provide for use of CD163 as a biomarker of inflammation, a method for detection of CD163 in biological samples such as plasma was developed. The assay of detection is an ELISA assay using a CD163-specific antibody such as MAC2-158 or MAC2-48 as the CD163 capture antibody and the commercially available biotinylated antibody RM3/1 as the CD163 detection antibody. Briefly, plates were coated with purified MAC2-158 or MAC2-48 antibody and incubated overnight at 4 C. After washing, non-specific binding was blocked by adding blocking buffer to each plate well and incubating for 30 minutes at room temperature. After washing, plasma samples to be tested were added and the plates are incubated overnight at 4 C. or at room temperature for 2 hours. After washing, the detection antibody was added, RM3/1, and the plates agin incubated. A streptavidin alkaline phosphatase tag was used and the plates were developed.
[0027] Using this assay, relative levels of CD163 were assayed in the plasma of 4 patients undergoing cardiac surgery performed with normothermic cardiopulmonary bypass. It is known that cardiac surgical patients exhibit a reproducible acute, inflammatory response as indicated by a rise in TNF, IL-6 and cortisol, followed by hepatic release of acute phase proteins. This response may be caused by several mechanisms, including tissue trauma, ischemia-reperfusion injury, exposure to foreign membranes (when cardiopulmonary bypass is used) and transient endotoxemia. In 4 of 4 samples from these patients that were tested, plasma CD163 increased approximately twofold at 60 minutes following cardiopulmonary bypass, and returning to slightly below baseline levels on post-operative day 1. In addition, levels of CD163 in plasma of these patients was shown to correlate with levels of interleukin-6 (IL-6) in plasma. This is an important finding because prior to surgical stress, infection, or other inflammatory processes, there is no detectable IL-6 in plasma of humans. Therefore, these data demonstrate the link of CD163 time-course with other markers of inflammation and provide the first demonstration that soluble CD163 acts as an acute phase protein during an inflammatory response.
[0028] In order to more closely mimic the in vivo inflammatory response to infection in a more controlled setting than the cardiac patients described above, healthy volunteers were administered a 4 ng/kg bolus infusion of LPS and monitored the levels of soluble CD163 in plasma. As described above, LPS had been shown to induce shedding of CD163 from monocytes in vitro. Plasma samples were taken at baseline (before administration of LPS), and then at various time points after LPS infusion up to 72 hours after infusion initiation. Levels of CD163 in plasma were measured using the assay of the present invention. Soluble CD163 levels in plasma increased as much as 7-fold compared to baseline levels, peaked at 1 to 2 hours, and remained elevated in 4 of 5 volunteers at 12 hours post LPS administration. In the one volunteer where levels had declined at 12 hours, levels remained elevated up to 4 hours before returning to baseline levels by 8 hours. Changes in levels of known acute phase proteins, glucocorticoids, and pro- and anti-inflammatory cytokines were also monitored in order to determine if their levels correlated with the appearance of soluble CD163 in plasma. Levels of CRP, an acute phase plasma protein secreted in hepatocytes in response to an inflammatory stimulus, increased in plasma by 8 hours but did not peak until 24 hours post LPS administration. Plasma levels of TNFA, IL-6 and IL-10, all known to be produced following LPS infusion, peaked at 1, 2, and 4 hours post LPS administration, respectively. Plasma cortisol levels began to increase at 4 hours post LPS administration but did not peak until 6 hours. Theses data demonstrated that soluble CD163 is one of the earliest changes induced by an acute inflammatory response that can be detected in plasma. Therefore, CD163 acts as an early signaling event in the inflammatory response cascade.
[0029] Accordingly, the present invention provides a method for detecting levels of CD163 in biological samples from individuals known to have or suspected of having inflammation or inflammatory conditions. By biological samples it is meant to include, but is not limited to, plasma, whole blood, serum, urine, sputum, semen, cerebrospinal fluid, or synovial fluid. The inflammatory condition can be due to variety of causes including, but not limited to, lupus, rheumatoid arthritis, infection, and surgery. The method involves contact of a biological sample, such as plasma, with a CD163-specific antibody such as MAC2-158 or MAC2-48, and then detection in the ELISA assay with a biotinylated antibody such as RM3/1. This method is particularly useful in monitoring for the presence or course of inflammation or inflammatory conditions in a patient.
[0030] The present invention also relates to compositions comprising CD163 for use in the prevention and treatment of inflammation in animals, including humans. In one embodiment of the invention, cells or tissues are contacted with CD163 and inflammation is prevented, suppressed or reversed. In another embodiment, a composition comprising CD163 in a pharmaceutically acceptable vehicle is administered to an animal suffering from inflammation or an inflammatory disease so that the inflammation or inflammatory disease is treated. Successful treatment is indicated by a reduction in the signs and symptoms of inflammation including a reduction in the presence of inflammatory mediators, such as cytokines. CD163 can be administered alone or in combination with another anti-inflammatory agent such as a glucocorticoid. In the context of the present invention, “effective amount” is an amount of CD163 capable of producing a desired pharmacological effect such as a reduction in the signs and symptoms of inflammation. Selection of additional anti-inflammatory agents to be administered in conjunction with CD163 can be performed routinely by one of skill in the art. Selection of the amount of CD163 to be administered can also be performed routinely by one of skill based upon results such as the cell culture studies presented herein.
[0031] The following non-limiting examples are provided to better illustrate the present invention.
EXAMPLES
Example 1
Isolation and Culture of Peripheral Blood Mononuclear Cells (PBMCs)
[0032] PBMCs were isolated from heparinized human whole venous blood using Ficoll-Hypaque (d=1.077g) after the method of Böyum (Boyum, A. 1968. Scand. J. Clin. Lab. Invest. Suppl. 97:77-89) . PBMCS were then washed three times with hepes buffered RPMI 1640 (Hazelton Biologicals, Lenexa, Kans.)/0.05% gentamicin (Elkins-Sinn, Inc., Cherry Hill, N.J.)/1% fetal bovine serum (FBS) (Hyclone Laboratories, Inc., Logan, Utah).
[0033] For cytokine treatment studies, isolated PBMCs were suspended in hepes buffered RPMI 1640/0.05% gentamicin/10% FBS at a concentration of 2.0×10 6 to 2.5×10 6 cells/ml and cultured in 96 well plates at 37° C. and 5% CO 2 in the presence of various mediators (Table 1). Mononuclear cells were stained for flow cytometric analysis after 24 hours in culture unless otherwise indicated. This enhanced cell recovery because monocytes, which initially adhere to plastic vessels, transiently detach from culture wells at 24-48 hours.
Example 2
Staining and Flow Cytometric Analysis
[0034] All staining procedures were performed at 4 C. Briefly, cultured PBMCs were incubated with normal human IgG (6 mg/ml) to block Fc receptor-specific binding of mAbs and 30 μg/ml of the isotype control mAb P3 or a saturating amount of mAb MAC2-48 (20 μg/ml) for one hour. Cells were then washed and stained for one hour with 17.5 μg/ml FITC labeled goat F(ab=) 2 anti-mouse Ig. The cells were again washed and fixed with 1% methanol free formalin.
[0035] For two color studies, cells were stained for one hour with 20 μg/ml biotinylated MAC2-48, RM3/1, or P3 plus 20 μg/ml FITC AML 2.23 or FITC control mouse mAb in the presence of at least 2 mg/ml normal human IgG in a total volume of 60 ml. After staining with primary mAbs, cells were washed and stained with SAPE at a 1:40 dilution. Flow cytometric analysis was performed on washed, unfixed cells soon after staining.
[0036] Cell fluorescence of monocytes gated using forward and side scatter was analyzed using a Becton Dickenson FACScan (Franklin Lakes, N.J.). Mean fluorescence intensity (MFI) was calculated by subtracting the MFI of the P3 stained mononuclear cells from the MFI of the corresponding Mac 2-48 stained cells.
Example 3
Northern Hybridization
[0037] Human monocytes were isolated and cultured overnight as described for western blots. Monocytes were then stimulated for 8 hours with 5 ng/ml IL-10 (R&D Systems) or 10 −8 M FP. Total RNA was isolated from IL-10 stimulated, glucocorticoid stimulated and control monocytes as described by Dreier, et al. (Dreier, J. et al. 1998. DNA Cell Biol. 17:321-323). 10 μg of total RNA per sample were electrophoretically separated in a 1% agarose, 2% formaldehyde gel and transferred onto a Hybond N + nylon membrane (Amersham Inc., Arlington Heights, Ill.) in 20× saline-sodium citrate (SSC) using an LKB 2016 VacuGene blotting apparatus. Antisense RNA probes for northern hybridization were generated from linearized DNA templates using a digoxigenin RNA labeling kit (Boehringer Mannheim, Mannheim, Germany) and T7 RNA polymerase (New England Biolabs, Schwalbach, Germany) as described by the manufacturer. Prehybridization was performed at 68° C. for 1 hr in a high SDS hybridization buffer (7% SDS, 5× SSC, 50% formamide, 50 mM sodium phosphate, 2% casein, 0.1% N-lauroylsarcosine, pH 7.0). Subsequently the heat-denatured probes (10 minutes at 95° C.) were added to the pre-hybridization solution (100 ng/ml) and hybridized at 68° C. for 16 hours. The nylon membrane was washed twice for 5 minutes at room temperature in a 2× SSC, 0.1% SDS solution and twice for 15 minutes at 68° C. in 0.5× SSC and 0.1% SDS. The hybridization results were visualized by chemiluminescent detection with anti-digoxigenin Fab=fragments conjugated with alkaline phosphatase and substrate CSPD as described by the manufacturer (Boehringer Mannheim). Equal loading of samples was examined by hybridization of RNA with an actin antisense RNA probe.
Example 4
ELISA Assay for CD163
[0038] ELISA plates were coated, 100 μl per well, with 5 μg/ml purified MAC2-158 (coating buffer of 0.1 M NaHCO 3 0.5 M NaCl, adjusted to pH 8.4 with HCl). Plates were incubated overnight at 4 C. and then washed 4 times with wash buffer (1× phosphate buffered saline and 0.05% Tween 20). Nonspecific binding was blocked by adding 200 μl blocking buffer to each well (phosphate buffered saline with 10% FBS) and incubating the plates for 30 minutes at room temperature. Plates were then washed 3 times with wash buffer. 100 μl plasma (1:10 dilution) was added and the plates incubated overnight at 4 C., or for 2 hours at room temperature. Each plate was washed 4 times with wash buffer. The detection antibody RM3/1 was added in blocking buffer (100 μl; phosphate buffered saline+10% FBS)) and the plates were incubated for 1 hour followed by washing 4 times with wash buffer. Streptavidin alkaline phosphatase (1/1000) was added in blocking buffer and the plates were incubated for 30 minutes at room temperature, followed by 4 washes with wash buffer. The reaction was developed with a PNPP system by dissolving one 15 mg PNPP tablet (Sigma Chemical Co.) in 15 ml PNPP diluent (0.05 M Na 2 CO 3 , 0.001 M MgCl 2 , pH 9.75) and adding 100 μl of solution to each well. Plates were developed for 5 to 30 minutes. 100 μl 1 M NaOH was added to stop the reaction. The plates were read on a spectrophotometer at 405 nM. | Methods for detecting the inflammatory biomarkers molecule CD 163 in biological samples are provided. Also provided are methods for monitoring the course of an inflammatory process or condition in a patient and compositions and methods for preventing and treating inflammation and inflammatory processes. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to a process of fabricating an elongated glass body, particularly a preform for optical waveguides on the basis of SiO 2 , in which a porous body is formed from powdery glass starting material and such body is sintered to obtain the glass body.
One such process is described in a copending commonly owned U.S. Pat. application Ser. No. 703,793, in which it is proposed to fill powdery glass starting materials with compositions changing in the radial direction under precompaction, into a compression mold from several coaxially disposed conveyor tubes. The fill-in pressure effecting the pre-compaction is effected therein either by screw conveyors or by a centrifugal force. In any case, the coaxial arrangement of various conveyor tubes and the simultaneous conveyance of different materials involves a considerable investment in appartus, which is a pronounced disadvantage.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to avoid the disadvantages of the prior art.
More particularly, it is one of the objects of the invention to provide a process of producing glass bodies from pulverulent material formed into porous bodies and then sintered, which avoids the disadvantages of the conventional processes of this type.
It is yet another object of the present invention to develop a process of this type which would render it possible to fabricate the glass bodies from such porous bodies with a high degree of reliability and dependability.
A concomitant object of the present invention is to provide a process of the above type which allows simplification of the apparatus used to perform the process so that this appartus is simple in construction, inexpensive to manufacture, easy to use, and reliable in operation nevertheless.
In pursuance of these objects and others which will become apparent hereafter, one feature of the present invention resides in a process of fabricating elongated glass bodies, particularly preforms for optical waveguides, from pulverulent starting materials, especially such including SiO 2 , comprising the steps of filling a plurality of pulverulent starting materials with different compositions one at a time into respective mutually adjacent coaxial confining zones of a confining space in such a manner as to be pre-compacted during the filling step and to form a pre-compacted composite body in the confining space; compressing the pre-compacted composite body subsequently to the filling step to convert the pre-compacted composite body into a porous composite body; and sintering the compressed porous composite body into the glass body.
BRIEF DESCRIPTION OF THE DRAWING
Above-mentioned and other features and objects of this invention will become more apparent by reference to the following description taken in conjuction with the accompanying drawing, in which:
FIG. 1 is a partially sectional side elevational view of a device for filling the powdery starting material into a compression mold illustrative of the type of apparatus usable in performing the process proposed by the invention; and
FIG. 2 is a longitudinal sectional view of a part of a conveying device for forming a tubular porous body that is usable in performing the inventive process.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following, the invention will now be described as it is to be used for fabricating a preform for optical waveguides, with the starting material containing SiO 2 as its base material, which, for the purpose of changing the refractive index, contains, as a rule, one or more doping agents such as GeO 2 , P 2 O 5 , F, or B 2 O 3 . It should be pointed out, however, that the process according to the invention is also suitable for fabricating articles other than optical waveguides, so long as the starting material which comes in question therefor is capable of being manufactured in powder form and of being compressed into a porous body, and the latter is capable of being sintered into a glass body.
The device as shown in FIG. 1 which is identical to that disclosed in the above-mentioned U.S. Pat. application Ser. No. 703,793 and is shown and described here for illustrative purposes only, comprises a storage bin 1 containing the powdery glass starting material, with the interior of the bin 1 being sealed against the ambient atmosphere.
Inside the storage bin 1, near its bottom, there is arranged a screw conveyor 3 which is driven by an external motor 2, with the aid of which the powder material contained in the stroage bin 1 can be conveyed through an elongated conveying tube 4 out of the storage bin 1. The conveying tube 4 projects into a compression mold which is to be filled with the powder material. In the given example, the compression mold is a flexible hose 5 which, at its end lying in the conveying direction, is closed by a cover 6. The fill-in pressure is produced in that the screw conveyor 3 passes the material by the conveying force produced by its motor 2 in direction toward the cover 6, and in that the cover 6 is acted upon by a counterforce in opoosition to the conveying direction.
A shape-stabilizing rigid body 7, constructed as a double-walled tube whose inner wall is perforated as shown in the drawing, and whose inner space between the two walls is capable of being subjected to either an increased or a reduced pressure, surrounds the hose 5 and thus forms a support for the hose 5 in the radially outward direction. To effect a pressure variation, an opening with a tubular joint (or socket) 8 is provided for in the outer wall of the tube 7, on which a conduit leading to a vacuum pump can be slid. The vacuum pump, such as a water-jet pump, produces in the interspace between the walls of the tube 7 a suction pressure which, through the perforated inner wall, acts upon the hose 5, pulls it in direction toward the inner wall and expands it to such an extent as to be smoothly applied to this inner wall. The thus constructed rigid shape retaining body 7, accordingly, simultaneously permits preexpansion of the hose 5 and a shape stabilization of the hose 5 during the fill-in process.
For sealing the interspace between the conveying tube 4 and the pre-expanded hose 5, the outlet end of the conveying tube 4 is surrounded by a sealing ring 9 which is attached to the conveying tube 4 and is operative for providing a constant frictional force between the conveying tube 4 and the pre-expanded hose 5, which force is not dependent on just how far the conveying tube 4 projects into the compression mold 5.
The end of the compression mold 5 lying in the conveying direction is sealed by the already mentioned cover 6 which, on its side facing the compression mold 5, is provided with a truncated cone-shaped extension 10 which is pushed to the end of the tube 7 that is covered by the hose 5, in such a manner that its jacketing surface is firmly applied to the tube end, thus sealing the latter. The cover 6 is attached to the tube 7 with the aid of holding means that is not shown, such as a clamp, which is capable of being mounted to the outside of the tube 7, or by a cap surrounding the cover 6 and capable of being screwed on to the outside of the tube 7.
When filling the powder material into the described compression mold 5, the material is pre-compacted by the action of the fill-in pressure. In the course of this operation, the conveying force of the screw conveyor 3 pushes the entire compression mold 5 inclusive of the shape retaining body 7 in opposition to the counterforce acting upon the cover 6, away from the conveying tube 4 in the conveying direction until, in this way, almost the entire interior space of the hose 5 is filled with the pre-compacted powder material. The motion of the compression mold 5 relative to the conveying tube 4 during the feed operation is indicated by an arrow shown below the compression mold 5, pointing in the conveying direction.
Following the fill-in operation, the vacuum pump is turned off and the air conduit is removed from the tube joint or socket 8. The pre-expanded hose 5, owing to the filled-in pre-compacted powder material, remains in its expanded state. The compression mold 5, inclusive of the shape retaining bod 7 surrounding it, is now removed from the fill-in device and is inserted into the hydraulic fluid of an isostatic press after its other end has also been closed by a cover corresponding to the cover 6 described hereinbefore. The hydraulic fluid of the isostatic press enters through the tube joint or socket 8 into the interspace of the double-walled tube 7, with the air contained therein escaping either through this joint or socket 8 as well, or through a further opening which is additiobally provided but has not been shown. Thereupon, the isostatic press subjects the hydraulic fluid to a pressure ranging between 100 and 300 bar, with this pressure acting through the perforated inner wall of the tube 7 upon the outer side of the pre-expanded hose 5 for pressing the latter together in the radial direction, so that the desired porous body will result. Although the isostatic press exerts a uniform pressure from all sides upon any structure contained in its hydraulic fluid, the pressure, in the present case, owing to the tube ends being closed by rigid covers 6, only acts in the radial direction upon the compression mold 5, so that during the compression process the longitudinal dimension of the filled-in material remains unchanged.
Upon completion of the pressing operation, the tube 7 is removed from the isostatic press, one or both covers 6 are opened, and the compressed body surronded by the hose 5, is removed from the tube 7. After this, the hose 5 is again expanded and the pressed porous body is removed therefrom. Prior to any further processing, it may become necessary to mechanically process the porous body on its surface until it shows to have the desired geometrical shape, for example, by way of grinding the surface.
The porous body is next subjected to a physical and/or chemical cleaning. As a physical cleaning there may be used cleaning in an electric arc or in a high-voltage plasma, and as a chemical cleaning there may be used heat treatment in a chlorine-containing atmosphere in order thus to remove from the porous body an possible impurities in the form of hydroxyl groups and transition metals.
The porous body which, owing to the described process, has a homogeneous material composition, can now be further processed into an optical waveguide, for example, in that it, by way of sintering, is transformed into a glass body, with the latter then being drawn out into a glass fiber.
In principle, the fill-in operation as described with reference to FIG. 1 can also be applied to such cases in which the porous body to be formed has no homogeneous composition, but a material composition changing in the radial direction. This is possible in that, in contradistinction to the foregoing part of the specification, where the compression mold 5 was described as having the shape of a hollow cylinder, so that the subsequently following compression would in any case result in a rod-shaped porous body, is designed in such a way that the resulting formed porous body is of tubular shape. For this purpose there is used a screw conveyor which, unlike the screw conveyor 3 as shown in FIG. 1, does not convey the material within the area of its axis, but within an area having a circular ring-shaped cross section disposed coaxially in relation to its axis of rotation. One such screw conveyor is shown in FIG. 2.
This type of screw conveyor 20 rotates in the interspace between an inner tube 21 and an outer tube 22 disposed coaxially in relation thereto, about the inner tube 21, so as to convey the powdery glass starting material through this interspace into the compression mold 3 and into an area coaxially distant from the axis.
At its front end, the arrangement as shown in FIG. 2 comprises two sealing rings 23 and 24 for sealing the area within which the powdery material is conveyed into the compression mold and which, just like the sealing ring 9 in the arrangement as shown in FIG. 1, provide for a constant position-independent frictional force. The inner sealing ring 23 is mounted to the inside of the inner tube 21 and is applied to the outer side of the rod-shaped or tubular base body, whereas the outer sealing ring 24 is mounted to the outer side of the outer tube 22 and is applied to the inner side of the hose 5 in the case of the compression mold 5 as shown in FIG. 1.
As the compression mold 5 for forming a tubular body there may be used either the type of compression mold 5 as shown in FIG. 1, which would have to be slightly modified, or else a compression mold as shown in FIG. 2. The modification of the compression mold 5 as shown in FIG. 1 consists in that, along its longitudinal axis and extending from one to the other end thereof, there is disposed a rod or a tube, for example, of silica glass which can be mounted e.g. at the cover 6 in a central recess and, following the fill-in process, in a corresponding recess of the other cover. The screw conveyor of the type as shown in FIG. 2 now conveys the powdery material in a way corresponding to that described hereinbefore with reference to FIG. 1, into the interspace between this rod or tube and the pre-expanded hose 5. Following the compression process, the rod-shaped or tubular base body can be easily removed from the center of the compressed porous body.
According to the invention, the filling of the compression mold which is shown in FIG. 1, is carried out as follows: as proposed above with respect to the fabrication of a tubular body, also with the process according to this invention, a rod-shaped base body, that is, a rod or a tube, for example, of silica glass, is disposed in the compression mold which is modified to accommodate such base body along the longitudinal axis by extending in the center from the one end to the other, and a powdery glass starting material is filled in such a way into the interspace between this base body and the inside wall of the compression mold with the aid of a screw conveyor, as to be pre-compacted in the course of this filling operation. The filled-in material, for example, has a composition which is suitable for the cladding of an optical waveguide. By the pre-compaction, the filled-in material is given such a consistency that the base body, upon completion of the fill-in process, can be removed without the filled-in material dropping into the resulting hollow space. It was surprisingly discovered that it is indeed possible to give the particulate material during the filled-in process such a consistency that the thus formed tubular body will be self-supporting and will thus serve to externally delimit the internally located confining zone, thus in effect serving as a mold for the following filled-in operation. Upon removal of the base body, a further powdery glass starting material in a different composition, such as core material, and likewise under a pre-compaction, is filled into the hollow space.
When this last mentioned material is to have a composition which is constant throughout the cross section, it is filled in in the way as shown in FIG. 1, with the aid of a centrally disposed screw conveyor and with the previously filled in tubular body serving to externally delimit the space being filled. When the composition of the material is to vary throughout the cross section, as is necessary for an optical waveguide having a graded index profile, then, following the removal of the base body, another base body of smaller diameter is disposed in the center of the hollow space along the longitudinal axis, and a powdery glass starting material of a still different composition is filled into the interspace with the aid of a screw conveyor of the type as shown in FIG. 2 which is adapted to the interspace, and under a precompaction, with the base body thereafter being removed and the next base body being introduced, etc., until finally the remaining hollow space is filled with a material suitable for the central area, with the aid of a centrally disposed screw conveyor. Accordingly, the first fill-in process is repeated several times with a varying material composition, with respectively a different base body and a screw conveyor adapted thereto, until the remaining hollow space is filled.
The process described hereinbefore, in which the adjacent coaxial areas of the compression mold are filled one at a time in turn, offers the advantage that each of the different fill-in steps can be controlled individually and independently of the others with respect to the fill-in pressure and the fill-in speed.
It should still be mentioned that in every phase of the described process, from the stage of fabricating the powdery starting material to the sintering into an elongated glass body suitable for use as a preform, care must be taken for preventing the material from becoming contaminated.
For this purpose, it is preferable for the storage bins containing the powder material to be always airtightly sealed, and for the feeding of the material into the compression mold to be carried out in a sealed atmosphere, for example, in an evacuated glove box. Into this glove box, the one conveyor tube or a plurality of such conveyor tubes projects from the outside through a vacuum-sealed passage. The compression mold is removed from this glove box only after it has been closed on both sides with a cover, and is then placed into the isostatic press.
A further measure for avoiding contaminations resides in that the heat treatment of the porous body is carried out in a chlorine-gas atmosphere, with the subsequent sintering into a glass body being carried out in an apparatus which is constructed to keep the porous body, during the heat treatment in the chlorine-gas atmosphere, for example, in that the porous body is moved from a low elevation toward a higher elevation through a first zone in which the heat treatment is carried out, and from there immediately into a second zone in which the sintering is carried out.
While we have described above the principles of our invention in connection with specific apparatus, it is to be clearly understood that this description is made only by way of example and not as a limitation to the scope of our invention as set forth in the objects thereof and in the accompanying claims. | For fabricating porous bodies from a glass starting material, particularly in connection with the fabrication of an optical waveguide preform, it is proposed to fill powdery glass starting material under a pre-compaction into a compression mold, and to compress it thereafter. When the porous body to be formed is to have a varying composition in the radial direction, as is necessary with a view to step index optical fibers or optical waveguides having a graded index of the refractive-index profile, then differently composed powdery glass starting materials are filled one at a time, in adjacent coaxial areas, into the compression mold. This is effected with respect to each of the individual areas with the aid of a screw conveyor under a continuous, adjustable pressure and at an adjustable conveying speed. If more than two coaxially disposed areas of different composition are to result, the corresponding material is filled several times in succession into the interspace between a base body disposed in the center of the compression mold in the longitudinal direction thereof, and the inside wall of the deposited material, before the central area is filled. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application of U.S. patent application Ser. No. 10/989,986, filed Nov. 16, 2004, the benefit of the earlier filing date of which is hereby claimed under 35 U.S.C. §120, and the entire contents of which are hereby incorporated by reference.
FIELD OF ART
[0002] The present invention is directed to a secure cabling system, and more specifically to a modular cabling system with secure junctions.
BACKGROUND
[0003] Security concerns have grown in recent years, including concerns over infrastructure security. Data and communication infrastructures have increased in importance as more individuals, businesses, and government organizations increase reliance on these infrastructures. Consequently, security for data and communication infrastructures has grown in importance. One substantial aspect of these infrastructures is the cabling and connections needed to form networks and other communication pathways.
[0004] Cabling systems in buildings are typically installed above suspended ceilings or below raised floors. Often, cables are simply routed on the framework of suspended ceilings and/or on the subfloor below raised floors. Some cables may be routed in raceways or conduits to better organize the routes and/or to aesthetically route cables within the space between the ceiling and floor. Distribution boxes and panels may also be used to subdivide large trunk lines into smaller branch lines that may be further subdivided and/or connected to computing and/or communication devices. To enable easy reconfiguration of the cabling, individual tiles of suspended ceilings and/or raised floors can be removed to access the cables and/or the distribution boxes. This easy access can create a security issue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates an exemplary embodiment for securing communication cable connections in floor and/or ceiling spaces of a building interior space;
[0006] FIG. 2 illustrates an exemplary embodiment of a concealed distribution box installed below raised floor with one floor tile removed;
[0007] FIG. 3 illustrates an exemplary embodiment of a double height concealed distribution box installed below a raised floor with one floor tile removed;
[0008] FIG. 4A is an isometric view of the double height concealed distribution box with its doors removed and no distribution cassettes or communication cables installed;
[0009] FIG. 4B an isometric view of the double height concealed distribution box with its doors 66 a and 66 b installed and closed;
[0010] FIG. 5A is an isometric view of side-access concealed distribution boxes;
[0011] FIG. 5B is an isometric view of a rear portion of side-access concealed distribution box;
[0012] FIG. 6A is an isometric view of an integrated distribution box with its cover and door removed;
[0013] FIG. 6B is an isometric view of an integrated distribution box with its cover and door installed;
[0014] FIG. 7 is an isometric view of a lockable wall outlet;
[0015] FIG. 8A is a top view of an exemplary security fastener; and
[0016] FIG. 8B is a front view of the exemplary security fastener.
DETAILED DESCRIPTION
[0017] The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments by which the invention may be practiced, This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Among other things, the present invention may be embodied as methods or devices. Accordingly, the following detailed description is, therefore, not to be taken in a limiting sense.
[0018] Throughout the specification, the term “connected” means a direct connection between the things that are connected, without any intermediary devices or components. The term “coupled,” means a direct connection between the things that are connected, or an indirect connection through one or more either passive or active intermediary devices or components. The term “cable” and “line” mean a communication medium. The meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.”
[0019] Briefly stated, the invention is direct to securing cable connections such as communication connections and/or electrical connections. FIG. 1 illustrates an exemplary embodiment for securing communication cable connections in floor and/or ceiling spaces of an internal space of a structure, such as a building interior space 10 . A floor space is created between a fixed floor 12 and a removable tile floor 14 . The removable tiles are supported above fixed floor 12 by floor supports such as floor support 16 at the corner of each tile. Other supports can be used along tile edges and/or central portions of the tiles. In this exemplary embodiment, each floor tile is fastened to one or more floor supports, although the tile need not be fastened. To further prevent access to the floor space, the tiles can be secured to the floor supports with security fasteners that can not be removed with a conventional tool such as a flat head screwdriver, a phillips head screwdriver, an allen wrench, a socket wrench or other conventional fastener tool. An exemplary security fastener is illustrated in FIGS. 8A and 8B . Security fasteners can also be used for attaching other components described below. The floor tiles can be covered by carpet tiles and/or other floor coverings. A similar configuration is provided for a ceiling space of building interior space 10 . A suspended ceiling 18 generally comprises a set of ceiling tiles supported by a framework that is supported from a fixed ceiling (not explicitly shown).
[0020] A communication distribution panel 20 is generally secured in a locked room or other space. Communication cables are routed into the floor space and/or into the ceiling space. A conduit 22 and/or raceways can be used to control routing. Trunk lines, such as trunk lines 24 a through 24 f , are muted in the floor space and/or ceiling space from communication distribution panel 20 to distribution boxes, such as concealed distribution boxes 30 a , and 30 b , and/or 130 . Trunk lines can also be routed to distribution boxes or outlets, such as integrated distribution boxes 40 a and 40 b , that pass through a hole in a floor, ceiling, wall, furniture, or other surface. The trunk lines can be prefabricated to predefined lengths and can be color coded for different communication protocols and/or purposes. The trunk lines can also be prefabricated with keyed connectors on one or both ends of each trunk line to prevent connection errors during installation. The types of connectors include RJ45 connectors, SMA connectors, FC connectors, ST connectors, twist-lock connectors, and the like. Alternatively, or in addition, a bunk line can be coupled to a distribution cassette (not show) that splits the trunk line into multiple branch line connections.
[0021] The distribution cassette, connector, and/or bare wire ends are installed inside a distribution box. A concealed distribution box can be accessed by removing a floor tile or a ceiling tile, respectively. An integrated distribution box extends at least partially through a floor tile and/or a ceiling tile such that the integrated distribution box is accessible without removing an entire tile. An integrated distribution box can be flush with a tile surface, recessed below a tile surface, or extend beyond a tile surface. In any case, locking mechanisms on the concealed and integrated distribution boxes prevent access to an interior cavity of the distribution boxes where the cassettes, connectors, and/or bare wires ends are located.
[0022] Additional trunk lines and/or branch lines, such as branch lines 26 a - 26 d , can be extended from the distribution boxes to other parts of the building interior. For example, branch line 26 a can be routed under the raised floor, up into a wall 15 , and coupled to a wall outlet 50 . Wall outlet 50 can include a locking mechanism to prevent access to branch line 26 a and/or to prevent access to an end of a device cable 28 a that is connected to a communication device, such as telephone 52 . Another branch line 26 b can be routed under the raised floor and directly into a piece of furniture 54 to a furniture outlet 56 . Furniture outlet 56 can also include a locking mechanism to prevent access to branch line 26 b and/or to prevent access to an end of another device cable 28 b , which is illustrated connected to a computer 58 . Alternatively, or in addition, a branch line 26 c can be routed directly out of an integrated distribution box, such as out of door 42 of integrated distribution box 40 a Door 42 includes a locking mechanism to prevent access to connections within integrated distribution box 40 a . Door 42 also prevents removal of branch line 26 c , which is shown connected to a portable computer 59 . As illustrated, branch lines can also be routed above ceiling tiles and/or dropped down to devices with or without conduits.
[0023] FIG. 2 illustrates an exemplary embodiment of concealed distribution box 30 installed below raised floor 14 with one floor tile removed. Trunk lines, such as trunk lines 24 a and 24 b , are routed through trunk openings 32 a and 32 b , respectively, of the concealed distribution box. Similarly, branch lines, such as branch lines 26 a , 26 b , and 26 d , are routed through branch openings, such as branch openings 34 a and 34 b . Connectors of the trunk lines and the branch lines are accessible via doors 36 a and 36 b , respectively. The doors are lockable with locking mechanisms 38 a and 38 b , respectively. Each lock can be keyed differently. The different keying can be done individually or by security classification (e.g., top secret classification versus secret classification), or both. Other locking mechanisms can include pad locks, and the like.
[0024] FIG. 3 illustrates an exemplary embodiment of a double height concealed distribution box installed below raised floor 14 with one floor tile removed. The doors of the distribution box are also removed, providing easier visibility of the internal portion of a multi-sided housing 60 . In this view, it is easier to see that connectors on trunk lines 24 g and 24 h are connected to distribution cassettes 70 a and 70 b , respectively. The distribution cassettes distribute trunk line fibers or wires (not shown) to branch line jacks, which interface with branch line connectors, such as branch line connector 74 a . In this embodiment, there are four distribution cassettes that are coupled to a connector panel 65 . Connector panel 65 is generally shaped as an “L” flange with slots for the distribution cassettes on one leg of the “L” and door hinges 67 a - 67 d attached to the other leg of the “L.”
[0025] FIG. 4A is an isometric view of the double height concealed distribution box with its doors removed and no distribution cassettes or communication cables installed. This distribution box and other embodiments are generally formed as multi-sided housing 60 surrounding a cavity 61 within which distribution cassettes, cable connectors, and cable ends can be installed. At least a portion of one side of the housing is open. A door enables access to cavity 61 . The housing, doors, and other components can be formed of metal, plastic, wood, composites, or other materials.
[0026] One or more trunk openings, such as trunk openings 62 a - 62 d, are formed or cut into housing 60 . The trunk openings are sized to allow the diameter of one or more trunk lines to fit in a trunk opening. However, the trunk openings are limited in size and/or positioned such that an end of a trunk line within the distribution box can not be accessed when the doors are closed. This can be accomplished by sizing the trunk opening smaller than a trunk line connector at the end of the trunk line within the distribution box. Alternatively, or in addition, the trunk opening can be offset, or otherwise located at a position that prevents access to the end of the trunk line through the trunk opening with a conventional tool. As a further security measure and/or to assist in cable routing, the trunk lines can be connected to a cassette at an angle, such as the angled corners shown in FIG. 3 .
[0027] Similarly, one or more branch openings, such as branch openings 64 a - 64 h are formed or cut into housing 60 . The branch openings are also sized and/or positioned such that an end of a branch line within the distribution box can not be accessed when the doors are closed.
[0028] Attached to housing 60 within cavity 61 is connector panel 65 . One or more slots, such as slots 69 a - 69 d are formed or cut in one leg of connector panel 65 . The slots can be used to secure distribution cassettes and/or to install individual connectors. Some or all of the connectors on the trunk lines and branch lines can be keyed with predefined slots, holes, pins, and/or other configurations to ensure that they couple only to mating jacks on the distribution cassettes and/or on individual jacks installed in connector panel 65 .
[0029] Also formed in or attached to housing 60 is a locking means. Housing 60 illustrates lock flanges 68 a and 68 b , which include a hole through which a padlock can be inserted to lock the doors.
[0030] FIG. 4B an isometric view of the double height concealed distribution box with its doors 66 a and 66 b installed and closed. In this embodiment, the doors are coupled with hinge pins (not shown) to hinges 67 a - 67 d , which are attached to the connector panel inside the housing. Other closure means are possible. For example, a door could pivot about a vertical pin, such that the door remains in the same plane as it rotates open about the vertical pin. Another example includes a door that slides in grooves formed near the edges of the housing.
[0031] FIG. 5A is an isometric view of side-access concealed distribution boxes 130 a and 130 b . These concealed distribution boxes can be stacked together, such as by bracket 140 , for installation in a ceiling space, a high floor space, a storage closet, or other concealed area. Bracket 140 can include threaded holes that do not to all the way through bracket 140 . Fasteners can then be installed from within the distribution boxes through aligned holes in the distribution boxes to bracket 140 , so that the fasteners are not accessible when the distribution boxes are locked shut. Alternatively, bracket 140 can be riveted to each distribution box or attached in other conventional ways. Flanges 150 a and 150 b can be used to secure one or more concealed distribution boxes to a support surface. Each side-access concealed distribution box includes at least one side door, such as doors 136 a - 136 d . The doors can be sized according to the size of cable connectors. For instance, the doors may be lager for metallic cables than for fiber optic cables. The doors can be opened and closed by rotation about pins, such as pins 170 a - 170 c. The pins are accessible only from the inside of the boxes. Alternative door mechanisms are possible, such as rotating the doors about hinges attached to any edge of a door opening. The doors are secured in a closed position by locking mechanisms, such as key locks 194 a - 194 d . Each lock can be keyed differently. The different keying can be done individually or by security classification (e.g., top secret classification versus secret classification), or both. A key lock can control a latch mechanism 138 that engages with a latch bracket (not shown) on the inside of a door. Other locking mechanisms include pad locks, combination locks, and the like. Distribution cassettes (not shown) can be mounted to a connector panel 165 to provide sets of distribution jacks 174 a and 174 b . Branch lines (not shown) can be routed from corresponding jacks through an opening, such as a branch line slot 134 , in a housing 160 .
[0032] FIG. 5B is an isometric view of a rear portion of side-access concealed distribution box 130 a . Branch line slots 134 a - 134 d are illustrated relative to trunk line slots 132 a and 132 b , which form openings through door 136 a . The trunk line openings and can be formed through the housing. However, locating the trunk line openings in the door can provide a little more room to accommodate trunk line connectors and a bend in the trunk lines. The trunk line connectors are coupled to distribution cassettes within the box housing for distribution by corresponding branch lines. Both the trunk line slots and branch line slots are sized to prevent a person from accessing a connector within the box.
[0033] FIG. 6A is an isometric view of an integrated distribution box 40 with its cover and door removed, Integrated distribution box 40 includes a housing 80 that is also generally formed as a multi-sided box to form a cavity 81 . Housing 80 includes trunk openings, such as trunk openings 82 a and 82 b . In this embodiment, the trunk openings are circular holes within a surface of housing 80 , which would be concealed by a floor or ceiling tile. However, the housing generally extends through a floor or ceiling tile. Support flanges 86 a - 86 d can be attached to housing 80 to help support a floor or ceiling tile.
[0034] Within cavity 81 , one or more connector panels, such as connector panels 85 a and 85 b , are attached to housing 80 . One or more distribution cassettes can be installed in the connector panels. Alteratively, or in addition, branch jacks, such as branch jack 84 , can be installed in the connector panels. Branch line connectors can then be coupled to the distribution cassettes and/or branch jacks. The branch line connectors and mating jacks can be keyed, color coded, and/or otherwise configured to ensure that intended connections are made.
[0035] FIG. 6B is an isometric view of an integrated distribution box 40 with its cover 90 and door 42 installed. Door 42 includes one or more slots, such as a slot 92 , that are large enough to allow cables to pass through, but small enough to prevent cable connectors from passing through. Door 42 also includes a locking mechanism. For instance, a key lock 94 can control a flange 96 to lock door 42 . Other locking mechanisms include a deadbolt, a pin, and the like.
[0036] FIG. 7 is an isometric view of lockable wall outlet 50 , which is configured similar to the integrated distribution box. Lockable wall outlet 50 includes a door 100 that has one or more slots, such as slots 102 a and 102 b , that are large enough to allow cables to pass through, but small enough to prevent cable connectors from passing through. Door 100 also includes a locking mechanism, such as a key lock 104 and a corresponding flange 106 . Other doors and locking mechanisms can be used to prevent access to cable connectors that are coupled to jacks within a cavity of the lockable wall outlet, such as jack 108 . Lockable wall outlet 50 can also be used as a furniture outlet, such as furniture outlet 56 shown in FIG. 1 .
[0037] FIG. 8A is a top view of a security fastener 110 for attaching a floor tile to a floor support and/or for attaching other components to other supports and/or to each other. FIG. 8B is a top view of a security fastener 110 . Security fastener 110 is illustrated as a screw, however, other embodiments include, a bolt, a knob, a latching device, and the like. A head 112 of security fastener 110 includes recessed holes 114 a - 114 c positioned in a triangular pattern. A corresponding tool (not shown) includes pins arranged in a pattern that matches recessed holes 114 a - 114 c . The pins of the tool are inserted into recessed holes 114 a - 114 c , and the tool is rotated in a manner similar to a screwdriver. However, the tool is not a conventional flat head screwdriver, phillips head screwdriver, alien wrench, socket wrench, or other conventional tool. Instead, the tool is specially designed and not readily available, making security fastener 110 difficult to remove.
[0038] The above specification, examples, and data provide a complete description of the manufacture and use of the composition of the invention. For example, the secure cabling system can be installed in mobile structures and/or vehicles that include a removable floor, ceiling, wall, or other surface. Alternatively, the secure cabling system can be implemented within furniture. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | Secure cable connections in a structure. Cables are routed between a fixed surface and a removable surface to connectors within a lockable enclosure. Removable surfaces include raised floors, suspended ceilings, and the like that generally comprise tiles for access to an area between the removable surface and the fixed surface. Cable connectors are coupled to distribution panels, distribution cassettes, individual jacks, and/or other connectors within the lockable enclosure, which prevent unauthorized access to the cable connections. Cables are prefabricated to desired lengths with color coding and/or keyed connectors. Distribution cassettes, panels, jacks, and/or other connectors are also prefabricated with matching colors and/or keyed connectors to minimize installation time and connection errors. Lockable enclosures include concealed enclosures behind removable surfaces, integrated enclosures within removable surfaces, wall outlets, furniture outlets, and the like. The enclosures generally include a lockable door and openings that prevent access to, and/or removal of cable connectors. | 7 |
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to improvements in compressor systems adapted to provide clean dry compressed gas, particularly compressed air, at a discharge point therefrom, and an absorber configuration for use in such systems.
2) Description of Related Art
There is increasingly a need to provide moisture free pressurized gas, particularly compressed air, in many industries and applications. Such moisture free compressed gas or air is normally achieved by using separate add on gas drying equipment such as refrigeration driers. Such additional drying equipment is typically expensive to produce, and complicated and costly to operate. The objectives therefore of the present invention are to provide a simplified inexpensive system for producing clear pressurized gas including compressed air and an improved moisture absorber for use in such systems.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the present invention provides in one aspect, a gas compressor system including a driven gas compressor means adapted to receive gas to be compressed and discharge compressed gas therefrom, said discharged compressed gas being delivered to a moisture absorber configured to receive and circulate therethrough a fluid capable of removing moisture from the compressed gas prior to the compressed gas being discharged as a dry compressed gas through filter means to remove any remaining said fluid therefrom, said fluid being circulated through a circuit including a moisture stripping means adapted to receive a portion of the dry compressed gas discharged from the moisture absorber and passing said portion of the dry compressed gas in moisture exchange relationship with said fluid prior to reintroducing said fluid into said moisture absorber, said fluid being heated after leaving said moisture absorber and before entering said moisture stripping means. With such an arrangement the fluid within the circuit need not be particularly hygroscopic in nature but improved performance may be expected if the fluid is in fact hygroscopic in nature, i.e. capable of absorbing or attracting moisture. It has been surprisingly found that by heating the fluid before it enters the moisture stripping means improves overall performance by minimizing the amount of dry compressed gas that needs to be diverted from the dry compressed gas discharge line from the system. Overall efficiency of the system is preferably improved by utilizing waste heat generated by the gas compression means. Alternatively, the fluid may be heated by an independent heater provided to heat the fluid before entering the moisture stripper. Preferably the discharged compressed gas from said gas compressor means is passed initially through a first cooler means to condense at least a portion of the moisture carried by the compressed gas which is collected and removed from the compressed gas flow prior to entering said absorber.
According to a second aspect of this invention, there is provided a gas compressor system including a driven gas compressor means adapted to receive gas to be compressed and discharge compressed gas therefrom, said discharged compressed gas being delivered to a moisture absorber configured to receive and circulate therethrough a fluid capable of removing moisture from the compressed gas prior to the compressed gas being discharged as a dry compressed gas through filter means to remove any remaining said fluid therefrom, said fluid being circulated through a circuit including a moisture stripping means adapted to receive a portion of the dry compressed gas discharged from the moisture absorber and passing said portion of the dry compressed gas in moisture exchange relationship with said fluid prior to reintroducing said fluid into said moisture absorber, said fluid being cooled after leaving said moisture stripping means and before entering said moisture absorber. Again performance is improved if the fluid has hygroscopic characteristics.
In accordance with a further aspect, the present invention also anticipates providing a drier for drying compressed gas, said drier being adapted to receive compressed gas to be dried from a gas compressor means, the compressed gas being delivered to a moisture absorber configured to receive and circulate therethrough a fluid capable of removing moisture from the compressed gas prior to the compressed gas being discharged as a dry compressed gas through filter means to remove any remaining said fluid therefrom, said fluid being circulated through a circuit including a moisture stripping means adapted to receive a portion of the dry compressed gas discharged from the moisture absorber and passing said portion of the dry compressed gas in moisture exchange relationship with said fluid prior to reintroducing said fluid into said moisture absorber, said fluid being heated after leaving said moisture absorber and before entering said moisture stripping means.
In accordance with a still further aspect, the present invention also anticipates providing a drier for drying compressed gas, said drier being adapted to receive compressed gas to be dried from a gas compressor means, the compressed gas being delivered to a moisture absorber configured to receive and circulate therethrough a fluid capable of removing moisture from the compressed gas prior to the compressed gas being discharged as a dry compressed gas through filter means to remove any remaining said fluid therefrom, said fluid being circulated through a circuit including a moisture stripping means adapted to receive a portion of the dry compressed gas discharged from the moisture absorber and passing said portion of the dry compressed gas in moisture exchange relationship with said fluid prior to reintroducing said fluid into said moisture absorber, said fluid being heated after leaving said moisture absorber and before entering said moisture stripping means, said fluid being cooled after leaving said moisture stripping means and before entering said moisture absorber.
According to yet another aspect of this invention, a novel form of moisture absorber column is proposed for use in compressor systems of the above discussed types. According to this aspect, the present invention provides a moisture absorber column including an outer housing defining a vertically disposed absorption zone, a plurality of vertically spaced partition members traversing the absorption zone and each having a plurality of gas flow openings formed therein, at least one conduit member extending through an aperture in each said partition member to have a first portion extending upwardly from the partition member and a second portion extending downwardly towards the next adjacent said partition member located below said partition member, the conduit member having liquid flow means at or adjacent a lower end arranged to allow liquid flow from within the conduit member across the partition member located beneath said conduit member, said absorber column having liquid inlet means arranged to deliver liquid to the uppermost said partition member and liquid outlet means to withdraw liquid from a region below the lowermost said partition member, gas inlet means arranged to deliver gas to the region below the lowermost said partition member whereby said gas flows upwardly through the gas flow openings fanned therein, and gas outlet means arranged to withdraw gas from the absorption zone above the uppermost said partition member. Conveniently, the absorber liquid travels downwardly through the absorption zone as the gas travels upwardly through the absorption zone of the column. The liquid flows initially over or across the uppermost partition member and gas flowing upwardly through the gas flow openings formed therein causes the liquid to bubble or froth upwardly and into the upper ends of the conduit member or members to flow downwardly to the next adjacent partition member below where the process is repeated. In this way maximum contact is established between the gas flow and the liquid flow such that moisture from the gas flow can be collected by the liquid flow to effectively dry the gas flow. In some situations, it may be desirable to maintain a pool of liquid in the absorber through which the gas is bubbled before it reaches the partition members. In this manner, it is ensured that there is always some contact between the liquid and gas, even at start up of the system. Conveniently the pool of liquid is maintained below the lowermost absorber partition member.
In accordance with a still further preferred aspect of this invention, it is proposed to provide a novel module for use in constructing an absorber column as aforesaid. Absorber columns intended for use in gas compressor systems may typically be essentially constructed from an upright cylindrical casing of a relatively small diameter, of the order of 4 to 8 inches. This makes the internal construction of the absorber somewhat difficult and therefore costly. According to this aspect, it is desired to provide a module for use in constructing a moisture absorber column, the module including a partition plate member having a plurality of spaced gas flow openings formed therein, and at least one conduit member extending through an aperture in the partition plate member whereby a first portion extends upwardly from the partition plate member and a second portion extends downwardly below the partition plate member, the second portion having a closed lower end with one or more liquid flow openings located at or adjacent the closed lower end. Modules of this type may simply be positioned, one after the other in a cylindrical outer casing making the construction of same relatively simple. Moreover, the form of construction allows easy adjustment by permitting repositioning of the conduit members relative to the partition plate members to particular applications prior to fixing same into a desired optimum position.
The present invention also anticipates providing a gas compressor system including a driven gas compressor means adapted to receive gas to be compressed and discharge compressed gas therefrom, said discharged compressed gas being passed to a moisture absorber column as described above.
Still further, the present invention also anticipates providing a compressed gas drier including a moisture absorber column as described above adapted to receive compressed gas to be dried from a gas compressor means and deliver said compressed gas to said gas inlet means of the moisture absorber column, said liquid outlet means communicating with a moisture stripping column through which the liquid discharged from said moisture absorber column is passed with moisture picked up by said liquid being at least partially stripped from said liquid by a part of the dry compressed gas flow exiting the gas outlet means of the absorber column being diverted through said moisture stripping column, the liquid after passing through said moisture stripping column being delivered to the liquid inlet means of the moisture absorber column.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Various preferred embodiments and features of aspects of this invention will become clearer from the following description given in relation to the accompanying drawings, in which:
FIG. 1 schematically illustrates a first preferred embodiment of a gas compressor system according to the present invention;
FIGS. 2 and 3 schematically illustrate two further preferred embodiments of similar gas compressor systems;
FIG. 4 illustrates a still further embodiment of a gas compressor system while also illustrating features of a preferred absorber construction;
FIG. 5 illustrates the preferred absorber construction shown in FIG. 3 with a common gas receiver vessel; and
FIG. 6 illustrates in partial side view, further features of the preferred absorber construction;
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1 , the illustrated compressor system includes a rotary compressor unit 10 driven by a motor 11 which receives a gas (typically air) to be compressed at 12 via an inlet valve 7 . The rotary compressor unit 10 may be a screw compressor of any known configuration or in fact any other form of rotary compressor. The system further includes a separator vessel 13 receiving compressed gas and entrained lubricant via line 14 with a preliminary separation of gas and lubricant occurring therein. The lubricant is collected in a lower region of the vessel 13 and returned via line 15 and a lubricant cooler 16 to a lower pressure region of the compressor unit 10 . Compressed gas leaves the vessel 13 via a preliminary filter means 17 and a minimum pressure valve 18 . The compressor system thus described is essentially conventional in nature and within the context of this invention might be substituted by any other known similar rotary compressor system.
The compressed gas flow leaving the separator vessel 13 is conveniently cooled in a gas cooler device 19 such that at least a portion of the moisture is cooled, condensed, collected and drained away at 20 from the system. The cool humid compressed gas flow is then passed via line 21 to an absorption column 22 where a shower of cool dry hygroscopic fluid is falling. As the compressed gas flow passes upwardly through this shower, moisture is absorbed into the hydroscobic fluid flow conveniently originates via diverting a portion of the lubricant flow in line 15 through a line 23 and thereafter passing same through a further lubricant cooler 24 prior to delivering same to the absorption column 22 . In an alternative arrangement the diverted flow might be after the cooler 16 with or without further cooling.
The lubricant falls to the bottom of the absorption column 22 where it is collected and conveniently passed via line 25 back to line 15 or some other lower pressure region of the compressor circuit including the compressor unit 10 . This lubricant flow then mixes with the main lubricant flow where it is heated and the absorbed moisture flashes into vapour. This vapour is subsequently condensed in the gas after cooler device 19 and at least partially drained away at 20 .
The cool dry compressed gas flow leaving the absorption column 22 passes through a final filter means 26 so that no droplets of coolant can escape with the clean dry compressed gas discharge at 27 . Conveniently lubricant purge lines 3 , 3 ′ are operatively associated with each of the filter means 17 and 26 to return any collected lubricant back to a lower pressure portion of the compressor system such as the compressor unit 10 itself. Further possible changes to the system may include integrating the absorption column 22 into the separator vessel 13 whereby a secondary vessel is not required. Alternatively, the absorption column 22 might be integrated into the air receiver tank as shown in FIG. 5 .
Referring now to FIGS. 2 and 3 , there is illustrated a compressor system 9 including a gas compression device 8 which in the illustration is a rotary compressor device similar to that described in the foregoing with reference to FIG. 1 . It should, however, be recognised that any other form of gas compressor devices including reciprocating devices could be used.
Similar to the system described with reference to FIG. 1 , the compressed gas flow leaving the separator vessel 13 may be conveniently cooled in a gas cooler device 19 such that at least a portion of the moisture contained within the gas is cooled, condensed, collected and drained away at 20 from the system. The cool humid compressed gas flow is then passed via line 21 to an absorber column 22 , preferably in the form of an upright column where a shower of cool dry hygroscopic fluid is falling. As the compressed gas flow passes upwardly through this shower, moisture is absorbed into the hygroscopic fluid flow. It should be appreciated that any other form of absorber might be used.
The lubricant falls to the bottom of the absorber column 22 where it is collected and conveniently passed via line 25 in a closed circuit 6 back to the absorber column 22 via a heat exchanger 28 and line 29 . The heat exchanger 28 may take up heat from the returning hot lubricant in line 15 from the separator vessel 13 . Alternatively, an electric coil 31 might be used to heat the liquid in the aforementioned closed circuit. A still further alternative may be to use heat from the exiting compressed gas in the cooler 19 as shown in dashed outline. Such heating of the fluid conveniently minimizes the amount of dry compressed gas that needs to be diverted from the dry compressed gas discharge line as described hereinafter.
The cool dry compressed gas flow leaving the absorber column 22 passes through a final filter means 26 so that no droplets of absorber liquid can escape with the clean dry compressed gas discharge at 27 possibly to a gas/air receiver tank. Conveniently a lubricant purge line 3 is operatively associated with the filter means 17 to return any collected lubricant back to a lower pressure portion of the compressor system such as the compressor unit 10 itself. Further possible changes to the system may include integrating the absorber column 22 into the separator vessel 13 whereby a secondary vessel is not required. Alternatively, the absorber column 22 might be integrated into the air receiver tank 32 as shown in FIG. 5 .
The compressor system of FIG. 3 is essentially similar to that of FIG. 2 except that in FIG. 2 the compressor system 9 is constructed as a common support platform 9 whereas in FIG. 3 , the absorber may be constructed as a support platform 5 different to the support platform 4 of the compressor 8 thus providing a separate gas drier assembly.
In FIGS. 2 and 3 a moisture stripper 32 , preferably in the form of a column, is provided cooperatively working with the absorber column 22 . Fluid exiting from the column 22 may pass via line 25 through the heat exchanger 28 or, in an alternative embodiment may pass via line 33 , to the moisture stripper column 32 . A portion of dry compressed gas may be taken from the discharge line 27 and delivered via line 34 to the stripper column 32 such that it may pass in contact with the fluid in the circuit 6 after it has left the absorber column 22 where it has picked up moisture. The dry air or gas delivered to the stripper column 32 effectively dries the fluid passing through the stripper column 32 before it enters the absorber column 22 . Moisture picked up by the gas/air passing through the stripper column is discharged via line 35 as vapour. Diverting dry compressed gas from the discharge line 27 in this way provides an inefficiency in the system and therefore it is desirable to minimize the amount of dry gas diverted from the line 27 . Liquid moisture absorber medium entering the absorber 22 should be cool for proper operation and accordingly, a cooler 70 may be provided in the line 23 following the pump 30 leading to the absorber 22 . The pump 30 may be any known type including electrically driven or air driven pumps utilizing compressed air from the discharge 27 . As a possible alternative to the cooler 70 , a heat exchanger 71 may be provided between the line 23 and the line 29 .
With arrangements as illustrated in FIGS. 2 and 3 , the liquid within the substantially closed circuit 6 need not be particularly hygroscopic in nature but improved performance may be achieved if it was hygroscopic in nature. Glycol based fluids may be suitable for this application including glycol based lubricants such as Ingersoll Rand's ULTRA™ type coolant and Kluber-Summit's SUPRA™ type coolant.
FIG. 4 illustrates a preferred construction of absorber for use in compressor systems as described above, or in fact for any other application. The compressor system 9 is similar in nature to that shown in FIGS. 1 and 2 except that the preliminary cooler 19 has been omitted and the line 35 is directed to the inlet gas flow 12 to the compressor 10 . Like features in the earlier embodiments have been given the same reference numerals in FIG. 4 .
The absorber column 22 has an outer upright cylindrical shell or casing 36 closed at an upper end by plates 37 , 38 and at a lower end by plate 39 . Located within the outer casing 36 are a plurality of plates 40 each with a plurality of small gas flow holes 41 in a predetermined array. The plates 40 each have three vertical tubes 42 or conduits passed through apertures in the plates 40 such that the position of the tubes 42 can be adjusted relative to the plates prior to being fixed in an adjusted position. As best seen in FIG. 6 , the tubes 42 are closed at the bottom by end caps 43 each having a reduced foot portion 44 to allow liquid flow around the foot portion. It will of course be appreciated that, depending on performance requirements, the number of tubes 42 per plate 40 can be varied depending on allowed space. Each tube 42 has at least one opening 45 adjacent the lower end caps 43 as well as at least one reduced volume flow opening adjacent their upper edges. The reduced volume flow openings may be one or more apertures 46 or notches 47 as illustrated in FIG. 6 . To enable an absorber column to be built of any desired capacity, a selected number of modules 48 consisting of a plate 40 and one or more tubes 42 can be stacked one on another within an outer cylindrical casing of desired length. Compressed gas may enter the absorber column 22 via line 21 and a port 49 in the lower end plate 39 . The gas essentially travels upwardly through the absorption zone 50 within the casing 36 by passing successively through the holes 41 .
Dry liquid is delivered, as shown in FIGS. 4 and 5 , via line 51 from the pump 30 to a port 52 in the upper end plates 38 , 37 . The liquid travels down the tube 53 in the absorber column 22 to be discharged onto the uppermost plate 40 . Gas travelling up through the holes 41 (as shown in FIG. 6 ) in this plate causes the liquid to bubble or froth up and flow eventually into the upper ends of the tubes 42 to flow down these tubes to the next lower plate 40 . This process is repeated in a cascade fashion until the liquid is collected in the lower chamber 56 and discharged therefrom via a port 55 in the lower plate 39 to line 29 or lines 29 , 33 returning to the moisture stripper 32 . In some applications it may be desired to keep a pool of liquid in the lower chamber 56 so that gas entering this chamber must pass through the liquid before reaching the lowermost plate 40 . Compressed gas leaving the absorber 22 may conveniently pass through a coalescent type final filter means to remove any liquid picked up via the drying process in the absorber. The filter means 26 may be mounted from one of the plates 37 , 38 to be positioned within the absorber. In some applications, a minimum pressure valve (mpv) 18 may be provided mounted to the gas outlet port 57 ( FIG. 4 ) or be separated therefrom (FIG. 3 ). | A system for delivering dry compressed gas is provided, the gas being separated from any entrained liquid lubricant and then passed through a moisture absorber column to interact with a moisture-removing fluid. The fluid is a liquid lubricant or is maintained in a separate closed circuit relative to the liquid lubricant. A moisture stripping device receives some of the gas from the absorber column, which is passed in moisture exchange relation with the fluid before the fluid enters the column. The column has a housing defining a vertical absorption zone, and partition plates each defining gas flow holes. The plates have at least one tube passing therethrough, with an open upper end above one plate, and a lower end adjacent the next lower plate. The fluid passes down the tubes and across a top surface of each plate, with the gas flow passing upwardly through the holes in the plates. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2006/061537, filed Apr. 12, 2006 and claims the benefit thereof. The International Application claims the benefits of German application No. 102005019863.5 filed Apr. 28, 2005, German application No. 102005028182.6 filed Jun. 17, 2005, and German application No. 102005032079.1 filed Jul. 8, 2005 all of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method for decoding a signal which has been coded by a hybrid coder. The invention further relates to a device suitably equipped for decoding.
BACKGROUND OF INVENTION
[0003] Different methods have proved to be especially effective for coding audio signals. Thus what is known as the CELP (Code Excited Linear Prediction) technology has proved especially useful for example for high-quality coding of voice signals which exhibit a good quality and with simultaneously low bit rates of the coded data stream. CELP operates in the time domain and is based on an excitation model for a variable filter. In this case the voice signal is represented both by filter parameters and also by parameters which describe the excitation signal.
[0004] The appropriate decoders are generally mentioned in relation to coders, with said decoders being able to decrypt or decode the coded data. The corresponding communication devices feature what is known as a codec to enable them to transmit and receive data which is required for communication.
[0005] For coding of music and voice signals which are to exhibit a very high quality especially at higher bit rates of the coded data stream, above all perceptual codecs (codec=coder/decoder) have become established. These perceptual codecs are based on a reduction of information in the frequency range and they utilize masking effects of the human hearing system, i.e. for example the fact that specific frequencies or changes that a human being cannot perceive are also not represented. This reduces the complexity of the coder or codec. Since these coders mostly operate with a transformation of the time signal in the frequency domain, in which case the transformation is undertaken for example using MDCT (Modified Discrete Cosine Transformation), these devices are also often referred to as transform coders or codecs. This term will be used within the context of this patent application.
[0006] In recent times what are known as scalable codecs have increasingly come into use. Scalable codecs are codecs which generate an excellent audio quality at a relatively high bit rate of the coded data stream. This produces relatively long packets to be transmitted periodically.
[0007] A packet is a plurality of data which arises within a period of time and which can also be transmitted together in this packet. Often important data is transmitted first in packets and less important data is transmitted later. The option exists however with these long packets of shortening the packet by removing part of the data, especially by truncating the part of the packet transmitted latest in time. This naturally brings with it a deterioration in quality.
[0008] Because of the characteristics previously mentioned it is best for scalable codecs to operate at low bit rates with CELP codecs and at higher bit rates with transform codecs. This has led to the development of hybrid CELP/transform codecs which code a basic signal with good quality according to the CELP method and additionally generate a supplementary signal according to the transform codec method with which the basic signal is improved. This then results in the desired excellent quality.
SUMMARY OF INVENTION
[0009] The disadvantage of using these transform codecs is the occurrence of what is known as a “pre-echo effect”. This involves a disturbance noise which is distributed evenly over the entire block length of a transform coder block. A block is understood as a totality of data which is coded together. For transform codecs a typical block length amounts to 40 msec. The disturbance noise of the pre-echo effect is caused by quantizing errors of transmitted spectral components. With an even signal level the overall level of this disturbance noise lies below the level of the useful signal. However if one has a useful signal with a zero level followed by a sudden high level, this disturbance noise is clearly audible before the onset of the high level. A well known example of this in literature is the signal waveform for clapping a castanet.
[0010] Different methods are already employed for reducing this effect. These however all operate with the transmission of additional information which in its turn makes the design of the coder very complex or forces the coders to work with temporarily increased bit rates.
[0011] Using this prior art as its starting point, an object of the present invention is to create a simple option of introducing a reduction of disturbance noise in signals coded using a hybrid coder in which no additional information is needed.
[0012] This object is achieved by the object of the independent claims. Advantageous further developments are the object of the dependent claims.
[0013] For this disturbance noise reduction in a decoded signal which is made up of a first signal originating for example from a CELP decoder and a second signal originating for example from a transform decoder, the following steps are executed:
[0014] An associated energy envelope is determined from the two decoded signal contributions in each case. Energy envelope is especially taken to mean the energy waveform of a signal in relation to time.
[0015] A code is formed from a comparison between the two envelopes, for example a ratio.
[0016] This ratio in its turn is used to obtain a gain factor.
[0017] This method has advantages especially if energy, in the coding method for example, which leads to the first decoded signal contribution is detected more reliably. Then a deviation can namely be detected by the ratio or the gain factor.
[0018] In particular the second decoded signal contribution can be multiplied by the gain factor. The above-mentioned deviation can be corrected in this way.
[0019] All signals can be subdivided into time segments, in which case especially the time segments which are used for the first decoded signal contribution can be shorter than those for the second.
[0020] Because of the higher time resolution, this means that energy deviations in the second signal contribution can be better corrected.
[0021] The first signal contribution can originate from a CELP decoder which decodes a CELP-coded signal, the second from a transform decoder which decodes a transform-coded signal. This transform-coded signal can especially also contain the first CELP-decoded signal contribution, which was transform-coded after the decoding, was added to the transform-coded signal transmitted from the transmitter (i.e. already in the frequency range) and is then decoded in the transform decoder as a contribution to the second signal contribution.
[0022] As an alternative to this a sum can also be formed from the transmitted CELP-coded signal and the transmitted transform-coded signal in the time domain.
[0023] The gain factor can especially be equal to the ratio. Then, if a suitable ratio is formed, a corresponding attenuation of the second decoded signal contribution can be produced if this principally contains the pre-echo noise.
[0024] The first decoder in particular can be one based on CELP technology and/or the second coder can be based on a transform decoder. This produces an especially effective noise reduction with simultaneous excellent quality of the decoded signal.
[0025] The modification of the received overall signal on the decoder side can especially only be undertaken if specific criteria are met.
[0026] In particular there is provision for the modification of the received overall signal to only be undertaken on the decoder side if the signal level change exceeds a specific threshold. This allows an especially effective pre-echo reduction since the pre-echo effect—as already described—primarily arises with changes in level, since then the pre-echo noise lies above the signal level. On the other hand the improvement in quality by the second coder is dispensed with not unnecessarily by this selective modification.
[0027] In accordance with a further aspect of the invention a method is created in which, building on the method explained, the decoded signal or its first and second decoded signal contributions are handled separately according to frequency ranges. This has the following advantage. On decoding, the required energy for these frequency bands is known for a number of frequency bands, namely from the energy of the individual first decoded signal contributions separated according to frequency ranges, for example CELP signals. An add-on signal can now be provided by the second decoded signal contribution which however can deviate significantly in its energy. It is particularly problematic when the energy of the second decoded signal contribution is significantly too high, for example as a result of pre-echo effects. The method now introduces for each individually handled frequency band a restriction of the energy (or of the level) of the second signal contribution depending on the energy of the first signal contribution. This method is all the more effective the more frequency bands are handled separately in this way.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Further advantages of the invention will be presented with reference to typical exemplary embodiments.
[0029] The figures show:
[0030] FIG. 1 a diagram of the major components on a coding side and a decoding side to illustrate the typical execution sequence of a coding/decoding process;
[0031] FIG. 2 a schematic diagram of a communication system for transmission of a coded signal between communication devices over a communication network;
[0032] FIG. 3 a decoding device or a noise suppression device to illustrate the reduction of pre-echo with the aid of gain adaptation, which is based on a CELP signal;
[0033] FIG. 4 a further embodiment for level adaptation or for reduction of pre-echo.
DETAILED DESCRIPTION OF INVENTION
[0034] FIG. 1 shows a schematic diagram of the execution sequence of a coding and decoding process with reference to an exemplary embodiment. On a coding side C an analog signal S to be transmitted to a receiver is preprocessed or prepared by being digitized for coding by a pre-processing device PP. The signal is further fragmented into time segments or frames in a fragmentation unit F. A signal prepared in this manner is fed to a coding unit COD. The coding unit COD features a hybrid coder comprising a first coder, a CELP coder COD 1 and a second coder, a transform coder COD 2 . The CELP coder COD 1 comprises a plurality of CELP coders COD 1 _A, COD 1 _B, COD 1 _C, which operate in different frequency ranges. This division into different frequency ranges enables especially accurate coding to be guaranteed. Furthermore this division into different frequency ranges provides very good support for the concept of a scalable codec, since, depending on the desired scaling, only one frequency range, a number of frequency ranges or all frequency ranges can be transmitted. The CELP coder COD 1 supplies a basic contribution S_G to the coded overall signal S_GES. The transform coder COD 2 supplies an additional contribution S_Z to the coded overall signal S_GES. The coded overall signal S_GES is transmitted by means of a communication device KC on the coding side C to a communication device KD on a decoding side D. Here the data or the received coded overall signal S_GES is processed (for example the signal is split up into the contributions S_G and S_Z) in a processing device PROC, with the processed data or the processed signal subsequently being transmitted to a decoding device DEC for subsequent decoding DEC (cf. also FIGS. 3 and 4 ). The decoding is followed by a noise reduction in a noise reduction unit NR which is shown in greater detail in FIG. 3 .
[0035] FIG. 2 shows a first communication device COM 1 (for example representing the components on the coding side C of FIG. 1 ) which features a transmit and receive unit ANTI (for example corresponding to the communication device KC) for transmitting and/or receiving data, as well as a central processing unit CPU 1 which is set up for implementing the components on the coding side C or for executing the coding method shown in FIG. 1 (processing on the coding side C). The data is transmitted by means of the transceiver unit ANT 1 over a communication network CN (which for example, depending on communication devices to be used, can be set up as an Internet, a telephone network or a mobile radio network). The data is received by a second communication device COM 2 (for example representing the components on the right-hand side of FIG. 1 ), which once again features a transceiver unit ANT 2 (for example corresponding to the communication device KB), as well as a central processing unit CPU 2 which is set up for implementing the components on the decoding side D or for executing a decoding method (processing on the decoding side D) in accordance with FIG. 1 . Examples of possible implementations of communication devices COM 1 and COM 2 , in which this method can be applied, are IP telephones, voice gateways or mobile telephones.
[0036] The reader is now referred to FIG. 3 in which the decoding device DEC and the noise reduction device NR can be seen with the main components for schematic depiction of the execution sequence of a pre-echo reduction.
[0037] A CELP coder signal S_COD,CELP (corresponding to the signal S_G) is decoded by means of a full-band CELP decoder DEC_GES,CELP. The decoded signal S_CELP is forwarded on the one hand to a (first) energy envelope determination unit GE 1 for determining the associated envelope ENV_CELP, on the other hand to a TDAC (Time domain aliasing cancellation) Coder COD_TDAC. The TDAC coding is an example of a transform coding.
[0038] The coded signal S_COD,CELP,TDAC is routed, together with the transform coding signal S_COD,TDAC originating from the receiver side (corresponding to the signal S_Z), to a transform decoder DEC_TDAC in order to create a decoded signal S_TDAC. The associated energy envelope ENV_TDAC is also determined from this decoded signal S_TDAC in a (second) energy envelope determination unit GE 2 . In a ratio determination unit D the ratio R of the energy envelopes to each other is determined as a code for each time segment. In a condition establishment unit BFE it is established whether the ratio R has a defined minimum spacing of 1 (1: both energy envelope curves are the same), i.e. the levels of the signals are the same or at least only deviate from each other by a predetermined percentage.
[0039] The result is then a gain factor or attenuation factor G which, in the case shown, is the same as the ratio R (code) with which the transform-decoded signal contribution S_TDAC is multiplied in a multiplication device M in order to obtain a final reduced-noise signal S_OUT. In more precise terms, it is assumed for example that the ratio R is formed by R=ENV_CELP/ENV_TDAC, and if it has been determined that this ratio may not fall below a predetermined threshold value SW, when the ratio falls below the threshold value SW, the transform-decoded signal contribution S_TDAC is multiplied by a gain factor G, for example G=R, which leads to an attenuation of the signal contribution S_TDAC. It is further possible, in the event that the threshold value SW is not undershot, to assign the value “1” to the gain factor G, so that for a multiplication of the signal contribution S_TDAC, which can then be undertaken in any event, the value S_TDAC remains unchanged.
[0040] Thus in the case of a deviation of the energy of the transform-decoded signal contribution S_TDAC, with the deviation also being the said pre-echo effect, the energy or the level of this signal contribution is moved to a more reliable value of the CELP channel-decoded signal S_CELP so that the final signal S_OUT is noise-reduced.
[0041] The reader is now referred to FIG. 4 , with reference to which a further embodiment for reducing the pre-echo effect is to be explained.
[0042] It is possible, instead of only one CELP codec, for a number of (CELP or other) codecs separated according to frequency ranges to be available. The embodiment shown in FIG. 4 largely corresponds to the embodiment shown in FIG. 3 and represents an expansion with regard to the latter, in that the method shown in FIG. 3 is not applied to the overall signal of CELP (or other) decoders and transform decoders but that the method is applied separately according to frequency ranges. This means that the overall signal or the individual signal contributions are first divided up in accordance with frequency ranges, with the method of FIG. 3 then being able to be applied for each frequency range to the individual signal contributions.
[0043] The advantage of this is explained below. The required energy for these frequency bands is known at the decoder for a number of frequency bands, namely from the energy of the individual CELP signals separated according to frequency ranges. The transform decoder now delivers an add-on signal, which however can deviate significantly in its energy. The situation is problematic above all if the energy of the signal from the transform decoder is significantly too high, e.g. as a result of pre-echo effects. The method now leads for each individually handled frequency band to a restriction of the transform codec energy depending on the CELP energy. This method is all the more effective the more frequency bands are handled separately in this way.
[0044] This will immediately become clear with reference to the following example:
[0045] Let the overall signal consist of a 2000 Hz tone which comes entirely from the CELP codec proportion. In addition, because of pre-echo effects, the transform codec now supplies a further noise signal with a frequency of 6000 Hz; the energy of the noise signal is 10% of the energy of the 2000 Hz tone.
[0046] Let the criterion for restriction of the transform codec proportion be that this may be at most as large as the CELP proportion. Case 1: No splitting according to frequency bands is done (first embodiment): Then the 6000 Hz noise signal is not suppressed since it has only 10% of the energy of the 2000 Hz tone from the CELP codec.
[0047] Case 2: The frequency bands A: 0-4000 Hz and B: 4000 Hz-8000 Hz are handled separately (further embodiment): In this case the noise signal is suppressed completely since in the upper frequency band the CELP proportion is zero, and thus the transform codec signal is also limited to the value zero.
[0048] In FIG. 4 (as in FIG. 3 ) a decoding device DEC and a noise reduction device NR with the main components for schematic presentation of the execution sequence of a level adaptation or pre-echo reduction can now again be seen. The reader is again referred to FIGS. 1 or 2 for the creation of coded signals or for the transmission to a receiver.
[0049] A CELP-coded signal S_COD,CELP (corresponding to signal contribution S_G) is decoded by means of a full-band CELP decoder DEC_GES,CELP′. The full-band CELP decoder in this case comprises two decoding devices, a first decoding device DEC_FB_A for decoding the signal S_COD,CELP in a first frequency band A and a second decoding device DEC_FB_B for decoding the signal S_COD,CELP in a second frequency band B. A first decoded signal S_CELP_A is routed to a (first) energy envelope determination unit GE 1 _A for determining the associated envelope ENV_CELP_A, while a second decoded signal S_CELP_B is routed to a (second) energy envelope determination unit GE 1 _B for determining the associated envelope ENV_CELP_B.
[0050] A transform coding signal S_COD,TDAC (corresponding to the signal S_Z) originating from the receiver side is routed to a transform decoder DEC_TDAC, in order to create a decoded signal S_TDAC, which in its turn is routed to a frequency band splitter FBS. This divides the signal S_TDAC into two signals, namely S_TDAC_A for frequency band A and S_TDAC_B for frequency band B. The subdivision into frequency bands can optionally also be undertaken in the frequency domain, before the return transformation into the time domain. This means that the delay especially associated with the frequency band splitters operating in the time domain (highpass, lowpass or bandpass filter) is avoided. The associated energy envelope curves ENV_TDAC_A or ENV_TDAC_B are also determined from these decoded frequency band-dependent signals S_TDAC_A and S_TDAC_B in a (third) energy envelope determination unit GE 2 _A or a (fourth) energy envelope determination unit GE 2 _B.
[0051] In a first gain determination unit BDA a gain factor (or also attenuation factor, since the gain is negative) G_A is determined for the frequency band A on the basis of the energy envelopes ENV_CELP_A and ENV_TDAC_A, while in a second gain determination unit BD_B a gain factor (attenuation factor) G_B is determined for frequency band B on the basis of the energy envelopes ENV_CELP_B and ENV_TDAC_B. The respective gain factors can be determined in accordance with the determination shown in FIG. 3 (cf. components D, BFE). In this case for example a respective ratio (code) R_A, R_B of the energy envelopes can again be formed for a respective frequency band A and B, namely R_A=ENV_CELP_A/ENV_TDAC_A or R_B=ENV_CELP_B/ENV_TDAC_B, with a threshold value SW_A or SW_B being determined for a respective frequency band, undershooting of which creates a respective gain factor G_A (for example G_A=R_A) or G_B (for example G_B=R_B) which is finally to be applied to a respective frequency-band-dependent signal S_TDAC_A or S_TDAC_B (in order to bring about an attenuation). If a respective threshold value is not undershot a respective gain factor G_A or G_B can be set to “1”, so that on multiplication a respective frequency-band-dependent signal S_TDAC_A or S_TDAC_B remains unchanged.
[0052] Finally the gain factor G_A is multiplied by the signal S_TDAC_A and the gain factor G_B is multiplied by the signal S_TDAC_B in a first multiplication unit M_A for frequency band A. Finally the multiplied (possibly attenuated) frequency-band-dependent signals are merged in order to obtain a final reduced-noise (full-frequency) signal S OUT′.
[0053] It should be noted that although only a splitting of the decoded signal contributions S_CELP_A, S_CELP_B, S_TDAC_A and S_TDAC_B into two frequency ranges A and B has been undertaken in this example, a splitting up into 3 or more frequencies can be possible and advantageous. | In one aspect, a noise suppression process for a decoded signal comprising a first decoded signal portion and a second decoded signal portion is provided. A first energy envelope generating curve and a second energy envelope generating curve of the first signal portion and of the second decoded signal portion are determined. An identification number depending on a comparison of the first and second energy envelope generating curves is formed. An amplification factor which depends on the identification number is derived. Multiplying the second decoded signal portion by the amplification factor, reduces pre-echo and post-echo interference noises. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/618,605 filed Feb. 10, 2015, which is a continuation of U.S. application Ser. No. 13/842,411 filed March 15, 2013, now U.S. Pat. No. 8,974,102, both of which are incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to providing auxiliary lighting systems. More particularly, this invention relates to auxiliary lighting systems for mobile platforms with an integral mounting system.
[0004] 2. Discussion of the Related Art
[0005] A mounted auxiliary light typically consists of one or more light sources in a protective housing. The light sources may be of various types, for example light-emitting diode (LED), high-intensity discharge (HID) or halogen. The protective housing comes with or is configured for a mounting system that allows the external mounted light to be secured to a base. The auxiliary light is typically powered by a wired connection to a battery, for example a vehicle battery.
[0006] A mounted auxiliary light is commonly used where the operator of a vehicle requires additional lighting beyond ambient lighting and lighting provided by the vehicle. For example, an off-road vehicle in a location with no exterior lights may require more lighting than that provided by the vehicle's headlights. The auxiliary light may be used in conjunction with, for example, vehicles, aircraft, watercraft, motorcycles, trailers and commercial equipment. The auxiliary light may also be used in a stationary location, for example, in an architectural use.
[0007] A mounted auxiliary light may be mounted to a portion of a vehicle or other structure. Because of the variance of structures and mounting locations, it is often desirable to have an adaptable mounting system which accommodates varying mounting locations and allows the external mounted light to rotate about one or more axes.
[0008] The user of a mounted auxiliary light may require a cover to, for example, protect the light or change the type of light emitted. Covers may be made of, for example, fabric or plastic and may be transparent or opaque.
SUMMARY OF THE INVENTION
[0009] Several embodiments of the invention advantageously address the needs above as well as other needs by providing an auxiliary lighting systems for mobile platforms with an integral mounting system.
[0010] In one embodiment, the invention can be characterized as a housing comprising an extrusion forming a first channel and a second channel; a lighting system in the first channel adapted to direct light away from the first channel; a mounting system in the second channel adapted to couple the extrusion to a vehicle; a first end cap including a first connector, the first end cap being coupled to a first end of the extrusion; a second end cap including a second connector, the second end cap being coupled to a second end of the extrusion; wherein the first connector and the second connector are electrically coupled to one another, and wherein the first connector and the second connector are electrically coupled to the lighting system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above and other aspects, features and advantages of several embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings.
[0012] FIG. 1 is a perspective view of the front of the light bar system.
[0013] FIG. 2 is a perspective view of the rear of the light bar system.
[0014] FIG. 3 is a side view of the light bar system.
[0015] FIG. 4 is a schematic wiring diagram of in-series connection of light bar systems.
[0016] FIG. 5 is a schematic wiring diagram for a light combination system.
[0017] Corresponding reference characters indicate corresponding components throughout the several views of the drawings. Skilled artisans will appreciate that elements in the figures 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 figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
DETAILED DESCRIPTION
[0018] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of exemplary embodiments. The scope of the invention should be determined with reference to the claims.
[0019] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0020] Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth.
[0021] In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0022] Referring first to FIG. 1 , a perspective view of a light bar system 100 according to one embodiment of the present invention is shown. Shown is a light bar assembly 102 , including a center housing 104 , an adjustment track 106 , a right end cap 108 , a power source wiring 110 , a right receptacle 112 , a left end cap 114 , a left receptacle 116 , a front cap 118 , a front lens 120 , a light-emitting diode (LED) array 122 , and a reflector array 124 . Also shown is a mounting assembly 126 , including an adjustment bracket 128 , an adjustment bracket hole 130 , a clevis 132 , a plurality of clevis holes 134 , a pivot bolt 136 , a pivot nut 138 , a pivot washer 140 , a mounting bolt 142 , a mounting washer 144 , a mounting nut 146 , an internal wiring system 158 , a PC board, a gasket 160 , and a PC board 162 . The center housing 104 is a channel-shape, with the top and bottom of the channel forming the top and bottom of the light bar assembly 102 . It is made of extruded metal or other suitable material. In one embodiment, the center housing 104 is approximately 2-3 inches high and 3-5 inches deep. The length of the center housing 104 varies with the embodiment of the invention, but in the preferred embodiment generally varies between 6 inches and 52 inches. The back of the center housing 104 is curved and incorporates a plurality of horizontal fins. At the top and bottom of the center housing 104 are longitudinal indentations approximately ⅛″ wide and ⅛″ deep which may be used to couple an external light cover to the light bar assembly 102 . At the bottom of the back of the center housing 104 , two continuous curved horizontal ridges protrude from the center housing 104 , forming the adjustment track 106 . The front portion of the center housing 104 is shaped to hold and support the reflector array 124 , the LED array 122 , front lens 120 and the internal wiring system 148 . The gasket 162 is formed by machine and completely circles the outer edge of the front lens 120 where the inside facing outer portion of the front lens 120 lens meets with an continuous interior indentation of the light bar assembly 102 .
[0023] The reflector array 124 size varies depending on the light bar variations. In general, there are one or more reflectors 148 in a row in the reflector array 124 . FIG. 1 represents an embodiment of the invention with eight reflectors 148 in a row. Each reflector 148 has a curved conical shape and is connected at the wide end by a flat portion of the reflector array 124 , similar to the construction of an egg carton. In one embodiment, there are two horizontal reflector 148 rows stacked on top of one another. FIG. 1 represents an embodiment of the invention with a single row in the reflector array 124 . An LED light 150 is coupled to the PC board 160 and positioned so that the LED light 150 extends through a small hole in the narrow end of the reflector 148 . The grouping of the LED lights 150 forms the LED array 122 .
[0024] In front of the reflector array 124 , a thin transparent front lens 120 , made of polycarbonate or other suitable material, covers the reflector array 124 . The front lens 120 is transparent so as not to affect the photometrics of the reflectors 148 . The reflector array 124 is coupled to the PC board 160 by screws or other suitable method. The front lens 120 is coupled to the front cap 118 which frames the front lens 120 and is coupled to the top and bottom of the center housing 104 , to the left end cap 114 on the left, and the right end cap 108 on the right. The reflectors 148 in the reflector array 124 may all be of the same type, for example, spot reflectors, or a combination of types of reflectors may be used. For example, the reflector array 124 may consist of a combination of flood and spot reflectors. This allows for a variety of photometric requirements to be satisfied. The right end cap 108 covers and seals the interior of the light bar assembly 102 on the right-hand side. The right end cap 108 contains a right receptacle 112 and, in one embodiment, power source wiring 110 . In another embodiment, the power source wiring 110 may be removed from the right receptacle 112 and switched to the left receptacle 116 . A receptacle plug 152 would be placed in the right receptacle 112 for safety and to protect the internal wiring. In another embodiment, when the power source wiring 110 is coupled to the left receptacle 116 , a connecting wire 154 may be used in the right receptacle 112 to connect the light bar assembly 102 to additional light bar assemblies 102 in series. The other end of the connecting wire 154 would be connected to the receptacle of the adjacent light bar assembly 102 . The left receptacle 116 works in a similar way, and may receive either power source wiring 110 , connecting wiring 154 , or a receptacle plug 152 . The right end cap 108 is coupled to the center housing 104 with a plurality of end cap attachment screws 156 . The left end cap 114 covers and seals the interior of the light bar assembly 102 on the left-hand side. The left end cap 114 also contains the left receptacle 116 . The left receptacle 116 works in a similar way to the right receptacle 112 , and may receive either power source wiring 110 , connecting wiring 154 , or a receptacle plug 152 .
[0025] The mounting assembly 126 includes the adjustment bracket 128 that is coupled to the adjustment track 106 in the back of the center housing 104 . The adjustment bracket 128 may be moved linearly along the entire length of the light bar assembly 102 to provide maximum adjustment. The bottom of the adjustment bracket 128 has an adjustment bracket hole 130 that is used to attach it to the clevis 132 . The clevis is U-shaped, with a plurality of clevis holes 134 , one in each side of the clevis. The pivot bolt 136 goes through one side of the clevis 132 , through the adjustment bracket hole 130 and through the other side of the clevis 132 , where is it secured with the pivot bolt washer 140 and the pivot bolt nut 138 . At the bottom of the U-shaped base of the clevis, 132 a threaded mounting bolt 142 extends vertically down from the base of the clevis 132 . The mounting bolt is used to mount the light bar system 100 to a support. The mounting nut 146 and mounting washer 144 are used to secure the mounting bolt 142 to the support. The adjustment bracket 128 pivots or rotates about the pivot bolt 136 location, allowing for the light bar assembly 102 to be adjusted to various angles relative to horizontal. The operation of the adjustment bracket 128 is described in more detail below. In addition, the adjustment bracket 128 may be reversed on the adjustment track 106 so that the bottom of the adjustment bracket 128 points upward. This allows for a greater range of support mounting options.
[0026] Referring next to FIG. 2 , a perspective view of the light bar system 100 is shown from the rear. Shown are the center housing 104 , the front cap 118 , the left end cap 114 , the right end cap 108 , a plurality of end cap attachment screws 156 , the adjustment track 106 , the adjustment bracket 128 , an adjustment screw 200 , the clevis 132 , the pivot bolt 136 , the mounting bolt 142 , the mounting washer 144 and mounting nut 146 . In this embodiment the right receptacle 112 is shown with the power source wiring 110 , and the left receptacle 116 is shown with the left receptacle plug 152 .
[0027] Referring next to FIG. 3 , an elevation of the right side of the light bar system 100 is shown. Shown are the front cap 118 , the right end cap 108 , the right receptacle 112 , the power source wiring 110 , the end cap adjustment screws 154 , the center housing 104 , a engagement block 300 , the adjustment bracket 128 , the adjustment bracket hole 130 , the adjustment track 106 , the adjustment screw 200 , the clevis 132 , the clevis hole 134 , the pivot bolt 136 , the pivot washer 140 , the pivot nut 138 , the mounting bolt 142 , the mounting washer 144 , the mounting nut 146 , the plurality of pivot locking pins 302 and the plurality of pivot locking depressions 304 . As described previously, the adjustment track 106 is formed by two continuous curved horizontal ridges protruding from the center housing 104 . The adjustment bracket 128 fits tightly over each leg of the adjustment track 106 and extends partly into the adjustment track 106 at the open portion of the adjustment track 106 . In the inside portion of the adjustment track 106 , the trapezoidal engagement block 300 fits in the inside of the adjustment track 106 and is bolted to the adjustment bracket 128 , locking the mounting assembly 126 in place along the adjustment track 106 . When the adjustment screw 200 is loosened, the engagement block 300 separates slightly from the adjustment bracket 128 , allowing the mounting assembly 126 to slide along the adjustment track 106 . When the mounting assembly 126 is at the desired location, the adjustment screw 200 is tightened, causing friction between the adjustment track 106 and the adjustment bracket 128 and engagement block 300 , securing the mounting assembly 126 in place.
[0028] As described above, the adjustment bracket 128 pivots relative to the clevis 132 through use of the pivot bolt 136 which passes through both the plurality of clevis holes 134 and the adjustment bracket hole 130 . The pivot washer 140 has a plurality of small pivot lock pins 302 which are coupled to the inside face of the pivot washer 140 . In the preferred embodiment the pivot washer 140 has two pivot lock pins 302 , located on opposite sides of the hole of the pivot washer 140 . The pivot lock pins 302 extend through corresponding holes in the adjacent clevis 132 side and rest in the plurality of pivot locking depressions 304 of the adjustment bracket 128 . The pivot locking depressions 304 are a plurality of shallow depressions in the adjustment bracket 128 arranged in a circular pattern around the adjustment bracket hole 130 . The pivot locking depressions 304 are located so that the pivot lock pins 302 may sit in differing pivot locking depressions 304 depending on the rotation of the adjustment bracket 128 relative to the clevis 132 . When the pivot bolt 136 is tightened, the pivot lock pins 302 are engaged by the corresponding pivot locking depressions 304 and the angle of the light bar assembly 102 is locked. When the pivot bolt 136 is loosened, the pivot washer 140 may be moved outward so that the pivot lock pins 302 clear the pivot locking depressions 304 . The adjustment bracket 128 may then be rotated relative to the clevis 132 until the pivot lock pins 302 line up with alternate pivot locking depressions 304 , altering the angle of the light bar assembly 102 . When the desired angle is reached, the pivot bolt 136 is tightened, locking the angle of the light bar assembly 102 .
[0029] Referring next to FIG. 4 , a schematic wiring diagram for in-series connecting of light bar assemblies is shown.
[0030] Referring next to FIG. 5 , a schematic wiring diagram for a light combination is shown. In the embodiment where there are two rows of lighting. Each row may have a different color of LED lights 150 . Instead of lighting both rows at the same time, the light combination circuit allows for one row of lights to be illuminated while the second row of light is not. This allows for different colors of light to be illuminated separately within the same light bar assembly 102 .
[0031] While the invention herein disclosed has been described by means of specific embodiments, examples and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A housing having an extrusion forming a first channel and a second channel; a lighting system in the first channel adapted to direct light away from the first channel; a mounting system in the second channel adapted to couple the extrusion to a vehicle; a first end cap including a first connector, the first end cap being coupled to a first end of the extrusion; a second end cap including a second connector, the second end cap being coupled to a second end of the extrusion; wherein the first connector and the second connector are electrically coupled to one another, and wherein the first connector and the second connector are electrically coupled to the lighting system. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/831,911, filed Jun. 6, 2013, which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0003] The extraction of hydrocarbons from deepwater oil and gas reservoirs requires the transportation of a production stream from the reservoirs to facilities for processing. Water, along with oil and gas, may be included in these production streams. During transportation, if the temperature of the production stream is low and the pressure is high, the system can enter the hydrate region where gas hydrates form. Gas hydrates are solids and behave like ice and, if formed in large quantities, may plug the pipeline. Hydrates may also plug or cause malfunction of other units, such as valves, chokes, separators, and heat exchangers.
[0004] Jumper lines are flowlines that are commonly used to connected subsea units together. Conventional jumper line configurations often incorporate a valley and a bend in order to provide flexibility to the jumper line. During shut ins, liquids may settle and segregate in the lower middle section of these jumper lines. During shut in restart cycles, these jumper lines are often at risk of forming gas hydrates.
[0005] It is desirable to develop a jumper line configuration that aids in preventing the formation of gas hydrates.
SUMMARY
[0006] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0007] In one embodiment, the present disclosure provides a jumper line system comprising: a first subsea device; a second subsea device; and a jumper line providing fluid communication between the first subsea device and the second subsea device, wherein the jumper line does not comprise a valley.
[0008] In another embodiment, the present disclosure provides a method of transporting hydrocarbons from a subsea well comprising: providing a subsea well; providing a manifold; connecting the subsea well to the manifold via a jumper line, wherein the jumper line does not comprise a valley; and flowing hydrocarbons from the subsea well to the manifold via the jumper line.
[0009] In another embodiment, the present disclosure provides a method of connecting two subsea devices comprising: providing a first subsea device; providing a second subsea device; providing a jumper line, wherein the jumper line comprises a first end section and a second end section and does not comprise a valley; connecting the first end section of the jumper line to the first subsea device; and connecting the second end section of the jumper line to the second subsea device.
[0010] The features and advantages of the present disclosure will be readily apparent to those skilled in the art. While numerous changes may be made by those skilled in the art, such changes are within the spirit of the invention
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the above recited features and advantages of the disclosure may be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to the embodiments thereof that are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are, therefore, not to be considered limiting of its scope. The figures are not necessarily to scale, and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
[0012] FIG. 1 is a side view illustration of a typical M-shaped jumper line geometry.
[0013] FIG. 2 is a side view illustration of a jumper line geometry in accordance with an embodiment of the present disclosure.
[0014] FIGS. 3A and 3B are top and side view illustrations of a jumper line geometry in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0015] The present disclosure relates generally to jumper line configurations. More specifically, in certain embodiments the present disclosure relates jumper line configurations for hydrate inhibition and associated methods.
[0016] The description that follows includes exemplary apparatuses, methods, techniques, and instruction sequences that embody techniques of the inventive subject matter. However, it is understood that the described embodiments may be practiced without these specific details.
[0017] Referring now to FIG. 1 , FIG. 1 illustrates a conventional jumper line configuration 100 . As can be seen in FIG. 1 , conventional jumper line configuration 100 may comprise a first subsea device 110 , a second subsea device 120 , and a jumper line 130 . Jumper line 130 may comprise one or more straight sections 131 , one or more elbows 132 , one or more peaks 133 , one or more valleys 134 , and one or more end sections 135 . In certain embodiments, the one or more peaks 133 are comprised of one or more elbows 132 . In certain embodiments, the one or more peaks 133 define the one or more valleys 133 .
[0018] In this conventional configuration, the valleys 134 and elbows 132 may provide flexibility to the jumper line. However, during shut ins, liquids may settle and segregate in the valleys 134 , as well as end sections 135 , of the jumper lines 130 thus increasing the risk of hydrates forming in the valleys 134 during shut in-restart cycles.
[0019] In certain embodiments, the present disclosure provides jumper line configurations that aid in the prevention of hydrate blockages. Examples of such jumper line configurations are illustrated in FIG. 2 and FIGS. 3A and 3B .
[0020] Referring now to FIG. 2 , FIG. 2 illustrates jumper line configuration 200 . As can be seen in FIG. 2 , jumper line configuration 200 may comprise a first subsea device 210 , a second subsea device, and a jumper line 230 .
[0021] In certain embodiments, first subsea device 210 and second subsea device 220 can comprise any type subsea equipment. Examples of suitable subsea devices include subsea Christmas trees, well heads, and manifolds. In certain embodiments, first subsea device 210 may comprise a well head. In certain embodiments, second subsea device 210 may comprise a manifold.
[0022] Jumper line 230 may be constructed out of any material suitable for use as a jumper line. Examples of suitable materials include carbon steel, allows of titanium and chrome, flexible pipes, or composite materials.
[0023] Jumper line 230 may comprise one or more straight sections 231 , one or more elbows 232 , peak 233 , and one or more end sections 235 . In certain embodiments, the one or more straight sections 231 may be horizontal or vertical along a primary axis. In certain embodiments, the primary axis is defined as the horizontal line that is in line with the overall flow of hydrocarbons from first subsea device 210 to second subsea device 220 . In certain embodiments, the one or more straight sections 231 may be inclined from 0 degrees to 90 degrees from the primary axis. In certain embodiments, the one or more straight sections 231 may be straight along the primary axis while incorporating a number of straight sections and elbows along a perpendicular axis. In certain embodiments, peak 233 is comprised of the one or more elbows 232 . In certain embodiments, the one or more elbows 232 may comprise one or more connectors. Unlike jumper line configuration 100 of FIG. 1 , jumper line configuration 200 does not comprise a valley defined by one or more peaks 233 . Rather, in certain embodiments, the maximum elevation of jumper line configuration 200 occurs at peak 233 , and no local maximum elevation occurs on either side of peak 233 .
[0024] In certain embodiments, jumper line 230 may further comprise one or more injection ports 236 wherein a hydrate inhibitor may be injected into the jumper line 230 . In certain embodiments, the one or more injection ports 236 may be disposed on the one or more end sections 235 .
[0025] In certain embodiments, jumper line 230 may further comprises one or more valves 237 that allow the end sections of jumper line 230 to be drained or provide means to move gas from the first subsea device 210 to the second subsea device 220 . In certain embodiments, the one or more valves 237 may be disposed on the one or more end sections 235 above the one or more injection ports 236 . In other embodiments, the one or more valves 237 may be disposed on the one or more ends sections 235 below the one or more injection ports 236 . In certain embodiments, the one or more valves 237 may be tree valves.
[0026] In certain embodiments, during shut ins, gas may segregate into the one or more peaks 233 of the jumper lines 230 and water may segregate into the one or more end sections 235 of jumper lines 230 . The one or more valves 237 may be manipulated to drain the water from the one or more end sections 235 , thus lowering the risk of forming hydrates when the lines are restarted.
[0027] Referring now to FIG. 3 , FIG. 3A illustrates a side view of jumper line configuration 300 and FIG. 3B illustrates a top view of jumper line configuration 300 . As can be seen in FIG. 3A , jumper line configuration 300 may comprise a first subsea device 310 , a second subsea device 320 , and a jumper line 330 . Jumper line 330 may comprise straight section 331 , one or more elbows 332 , peak 333 , and one or more end section 335 . Jumper line 330 may further comprise one or more injection ports 336 and one or more valves 337 .
[0028] In certain embodiments, straight section 331 may be inclined with respect to the primary axis. In FIG. 3 , peak 333 is comprised of a single elbow 332 . Similar to jumper line configuration 200 , jumper line configuration 300 does not comprise a valley defined by one or more peaks 333 . Rather, in certain embodiments, the maximum elevation of jumper line configuration 300 occurs at peak 333 , and no local maximum elevation occurs on either side of peak 333 . However, as shown in FIG. 3B , jumper line 330 may comprise one or more secondary elbows 338 . The one or more secondary elbows 338 may be arranged in a configuration that does not result in the formation of a valley in jumper line 330 along the primary axis. For example, in certain embodiments, the one or more secondary elbows 338 may be in an axis perpendicular to the primary axis and produce one or more bends 339 in jumper line 330 in the same plane as the flow within the jumper line 330 . In certain embodiments, the one or more secondary elbows 338 may provide flexibility to the jumper line configuration 300 .
[0029] The jumper line configuration discussed herein may have several advantages. One advantage is that the jumper line configurations discussed herein are able to provide bends without having valleys, thus increasing the flexibly while limiting the formation of hydrates. Another advantage is that using the jumper line geometry discussed herein, gas may segregate into the higher part so of the jumper line and water may segregate in the low sections, thus allowing water to be drained during shut ins.
[0030] While the embodiments are described with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.
[0031] Plural instances may be provided for components, operations or structures described herein as a single instance. In general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter. | A jumper line system comprising: a first subsea device; a second subsea device; and a jumper line providing fluid communication between the first subsea device and the second subsea device, wherein the jumper line does not comprise a valley. | 4 |
FIELD OF THE INVENTION
The present disclosure relates to structures such as manufactured and modular housing and the like. More particularly, the present disclosure relates to a modular structure having modular units multiple ones of which can be selectively attached to each other in the fabrication of a residence or other building.
BACKGROUND OF THE INVENTION
Fabricated structures such as manufactured housing, trailer structures, modular housing and the like are commonly used for housing and business use. Conventional fabricated structures may include a floor assembly and walls and a roof, which are supported by the floor assembly. Each of the floor assembly, the walls and the roof of the structures may be fabricated using one type of material or a combination of materials including plywood, oriented strand board, fiberboard, panels made of compressed Kraft paper and metal sheeting, for example.
Conventional fabricated structures may have a number of drawbacks. The materials and fabrication techniques that are used in the manufacture of fabricated structures may be expensive. Additionally, the floor, walls and roof of fabricated structures may have poor moisture resistance and may be heavy and difficult to install. Moreover, fabricated structures may have a flimsy construction, which renders the structures vulnerable to high winds during hurricanes, tornadoes, and other storm conditions.
Therefore, a modular structure is needed which is simple in construction, durable, transportable, and inexpensive and which includes modular units, multiple ones of which can be selectively attached to each other in the fabrication of a residence or other building.
SUMMARY OF THE INVENTION
The present disclosure is generally directed to a modular structure that may be constructed of a strong and durable material such as a lightweight concrete material and is simple and inexpensive to fabricate and transportable from a fabrication facility to a deployment site. The modular structure may include single or multiple modular units, which can be selectively attached to each other to form a residence or other building of selected size and configuration.
In one aspect, the modular structure may include:
at least one modular unit comprising:
a structure base; a structure enclosure carried by the structure base; and wherein each of the structure base and the structure enclosure is fabricated primarily of a material being a lightweight concrete material bonded to and covering a reinforcing material.
In another aspect, the reinforcing material is steel in the form of what is commonly known as “rebar”.
Another aspect provides a structure that is assembled utilizing a forming process, wherein the structure is fabricated via forming a structure base, followed by forming and pouring wall and roof portions during a single mold pouring process. The wall and roof portions form a unitary enclosure. The unitary structure may be created utilizing a process by which the wall and roof portions are formed and poured in a single concrete pour, such as via a tunnel forming process, a wall and shored ceiling forming process, and any other process allowing such unit homogeneity.
In another aspect, the structure base may include a perimeter footer and optional cross rib supports as structurally required and a floor normally extending the length and width of the modular unit, including the area within the extremities of the footer.
In still another aspect, a plurality of structure reinforcing elements, which may include reinforcing steel or other reinforcing materials, may extend from the structure base into the structure enclosure.
In another aspect, the structure enclosure may include a pair of spaced-apart side walls carried by the structure base and at least one structure roof section carried by the side walls.
In still another aspect, at least one end wall may be carried by the structure base and at least one structure roof section carried by the end walls and side walls.
In yet another aspect, a plurality of connector plate assemblies may be carried by at least one of the structure base and the structure enclosure.
In another aspect, each wall may include such openings as may be required in the structure enclosure to allow for the placement of doors and windows in the enclosure as may be architecturally specified.
In a still further aspect, the plurality of connector plate assemblies may each include a connector plate and a plurality of connector plate anchor members carried by the connector plate and extending into the structure base and/or the structure enclosure.
In another aspect, a connector bracket having a bracket base may be provided on the connector plate and a bracket flange may be provided on the bracket base.
In another aspect, a plurality of lift insert assemblies may be carried by the structure base and the structure enclosure.
In another aspect, the plurality of lift insert assemblies may each include a plurality of list insert anchor members carried by the lift assembly plate which includes a plate flange with thru hole for lifting of the modular unit.
These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrative embodiments of the disclosure will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:
FIG. 1 is a perspective view of a structure base of a modular unit;
FIG. 2 is an exploded perspective view of a modular unit, more particularly illustrating an exemplary method of attaching a structure enclosure to a structure base of the modular unit;
FIG. 3 is a perspective view, partially in section, of a modular unit, additionally illustrating enlarged perspective views of an exemplary connector plate assembly and an exemplary unit lift assembly, respectively;
FIG. 4 is a perspective view of a modular structure formed having a pair of modular units, more particularly illustrating an exemplary method of attaching the modular units in end-to-end relationship to each other in fabrication of a first illustrative embodiment of a modular structure;
FIG. 5 is a perspective view of a modular structure formed having a pair of modular units attached to each other in end-to-end relationship with respect to each other in fabrication of an illustrative embodiment of the modular structure;
FIG. 6 is a perspective view of a modular structure formed having a pair of attached modular units, more particularly illustrating attachment of a third modular unit to an end of the adjacent attached modular units in fabrication of an illustrative embodiment of the modular structure forming an end to end configuration;
FIG. 7 is a perspective view of a modular structure formed having three modular units attached to each other in end-to-end relationship to each other in fabrication of an illustrative embodiment of the modular structure;
FIG. 8 is a perspective view of another illustrative embodiment of the modular structure, with one modular unit oriented in perpendicular relationship with respect to another modular unit;
FIG. 9 is an exploded perspective view of an illustrative unit connector assembly in attachment of adjacent modular units to each other in fabrication of an illustrative embodiment of the modular structure;
FIG. 10 is a perspective view of the illustrative unit connector assembly illustrated in FIG. 9 , more particularly insertion of a fastener through a pair of connector brackets in the unit connector assembly; and
FIG. 11 is a perspective view of the illustrative unit connector assembly illustrated in FIG. 9 , with the connector brackets fastened to each other in the unit connector assembly.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.
The present disclosure is generally directed to a modular structure that may be constructed of a strong and durable material such as a lightweight concrete material and is simple and inexpensive to fabricate. The modular structure may include a single modular unit or multiple modular units, which can be selectively attached to each other to form a residence or other building of selected size and configuration.
Referring to the drawings, an illustrative embodiment of the modular structure is generally indicated by reference numeral 100 . As illustrated in FIGS. 4-7 , the modular structure 100 may include multiple modular units 101 which can be selectively attached to each other to fabricate a modular structure 100 having a selected size and configuration, as will be hereinafter described. As illustrated in FIGS. 1 and 2 , each modular unit 101 of the modular structure 100 may include a structure base 102 . A structure enclosure 130 may be provided on the structure base 102 . The structure base 102 and the structure enclosure 130 may each be a lightweight material such as molded lightweight or foamed concrete, for example and without limitation. The modular unit 101 can be formed via a two-stage pouring process into forms, a process of fabricating the structure base 102 , then forming or molding the structure enclosure 130 onto the structure base 102 , or forming via two separate processes and subsequently attaching the two components to one another.
As illustrated in FIG. 1 , the structure base 102 may include a footer 103 , located on two or more sides, and a floor 104 that covers the footer 103 and the area inside the footer 103 , formed as an integral structure. The footer 103 can optionally be provided along the entire perimeter of the floor 104 . In some embodiments, the structure base 102 and the structure enclosure 130 of each modular unit 101 may have a generally elongated, rectangular shape. Accordingly, the footer 103 and any corresponding structural footer ribs (not shown) inside of the perimeter footer 103 may be thicker than the floor 104 and may be disposed in generally parallel, spaced-apart relationship to each other. A foundation space 105 may be defined by and between the perimeter footer 103 . In some implementations, a footer 103 may be required along the entire perimeter of the floor 104 such that all four edges are thicker than the center of the structure base 102 . In some implementations, structure reinforcing elements 110 may extend beyond the plane of the floor 104 proximate an area along at least two edges of the structure base, each edge corresponding to a structure wall 131 , 138 . The structure reinforcing elements 110 are preferably arranged in a spaced-apart relationship to each other. In some embodiments, the structure reinforcing elements 110 may extend along three or all four edges of the structure foundation 102 . The structure reinforcing elements 110 may be rebar or tensioning bars or beams, as examples and without limitation. As illustrated in FIG. 3 , the structure base 102 may include a foundation support structure, which may be a network of wood, metal, and/or other reinforcing material as exemplified by the potential requirement for fabrication of composite flooring, and the like. In some embodiments, the lightweight concrete may be foamed concrete, for example and without limitation.
As illustrated in FIGS. 2 and 3 , the structure enclosure 130 of each modular unit 101 may include a pair of spaced-apart side walls 131 which extend upwardly from the structure base 102 . In some embodiments, the structure reinforcing elements 110 ( FIG. 1 ) which extend from the structure base 102 may extend into the side walls 131 of the structure enclosure 130 to anchor the structure enclosure 130 on the structure base 102 and to meet the structural requirements for rebar laps and to tie the rebar or other reinforcing material in the base to the reinforcing materials in the enclosure. Window openings 132 and/or door openings 133 may extend through each side walls 131 .
At least one roof section 136 may be provided on the side walls 131 . In some embodiments, a gabled roof 136 may extend from the respective side walls 131 . In some embodiments, a single roof section, such as a flat or shed roof, (not illustrated) may be supported by the side walls 131 . An end wall 138 ( FIG. 4 ) may be provided on at least one end of the structure enclosure 130 and may provide additional support to the roof 136 . A modular unit 101 having an end wall 138 ( FIG. 4 ) may be referred to as a terminal unit. A modular unit 101 having the end wall 138 omitted may be referred to as a central modular unit.
As illustrated in FIG. 3 , in some embodiments, the structure enclosure 130 of each modular unit 101 may include an interior finish support furring 140 and ceiling beams 141 , which is generally fabricated of furring strips or long thin strips of wood or metal used to make backing surfaces to support the finished surfaces in a room. A surface finish material 146 , such as drywall, for example and construction components which may include insulation and plumbing and electrical appurtenances and without limitation, is provided on or within or between the interior finish support furring 140 to provide a finished appearance and necessary utility to the side walls 131 , the roof sections 136 and the structure end wall 138 . Other finish items can be installed, such as windows, doors, insulation, plumbing, electrical components, and the like, at the manufacturing location, at the site of the assembly of the modular structure 100 .
As illustrated in FIGS. 5-7 , unit connector assemblies 112 may be used to attach adjacent modular units 101 to each other in the modular structure 100 . As illustrated in FIG. 9 , each unit connector assembly 112 may include a connector plate assembly 117 , which is provided at each connecting end of each modular unit 101 . Each connector plate assembly 117 may include a connector plate 113 which may be steel, for example and without limitation. Multiple connector plate anchor members 114 may extend from a first connector plate surface 126 of the connector plate 113 . Each connector plate anchor member 114 may include a generally elongated anchor member shaft 115 , which extends from the connector plate 113 and a shaft head 116 , which terminates the anchor member shaft 115 . In fabrication of the modular structure 100 , the connector plate 113 of each connector plate assembly 117 may be partially embedded in, flush/or standing proud with the foundation side portion 103 of the structure base 102 . The connector plate anchor members 114 may extend into the structure base 102 to anchor the connector plate 113 to the structure base 102 . As illustrated in FIGS. 1 and 2 , in some embodiments, at least two connector plate assemblies 117 may be provided at each end and on respective sides of the structure base 102 to facilitate assembly of at least two unit connector assemblies 112 on each connecting end of each modular unit 101 . Additional connector plate assemblies 117 may be provided on the respective roof sections 136 , as illustrated, and/or on the respective side walls 131 of the structure enclosure 130 of each modular unit 101 .
As further illustrated in FIG. 9 , in each unit connector assembly 112 , which attaches adjacent modular units 101 to each other in the modular structure 100 , a pair of connector brackets 118 may attach the connector plate assemblies 117 on the respective modular units 101 . Each connector bracket 118 may be an L-shaped angled connector bracket having a bracket base 119 and a bracket flange 120 , which extends from the bracket base 119 . A strengthening wedge or structural fillet (not illustrated) may be included on each connector bracket 118 . As illustrated in FIG. 10 , the bracket base 119 of each connector bracket 118 may be attached to a second connector plate surface 127 on the connector plate 113 of each corresponding connector plate assembly 117 such as via a weld 128 , for example and without limitation. A fastener 124 may be extended through registering fastener openings 121 provided in the bracket flanges 120 of the adjacent connector brackets 118 . A nut 125 may be threaded on the fastener 124 .
As illustrated in FIGS. 1-3 , in some embodiments, multiple unit lift assemblies 150 may be provided along the exterior surface about a perimeter of the structure base 102 to facilitate lifting and transport of each modular unit 101 as deemed necessary. As illustrated in FIG. 3 , each unit lift assembly 150 may include a lift assembly plate 151 which may be embedded in the structure base 102 . The lift assembly plate 151 may have anchor members, similar to the connector plate anchor members 114 , which may extend into the structure base 102 to anchor the lift assembly plate 151 to the structure base 102 . A lifting flange 152 may extend from the lift assembly plate 151 . A lifting plate opening 153 may extend through the lifting flange 152 . Each unit lift assembly 150 may have an alternative design which is suitable to facilitate lifting of each modular unit 101 using a suitable lifting or hoisting apparatus (not illustrated).
Each modular unit 101 of the modular structure 100 may be fabricated using conventional molding techniques known by those skilled in the art. In one method of fabrication, the structure base 102 may be poured initially and cured, after which the structure enclosure 130 may be poured on the structure base 102 and cured. A foundation mold (not illustrated), which corresponds to the size and shape of the structure base 102 to be fabricated may then be placed around the base structure. Lightweight concrete may then be poured into the base form, which is subsequently separated from the structure base 102 after hardening and curing of the lightweight concrete. The structure enclosure 130 is then formed onto the structure base 102 , using a similar forming and pouring process. Once cured, the form can be removed and additional finishing can be accomplished on the modular unit 101 . Furring 140 ( FIG. 3 ) may then be assembled onto the modular unit 101 for finishing. A surface finish material 146 may then applied covering the furring 140 , providing features, looks, and the feel of commonly constructed structures. A dropped ceiling may be installed as illustrated in FIG. 3 . Flooring 142 can be disposed upon the exposed interior surface of the structure base 102 .
In yet another method of fabrication of each modular unit 101 , the structure base 102 and the structure enclosure 130 may be molded independent of each other and subsequently assembled as a unitary structure. The structure enclosure 130 may then be placed on the structure base 102 . Prior to placement of the structure enclosure 130 on the structure base 102 , reinforcing element channels (not illustrated) may be provided in each side wall 131 of the structure enclosure 130 to receive the respective structure reinforcing elements 110 of the structure base 102 as the structure enclosure 130 is lowered onto the structure base 102 .
As illustrated in FIGS. 4-7 , a modular structure 100 may be assembled in a linear configuration by attaching multiple modular units 101 to each other in end-to-end relationship. Accordingly, as illustrated in FIG. 4 , the open ends of a pair of modular units 101 may be attached or coupled to each other by fastening the connector plate assemblies 117 at the end of one modular unit 101 to the respective connector plate assemblies 117 at the facing end of the other modular unit 101 . This may be accomplished as was heretofore described with respect to FIGS. 9-11 , by attaching the connector brackets 118 to the connector plates 113 of the respective connector plate assemblies 117 ; extending a fastener 124 through the registering fastener openings 121 in the connector brackets 118 ; and threading a nut 125 on the fastener 124 . As illustrated in FIGS. 5-7 , it will be appreciated by those skilled in the art that any number of additional modular units 101 may be sequentially attached or coupled to the terminal modular unit 101 in like manner to assemble a modular structure 100 having a selected length and number of modular units 101 . The terminal modular units 101 on the respective ends of the modular structure 100 may be fabricated with one structure end wall 138 , whereas the modular units 101 between the terminal modular units 101 may be fabricated without the structure end wall(s) 138 , to provide a continuous structure interior 134 ( FIGS. 4 and 6 ) throughout the length of the modular structure 100 . In some embodiments, an expansion joint (not illustrated) may be placed between the adjacent modular units 101 in the modular structure 100 to accommodate expansion and contraction of the modular units 101 with respect to each other. Each expansion joint may be an extruded resilient material such as rubber, silicone or the like. It is desirable that the modular structure 100 be fabricated of a shape and size suitable for transporting on public roadways. Prior to assembly of the modular structure 100 , the unit lift assemblies 150 provided along the sides of the structure base 102 of each modular unit 101 may be engaged by a suitable lifting or hoisting apparatus (not illustrated) to lift each modular unit 101 onto a transport vehicle (not illustrated) such as a truck or railcar for transport of the modular units 101 to the site of assembly of the modular structure 100 .
As illustrated in FIG. 8 , in some applications the modular structure 100 may be assembled in a non-linear configuration, referenced as modular structure 200 . Accordingly, a first one of the modular units 101 may be fabricated with a side opening (not illustrated) in a side wall 131 thereof. The open end of a second modular unit 101 may then be placed in communication with the opening in the first modular unit 101 and the second modular unit 101 coupled to the first modular unit 101 via multiple unit connector assemblies 112 . The roof sections 136 of the second modular unit 101 may then be extended to the pitch of the roof sections 136 on the first modular unit 101 by fabrication of a roof frame 144 followed by the application of a covering material to the roof frame 144 .
It will be appreciated by those skilled in the art that the simplicity in construction of the modular structure enables a number of variations of the modular structure configurations depending on the particular needs and desires of the user. Although the preferred embodiments taught herein show the assembly of adjacent modular units 101 having the openings positioned proximate the other, it is understood that a modular unit 101 can be assembled to an adjacently positioned modular unit 101 at any location, angle, and the like. A pathway can be provided between the two connecting modular units 100 as needed.
While the illustrative embodiments of the disclosure have been described above, it will be recognized and understood that various modifications can be made to the embodiments and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the disclosure. | A modular structure includes at least one modular unit comprising a structure base and a structure enclosure carried by the structure base. Each of the structure base and the structure enclosure comprises lightweight concrete providing a significantly improved structure over the currently used fabrication processes. The modular structure is fabricated utilizing tunnel fabrication processes, creating a unitary structure. The structure can be finished at a manufacturing location, then transported and installed at the desired location. Connector plate assemblies are molded into the structure for securing two adjacent modules. Adjacent modules can be oriented perpendicular, parallel, or any angle therebetween to each other. | 4 |
FIELD OF THE INVENTION
The present invention relates to the use of okadaic acid as a positive control and a standard in testing for ciguatoxin-contaminated fish.
BACKGROUND OF THE INVENTION
Ciguatera poisoning is a particular type of fish poisoning which results from the ingestion of contaminated fish. Intoxication is associated with the consumption of toxins produced by the tropical dinoflagellates, including Gambierdiscus toxicus, which are subsequently passed along the marine food chain to man. Ciguatoxins are polyether marine toxins, and approximately 27 different ciguatoxins are known, approximately 23 of which are toxic to man. Ciguatera toxins are odorless, tasteless, heat-stable, and generally undetectable by simple chemical tests.
Humans are susceptible to ciguatera poisoning, both from eating toxic herbivores which ingest the dinoflagellates while feeding on red or brown algae, and from eating carnivores which have eaten the toxic herbivores. An accurate assessment of the incidence of ciguatera poisoning is not available; however, it is estimated that, each year, from 10,000 to 50,000 people who live in or visit tropical and subtropical areas suffer from ciguatera poisoning. Additionally, the threat of this contamination results in enormous economic losses in the recreational and commercial exploitation of fishery resources in the affected areas. With increased utilization of tropical reef fish in the continental United States, through interstate commercial trade and tourist travel, incidents of ciguatera poisoning are on the increase.
The onset of the clinical symptoms of ciguatera poisoning occurs within 10 minutes to 24 hours following the consumption of contaminated fish. Ciguatera poisoning affects the digestive system (resulting in abdominal pain, diarrhea, vomiting, nausea); the cardiovascular system (resulting in bradycardia, hypotension, tachycardia); and the neurological system (resulting primarily in paraesthesia and dysesthesia).
Immunological methods have been developed for the identification of ciguatoxin in fish, such as those described in U.S. Pat. No. 4,816,392. These methods offer a relatively simple method of assaying for ciguatoxin. However, such assays incorporate the requirement for "controls." Positive and negative controls are necessary in such assay reactions so that the user of the assay can determine if the reagents are functioning correctly. Also, positive and negative controls provide standard reactions with which the user can compare test assay results to determine if a positive or negative reaction has been obtained. The term "positive control" as used herein means a composition which reacts with antibodies or other assay reagents in a manner similar to ciguatoxin-containing fish extracts to give a positive reaction when assayed. The term "negative control" refers to a sample which contains all the components of a test assay sample, except for a ciguatoxin-containing fish extract or such toxins, and which does not react with antibodies against ciguatoxin, therefore giving a negative reaction when assayed.
Previously, fish extracts have been used as a positive control for ciguatoxin assays. However, such extracts vary in their composition, with respect to the ciguatoxins they contain and the concentration of the ciguatoxin(s) present, and, therefore, also vary in their reactivity. As a result, fish extracts exhibit variable reactivity and give results that are not reproducible. Also, to determine the toxicity of ciguatoxin in fish extracts, toxicity assays, such as assaying the toxicity of the ciguatoxin in mice, have to be performed. Such assays are time-consuming and expensive.
An additional drawback of the use of fish ciguatoxin extracts is that, for mass production of kits for the assaying of fish which may contain ciguatoxin or other "screening" assay methods, enormous numbers of toxic fish would be required for the production of ciguatoxin extract for the positive controls. The requirement for such large amounts of ciguatoxin extracts could make the routine testing of fish impractical or too expensive to be feasible, and results would vary with different fish ciguatoxin extract preparations.
There exists a need, therefore, for a composition which will reliably and reproducibly react in a ciguatoxin assay to mimic the results that would be obtained with a ciguatoxin-contaminated fish and which is readily available and relatively inexpensive.
SUMMARY OF THE INVENTION
The present invention relates to a composition comprising okadaic acid for use as a positive control in assays for the detection of ciguatoxins and methods for making such compositions.
In a preferred embodiment, the okadaic acid composition further comprises a carrier selected from the group consisting of fish extract, oils, oil/organic solvent mixtures, fatty-acid solutions, and non-ionic detergent solutions, wherein: the oil is selected from the group consisting of soybean oil, jojoba oil, olive oil, safflower oil, or mixtures thereof; the organic solvent of the oil/organic solvent mixture is selected from the group consisting of hexane, butanol, or mixtures thereof; the fatty acid is selected from the group consisting of lauric acid, linoleic acid, myristic acid, palmitic acid, stearic acid, oleic acid, and mixtures thereof; and the non-ionic detergent is selected from the group consisting of the polyoxyethylenesorbitan detergents, and mixtures thereof.
In a preferred embodiment of the present invention, the okadaic acid composition results in a reaction, when assayed, equal to the intensity obtained with assays of about 25 mg/ml toxic fish extract.
The present invention also relates to a kit for detecting the presence of ciguatoxin or related polyether marine toxins in fish, which comprises supports for binding toxin, negative control supports, positive control supports impregnated with a composition comprising okadaic acid, a fixer for fixing toxin to the support, an assay reagent for assaying toxin or okadaic acid bound to the fixed support, and a buffer solution for washing the fixed toxin-bound supports after they have been contacted with the assay reagent.
DETAILED DESCRIPTION
The present invention relates to a composition comprising okadaic acid and a method for using the composition as a positive control in assays for the detection of fish contaminated by ciguatoxin, which is also referred to as toxin. The okadaic acid composition, which mimics assay results obtained with ciguatoxin-contaminated fish, also has uses as a "standard" for use in quantitating the sensitivity and specificity of preparations of antibodies against ciguatoxin or other ciguatoxin assay components. Okadaic acid also has uses in comparing and developing new assay methods to the results obtained with assay procedure that have previously been developed, and in quality control of assay reagents and components that are mass-produced over a period of time.
ANTIBODY CIGUATOXIN ASSAY METHODS
Methods for assaying ciguatoxins in fish, such as that described in U.S. Pat. No. 4,816,392, have used sticks coated with correction fluid to adsorb ciguatoxin from the flesh of contaminated fish. A sample of the ciguatoxin that may be present in the fish is adsorbed onto the correction fluid of the stick by inserting the stick into and contacting it with the flesh of the fish. The ciguatoxin adsorbed onto the correction fluid is then bound to an antibody against ciguatoxin, the antibody having previously been coupled to horseradish peroxidase. The presence of ciguatoxin is determined by assaying for the horseradish peroxidase activity. The term "antibody against ciguatoxin" as used herein means an antibody which binds to antigenic determinants of ciguatoxin and may include monoclonal or polyclonal antibodies. Such antibodies can be prepared by conventional techniques which are known in the art. The animals used for the preparation of the antibodies are immunized with a ciguatoxin-containing fish extract (also referred to as "toxic fish extract") or a ciguatoxin analog.
Other assay procedures use "immunobeads," which comprise colored latex beads coated with antibody against ciguatoxin. Suitable immunobeads are made from blue-colored latex beads of about 0.3 to about 0.4 μm in diameter, such as those supplied by Seradyn, Inc., Particle Technology Division Ind., of Indianapolis, Ind. However, other-sized latex beads may be used.
Fish are screened by binding ciguatoxin, which may be present in the tissue of the fish, to a test support. Suitable supports may be bamboo sticks, which are coated with an organic-base solvent correction fluid such as LIQUID PAPER, supplied by Pentel of America, Ltd., Torrance, Calif., to form paddle supports, or membrane supports. Membrane supports comprise membrane material, such as that supplied by Millipore, of Bedford, Mass., under the name "MILLIPORE IMMOBILON-P MEMBRANE #IPVH," attached to a "dipstick." Polystyrene strips are suitable for use as dipsticks. The membranes are attached to the dipsticks by using an adhesive, such as "3M MEDICAL GRADE ADHESIVE #3044," or other suitable means of attachment.
After the support has been contacted with the fish tissue or extracts, it is contacted with the immunobeads. If ciguatoxin is present in the fish, the antibodies bind to the ciguatoxin on the support. Since the antibodies are also bound to the colored latex beads, the colored latex beads become bound to the ciguatoxin on the support. Therefore, a positive result, indicating the presence of ciguatoxin in the fish tissue, is observed by a change in color of the support due to colored latex beads being bound to the support.
When the antibody-horseradish peroxidase assay method is used, a positive result is observed by the accumulation of product from the enzyme assay.
In use, the assay reactions, described above, are compared to negative and positive controls. The negative controls are test supports which have not been exposed to ciguatoxins or their analogs.
CIGUATOXIN ASSAYS
Ciguatoxin is isolated by cutting an incision into the filet portion of a fish, near the head region. The LIQUID PAPER-coated end or membrane end of a "test" support is inserted into the incision and pushed up and down, to contact the fish tissue. The support is then air-dried and fixed quickly by dipping in absolute methanol for about 1 to about 3 seconds, and is again air-dried. The coated methanol-fixed end of the support is immersed into an immunobead suspension or other assay reagent. After 5 minutes' immersion in the immunobead suspension, the support is washed in phosphate-buffered saline, or other suitable wash solution, and examined.
If a distinct coloration of the support is observed, similar to that obtained with the positive control, after 5 minutes' immersion in the immunobead suspension, the test is considered positive, and the fish should not be eaten.
If, after 5 minutes' immersion in the immunobead suspension, the support has no color or very diffuse color, similar to that obtained with the negative control, the support is immersed in the immunobead suspension for an additional 5 minutes. If, after a total of 10 minutes, no color or very diffuse color of the support is observed, the result of the test is considered to be negative. In the case of a negative result, the same procedure, i.e., inserting a support into a fish and immersing the support in an immunobead suspension for up to 10 minutes, is repeated by inserting an additional support into a different area of the same fish. If the support is again negative after 10 minutes, the fish is considered safe to eat.
Intermediate readings, in which some coloration of at least one of the two supports used is observed after 10 minutes, or in which one support gives distinct coloration, indicate that the fish is probably contaminated and should not be eaten.
Negative control supports (supports which are identical to the paddle supports described above but which have not been exposed to ciguatoxins or their analogs) are subjected to the same treatment as described above for the test paddle supports. Similarly, a sample which gives a positive result (positive control) is also subjected to the same treatment as described for the test paddle supports. The negative and positive control supports are used to ensure that the reagents used in the assay are functioning correctly, and also for comparing with the test paddle supports to determine if a positive or a negative result has been obtained.
POSITIVE CONTROLS COMPRISING OKADAIC ACID
Assays for ciguatoxin ideally require the use of a positive control to determine if the reagents used in the assay are functioning correctly. Thus, when a negative result is obtained, it can be determined that the negative result is due to the lack of ciguatoxin contamination in the fish being tested, rather than due to a malfunction of the assay method. Also, the antibodies used in the assays need to be titered, to determine the useful range of antibody to be used in assay reactions. Such assays are important, since the use of too little antibody may cause the reaction to give a false negative result, and the use of too much antibody means that the assays are wasteful of this valuable reagent.
Previously, fish extracts had been used as the positive control for ciguatoxin assays and for titering antibodies and other assay reagents. However, these extracts vary in their composition, with respect to the ciguatoxins present in the extract and the concentration of the ciguatoxin present, and, therefore, also vary in their reactivity. Also, since the composition of the fish extract is unknown the use of fish extracts introduces a variable, into the assays for ciguatoxin contaminated fish, that can not be controlled. Therefore, fish ciguatoxin extracts exhibit variable reactivity and give results that are not reproducible or reliable.
Okadaic acid, which is commercially available from Sigma Chemical Co. of St. Louis, Mo., Catalog No. O-1506, has been found to mimic ciguatoxins in ciguatoxin assays. Compositions comprising okadaic acid have a known formulation and concentration and which give predictable and reproducible reactivity when assayed in ciguatoxin assays.
The reproducibility of the reactions obtained with okadaic acid allows assay parameters to be standardized so that assay kits or the like can be mass-produced. Okadaic acid is used as a means of quality control to ensure that kits produced are of a standard, acceptable quality and that the quality of the kits produced does not change over time.
For use in ciguatoxin assays, okadaic acid is mixed with a carrier. Carriers suitable for use in the present invention are carriers such as: fish extract obtained from either toxic or non-toxic fish and prepared as described below or by other suitable methods; oil/organic solvent mixtures; non-ionic detergent solutions; or fatty-acid solutions.
Positive controls are prepared by immersing a support, as described above, in an okadaic acid/carrier mixture. The positive control is then assayed as described above or by other suitable assay methods.
PREPARATION OF FISH EXTRACTS
Fish extracts, from either toxic or non-toxic frozen fish, are prepared by weighing out about 250 g of fish. The fish tissue may be autoclaved for about 10 minutes, if desired, to facilitate de-boning and to aid in the preparation of the fish extract. The bones are removed, and the tissue is homogenized in a blender at high speed for about 10 minutes. The homogenized tissue is diluted 50% w/v with acetone, and the mixture is blended for about another 5 minutes. The mixture is then centrifuged at about 2,000 rpm for about 15 minutes, at 4° C., to separate the phases. The upper, acetone phase is decanted and collected, and the acetone extraction procedure is repeated, on the residue/aqueous phase, three more times. The extract is stored at about -18° C. for about 10 to about 20 hrs. The solution is filtered in a cold Buchner funnel, and any residue is discarded. Acetone is removed from the non-volatile material by rotary evaporation.
Two volumes of methanol are added to the non-volatile material remaining after rotary evaporation, and the solution is mixed. The mixture is extracted three times with about a 1/3 volume of hexane. The hexane phase is separated from the methanol-containing phase and discarded. The methanol is separated from the non-volatile material by rotary evaporation.
An approximately-equal volume of chloroform is added to the non-volatile material, and the mixture is shaken to extract the non-volatile material. The chloroform phase is then collected. The chloroform extraction is repeated two more times. The chloroform extracts are combined, and the chloroform is evaporated in a steam bath. The residue remaining after the chloroform is evaporated is crude fish extract.
Crude extract may be further purified by thin-layer chromatography (TLC) on silica gel TLC plates or by column chromatography.
The thin-layer chromatographic plate is developed with a chloroform/methanol mixture at a ratio of 8:2. The ciguatoxin fraction is recovered from the TLC plate, after the TLC plate has been run to separate the components of the crude extract, by scraping into a container the TLC medium from the section of the TLC plate containing the polyether fraction. The purified fish extract is then eluted from the collected TLC medium with chloroform:methanol in a ratio of 95:5. The eluate is evaporated to dryness and resuspended in about 5% Tween 60.
When column chromatography is used for the further purification of the crude extract, silicic acid, supplied by Mallicrodt, is used as the chromatography medium. Preferably, 100 mesh silicic acid is used, and it is activated at 100° C. for 1 hour, prior to use. The silicic acid is poured into a column of about 2 cm by about 5 cm, for use. The chromatographic medium is prepared by adding about a 1 cm layer of anhydrous Na 2 SO 4 on top of the chromatographic medium in the column and equilibrating the chromatographic medium with chloroform. The crude extract is dissolved in chloroform to a concentration of about 40 mg/ml and applied to the chromatographic medium. The chromatographic medium is washed with about 20 ml of chloroform to elute triglycerides, fatty acids, cholesterol, and other non-polar compounds from the chromatographic medium. Ciguatoxins and other polyethers are eluted with a mixture of chloroform and methanol in a ratio of 95:5. The eluate is evaporated to dryness and resuspended in about 5% Tween 60.
CARRIERS SUITABLE FOR USE WITH OKADAIC ACID
When okadaic acid and fish-extract carriers are used as the positive control, supports, as described above, are immersed in solutions comprising about 0.1 μg/ml to about 0.8 μg/ml okadaic acid and about 2 to about 10 mg/ml fish extract. Concentrations above 0.8 μg/ml can be used; however, a reaction is obtained that is much stronger than the reaction which would be expected to be observed for a positive test support. Such a result could lead the user of the test to incorrectly determine, by comparison of a positive test support with the positive control, that the reaction obtained with the test strip was negative, rather than positive. Concentrations below about 0.1 μg/ml result in a reaction that is very weak and difficult to distinguish from the negative control.
The amount of fish extract used as carrier can be decreased as the amount of okadaic acid is increased. Preferably, a concentration of about 0.5 μg/ml okadaic acid with about 4 mg/ml of fish extract carrier is used, since this concentration simulates the expected results which would be obtained with a positive test support of about 25 mg/ml of ciguatoxin-containing fish extract. The minimum ciguatoxin assay result, which will cause toxicity to humans when the contaminated fish tissue is consumed, is considered to be equivalent to the assay results obtained with about 25 mg/ml ciguatoxin-containing fish extract. However, other concentrations of okadaic acid and fish extract carriers can be used, and can be varied to suit the needs of the assay being performed.
Oil/organic solvent mixtures suitable for use as carrier in the present invention are mixtures such as olive oil in butanol, safflower oil in butanol, olive oil in hexane, safflower oil in hexane, soybean oil in hexane, and jojoba oil in hexane, although other mixtures of oil and organic solvents can also be used. Preferably, the ratio of oil:organic solvent is about 1:10. About 0.1 to about 0.8 μg/ml okadaic acid is added to the oil/organic solvent mixtures. Most preferably, about 0.5 μg/ml okadaic acid is used, which gives a result similar to that obtained with 25 mg/ml of toxic fish extract.
Preparations of oil alone can be used as a carrier for the okadaic acid; however, such preparations leave an oily film on the support. The incorporation of an organic solvent into the preparation reduces the amount of oil left on the support and aids in the drying of the support after impregnation with the okadaic acid composition.
Non-ionic, detergent solutions suitable for use as carrier in the present invention are aqueous solutions prepared with detergents such as the polyoxyethylenesorbitans (Tween 20, Tween 40, Tween 60, Tween 80 and Tween 85). Preferably, about 5%, by volume, non-ionic detergent is used. About 0.1 to about 0.8 μg/ml okadaic acid is added to the detergent solutions. Most preferably, about 0.5 μg/ml okadaic acid is used, which gives a result similar to that obtained with 25 mg/ml of toxic fish extract.
Fatty-acid solutions suitable for use as carrier in the present invention include fatty acids such as lauric acid, linoleic acid, myristic acid, palmitic acid, stearic acid, oleic acid, and mixtures thereof. Preferably, about 5%, by volume, aqueous fatty-acid solutions are used. About 0.1 to about 0.8 μg/ml okadaic acid is added to the fatty-acid solutions. Most preferably, about 0.5 μg/ml okadaic acid is used, which gives a result similar to that obtained with 25 mg/ml of toxic fish extract.
ASSAY METHODS WITH OKADAIC ACID
Determination of the sensitivity and specificity of antibody or immunobead preparations can be conducted by coating a number of different supports with a solution containing either 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 μg/ml of okadaic acid, or other suitable concentration ranges in the presence of carrier. When the okadaic acid-supports are exposed to the immunobeads, the immunobead antibodies bind to the okadaic acid, resulting in the presence of a blue color on the support which will not be washed off by rinsing in a wash solution such as phosphate-buffered saline. The intensity of the blue color increases with increasing concentrations of okadaic acid. It is preferred that the immunobeads bound to the support result in a distinct blue color, with supports coated with at least about 0.4 to about 0.6 μg/ml okadaic acid. Most preferably, the distinct blue color will be developed with supports coated with at least about 0.5 μg/ml of okadaic acid. If the immunobeads do not result in a distinct blue color with at least 0.6 μg/ml okadaic acid, the immunobeads may not be sufficiently sensitive to reliably detect contaminated fish. If the immunobeads react with less than about 0.4 μg/ml okadaic acid to give a distinct blue color, an excessive amount of antibody has been bound to the latex bead, and preparation of immunobeads with such high amounts of antibodies is wasteful of this valuable reagent. Similar assays can be conducted with antibodies coupled to enzymes or other assay methods.
The intensity of the distinct blue color of the positive reaction is chosen so that the color of a positive reaction (for example, the reaction obtained with a positive control) is clearly distinguished from a negative reaction (for example, the reaction obtained with a negative control) when the positive and negative reactions are compared side-by-side.
USE OF OKADAIC ACID IN FIELD KITS
The composition of the present invention is also appropriate for use in field kits for the detection of ciguatoxin contamination in fish. Field kits are particularly useful for sportsfisherman, who can test the fish they catch. The okadaic acid positive control is useful in such field kits to ensure that the user of the field kit can evaluate the results obtained with the test support and can distinguish between a positive and a negative assay result.
Such field kits comprise:
negative controls, which are supports which have not been exposed to ciguatoxin-containing fish extract, ciguatoxin analogs, or okadaic acid;
positive controls, which are supports that have been exposed to compositions comprising okadaic acid;
test supports, which are supports which are to be contacted with fish extracts or the flesh of fish suspected of being contaminated with ciguatoxin;
a fixation reagent, which is preferably absolute methanol;
an assay reagent, such as an immunobead suspension; and
a wash solution, such as phosphate-buffered saline.
The supports suitable for practice of this invention are bamboo, with one end coated with correction fluid, membranes attached to a dipstick, or other suitable supports.
EXAMPLE 1
Assay of Toxic Fish Extract Using an Immunobead Assay
Membrane supports were exposed to various concentrations of a fish extract derived from toxic Po'ou fish (Wrasse fish). The membrane portion of a membrane support was inserted into solutions which contained either 1, 5, 10, or 25 mg/ml of fish extract. The membrane supports were removed and air-dried for about 5 minutes or until the membranes were dry.
The membrane supports were fixed by immersing the membranes in absolute methanol for about 1 second. The membrane supports were again air-dried for about 5 minutes. Each of the membrane supports was then immersed in 0.5 ml of an immunobead suspension and allowed to remain in the immunobead suspension, undisturbed, for about 5 minutes. After 5 minutes, the membrane supports were removed from the immunobead suspension and washed three times with phosphate-buffered saline. Any excess liquid was removed by blotting the support with a paper towel.
The color developed on the test membrane supports was evaluated and the results scored.
The results of the assays conducted with various concentrations of toxic fish extract are summarized in Table I. Also included, for comparison, are similar assays conducted with paddle supports. The paddle support assays were performed as described above for the membrane supports, except paddle supports were used in place of the membrane supports.
TABLE I______________________________________Toxic Paddle MembraneFish Extract.sup.b Support Support______________________________________ 1 mg/ml .sup. 10/10.sup.a 4/4 5 mg/ml 10/10 4/410 mg/ml 9/10 15/1525 mg/ml 7/7 14/14______________________________________ .sup.a Number positive results/number of supports assayed. .sup.b Color intensity increased with increased concentration of extract.
The results indicate that membrane and paddle supports are sensitive to and effective in the detection of toxin.
EXAMPLE 2
Assays of Mixtures of Toxic Fish Extract and Okadaic Acid
The assay procedure described in Example 1 was repeated, except that 0.2 μg/ml of okadaic acid (OA) was added to each of the toxic fish extract solutions.
The color developed on the test membrane and paddle supports was evaluated and the results scored. The results of the assays are summarized in Table II.
TABLE II______________________________________Toxic Fish Extract Paddle MembranePlus Okadaic Acid.sup.b Support Support______________________________________ 1 mg/ml + 0.2 μg OA .sup. 4/4.sup.a 4/4 5 mg/ml + 0.2 μg OA 4/4 4/410 mg/ml + 0.2 μg OA 4/4 4/4______________________________________ .sup.a Number positive results/number of supports assayed. .sup.b Color intensity increased with increased concentration of extract. .sup.c Color intensity of 10 mg toxic extract/ml + 0.2 μg OA was equal to 25 mg/ml toxic fish extract.
The results indicate that okadaic acid does not interfere with the test and that okadaic acid is also detected by the assay procedures.
EXAMPLE 3
Assay of Okadaic Acid-Impregnated Fish
The assay procedure described in Example 1 was repeated, except that membrane supports were exposed to toxic or non-toxic barracuda flesh or non-toxic barracuda flesh which had been impregnated with 0.1, 0.2, 0.3 or 0.4 μg okadaic acid and blended with the tissue. The test supports were inserted into the artificially contaminated flesh of the fish.
The color present on the test membrane supports was evaluated and the results scored. The results of the assays are summarized in Table III.
TABLE III______________________________________ MembraneSample Support______________________________________Toxic fish (cooked).sup.a .sup. 6/6.sup.bNon-toxic fish (uncooked) 0/3Non-toxic fish + 0.1 μg OA 7/7Non-toxic fish + 0.2 μg OA 7/7Non-toxic fish + 0.3 μg OA 7/7Non-toxic fish + 0.4 μg OA 16/16______________________________________ .sup.a Sample implicated in a ciguatera poisoning outbreak. .sup.b Number positive results/number of supports assayed. .sup.c Color intensity increased with increased concentration of okadaic acid.
The results indicate that okadaic acid does not interfere with the assay method and that okadaic acid is detected by the assay procedures.
EXAMPLE 4
Assay of Toxic Fish Extracts and Okadaic Acid Mixture
The assay procedure described in Example 1 was repeated, except that membrane supports were exposed to 4 mg/ml toxic fish extract to which either 0.1, 0.2, 0.3, 0.4, or 0.5 μg/ml of okadaic acid had been added.
The color developed on the test membrane supports was evaluated and the results scored to determine the usefulness of okadaic acids as a positive control. The results of the assays are summarized in Table IV.
TABLE IV______________________________________ MembraneSample.sup.b Support______________________________________4 mg/ml toxic fish extract + 0.1 μg OA .sup. 4/4.sup.a4 mg/ml toxic fish extract + 0.2 μg OA 4/44 mg/ml toxic fish extract + 0.3 μg OA 4/44 mg/ml toxic fish extract + 0.4 μg OA 4/44 mg/ml toxic fish extract + 0.5 μg OA 15/15______________________________________ .sup.a Number positive results/number of supports assayed. .sup.b Color intensity increased with increased concentration of extract.
The results indicate that increasing okadaic acid results in a corresponding increase in the intensity of the assay result obtained.
The above description of exemplary embodiments for assays using okadaic acid are for illustrative purposes. Because of variations which will be apparent to those skilled in the art, the present invention is not intended to be limited to the particular embodiments described above. Also, the invention disclosed may be practiced in the absence of any element which is not specifically disclosed in the specification. The scope of the invention is defined by the following claims. | A composition comprising okadaic acid for use as a positive control in assays for the detection of ciguatoxins and methods for making such compositions. In a preferred embodiment, the okadaic acid composition further comprises a carrier selected from the group consisting of fish extract, oils, oil/organic solvent mixtures, fatty-acid solutions, and non-ionic detergent solutions. A kit for detecting the presence of ciguatoxin or related polyether marine toxins in fish, comprising positive control supports impregnated with a composition comprising okadaic acid. | 8 |
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured, used, and licensed by or for the United States Government for governmental purposes without the payment to me of any royalty thereon.
BACKGROUND OF THE INVENTION
The present invention relates particularly to a fin assembly designed to increase fin surface area for projectiles.
Firing range tests of 60 mm (millimeter) solid fuel ramjet projectiles from a 120 mm gun revealed certain significant deviations from expected trajectory. Among the explanations for such behavior are: damaged fins (e.g., attributable to in-flight metal burning, or to in-bore contact with the propellant granules during the projectile release from its primer case), and insufficient fin normal force required for static stability. In an attempt to solve the problem, the area of each fin 10 (FIG. 1) ahead of the leading edge 12 of the fin was increased, as illustrated by the dashed area 15, to provide an additional normal force, viz. Δ 1 F f , but the resulting increase in stabilization was found to be insufficient. This undesirable result is attributable to the smaller fin moment arm x 1cp (of that additional force for the increased area) relative to the center of gravity (CG) of the finned projectile 17.
It was recognized that the addition of surface area 20 at the trailing edge 22 of fin 10-1 (and of the other fins 10-2, 10-3 and 10-4, the latter being hidden by the body of projectile 17 in FIG. 1), rather than at the leading edge, would be more effective because that solution would serve to produce a larger fin moment arm x 2cp , and additional normal force Δ 2 F 1 . However, such a solution could not be implemented because of the limitation on the distance Δx f , owing to projectile packaging constraints.
In part, the packaging constraints are better understood by reference to FIG. 2 as well as to FIG. 1. The projectile 17 is packaged for use in a conventional propellant case assembly. The case assembly includes a pusher disk 30 having a rotating band/obturator 32, and is partly inserted into the propellant charge casing 35. The set of geometrical constraints on the fin design includes the following. The fin height h (FIG. 1) is fixed because the maximum diameter d f is limited by the bore size of the gun. The fin root chord length cannot be extended beyond the base of the projectile in excess of the length Δx f (FIG. 1), because of projectile packaging considerations for the attachment to the primer case containing the propellant charge. Also, the number of fins of the projectile cannot be increased to exceed four, such as to six as a means to increase the fin surface area, because of a limitation on the number of sabot pieces permitted for positioning the projectile in the gun barrel.
It is a principal object of the present invention to increase the stabilization of finned projectiles during flight, to be able to maintain the trajectory of the projectile.
Another object of the invention is to provide a finned projectile with improved stability, and thereby with the capacity to more accurately follow a desired trajectory, without violating the many practical constraints on size, shape and number of the fins imposed on the projectile.
SUMMARY OF THE INVENTION
The invention arose from the recognition that it would be desirable to increase the existing fin surface area of the finned projectile as a means for stabilizing the projectile in flight, subject to various packaging and propellant charge case spacing constraints on a suitable design. An increase in the fin surface area would increase the normal force produced by the fins, thereby increasing the fin force moment about the center of gravity (CG) of the projectile and, therefor, increasing the pitching motion stability of the projectile.
According to a presently preferred embodiment of the invention, a finned projectile intended to be launched toward a selected target has a projectile body and a plurality of fins attached to the projectile body to provide stability thereto in flight. At least some of the fins constitute main or host fins which include means for in-flight increasing of the surface area thereof to further enhance the stability of the projectile during flight, whereby to maintain the desired trajectory of the projectile toward the selected target. Other means operatively associated with the surface area increasing means are employed to maintain the increased surface area in flight.
In the preferred embodiment, the surface area increasing means includes a supplemental fin secured to a respective one of each of the main fins, and means for deploying the supplemental fin to a displaced position relative to its main fin including a pin and channel arrangement for slidably retaining the supplemental fin and associated main fin together for deployment under forces on the projectile during launching and flight thereof. The main and supplemental fin assembly further includes means for preventing deployment of the supplemental fin during normal handling of the projectile, and means for locking the supplemental fin in a fully deployed position relative to its associated main fin.
Therefore, it is still another object of the present invention to provide a finned projectile with increased fin surface area and to maintain that increased surface area while the projectile is in flight.
Yet another object is to provide a finned projectile with a deployable fin structure which does not interfere with the projectile packaging in its propellant charge casing.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and still further objects, features, and attendant advantages of the invention will be better understood and appreciated from a consideration of the following detailed description of a presently preferred embodiment, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side view of the general configuration of a prior art finned projectile, described above;
FIG. 2 is a side section view of a portion of the prior art finned projectile of FIG. 1 in a conventional assembly including pusher disk and propellant charge casing, described above;
FIGS. 3a and 3b are a side view, partly in section, and an end view, respectively, of a finned projectile with supplementary fins according to a presently preferred embodiment of the invention;
FIG. 4 is a partial side view of the projectile body and a main fin/supplemental fin assembly according to the invention, showing the supplemental fin in its fully deployed position during flight of the projectile;
FIGS. 5a and 5b, and 6a and 6b, are side and cross-sectional views of the main fin and supplemental fin, respectively, before assembly thereof; and
FIGS. 7a and 7b are fragmentary section views of the fin assembly using different fastener embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 3a and 3b of the drawings, a presently preferred embodiment of a finned projectile according to the invention is illustrated therein. The projectile body 40 is provided with four main fins 42-1, 42-2, 42-3 and 42-4. Only two of these four fins are shown in FIG. 3a for the sake of simplicity and clarity, but it will be understood that all four are constructed in the same fashion. The main fins are either welded to the projectile body 40 or machined with the body from a single piece of metal, in a conventional manner. In either case, small fillets 45 (FIG. 3b) may exist at either side of the point of attachment of the fin with the body.
Supplemental fins 47-1, 47-2, 47-3 and 47-4 are mounted on one side of the main fins 42-1, 42-2, 42-3 and 42-4, respectively, with pins or rivets 50 holding the two fin parts of each such assembly together. These pins pass through slightly larger holes 51 in the supplemental fins 47 and through long slotted channels 54 in the main fins 42 (see, also, FIGS. 5a and 5b, and 6a and 6b). The channels have parallel sides which are spaced apart by a distance larger than the pin shaft diameter, sufficient to accommodate easy sliding of the pins 50 in the slots 54, and the pins are held captive but slidable in the channels by virtue of the larger heads at either end thereof.
The pins 50, holes 51, and channels 54 of each pair thereof in a main fin/supplemental fin assembly are preferably identical in their respective dimensions, but are offset (shifted) from one another according to the angle of the leading edge 56 of the main fin 42 as shown in FIG. 3a. Each of the parallel channels has an end portion 59 which is angled downwardly and rearwardly relative to the longer portion of the channel 54 and the projectile body 40. The end portion 59 serves to capture and lock the respective pin 50 in place after the supplemental fin 47 is forced backward along its respective channel upon launch, and ultimately into its fully deployed position during flight of the projectile, as shown in FIG. 4. In this way, the latter fin is maintained in the fully deployed position, being prevented from forward movement to the original or any intermediate position after the projectile is launched.
Preferably, each of the slotted channels in the main fins is filled initially with a putty material 60 (FIG. 3a) having the following properties. The putty is selected to be sufficiently pliable in its original state to bond easily to the metal surfaces of the fins, both main and supplemental in the region of the channel, and harden up quickly to be sufficiently firm so that it does not yield easily to pressure, whereby to assure its retention in the channel and to prevent the supplemental fin from sliding during handling, transportation, and storage of the projectile. Further, the putty is selected to have the property that, after setting (i.e. hardening), it is sufficiently brittle to shatter into small pieces at impact as the pin moves backward in the channel under the inertia of the supplemental fin as the projectile accelerates during launch. The putty should retain its after-setting properties of hardness and brittleness, so that it does not become excessively harder, softer, more brittle or easily chipped with aging over a considerable period of time, in the range, for example, of from thirty to forty years. This assures that the supplemental fins will be retained in place and yet ready for deployment at launch and during flight of the projectile despite a potentially lengthy period of storage before use in combat. Finally, the putty may be burnable as it is subjected to the intense heat inside the gun tube during launch, but should not emit corrosive gases or other by-products during burning that could damage the inner surface of the gun tube.
A suitable putty material, for example, is Omega CC High Temperature Cement, which is produced by Omega Engineering, Inc. of Stamford, Conn., and is the preferred material for use in the presently preferred embodiment of the invention.
As shown in FIG. 3a, the putty 60 is applied to fill the respective slotted channel 54 except for the forward and rearward regions in the immediate vicinity of the respective pin 50 and locking slot 59. The empty space near the pin 50 assures that there will be an initial impact of the pin on the putty to cause shattering of the latter during launching of the projectile. The empty space at the inclined locking slot 59 avoids the prospect that putty residuals might enter the locking slot in sufficient quantity to prevent the pin from sliding into and assuming a locked condition within the locking slot both at the launch instant and later during flight.
Notwithstanding the preferred use of such putty material, the invention is not limited to such use. It will be apparent to those skilled in the mechanical arts that other means, to prevent unwanted sliding of the supplemental fins except during launch and in flight of the projectile while assuming the fully deployed and locked position, may be utilized in place of the putty. For example, one or more springs or other mechanical devices (not shown) may be employed for such purpose.
Upon launching of the finned projectile, the supplementary fins 47 commence movement rearwardly of the projectile body 40 under the inertial force attributable to launch acceleration. As the projectile emerges from the gun tube, the aerodynamic force on the leading edge of the supplementary fin causes the latter to complete its movement to a fully deployed and locked position, with the pins 50 finally retained in their respective locking slots 59 (FIG. 4). The supplementary fin 47 is held in its fully deployed and locked position by air resistance that forces the fin to its extreme rearward position. The opposing surfaces 62 and 67 of the main and supplemental fins, respectively, are preferably coated with a non-sticking, non-rusting material, such as Teflon (trademark of DuPont), for example, to prevent the two fins from binding or adhering together during long periods of storage under adverse (e.g., humid) environmental conditions. This coating is also preferred for the pins 50 to prevent rusting and also help easy sliding during deployment.
Referring again to FIG. 4, upon full deployment of the supplementary fins 47 the leading edge 68 of each of them is positioned ahead of the leading point 70 of the respective channels 54 in the main fins 42. This assures that there will be no complete opening through a channel, i.e. that the supplemental fin substantially provides a backing or cover surface 67 for its respective open slot channel, to avoid air leaks through the channels. Such leaks would tend to reduce the efficiency of the configuration by increasing the drag force on the projectile and reducing the normal forces produced by the fins.
As previously noted, FIGS. 5a and b, and 6a and b, illustrate the main fin and the supplemental fin separately and in cross-section, respectively. FIGS. 7a and b show different configurations of the pin, hole and channel arrangement. Referring to all of these Figures, the holes in the supplemental fin are, of course, arranged to match with the channels in the main fin. If the pins are provided with heads that protrude outside the fin surfaces, as shown in FIG. 7a, the result will be a slightly increased drag on the projectile during flight, and may reduce the fin normal force. Accordingly, the pins may be provided with a head design which, in conjunction with countersunk hole and channel, allows a recessed, non-protruding head assembly, as shown in FIG. 7b. However, the latter design has the disadvantage of manufacturing difficulties because of the thinness of the fins.
It will thus be seen that the present invention offers significant advantages in in-flight stability, and therefore in maintaining the trajectory toward a desired target, for finned projectiles. The assembly of the host fin and the supplemental fin provides a structure which is nearly as compact as a single fin configuration alone. The assembly and presence of the supplemental fin does not interfere with the projectile packaging or the propellant charge casing. Deployment of the supplemental fin commences with inertia forces at the time of launching of the projectile, and full deployment is achieved, and the supplemental fin is locked in place in that position, by the aerodynamic forces (i.e., drag forces) after the projectile leaves the muzzle of the gun and the pusher disk falls to earth, typically within hundreds of feet from the muzzle. Although the invention has been described with reference to a specific finned projectile, it is useful in finned projectiles generally.
Although a preferred embodiment of the invention has been shown and described herein, variations and modifications may be implemented without departing from the true spirit and scope of the invention, and it is therefore desired that the invention be limited only by the appended claims. For example, any technician familiar with the art can easily change the sliding mechanism in the described preferred embodiment, by placing the slotted channels in the supplemental fins, while placing the pin holes on the main fins. | A finned projectile intended to be launched toward a target has a project body and a plurality of main fins attached to the projectile body to provide stability thereto in flight. In the preferred embodiment, each main fin includes a supplementary fin movably secured thereto for increasing the overall surface area to further enhance the stability of the projectile after launch. A pin and channel arrangement is used for slidably retaining the supplemental fin and the main fins together for deployment under forces on the projectile during launch and flight thereof. The channel arrangement further includes a portion which angles suddenly to lock the supplementary fin in the deployed position. The preferred embodiment also includes putty disposed within the channel for preventing deployment of the supplementary fin during normal handling of the projectile. The putty is shattered upon initial impact with the pin during launching of the projectile. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] is application is a National Phase Patent Application and claims the priority of International Application Number PCT/CN2006/003014, filed on Nov. 10, 2006, which claims priority of Chinese Patent Application Number 200610095384.0, filed on Jan. 11, 2006.
FIELD OF THE TECHNOLOGY
[0002] The present invention relates to device and method for preparing filament yarn of composite nanofibers. It belongs to the technical field of manufacturing special fibers.
BACKGROUND OF THE INVENTION
[0003] With social development and improvement of people's lives, fiber industry has faced great challenges in recent years as single components could not meet the requirement of fibers with more functions. Various types of composite fibers have been developed, such as core-sheath, filling, bilateral, sea-island and other types of composite fibers. US Patent (No. 4,717,325) designed a spinneret assembly with composite feed plates. Passages are aligned with the orifices in the first plate and feed core material. Each core material passage is surrounded by several feed passages for sheath material, forming core-sheath type composite fibers.
[0004] Electrospinning, an efficient and versatile method that uses an electric field to manufacture polymer nanofibers, has attracted more and more attention. Electrospun fibers have large porosity and high surface area to volume ratio, making them excellent candidates for a number of applications as high efficient filters, biomedical materials, chemical sensors, protective materials, nano-composite materials, etc.
[0005] However, there exist problems of fiber loss and unstable dispersion due to the nano-/micro-meter size of the electrospun fibers, and repellent force between nanofibers carried charges with same polarity. Electrospun nanofibers are often collected as randomly oriented structures in the form of nonwoven mats. It is difficult to manufacture continuous nanofiber yarns or filaments.
[0006] Although tremendous progress has been made in the fabrication of aligned nanofibers by electrospinning, a major challenge remains in the search for an efficient means to manufacture continuous aligned filament yarns. Electrospun fibers can be aligned more or less parallel to each other when a drum rotating at high speed is used as the collector. Another method is to deposit nanofibers into water to eliminate the charges of nanofibers which are collected together, and yarns are drawn out. Others obtain aligned fiber yarns by linking and twisting the electrospun nanofibers deposited on the steel drum.
[0007] Therefore, it is necessary to invent a more efficient method to prepare filament yarn of composite nanofibers.
SUMMARY OF THE INVENTION
[0008] The present invention is to provide device and method for preparing filament yarn of composite nanofibers which can manufacture filament yarn of composite nanofibers simply and efficiently.
Technical Process
[0009] Device for preparing filament yarn of composite nanofibers, comprising: pairs of electrospinning nozzles, filament guiding roller pair, frame, fixed sticks and base. Two columns of oppositely disposed pairs of electrospinning nozzles are fixed on frame. Each pair of electrospinning nozzles is in either same or different planes. The frame is connected to base by vertical fixed sticks. Filament guiding roller pair is located in the plane of frame with same distance away from two spouts of each electrospinning nozzles pair. The frame is set at an adjustable acute angle to the fixed sticks. The roller pair is at the end of pairs of electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 2-50 cm. Distance between two spouts of oppositely disposed pair of electrospinning nozzles is 10-100 cm. Plane of frame is set at angle of 0-90° to fixed sticks. The detailed procedures for preparing filament yarn of composite nanofibers are as follows:
[0000] 1) Polymer solutions are fed to pairs of electrospinning nozzles on frame.
2) High electrical voltages with opposite polarities are applied to two oppositely disposed pairs of electrospinning nozzles, respectively.
3) Nanofibers with opposite charges from each pair of electrospinning nozzles attract and strike together during the journey in the air, or the nanofibers attract and deposit on polymer fibrous carrier drawn down, forming composite nanofibers. The composite nanofibers are pulled and/or stretched, resulting in continuous filament yarn of composite nanofibers.
4) The filament yarn of composite nanofibers fabricated by the first pair of electrospinning nozzles are drawn down and used as a carrier to receive the nanofibers with opposite charge electrospun out from the second pair of nozzles. The coated filament yarn of composite nanofibers is then drawn down and/or stretched, forming two-layer filament yarn of composite nanofibers.
5) In turn, filament yarn of composite nanofibers fabricated by former pair of electrospinning nozzles are drawn down and used as a carrier to receive the nanofibers with opposite charge electrospun out from latter pair of nozzles. The coated filament yarn of composite nanofibers is then drawn down and/or stretched by filament guiding roller pair 2 , forming multi-layer filament yarn of composite nanofibers.
[0010] High electrical voltages with opposite polarities applied to two oppositely disposed pairs of electrospinning nozzles are fixed at 3-200 kV, respectively. Polymer solutions fed to electrospinning nozzles are polymer solutions, additive-containing polymer solutions, or mixture of inorganic particles and polymer solutions. Polymers are any of polyolefin, halogen-substituted polyolefin, silicone, polyether, polyamide, polyester, polycarbonate, polyurethane, epoxy resin, polyacrylonitrile, polyacrylic acid, polyacrylates, polyphenyl ether, polyanhydride, poly(α-amine acid), polyphenyl sulfide ether, or mixtures of above two or more polymers, or any of cellulose, cellulose derivatives, dextran, silk fibroin, chitosan, chitosan derivatives, hyaluronic acid, hyaluronic acid derivatives, collagen, carrageenan, sodium alginate, calcium alginate, chondroitin sulphate, gelatin, agar, dextran, fibril, fibrinogen, keratin, casein, albumin, elastin, or their derivatives or mixtures of above two or more polymers, or any of bioabsorbable synthetic polymers, such as poly-L-lactic acid, poly-(D,L)-lactic acid, poly glycolic acid, polycaprolactone, polybutyrolactone, polyvalerolactone, poly-p-dioxane, polyanhydride, poly(α-amine acid), or copolymer synthesized from two or more monomers as follows: L-lactic acid, D, L-lactic acid, glycolic acid, 3-hydroxyl butanoic acid, 3-hydroxyl pentanoic acid, caprolactone, butyrolactone, valerolactone, amine acid, or mixtures of above two or more polymers. Inorganic particles are nano-antibacterial agents, catalysts, or carbon nanotubes.
[0011] Additives are any of antibiotics, immunosuppressants, antibacterial agents, hormone, vitamin, amino acids, peptides, proteins, enzymes, growth factor, antibacterial drugs, dope, hemostasis agents, anodyne, anti-hyperpiesia agents and anti-tumour agents, or mixtures of above two or more agents.
ADVANTAGES
[0012] The present invention has following advantages:
[0000] (1) The present invention utilizes a method for preparing filament yarn of composite nanofibers, where electrospinning nozzles oppositely disposed are electrically charged by high DC voltages with opposite polarities. Nanofibers electrospun from the two nozzles which carry charges with opposite polarities attract each other, strike together, and neutralize their charges. The present method shows a less dispersion and loss of nanofibers in the air. Furthermore, grounded metal collector used in conventional electrospinning method is unnecessary in the present invention.
(2) In the present invention, frame is set at an adjustable acute angle to fixed sticks to avoid any slightly disturbed or unstable spinning jet.
(3) The present invention can manufacture filament yarn of composite nanofibers simply and efficiently.
(4) In the present invention, different polymer solutions or additive-containing polymer solutions can be fed to two spouts of electrospinning nozzles pair oppositely disposed respectively, resulting in the formation of composite filament yarn of multi-component nanofibers.
(5) In the present invention, filament yarn of composite nanofibers with different composition and nano-structure can be produced by the use of multiple pairs of electrospinning nozzles. Thicker multi-layer filament yarn of composite nanofibers may exhibit good mechanical properties.
(6) In the present invention, nanofibers from oppositely disposed electrospinning nozzles which carry charges with opposite polarities can deposit on polymer fiber carrier, and then drawn down by filament guiding roller pair set under frame with a less dispersion or loss of nanofibers. And, multi-layer filament yarn of composite nanofibers with polymer fiber carrier as core is produced having excellent mechanical properties.
(7) The present invention can produce filament yarns of composite nanofibers including nano-particles as combined with electro-spraying technique.
(8) The present invention can manufacture filament yarn of composite nanofibers having potential applications in tissue engineered scaffolds and textiles, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is structure scheme of the present invention.
[0014] FIG. 2 is principle scheme of the present invention.
[0015] The two figures include pairs of electrospinning nozzles 1 , filament guiding roller pair 2 , frame 3 , fixed sticks 4 and base 5 .
[0016] FIG. 3 is photograph of PLLA filament yarns of composite nanofibers.
[0017] FIG. 4 is photograph of PLLA filament yarns of composite nanofibers.
[0018] FIG. 5 is SEM image of PLLA filament yarns of composite nanofibers.
[0019] FIG. 6 is SEM image of PU/PVDF filament yarn of composite nanofibers.
[0020] FIG. 7 is SEM image of PAN filament yarn of composite nanofibers.
[0021] FIG. 8 is SEM image of PVDF filament yarn of composite nanofibers.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Device for preparing filament yarn of composite nanofibers, comprising: pairs of electrospinning nozzles 1 , filament guiding roller pair 2 , frame 3 , fixed sticks 4 and base 5 . Two columns of oppositely disposed pairs of electrospinning nozzles 1 are fixed on frame 3 . Each pair of electrospinning nozzles is in either same or different planes. The frame 3 is connected to base 5 by vertical fixed sticks 4 . Filament guiding roller pair 2 is located in the plane of frame 3 with same distance away from two spouts of each electrospinning nozzles pair. The roller pair 2 is at the end of pairs of electrospinning nozzles 1 . The frame 3 is set at an adjustable acute angle to the fixed sticks 4 .
[0023] The detailed procedures for preparing filament yarn of composite nanofibers are as follows:
[0000] 1) Polymer solutions are fed to pairs of electrospinning nozzles 1 on frame 3 .
2) High electrical voltages with opposite polarities are applied to two oppositely disposed pairs of electrospinning nozzles 1 , respectively.
3) Nanofibers with opposite charge from each pair of electrospinning nozzles attract and strike together during the journey in the air, forming composite nanofibers. The composite nanofibers are pulled and/or stretched, resulting in continuous filament yarn of composite nanofibers.
4) The filament yarn of composite nanofibers fabricated by the first pair of electrospinning nozzles are drawn down and used as a carrier to receive the nanofibers with opposite charge electrospun out from the second pair of nozzles. The coated filament yarn of composite nanofibers is then drawn down and/or stretched, forming two-layer filament yarn of composite nanofibers.
5) In turn, filament yarn of composite nanofibers fabricated by former pair of electrospinning nozzles are drawn down and used as a carrier to receive the nanofibers with opposite charge electrospun out from latter pair of nozzles. The coated filament yarn of composite nanofibers is then drawn down and/or stretched by filament guiding roller pair 2 , forming multi-layer filament yarn of composite nanofibers.
[0024] The detailed procedures for preparing filament yarn of composite nanofibers can also be: 1) Polymer solutions are fed to pairs of electrospinning nozzles 1 on frame 3 . 2) High electrical voltages with opposite polarities are applied to two oppositely disposed pairs of electrospinning nozzles 1 , respectively. 3) Nanofibers with opposite charge from each pair of electrospinning nozzles 1 attract and deposit on polymer fibrous carrier drawn down, forming composite nanofibers. The composite nanofibers are pulled and/or stretched, resulting in continuous filament yarn of composite nanofibers.
[0025] Distance between two neighbouring electrospinning nozzles 1 on the same column of frame 3 is 2-50 cm. Distance between two spouts of oppositely disposed pair of electrospinning nozzles 1 is 10-100 cm. Plane of frame 3 is set at angle of 0-90° to fixed sticks 4 . High electrical voltages with opposite polarities applied to two oppositely disposed pairs of electrospinning nozzles 1 are fixed at 5-200 kV, respectively.
[0026] Polymer solutions fed to electrospinning nozzles are polymer solutions, additive-containing polymer solutions, or mixture of inorganic particles and polymer solutions. Polymers are any of polyolefin, halogen-substituted polyolefin, silicone, polyether, polyamide, polyester, polycarbonate, polyurethane, epoxy resin, polyacrylonitrile, polyacrylic acid, polyacrylates, polyphenyl ether, polyanhydride, poly(α-amine acid), polyphenyl sulfide ether, or mixtures of above two or more polymers, or any of cellulose, cellulose derivatives, dextran, silk fibroin, chitosan, chitosan derivatives, hyaluronic acid, hyaluronic acid derivatives, collagen, carrageenan, sodium alginate, calcium alginate, chondroitin sulphate, gelatin, agar, dextran, fibril, fibrinogen, keratin, casein, albumin, elastin, or their derivatives or mixtures of above two or more polymers, or any of bioabsorbable synthetic polymers, such as poly-L-lactic acid, poly-(D,L)-lactic acid, poly glycolic acid, polycaprolactone, polybutyrolactone, polyvalerolactone, poly-p-dioxane, polyanhydride, poly(α-amine acid), or copolymer synthesized from two or more monomers as follows: L-lactic acid, D, L-lactic acid, glycolic acid, 3-hydroxyl butanoic acid, 3-hydroxyl pentanoic acid, caprolactone, butyrolactone, valerolactone, amine acid, or mixtures of above two or more polymers. Inorganic particles are nano-antibacterial agents, catalysts, or carbon nanotubes. Additives are any of antibiotics, immunosuppressants, antibacterial agents, hormone, vitamin, amino acids, peptides, proteins, enzymes, growth factor, antibacterial drugs, dope, hemostasis agents, anodyne, anti-hyperpiesia agents and anti-tumour agents, or mixtures of above two or more agents.
[0027] The present invention can manufacture filament yarn of composite nanofibers having potential applications in regeneration medicine and textiles, etc.
EXAMPLE 1
[0028] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 90° to fixed sticks 4 .
[0029] 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 15 g poly-lactide-co-glycolide (Poly-LA-co-GA, PLGA, weight ratio of LA:GA=50:50, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame 3 is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 90° to fixed sticks 4 . High DC voltages of +20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.5 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair which is set at the end of pairs of electrospinning nozzles on the plane of the frame. The drawing speed of filament guiding roller pair was 8 cm/s. And, three-layer filament yarn of PLLA/PLGA composite nanofibers is obtained.
EXAMPLE 2
[0030] A device for electrospinning is used comprising frame 3 having four pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 90° to fixed sticks 4 .
[0031] 10 g poly-L-lactic acid (PLLA, Mq=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 4 spinnerets. 10 g polycaprolactone (PCL, Mw=90,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 4 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame 3 is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 90° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.5 mm, respectively. The drawing speed of filament guiding roller pair 2 was 8 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, multi-layer filament yarn of PLLA/PCL composite nanofibers is obtained.
EXAMPLE 3
[0032] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 90° to fixed sticks 4 .
[0033] 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 3 spinnerets of which inner diameter is 0.8 mm. 35 g zein (Mw=35,000 g/mol) was dissolved in 100 ml aqueous ethanol solution with ethanol/water volume ratio of 80/20, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets of which inner diameter is 1.2 mm. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 90° to fixed sticks 4 . High DC voltages of +25 kV were applied to two columns of oppositely disposed electrospinning nozzles, respectively. The drawing speed of filament guiding roller pair 2 was 8 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, three-layer filament yarn of PLLA/zein composite nanofibers is obtained.
EXAMPLE 4
[0034] A device for electrospinning is used comprising frame 3 having four pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 90° to fixed sticks 4 .
[0035] 10 g polyacrylonitrile (PAN, Mw=130,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 4 spinnerets. 10 g polyphenyl ether sulphone (PES, melt flow rate 3.9 g/10 min, 320° C.) was dissolved in 100 ml dimethyl sulphone, and the prepared solution was fed to the other column of electrospinning nozzles containing 4 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 90° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.5 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 8 cm/s. And, multi-layer filament yarn of PAN/PPES composite nanofibers is obtained.
EXAMPLE 5
[0036] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0037] 10 g poly-L-lactic acid (PLLA, M11=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 15 g poly-lactide-co-glycolide (Poly-LA-co-GA, PLGA, weight ratio of LA:GA=50:50, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 15 g polyurethane (PU) was dissolved in 100 ml N, N-dimethyl formamide. 10 g polycaprolactone (PCL, Mw=90,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide. After complete dissolution, solutions were fed to two columns of oppositely disposed 4 electrospinning nozzles, respectively. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of PLLA/PLGA/PU/PCL composite nanofibers is obtained.
EXAMPLE 6
[0038] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0039] 1 g hyaluronic acid (HA, Mw=100,000 g/mol) was dissolved in 100 ml distilled water. 0.5 g chitosan was dissolved in 100 ml 0.1 mol/L acetic acid solution. 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 15 g poly-lactide-co-glycolide (Poly-LA-co-GA, PLGA, weight ratio of LA:GA=50:50, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 15 g polyurethane (PU) was dissolved in 100 ml N, N-dimethyl formamide. 10 g polycaprolactone (PCL, Mw=90,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide. After complete dissolution, solutions were fed to two columns of oppositely disposed 6 electrospinning nozzles, respectively. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of HA/chitosan/PLLA/PLGA/PU/PCL composite nanofibers is obtained.
EXAMPLE 7
[0040] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0041] 1 g hyaluronic acid (HA, Mw=100,000 g/mol) was dissolved in 100 ml distilled water, and the prepared solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of HA/PLLA composite nanofibers is obtained.
EXAMPLE 8
[0042] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0043] 1 g hyaluronic acid (HA, Mw=100,000 g/mol) was dissolved in 100 ml distilled water, and 0.2 g brophenol was added into the solution. After complete dissolution of brophenol, the solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent consisting of 50 ml acetone and 50 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of HA/brophenol/PLLA composite nanofibers is obtained.
EXAMPLE 9
[0044] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0045] 10 g polyacrylonitrile (PAN) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 15 g polyurethane (PU) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Drawing speed of filament guiding roller pair is 5 cm/s. Nanofibers from the oppositely disposed electrospinning nozzles which carry charges with opposite polarities deposited on polyester fibers and then drawn out by filament guiding roller pair 2 set under frame. Multi-layer filament yarns of composite nanofibers whose core is polyester fibers with shell of composite PAN/PU nanofibers were drawn out and collected by the filament guiding roller pair.
EXAMPLE 10
[0046] A device for electrospinning is used comprising frame 3 having four pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 45° to fixed sticks 4 .
[0047] 10 g polyurethane (PU) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 4 spinnerets. 10 g polycaprolactone was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 4 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 45° to fixed sticks 4 . High DC voltages of +15 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. Drawing speed of filament guiding roller pair 2 is 5 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by the filament guiding roller pair, collecting as continuous multi-layer filament yarn of PU/PCL composite nanofibers.
EXAMPLE 11
[0048] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0049] 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 100 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to the two columns of oppositely disposed 4 electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. The drawing speed of filament guiding roller pair 2 was 5 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, filament yarn of PLLA composite nanofibers is obtained.
EXAMPLE 12
[0050] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0051] 10 g polycaprolactone (PCL) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the first pair of electrospinning nozzles. 15 g poly-lactide-co-glycolide (Poly-LA-co-GA, PLGA, weight ratio of LA:GA=50:50, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, 0.3 g brophenol was then added into the solution. After complete dissolution of brophenol, the solution was fed to the second pair of electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of +10 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, two-layer filament yarn of PCL/PLGA composite nanofibers is obtained.
EXAMPLE 13
[0052] A device for electrospinning is used comprising frame 3 having ten pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 30° to fixed sticks 4 .
[0053] 50 g poly-L-lactic acid (PLLA, Mq=150,000 g/mol) was dissolved in a mixed solvent of 250 ml acetone and 250 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 10 spinnerets. 5 g hyaluronic acid (HA, Mw=1,000,000 g/mol) was dissolved in 500 ml distilled water, and the prepared solution was fed to the other column of electrospinning nozzles containing 10 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Planes of frame and fixed sticks were set at an angle of 30°. High DC voltages of ±50 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Drawing speed of filament guiding roller pair 2 is 5 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by the filament guiding roller pair, collecting as continuous filament yarn of PLLA/HA composite nanofibers with diameter of ca. 150 micros.
EXAMPLE 14
[0054] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 30° to fixed sticks 4 .
[0055] 0.5 g chitosan was dissolved in 100 ml 0.1 mol/L acetic acid solution, and the prepared solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 10 g polycaprolactone (PCL) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 20 cm. Planes of frame and fixed sticks were set at an angle of 30°. High DC voltages of +20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.6 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of chitosan/PCL composite nanofibers is obtained.
EXAMPLE 15
[0056] A device for electrospinning is used comprising frame 3 having four pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 90° to fixed sticks 4 .
[0057] 10 g polycarbonate (PC, Mw=100,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 4 spinnerets. 10 g polyphenyl ether sulphone (PES, melt flow rate 3.9 g/10 min, 320° C.) was dissolved in 100 ml dimethyl sulphone, and the prepared solution was fed to the other column of electrospinning nozzles containing 4 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 90° to fixed sticks 4 . High DC voltages of +20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.5 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 8 cm/s. And, multi-layer filament yarn of PC/PPES composite nanofibers is obtained.
EXAMPLE 16
[0058] A device for electrospinning is used comprising frame 3 having four pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 30° to fixed sticks 4 .
[0059] 10 g polyacrylonitrile (PAN, Mw=130,000 g/mol) was dissolved in 100 ml N, N-dimethyl fommamide, and 0.1 g single wall carbon nanotubes were added into the solution. After completely homogeneous dispersion of the nanotubes by ultrasonic vibration, the solution was fed to one column of electrospinning nozzles containing 4 spinnerets. 10 g polyphenyl ether sulphone (PES, melt flow rate 3.9 g/10 min, 320° C.) was dissolved in 100 ml dimethyl sulphone, and the prepared solution was fed to the other column of electrospinning nozzles containing 4 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Planes of frame and fixed sticks were set at an angle of 30°. High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.5 mm, respectively. Drawing speed of the filament guiding roller pair is 8 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by the filament guiding roller pair, collecting as continuous filament yarn of single wall carbon nanotubes and PC/PPES composite nanofibers.
EXAMPLE 17
[0060] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0061] 1 g hyaluronic acid (HA, Mw=100,000 gμmol) was dissolved in 100 ml distilled water, and 10 mg bone morphogenetic protein were added into the solution. After completely dissolution of the bone morphogenetic protein, the solution was fed to one column of electrospinning nozzles containing 3 spinnerets. 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 3 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of HA/PLLA composite nanofibers is obtained.
EXAMPLE 18
[0062] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0063] 20 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 100 ml acetone and 50 ml N,N-dimethyl formamide, and 1 g β-tricalcium phosphate (β-TCP) nano-particles with diameters of ca. 300 nm were added into the solution. After completely homogeneous dispersion of the nano-particles by ultrasonic vibration, the solution was fed to two columns of oppositely disposed 4 electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 0° to fixed sticks 4 . High DC voltages of ±50 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . The drawing speed of filament guiding roller pair 2 was 5 cm/s. And, filament yarn of PLLA/β-TCP composite nanofibers is obtained.
EXAMPLE 19
[0064] A device for electrospinning is used comprising frame 3 having twenty-five pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0065] 100 g poly-L-lactic acid (PLLA, Mη=150,000 g/mol) was dissolved in a mixed solvent of 500 ml acetone and 500 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 25 spinnerets. 10 g hyaluronic acid (HA, Mw—1,000,000 g/mol) was dissolved in 1000 ml distilled water, and the prepared solution was fed to the other column of electrospinning nozzles containing 25 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 2 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of ±120 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. Drawing speed of the filament guiding roller pair 2 is 10 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by the filament guiding roller pair, collecting as continuous filament yarn of PLLA/HA composite nanofibers with diameter of ca. 200 micros.
EXAMPLE 20
[0066] A device for electrospinning is used comprising frame 3 having ten pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0067] 50 g poly-L-lactic acid (PLLA, M=150,000 g/mol) was dissolved in a mixed solvent of 250 ml acetone and 250 ml N,N-dimethyl formamide, and the prepared solution was fed to two columns of oppositely disposed 20 electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 8 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of +80 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. Drawing speed of filament guiding roller pair 2 is 5 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by the filament guiding roller pair, collecting as continuous PLLA composite nanofiber yarns with diameter of ca. 100 micros.
EXAMPLE 21
[0068] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0069] 10 g poly-L-lactic acid (PLLA, M11=150,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 2 spinnerets. 1.5 g collagen was dissolved in 30 ml hexafluoro-2-propanol (HFIP), and the prepared solution was fed to the other column of electrospinning nozzles containing 2 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of ±30 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. The drawing speed of filament guiding roller pair 2 was 3 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, filament yarn of PLLA/collagen composite nanofibers is obtained.
EXAMPLE 22
[0070] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 30° to fixed sticks 4 .
[0071] 10 g poly (vinylidenefluoride) (PVDF) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide, and the prepared solution was fed to two columns of oppositely disposed 4 electrospinning nozzles. Distance between two neighbouring electrospinning nozzles on the same column of frame is 15 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 40 cm. Plane of frame 3 is set at angle of 30° to fixed sticks 4 . High DC voltages of ±30 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. The drawing speed of filament guiding roller pair 2 was 3 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, filament yarn of PVDF composite nanofibers is obtained.
EXAMPLE 23
[0072] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0073] 10 g poly (vinylidenefluoride) (PVDF) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 2 spinnerets. 15 g polyurethane (PU) was dissolved in 100 ml N, N-dimethyl formamide, and the prepared solution was fed to the other column of electrospinning nozzles containing 2 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. The drawing speed of filament guiding roller pair 2 was 3 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, filament yarn of PVDF/PU composite nanofibers is obtained.
EXAMPLE 24
[0074] A device for electrospinning is used comprising frame 3 having two pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0075] 10 g poly-L-lactic acid (PLLA, M11=150,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N,N-dimethyl formamide, and the prepared solution was fed to one column of electrospinning nozzles containing 2 spinnerets. 10 g poly (vinyl pyrrolidone) (PVP K30, BASF) was dissolved in 50 ml acetone, and the prepared solution was fed to the other column of electrospinning nozzles containing 2 spinnerets. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of ±20 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 1.2 mm, respectively. The drawing speed of filament guiding roller pair 2 was 3 cm/s. Nanofibers exiting from the electrospinning nozzles were induced and drawn out by filament guiding roller pair 2 which is set at the end of pairs of electrospinning nozzles on the plane of the frame 3 . And, filament yarn of PLLA/PVP composite nanofibers is obtained.
EXAMPLE 25
[0076] A device for electrospinning is used comprising frame 3 having three pairs of electrospinning nozzles 1 in two columns, filament guiding roller pair 2 set at the end of pairs of electrospinning nozzles. The frame 3 was set at angle of 0° to fixed sticks 4 .
[0077] 10 g poly-L-lactic acid (PLLA, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 15 g poly-lactide-co-glycolide (Poly-LA-co-GA, PLGA, weight ratio of LA:GA=50:50, Mη=100,000 g/mol) was dissolved in a mixed solvent of 50 ml acetone and 50 ml N, N-dimethyl formamide. 1 g hyaluronic acid (HA, Mw=100,000 g/mol) was dissolved in 100 ml distilled water. 0.3 g chitosan was dissolved in 100 ml 0.1 mol/L acetic acid solution. 1.5 g collagen was dissolved in hexafluoro-2-propanol (HFIP). 10 g polycaprolactone (PCL, Mw=90,000 g/mol) was dissolved in 100 ml N, N-dimethyl formamide. After complete dissolution, solutions were fed to two columns of oppositely disposed 6 electrospinning nozzles, respectively. Distance between two neighbouring electrospinning nozzles on the same column of frame is 10 cm, and distance between two tips of oppositely disposed pair of electrospinning nozzles is 30 cm. Plane of frame 3 is set parallel to fixed sticks 4 . High DC voltages of +15 kV were applied to two columns of oppositely disposed electrospinning nozzles with inner diameter of 0.8 mm, respectively. Filament yarn of composite nanofibers fabricated by former pair of electrospinning nozzles are drawn out and subsequently wrapped around composite nanofibers from latter pair of two oppositely charged electrospinning nozzles. The nanofibers are then drawn out and/or stretched by filament guiding roller pair, forming filament yarn of composite nanofibers. | Device and method for preparing filament yarn of composite nanofibers. The device includes pairs of electrospinning nozzles on a frame and filament guiding roller pair under the frame. The spouts of each pair of nozzles are oppositely facing. The method includes feeding polymer solutions to the pairs of nozzles, applying high DC voltage with opposite polarity respectively to each one of the pairs of nozzles, forming composite nanofibers by attracting nanofibers with opposite charge from each nozzle and striking together of the charged nanofibers, pulling/stretching the composite nanofibers to form filament yarn of composite nanofibers, drawing down the filament yarn of composite nanofibers from the first pair of nozzles and using it as a carrier to receive the nanofibers with opposite charge electrospun from the second pair of nozzles and coated by the same so as to form multi-layer (e.g., two- or more-layer) filament yarn of composite nanofibers. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 07/509,942, filed Apr. 16, 1990.
FIELD OF THE INVENTION
This invention relates to the inhibition of cell proliferation. More specifically, this invention relates to the use of styryl-substituted monocyclic and bicyclic heteroaryl compounds in inhibiting cell proliferation, including compounds which are useful protein tyrosine kinase (PTK) inhibitors.
Normal cellular reproduction is believed to be triggered by the exposure of the cellular substrate to one or more growth factors, examples of which are insulin, epidermal growth factor (EGF) and platelet-derived growth factor (PDGF). Such growth factors are typically specific for corresponding growth factor receptors which are imbedded in and which penetrate through the cellular membrane. The initiation of cellular reproduction is believed to occur when a growth factor binds to the corresponding receptor on the external surface of the cellular membrane. This growth factor-receptor binding alters the chemical characteristics of that portion of the receptor which exists within the cell and which functions as an enzyme to catalyze phosphorylation of either an intracellular substrate or the receptor itself, the latter being referred to as autophosphorylation. Examples of such phosphorylation enzymes include tyrosine kinases, which catalyze phosphorylation of tyrosine amino acid residues of substrate proteins.
Many diseased states are characterized by the uncontrolled reproduction of cells. These diseased states involve a variety of cell types and include disorders such as leukemia, cancer, psoriasis, atherosclerosis and restenosis injuries. The inhibition of tyrosine kinase is believed to have utility in the control of uncontrolled cellular reproduction, i.e., cellular proliferative disorders.
Initiation of autophosphorylation, i.e., phosphorylation of the growth factor receptor itself, and of the phosphorylation of a host of intracellular substrates are some of the biochemical events which are involved in mitogenesis and cell proliferation. Autophosphorylation of the insulin receptor and phosphorylation of substrate proteins by other receptors are the earliest identifiable biochemical hormonal responses.
Elimination of the protein tyrosine kinase (PTK) activity of the insulin receptor and of the epidermal growth factor (EGF) receptor by site-directed mutagenesis of the cellular genetic material which is responsible for generation of insulin and EGF results in the complete elimination of the receptors, biological activity. This is not particularly desirable because insulin is needed by the body to perform other biological functions which are not related to cell proliferation. Accordingly, compounds which inhibit the PTK portion of the EGF receptor at concentrations less than the concentrations needed to inhibit the PTK portion of the insulin receptor could provide valuable agents for selective treatment of cell proliferation disorders.
REPORTED DEVELOPMENTS
U.S. Pat. Nos. 4,678,793 and 4,826,984 disclose pharmaceutical compositions including styryl 4,4-dimethyl (bicyclic heteroaryl) compounds as active agents for treating cancer, psoriasis, acne, etc. U.S. Pat. No. 4,769,384 discloses pharmaceutical compositions including styryl benzimidazole compounds as active agents for treating ulcers of the stomach and duodenum.
It has been reported that the most potent inhibitors of EGF receptors inhibit EGF-induced proliferation of A431/clone 15 cells with little or no effect on the proliferation of such cells when induced by other growth factors. It has been reported also that erbstatin inhibits the autophosphorylation of the EGF receptor in membranes of A431 cells. Low concentrations of erbstatin are required to inhibit EGF receptor autophosphorylation, whereas much higher concentrations of erbstatin are required to inhibit cyclic adenosine 3',5'-monophosphate (cAMP)-dependent protein kinase.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a method of inhibiting cell proliferation in a patient suffering from such disorder comprising the administration to the patient of a styryl-substituted heteroaryl compound exhibiting protein tyrosine kinase inhibition activity wherein the heteroaryl group is a monocyclic ring with 1 or 2 heteroatoms, or a bicyclic ring with 1 to about 4 heteroatoms, said compound optionally substituted or polysubstituted, with the proviso that when said ring is polysubstituted, the substituents do not have a common point of attachment to said ring.
Another aspect of the present invention relates to novel compounds which are those compounds of the aforementioned type wherein no substituent on the heteroaryl group is a carboxy group or an ester group.
Still another aspect of the present invention relates to pharmaceutical compositions comprising, in admixture with a pharmaceutically acceptable carrier, a pharmaceutically-effective amount of a novel compound of the aforementioned type.
With respect to the method aspects of this invention, the compounds described by Formula I below constitute a class of the aforementioned styryl-substituted heteroaryl compounds for use in the practice of the present invention: ##STR1## wherein: R 1 is alkyl, --H, --CN, --OH, --COOR, --CONRR or --CSNRR;
R is alkyl, --H or aralkyl;
R 2 is an about 5- to about 7-membered monocyclic aryl ring including 1 or 2 N, O or S atoms or 1 or 2 N-oxide groups, or an about 8- to about 12-membered bicyclic aryl ring including 1 to about 4 N, O or S atoms or 1 to about 4 N-oxide groups, said ring optionally substituted with one to about three R 9 groups, said R 9 substituents having no common points of attachment to said ring;
R 3 is alkyl, --H, 13 CN, --OH, --COOR, --CONRR, --CSNRR or --CH 2 CN;
R 4 , R 5 , R 6 , R 7 and R 8 are each independently alkyl, --H, --CN, halo, --OR, --CHO, --COOH, --NRR or an N-oxide thereof, --NO 2 , --NHCOCH 3 , --SR, --CF 3 , --CH═CHCOOH, --NHCO(CH 2 ) 2 COOH, morpholino or heteroaryl; each R 9 is independently alkyl, --CN, halo, --O, --CHO, --COOH, --NRR or an N-oxide thereof, --NO 2 , --NHCOCH 3 , --SR, --CF 3 , --CH=CHCOOH, --NHCO(CH 2 ) 2 COOH, morpholino, heteroaryl or ##STR2## R 3 and R 7 together may be --CH 2 CH 2 --, --CH 2 CH 2 CH 2 -- or, starting from R 3 , --CONH--; or
a pharmaceutically acceptable salt thereof.
Also in accordance with the present invention, novel compounds within the scope of the compound and pharmaceutical composition aspects of the present invention are described by Formula I above wherein:
R 1 is alkyl, --CN, --COOR, --CONRR or --CSNRR;
R is alkyl, --H or aralkyl;
R 2 is an about 5- to about 7-membered monocyclic aryl ring including 1 or 2 N, O or S atoms, or an about 8- to about 12-membered bicyclic aryl ring including 1 to about 4 N, O or S atoms, said ring optionally substituted with one to about three R 9 groups, said R 9 substituents having no common points of attachment;
R 3 is alkyl, --H, --COOR, --CONRR, --CSNRR or --CH 2 CN;
R 4 and R 6 are each independently alkyl, --H, --CN, halo, --OR, --CHO, --COOH, --NRR, --NO 2 , --NHCOCH 3 , --SR, --CF 3 , --CH═CHCOOH, --NHCO(CH 2 ) 2 COOH, morpholino or heteroaryl; R 5 , R 7 and R 8 are each independently alkyl, --H, --CN, --OR, --CHO, --COOH, --NHCOCH 3 , --SR, --CF 3 , --CH=CHCOOH, --NHCO(CH 2 ) 2 COOH, morpholino or heteroaryl;
with the provisos that at least two of R 4 , R 5 , R 6 , R 7 and R 8 are not --H, and R 4 , R 5 or R 6 cannot be --OR when R 7 or R 8 is --OR; and
each R 9 is independently alkyl, --CN, halo, --OR, --CHO, --NRR, --NO 2 , --NHCOCH 3 , --SR, --CF 3 , --CH=CHCOOH, --NHCO(CH 2 ) 2 COOH, morpholino, heteroaryl or ##STR3## R 3 and R 7 together may be --CH 2 CH 2 --, --CH 2 CH 2 CH 2 -- or, starting from R 3 , --CONH--.
Compounds within the scope of the present invention have also a specific affinity toward the substrate site of the tyrosine kinase domain of EGF receptors, inhibit EGF receptor kinase more than they inhibit PDGF receptor kinase and also effectively inhibit EGF-dependent autophosphorylation of the receptor.
DETAILED DESCRIPTION OF THE INVENTION
As employed above and throughout the disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
"Alkyl" means a saturated aliphatic hydrocarbon which may be either straight- or branch-chained containing from about 1 to about 6 carbon atoms.
"Lower alkyl" means an alkyl group as above, having 1 to about 4 carbon atoms which may be straight- or branch-chained such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl or tert-butyl.
"Alkoxy" means an alkyl-oxy group in which "alkyl" is as previously described. Lower alkoxy groups are preferred. Exemplary groups include methoxy, ethoxy, n-propoxy, i-propoxy and n-butoxy.
"Aryl" means an unsaturated or partially unsaturated ring system. Preferred aryl groups are pyridyl and indolyl
"Acyl" means an organic radical derived from an organic acid, a carboxylic acid, by the removal of its acid hydroxyl group. Preferred acyl groups are lower alkyl carboxylic acid groups such as acetyl and propionyl. Benzoyl is also preferred.
"Halo" means a halogen. Preferred halogens include chloride, bromide and fluoride.
Preferred aralkyl groups are benzyl and phenethyl.
It is believed that therapeutically useful PTK inhibiting compounds should be competitive with the substrate of EGF receptor tyrosine kinase (EGFRK) and not with adenosine triphosphate (ATP). The PTK inhibitors quercetin and genistein, which compete with ATP, inhibit other protein kinases and as a result are highly cytotoxic. As a test of selectivity, compounds which inhibit EGFRK better than they inhibit insulin receptor kinase (IRK) and/or PDGF receptor kinase are of considerable value.
It is theorized that solubility of the compounds of the present invention both in water and in mildly hydrophobic solvents will enhance the probability that they traverse the cell membrane. Various insoluble compounds, however, have exhibited significant EGFRK inhibition in in vitro testing.
A preferred class of compounds useful in the practice of the present invention include those described by Formula I where:
R 1 is --CN, --COOR, --CONRR or --CSNRR;
R is lower alkyl, --H or aralkyl;
R 2 is
a 6-membered monocyclic aryl ring including 1 or 2 N, O or S atoms, or a 9- or 10-membered bicyclic aryl ring including 1-4 N, O or S atoms, said ring optionally substituted with one to about three R 9 groups, said R 9 substituents having no common points of attachment to said ring;
R 3 is --H;
R 4 , R 5 , R 6 , R 7 and R 8 are each independently lower alkyl, --H, lower alkoxy or --OH, with the provisos that at least two of R 4 , R 5 , R 6 , R 7 and R 8 are not --H, and R 4 , R 5 or R 6 cannot be lower alkoxy when R 7 or R 8 is lower alkoxy;
R 4 and R 6 are also each independently halo;
each R 9 is independently lower alkyl, halo, lower alkoxy, --OH or ##STR4## a pharmaceutically acceptable salt thereof.
More preferred compounds for use in the practice of this invention include those of Formulae II and III below: ##STR5## where R 1 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 are as described immediately above, R 10 is --H, alkyl, aralkyl or ##STR6## a pharmaceutically acceptable salt thereof.
Even more preferred compounds are described by Formulae II and III where:
R 1 is --CN, --COOR or --CONRR;
R 4 , R 5 , R 6 , R 7 and R 8 are independently lower alkyl, --H, lower alkoxy or --H, with the provisos that at least two of R 4 , R 5 , R 6 , R 7 and R 8 are not --H, and R 4 , R 5 or R 6 cannot be lower alkoxy when R 7 or R 8 is lower alkoxy;
R 4 and R 6 are also each independently halo;
R is lower alkyl or --H; and
there are no R 9 substituents.
The most preferred compounds are described by Formula II where R 1 is --CN; R 5 , R 7 and R 8 are each independently --H; and R 4 and R 6 are each independently alkyl, halo, --OR or --CF 3 .
Compounds of this invention may be useful in the form of the free base, in the form of salts and as a hydrate. All forms are within the scope of the invention. Acid addition salts may be formed and are simply a more convenient form for use; and in practice, use of the salt form inherently amounts to use of the base form. The acids which can be used to prepare the acid addition salts include preferably those which produce, when combined with the free base, pharmaceutically acceptable salts, that is, salts whose anions are non-toxic to the animal organism in pharmaceutical doses of the salts, so that the beneficial properties inherent in the free base are not vitiated by side effects ascribable to the anions. Although pharmaceutically acceptable salts of said basic compound are preferred, all acid addition salts are useful as sources of the free base form even if the particular salt per se is desired only as an intermediate product as, for example, when the salt is formed only for purposes of purification and identification, or when it is used as an intermediate in preparing a pharmaceutically acceptable salt by ion exchange procedures.
Pharmaceutically acceptable salts within the scope of the invention include those derived from the following acids: mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid and sulfamic acid; and organic acids such as acetic acid, citric acid, lactic acid, tartaric acid, malonic acid, methanesulfonic acid, ethanesulfonic acid, benzenesulfonic acid, p-toluenesulfonic acid, cyclohexylsulfamic acid, quinic acid, and the like.
The corresponding acid addition salts comprise the following: hydrochloride, sulfate, phosphate, sulfamate, acetate, citrate, lactate, tartarate, methanesulfonate, ethanesulfonate, benzenesulfonate, p-toluenesulfonate, cyclohexylsulfamate and quinate, respectively.
The acid addition salts of the compounds of this invention are prepared either by dissolving the free base in aqueous or aqueous-alcohol solution or other suitable solvents containing the appropriate acid and isolating the salt by evaporating the solution, or by reacting the free base and acid in an organic solvent, in which case the salt separates directly or can be obtained by concentration of the solution.
Compounds useful in the pharmaceutical composition and method aspects of this invention can be prepared by known methods, for example, Knoevenagel condensation reactions such as those disclosed in U.S. Pat. No. 3,149,148.
Compounds of this invention may be prepared by the following reaction sequence: ##STR7##
Knoevenagel condensation of a substituted benzaldehyde in a polar media with an active methylene compound of the formula R 1 CH 2 R 2 in the presence of ammonia or amines such as piperidine and raised heat results in the products of this invention. When substitution of the R 3 group is desired, the corresponding ketone starting material is used. Reaction temperatures in the range of 25° C. to reflux and reaction times vary depending on the materials being used in the condensation.
Compounds of this invention are either commercially available, known in the literature or can be made by known procedures. For example, U.S. Pat. No. 4,600,712 discloses fungicides of Formula I where, for example, R 1 is cyano, R 2 is pyridyl and R 5 and R 7 or R 8 are chloro. U.S. Pat. Nos. 3,337,565 and 3,337,568 disclose compounds which interfere with carbohydrate metabolism of Formula I where, for example, R 1 is cyano or hydroxy, R 2 is pyridyl and R 3 is hydroxy. U.S. Pat. No. 3,196,158 discloses adrenal cortex inhibitors of Formula I where, for example, R 1 is cyano, R 2 is pyridyl and R 7 or R 8 are halo. U.S. Pat. No. 3,157,663 discloses adrenal cortex inhibitors where, for example, R 1 is cyano, R 2 is pyridyl and R 5 , R 7 or R 8 are amino or nitro groups. Buu-Hoi et al., Journal of the Chemical Society (C), pp. 2069-70 (1969) disclose the conversion of 1,2-diarylacrylonitriles to the corresponding 3-arylcoumarins, wherein the 2-aryl group bears an ortho-alkoxy-substituent. Although the foregoing publications disclose some compounds of the type that can be used in accordance with the method aspects of the present invention, they do not disclose the use of such compounds for inhibiting cell proliferation.
Various R, R 1 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 and R 9 substituents on the phenyl and heterocyclic ring or chain can be present in the starting compound or added after formation of the condensation product by methods known in the art for substitution or conversion on one group to another. If the substituents themselves are reactive, then the substituents can themselves be protected according to the techniques known in the art. A variety of protecting groups known in the art, may be employed. Examples of many of these possible groups may be found in "Protective Groups in Organic Synthesis" by T. W. Green, John Wiley and Sons, 1981. For example, nitro groups can be added to the aromatic ring by nitration and the nitro group converted to other groups, such as amino by reduction, and halo by diazotization of the amino group and replacement of the diazo group. Acyl groups can be substituted onto the aryl groups by Friedel-Crafts acylation. The acyl groups can then be transformed to the corresponding alkyl groups by various methods, including the Wolff-Kishner reduction and Clemmenson reduction. Amino groups can be alkylated to form mono- and di-alkylamino groups; and mercapto and hydroxy groups can be alkylated to form corresponding ethers. Primary alcohols can be oxidized by oxidizing agents known in the art to form carboxylic acids or aldehydes, and secondary alcohols can be oxidized to form ketones. Tertiary amino groups can be converted to the corresponding N-oxides by oxidizing agents known in the art, for example, hydrogen peroxide and peracids. Thus, substitution or alteration reactions can be employed to provide a variety of substituents throughout the molecule of the starting material, intermediates, or the final product.
Compounds within the scope of this invention exhibit significant activity as protein tyrosine kinase inhibitors and possess therapeutic value as cellular antiproliferative agents for the treatment of certain conditions including psoriasis, atherosclerosis and restenosis injuries. It is expected that the invention will be particularly applicable to the treatment of atherosclerosis. With regard to the treatment of some conditions, for example, atherosclerosis, certain people may be identified as being at high risk, for example, due to genetic, environmental or historical factors. Compounds within the scope of the present invention can be used in preventing or delaying the occurrence or recurrence of such conditions or otherwise treating the condition.
The compounds of the present invention can be administered to a mammalian host in a variety of forms adapted to the chosen route of administration, i.e., orally, or parenterally. Parenteral administration in this respect includes administration by the following routes: intravenous, intramuscular, subcutaneous, intraocular, intrasynovial, transepithelial including transdermal, ophthalmic, sublingual and buccal; topically including ophthalmic, dermal, ocular, rectal and nasal inhalation via insufflation and aerosol and rectal systemic.
The active compound may be orally administered, for example, with an inert diluent or with an assimilable edible carrier, or it may be enclosed in hard or soft shell gelatin capsules, or it may be compressed into tablets, or it may be incorporated directly with the food of the diet. For oral therapeutic administration, the active compound may be incorporated with excipient and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 6% of the weight of the unit. The amount of active compound in such therapeutically useful compositions is such that a suitable dosage will be obtained. Preferred compositions or preparations according to the present invention are prepared so that an oral dosage unit form contains between about 1 and 1000 mg of active compound.
The tablets, troches, pills, capsules and the like may also contain the following: A binder such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, lactose or saccharin may be added or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring. When the dosage unit form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier. Various other materials may be present as coatings or to otherwise modify the physical form of the dosage unit. For instance, tablets, pills, or capsules may be coated with shellac, sugar or both. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any dosage unit form should be pharmaceutically pure and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and formulations.
The active compound may also be administered parenterally or intraperitoneally. Solutions of the active compound as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxypropylcellulose. Dispersion can also be prepared in glycerol, liquid polyethylene glycols, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersions. In all cases the for must be sterile and must be fluid to the extent that easy syringability exists. It may be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and liquid polyethylene glycol, and the like), suitable mixtures thereof, and vegetable oils. The proper fluidity can be maintained, for example, by the use of a coating such as lecithin, by the maintenance of the required particle size in the case of dispersion and by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by use of agents delaying absorption, for example, aluminum monostearate and gelatin.
Sterile injectable solutions are prepared by incorporating the active compound in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the various sterilized active ingredient into a sterile vehicle which contains the basic dispersion medium and the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and the freeze drying technique which yield a powder of the active ingredient plus any additional desired ingredient from previously sterile-filtered solution thereof.
The therapeutic compounds of this invention may be administered to a mammal alone or in combination with pharmaceutically acceptable carriers, as noted above, the proportion of which is determined by the solubility and chemical nature of the compound, chosen route of administration and standard pharmaceutical practice.
The dosage of the present therapeutic agents which will be most suitable for prophylaxis or treatment will vary with the form of administration, the particular compound chosen and the physiological characteristics of the particular patient under treatment. Generally, small dosages will be used initially and if necessary, will be increased by small increments until the optimum effect under the circumstances is reached. The therapeutic human dosage, based on physiological studies using rats, will generally be from about 0.01 mg to about 100 mg/kg of body weight per day or from about 0.4 mg to about 10 g or and higher although it may be administered in several different dosage units from once to several times a day. Oral administration requires higher dosages.
EXAMPLES
Embodiments of the present invention and comparative examples are described in the following non-limiting examples which include a description of pharmacological test procedures believed to correlate to therapeutic activity in humans and other animals. Examples 1-13 below are illustrative of compounds within the scope of the present invention. In examples 1A and 1B, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are chloro. In example 2, the N-oxide of the compound of example 1A is prepared. In example 3, R 1 is cyano, R 2 is pyridyl and R 4 and R 5 are methoxy. In example 4, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are tert butyl. In example 5, R 2 is cyano, R 2 is indolyl and R 4 and R 5 are methoxy. In example 6, R 1 is cyano, R 2 is indolyl, R 4 and R 5 are methoxy and R 9 is 4-nitrophenylsulfonyl. In example 7, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are methoxy. In example 8, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are methoxy. In example 9, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are tert butyl. In example 10, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are trifluoromethyl. In example 11, R 1 is cyano, R 2 is pyridyl and R 4 and R 6 are methoxy. In example 12, R 1 is cyano, R 2 is indolyl and R 4 and R 6 are trifluoromethyl. In example 13, R 1 is cyano, R 2 is indolyl and R 4 and R 6 are tert butyl. Example 14 is illustrative of various compounds within the scope of the invention.
EXAMPLE 1IA
trans-2 -(3-Pyridyl)-3-(3,5-dichlorophenyl)-2-propenenitrile
To a stirred solution of 400 g (2.3 mole) 3,5-dichlorobenzaldehyde in 11.4 liters absolute ethanol were added 283.5 g (2.4 mole) 3-pyridylacetonitrile and 720.9 g of K 2 CO 3 . Within 2 minutes of the K 2 CO 3 addition, a solid precipitate formed. The reaction mixture was stirred about 2.5 hours. Water (22.9 liters) was added to the stirred reaction mixture. After stirring for 1 hour, the mixture was filtered and the filter cake was washed with water (10 liters), dried and recrystallized from isopropanol. Five hundred thirty four g (85% yield) of trans-2-(3-pyridyl)-3-(3,5-dichlorophenyl)-2-propenenitrile were obtained, m.p. 150°-151° C.
EXAMPLE 1B
Mixture of cis- and trans-2-(3-pyridyl)-3-(3,5-dichlorophenyl)-2-propenenitrile
To a stirred solution of 3.0 g (17.1 mmole) 3,5-dichlorobenzaldehyde in 200 ml absolute ethanol were added 1.83 ml (17.1 mmole) 3-pyridylacetonitrile and 1 equivalent K 2 CO 3 (2.36 g). The reaction flask was equipped with a reflux condenser and the stirred reaction mixture was refluxed for 2 hours, filtered and concentrated. The resulting residue was purified by flash chromatography on silica gel, eluting with 4:1 hexane/ethyl acetate to give a mixture of cis- and trans-2-(3-pyridyl)-3-(3,5-dichlorophenyl)-2-propenenitrile.
EXAMPLE 2
trans-2-(3-pyridyl)-3-(3,5-dichlorophenyl)-2-propenenitrile, N-oxide
To a stirred, ice-cooled solution of the compound prepared in Example 1A (1.0 g, 3.6 mmole) in 30 ml CH 2 Cl 2 were added dropwise a solution of m-chloroperbenzoic acid (m-CPBA) (0.63 g, 3.6 mmole) in 20 ml CH 2 Cl 2 . After stirring for about 1 hour, a white solid precipitated out of the reaction solution. The reaction mixture was stirred overnight, after which an additional equivalent of mCPBA (0.63 g) was added. The reaction mixture was stirred several hours, filtered, and the filter cake was washed with CH 2 Cl 2 . The combined CH 2 Cl 2 solutions were washed twice with 10% NaHCO 3 , dried (MgSO 4 ) and concentrated in vacuo to give 0.8 g (75%) of the title compound as a white solid, m.p. 252° C. (decomposes).
EXAMPLE 3
2-(2-Pyridyl)-3-(3.4-dimethoxyphenyl)-2-propenenitrile
To a stirred solution of 2.0 g (12.0 mmole) 3,4-dimethoxybenzaldehyde in 75 ml absolute ethanol are added 1.56 g (13.3 mmole) 2-pyridylacetonitrile and 12 drops piperidine. The reaction flask is equipped with a condenser and a drying tube (using anhydrous CaSO 4 ), and the reaction is stirred and heated. After refluxing for 6 hours, the reaction is allowed to cool to room temperature and stirred overnight for 16 hours. The solvent is removed by rotary evaporation, and the residue purified by flash chromatography on silica gel, eluting with hexane-ethyl acetate, 4:1. The yellow solid is recrystallized from acetone-hexane to give 2-(2-pyridyl)-3-(3,4-dimethoxy-phenyl)-2-propenenitrile, m.p. 112°-14 114° C.
EXAMPLE 4
2-(2-Pyridyl)-3-(3,5-di-tert-butylphenyl)-2-propenenitrile
To a stirred solution of 2.0 g (9.17 mmole) 3,5-di-tertbutylbenzaldehyde in 75 ml absolute ethanol are added 1.19 g (10.1 mmole) 2-pyridylacetonitrile and 12 drops piperidine. The reaction flask is equipped with a condenser and a drying tube (using anhydrous CaSO 4 ), and the reaction is stirred and heated. After refluxing for 8 hours, the reaction is allowed to cool to room temperature and stirred overnight for 16 hours. The solvent is removed by rotary evaporation, and the residue purified by flash chromatography on silica gel, eluting with hexane-ethyl acetate, 98:2. The colorless solid is washed with cold ether-hexane to give 2-(2-pyridyl)-3-(3,5-di-tert-butylphenyl)-2-propenenitrile, m.p. 90°-93° C.
EXAMPLE 5
2-(3-Indolyl)-3-(3,4-dimethoxyphenyl)-2-propenenitrile
To a stirred solution of 2.0 g (12.0 mmole) 3,4-dimethoxybenzaldehyde in 75 ml absolute ethanol are added 2.07 g (13.3 mmole) 3-indolylacetonitrile and 1.83 g (13.3 mmole) anhydrous potassium carbonate. The reaction flask is equipped with a condenser and a drying tube (using anhydrous CaSO 4 ), and the reaction was stirred and heated. After refluxing for 24 hours, the reaction is allowed to cool to room temperature. The reaction mixture is filtered to remove the salts, and the solvent is removed by rotary evaporation. The residue is purified by flash chromatography on silica gel, eluting with hexane-ethyl acetate, 3:1. The yellow solid is recrystallized from acetone-hexane to give 2-(3-indolyl)-3-(3,4-dimethoxyphenyl)-2-propenenitrile, m.p. 139°-141° C.
Following the procedures of Examples 3-5, the following compounds may be prepared.
EXAMPLE 6
2-[1-(4-Nitrophenylsulfonyl)indol-3-yl]-3-(3,4-dimethoxyphenyl)-2-propenenitrile, m.p. 204°-206° C.
EXAMPLE 7
2-(3-Pyridyl)-3-(3,4-dimethoxyphenyl)-2-propenenitrile, m.p. 112°-115° C.
EXAMPLE 8
2-(3-Pyridyl)-3-(3,5-dimethoxyphenyl)-2-propenenitrile, m.p. 103°-105° C.
EXAMPLE 9
2-(4-Pyridyl)-3-(3,5-di-tert-butylphenyl)-2-propenenitrile, m.p. 105°-107° C.
EXAMPLE 10
2-(2-Pyridyl)-3-[3,5-bis(trifluoromethyl)phenyl]-2propenenitrile, m.p. 101°-103° C.
EXAMPLE 11
2-(4-Pyridyl)-3-(3,5-dimethoxyphenyl)-2-propenenitrile, m.p. 135°-137° C.
EXAMPLE 12
2-(3-Indolyl)-3-[3,5-bis(trifluoromethyl)phenyl]-2-propenenitrile, m.p. 222°-223° C.
EXAMPLE 13
2-(3-Indolyl)-3-(3,5-di-tert-butylphenyl)-2-propenenitrile, m.p. 134°-136° C.
EXAMPLE 14
When 3,4-dimethoxybenzaldehyde of Example 3 is replaced by the compounds of Table I below and 2-pyridylacetonitrile is replaced by the compounds of Table II below, then the corresponding product is prepared.
TABLE I______________________________________ 3,4,5-trimethoxybenzaldehyde 4-methoxybenzaldehyde 3-methoxybenzaldehyde 3,4-dihydroxybenzaldehyde 3,4-dimethylbenzaldehyde 4-acetylaminobenzaldehyde 4-methylthiobenzaldehyde 3-chlorobenzaldehyde 4-chlorobenzaldehyde 3-fluorobenzaldehyde 4-fluorobenzaldehyde 3-nitrobenzaldehyde 4-nitrobenzaldehyde 4-morpholinobenzaldehyde 4-carbethoxybenzaldehyde 3-carbethoxybenzaldehyde 2,4-difluorobenzaldehyde 2,4-dimethoxybenzaldehyde 3,5-di-tertbutylbenzaldehyde 3,4-dimethoxybenzaldehyde 3,5-dipropylbenzaldehyde 3,4-dipropylbenzaldehyde 2,5-dimethylbenzaldehyde 2,5-dimethoxybenzaldehyde 3-trifluoromethylbenzaldehyde 3,5-di-trifluoromethylbenzaldehyde 3-chloro-5-methoxybenzaldehyde 2-chloro-4-methoxybenzaldehyde 3-chloro-4-methoxybenzaldehyde 3,5-dichloroacetophenone 2,4-dichloroacetophenone 3,4-dichloroacetophenone______________________________________
TABLE II______________________________________ 2-pyridylacetamide 2-pyridylacetic acid methyl-2-pyridylacetate 3-pyridylacetamide methyl-3-pyridylacetate 4-pyridylacetamide methyl-4-pyridylacetate 6-methyl-2-pyridylacetonitrile 4-methyl-2-pyridylacetonitrile 6-chloro-2-pyridylacetonitrile 4-carbethoxy-2-pyridylacetonitrile 2-thienylacetonitrile 2-imidazolylacetonitrile 2-quinolylacetonitrile 3-furylacetonitrile 3-(2H-chromen)ylacetonitrile methyl-2-pyrimidinylacetate 3-dimethylaminopyridine 3-(2H-pyranyl)acetonitrile 2-pyridylacetonitrile 3-pyridylacetonitrile 4-pyridylacetonitrile 3-indolylacetonitrile 2-benzothiazolylacetonitrile 1-isoquinolylacetonitrile 3-benzothiazinylacetonitrile______________________________________
Compounds of this invention are subjected to various biological tests, the results of which correlate to useful cellular antiproliferative activity. These tests are useful in determining EGF receptor kinase, PDGF receptor kinase and insulin receptor kinase inhibition activities of the compounds disclosed herein.
EGF-Receptor Purification
EGF-receptor purification is based on the procedure of Yarden and Schlessinger. A431 cells are grown in 80 cm 2 bottles to confluency (2×10 7 cells per bottle). The cells are washed twice with PBS and harvested with PBS containing 1.0 mmol EDTA (1 hour at 37° C.), and centrifuged at 600g for 10 minutes. The cells are solubilized in 1 ml per 2×10 7 cells of cold solubilization buffer (50 mmol Hepes buffer, pH 7.6, 1% Triton X-100, 150 mmol NaCl, 5 mmol EGTA, 1 mmol PMSF, 50 μg/ml aprotinin, 25 mmol benzamidine, 5 μg/ml leupeptic, and 10 μg/ml soybean trypsin inhibitor) for 20 minutes at 4° C. After centrifugation at 100000g for 30 minutes, the supernatant is loaded onto a WGA-agarose column (100 μl of packed resin per 2×10 7 cells) and shaken for 2 hours at 4° C. The unabsorbed material is removed and the resin washed twice with HTN buffer (50 mmol Hepes, pH 7.6, 0.1% Triton X-100, 150 mmol NaCl), twice with HTN buffer containing 1M NaCl, and twice with HTNG buffer (50 mmol Hepes, pH 7.6, 0.1% Triton X-100, 150 mmol NaCl, and 10% glycerol). The EGF receptor is eluted batchwise with HTNG buffer containing 0.5 M N-acetyl-D-glucosamine (200 μl per 2×10 7 cells). The eluted material is stored in aliquots at -70° C. and diluted before use with TMTNG buffer (50 mmol Tris-Mes buffer, pH 7.6, 0.1% Triton X-100, 150 mmol NaCl, 10% glycerol).
EGFR Kinase Catalyzed Phosphorylation of Poly(GAT) and its Inhibition
WGA-purified EGFR (0.25 μg/assay) is preactivated with EGF (0.85 μM) in 50 mmol Tris-Mes buffer, pH 7.6 for 20 minutes at 4° C. The assay is initiated by addition of a mixture which contains Mg(Ac) 2 (60 mmol), [γ- 32 P]ATP (125 μM, 2-5 μCi/assay), poly(GAT) (0.0625 mg/ml, 0.125 mg/ml, 0.25 mg/ml), and six concentrations of inhibitor in duplicates. The temperature of the assay is 22° C. and the production of phosphorylated copolymer is found to be linear up to 20 minutes. The PTK inhibitors tested are solubilized in water or a mixture of ethanol and water such that the final concentration of ethanol does not exceed 4% in the assay. Up to 4% ethanol in the assay has no effect on the EGFR kinase activity. The concentration of EGF in the assay is 300 nM in a final volume of 40 μl. After 5, 10 or 20 minutes, aliquots of 25 μl are applied onto Whatman 3-mm paper cuttings, which are then soaked in cold 10% TCA containing 0.01M sodium pyrophosphate. After being washed overnight at 4° C., the paper cuttings are dried and counted, measuring 32 P Cerenkov radiation. Concentration dependence on poly(GAT) was Michaelian with a K m = 0.076 ± 0.007 mg/ml or 0.069 ± 0.007 mmol if calculated per Glu 6 Ala 3 Tyr(GAT) unit. The EGF response for the poly(GAT) phosphorylation is graphed. The K m for ATP in the assay was found to 2.9 μM.
Time Dependence of EGF-Receptor Autophosphorylation
WGA-purified EGF receptor from A431 cells (0.5 μg/assay) is activated with EGF (800 nM) for 20 minutes at 4° C. The reaction is initiated by the addition of Mg(Ac) 2 (60 mmol), Tris-Mes buffer, pH 7.6 (50 mmol), and [ 32 P]ATP (20 μM, 5 μCi/assay). The reaction is conducted at either 4° or 15° C. and terminated by addition of sodium dodecyl sulfate (SDS) sample buffer (10% glycerol, 50 mmol Tris, pH 6.8, 5% β-mercaptoethanol, and 3% (SDS). The samples are run on a 8% SDS polyacrylamide gel (SDS-PAGE) (prepared from 30% acrylamide and 0.8% bis-(acrylamide) and contained 0.375M Tris, pH 8.8, 0.1% SDS, 0.05% TEMED, and 0.46% ammonium persulfate). The gel is dried and autoradiography performed with Agfa Curix RP2 X-ray film. The relevant radioactive bands are cut and counted in the Cerenkov mode. The fast phase of autophosphorylation continues for another 10 minutes. The extent of phosphorylation completed in the first 10-s at 15° C. comprises 1/3 of the total autophosphorylation signal and probably reflects the phosphorylation of the first site on the receptor. The 10-s interval is therefore chosen for use in subsequent autophosphorylation experiments.
ATP and EGF Dependence of Autophosphorylation
WGA-purified EGF receptor from A431 cells (0.5 μg/assay is activated with EGF (0.85 μM) for 20 minutes at 4° C. The assay is performed at 15° C. and initiated by addition of Mg(Ac) 2 (60 mmol), Tris-Mes buffer, pH 7.6 (50 mmol), [ 32 P]ATP (carrier free, 5 μCi/assay), and increasing concentrations of nonradioactive ATP. The assay is terminated after 10-s by addition of SDS sample buffer. The samples are run on a 6% SDS polyacrylamide gel. The gel is dried and autoradiographed as described above. The relevant radioactive bands are cut and counted in the Cerenkov mode. the K m for ATP determined in this fashion is found to be 7.2 μM. With use of the 10-s assay protocol, the EGF concentration dependence of EGFRK autophosphorylation is determined.
Inhibition of Copoly(Glu 4 Tyr) Phosphorylation by Insulin-Receptor Kinase (InsRK)
Rat liver membranes are prepared from the livers of 6-week-old rats as described by Cuatrecasas. WGA-purified insulin receptor is prepared according to Zick et al. WGA-purified rat liver InsRK (1.25 μg) is preincubated with or without 330 nM insulin in 50 mmol Tris-Mes buffer, pH 7.6, for 30 minutes at 22° C. The assay is performed at 22° C. and initiated by addition of a mixture which contains Mg(Ac) 2 (60 mmol), NaVO 3 (40 μM), [γ- 32 P]ATP (125 μM, 3-5 μCi/assay), and poly(GT) [poly(Glu 4 Tyr)]at three concentrations: whenever an inhibitor is tested, it is added at the proper concentration. The final concentration of insulin in the assay is 125 nM. The total volume of the assay is 40 μl. After 20 minutes, aliquots of 30 μl are applied on Whatman 3-mm paper and soaked in cold 10% TCA, containing 0.01M sodium pyrophosphate. After being washed overnight, the papers are dried and counted, measuring Cerenkov radiation. The InsRk-catalyzed phosphorylation of poly(GT) obeys Michaelis-Menten kinetics.
Inhibition of EGFR Autophosphorylation
A431 cells were grown to confluence on human fibronectin coated tissue culture dishes. After washing 2 times with ice-cold PBS, cells were lysed by the addition of 500 μl dish of lysis buffer (50 mmol Hepes, pH 7.5, 150 mmol NaCl, 1.5 mmol MgCl 2 , 1 mmol EGTA, 10% glycerol, 1% triton X-100, 1 mmol PMSF, 1 mg/ml aprotinin, 1 mg/ml leupeptin) and incubating 5 minutes at 4° C. After EGF stimulation (500 μg/ml 10 minutes at 37° C.) immunoprecipitation was performed with anti EGF-R (Ab 108) and the autophosphorylation reaction (50 μl aliquots, 3 μCi [γ- 32 P]ATP) sample was carried out in the presence of 2 or 10 μM of compound, for 2 minutes at 4° C. The reaction was stopped by adding hot electrophoresis sample buffer. SDS-PAGE analysis (7.5% els) was followed by autoradiography and the reaction was quantitated by densitometry scanning of the x-ray films. In order to test the compounds for selective inhibition, the procedure is repeated using PDGF stimulation in place of EGF stimulation. "IC 50 ," as used below, refers to the concentration of inhibitor (μM) at which the rate of autophosphorylation is halved, compared with media containing no inhibitor. Preferably, the IC 50 values for EGF will be lower than for PDGF, indicating a high degree of EGF specificity of the inhibitory compounds The results of this test are summarized in Table III below.
TABLE III______________________________________ IC.sub.50 (μM)Example EGF PDGF______________________________________2 0.1 203 0.5 65 0.4 106 20 >507 0.4 30______________________________________
These results show that the compounds of the present invention inhibit EGF receptor kinase better than they inhibit PDGF receptor kinase.
Inhibition of Cell Proliferation as Measured by Inhibition of DNA Synthesis
Cells were seeded at 1×10 5 cells per well in 24-well Costar dishes pre-coated with human fibronectin (by incubating for 30 minutes at room temperature with 10 μg/0.5 ml/well). The cells were grown to confluence for 2 days. The medium was changed to DMEM containing 0.5 calf serum for 36-48 hours and the cells were then incubated with PDGF, EGF (Toyobo, New York, N.Y.) (20 ng/ml) or serum (10% calf serum, FCS) and different concentrations of the inhibitory compounds. [ 3 H]thymidine, (NEN, Boston, MA) was added 16-24 hours later at 0.5μCi/ml for 2 hours. TCA precipitable material was quantitated by scintillation counting (C). Results of this assay are summarized in Table IV below. "IC 50 ," as used below, refers to the concentration of inhibitor (nM) at which [ 3 H]thymidine incorporation is halved, compared with media containing no inhibitor. As FCS contains a broad range of growth factors, the IC 50 values for PDGF should be lower than for FCS, indicating that the compounds do not act as general inhibitors.
TABLE IV______________________________________FCSFple IC.sub.50 IC.sub.50______________________________________2 30 ± 17 1003 14 ± 10 27 ± 5% @ 1 μM4 9 ± 2 5006 17 15% @ 1 μM______________________________________
These results indicate that the compounds of the invention do not inhibit a broad range of growth factor receptors.
Cell Culture
Cells termed HER 14 and K721A (=DK) were prepared by transfecting N1H3T3 cells (clone 2.2) (From C. Fryling, NCI, NIH), which lack endogenous EGF-receptors, with cDNA constructs of wild-type EGF-receptor or mutant EGF-receptor lacking tyrosine kinase activity (in which Lys 721 at the ATP-binding site was replaced by an Ala residue, respectively). All cells were grown in DMEM with 10% calf serum (Hyclone, Logan, Utah).
The results obtained by the above experimental methods evidence the useful protein tyrosine kinase inhibition properties of the compounds within the scope of the present invention.
Comparative Examples
The following comparative examples illustrate the improved cell proliferation inhibition of compounds of the present invention in comparison to compounds of the prior art. In comparative Example C-1, the preparation of a prior art compound, where R 1 is cyano, R 2 is pyridyl and R 5 and R 8 are chloro is described. The inhibitory activities of the compounds of Examples 1A and 2 are compared to the inhibitory activity of the compound prepared in comparative Example C-1.
EXAMPLE C-1
2-(3-pyridyl)-3-(2,4-dichlorophenyl)-2-propenenitrile
To a stirred solution of 2,4-dichlorobenzaldehyde (5.0 g, 29 mmole) and 3-pyridylacetonitrile (3.05 ml, 29 mmole) in 150 ml absolute ethenol were added 3.95 g K 2 CO 3 . After stirring for about 15 minutes, a white solid precipitated out of the reaction mixture. The reaction mixture was stirred overnight and filtered. The filter cake was washed with absolute ethanol and dissolved in CH 2 Cl 2 . The CH 2 Cl 2 solution was filtered and concentrated in vacuo. The resulting white solid was recrystallized from 3:2 hexane/ethyl acetate to give 6.0 g (76%) of the title compound.
The inhibition of EGFR autophosphorylation by the compounds of Examples 1A and 2 was compared to the prior art compound of Example C-1. The EGFR autophosphorylation inhibition was evaluated using the same procedure as described hereinbefore. The results are reported in Table V below.
TABLE V______________________________________Example IC.sub.50 (μM)______________________________________1A 22 ≧50C-1 ≧50______________________________________
These results demonstrate that the compound of Example 1A is a more potent inhibitor of EGF receptor kinase than C-1. For this particular compound of the invention (Example 1-A), it can be seen from the test results that it has also a much better activity than that of its corresponding N-oxide. | Methods of inhibiting cell proliferation in a patient suffering from such disorder comprising the use of a styryl-substituted heteroaryl compound wherein the heteroaryl group is a monocyclic ring with 1 or 2 heteroatoms, or a bicyclic ring with 1 to about 4 heteroatoms, said compound optionally substituted or polysubstituted, with the proviso that when said ring is polysubstituted, the substituents do not have a common point of attachment to said ring, and those compounds wherein no substituent on the heteroaryl group is a carboxy group or an ester group, and pharmaceutical compositions comprising such compounds. | 2 |
This invention generally relates to cathode ray tubes and, more particularly, to an apparatus and method for retaining a damper wire in a cathode ray tube to reduce vibration in a grille type mask.
BACKGROUND OF THE INVENTION
A color picture tube includes an electron gun for forming and directing three electron beams to a screen of the tube. The screen is located on the inner surface of the face plate of the tube and comprises an array of elements of three different color emitting phosphors. A shadow mask, which may be either a formed aperture or a grill type mask, is interposed between the gun and the screen to permit each electron beam to strike only the phosphor elements associated with that beam.
The shadow mask is subject to vibration from external sources (e.g., speakers near the tube). Such vibration varies the positioning of the apertures through which the electron beam passes, resulting in visible display fluctuations. Ideally, these vibrations need to be eliminated or, at least, mitigated to produce a commercially viable television picture tube.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for retaining a damper wire used in a cathode ray tube to reduce vibration in a grill type mask assembly of a cathode ray tube. The damper wire is retained across a mask by a bimetal damper spring having a first end and an opposing second end. The second end is coupled to the frame of the grill type mask assembly. A tab located proximate the first end of the damper spring is adapted to accept the damper wire that traverses the mask. In an alternative embodiment, the damper wire is “tied” to the tab such that the spring maintains a constant tension on the damper wire.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 is a side view, partly in axial section, of a color picture tube, including a grill type mask-frame-assembly according to the present invention;
FIG. 2 is a perspective view of the grill type mask-frame-assembly of FIG. 1 ;
FIG. 3 depicts a prior art damper spring arrangement;
FIG. 4 is a cross sectional view of a prior art damper spring depicting positional movement during temperature changes;
FIG. 5 is a perspective view of a bimetal damper spring;
FIG. 6 is a cross sectional view of a bimetal spring depicting positional movement during temperature changes;
FIG. 7 depicts a perspective view of a bimetal damper spring having a concave first end; and
FIG. 8 depicts an embodiment of the invention having a damper wire tied to a respective tab.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
FIG. 1 shows a cathode ray tube 10 having a glass envelope 12 comprising a rectangular face plate panel 14 and a tubular neck 16 connected by a rectangular funnel 18 . The funnel 18 has an internal conductive coating (not shown) that extends from an anode button 20 to a neck 16 . The panel 14 comprises a viewing face plate 22 and a peripheral flange or sidewall 24 that is sealed to the funnel 18 by a glass frit 26 . A three-color phosphor screen 28 is carried by the inner surface of the face plate 22 . The screen 28 is a line screen with the phosphor lines arranged in triads, each triad including a phosphor line of each of the three colors. A grill type mask 30 is removably mounted in a predetermined spaced relation to the screen 28 . An electron gun 32 (schematically shown by the dashed lines in FIG. 1 ) is centrally mounted within the neck 16 to generate three in-line electron beams, a center beam and two side beams, along convergent paths through the mask 30 to the screen 28 .
The tube 10 is designed to be used with an external magnetic deflection yoke, such as the yoke 34 shown in the neighborhood of the funnel to neck junction. When activated, the yoke 34 subjects the three beams to magnetic fields that cause the beams to scan horizontally and vertically in a rectangular raster over the screen 28 .
The grill type mask 30 , shown in greater detail in FIG. 2 , includes two long sides 36 and 38 and two short sides 40 and 42 . The two long sides 36 and 38 of the mask parallel a central major access, x, of the tube. The grill type mask 30 includes: strands 44 that are parallel to the central minor access y and to each other. In a preferred embodiment, the strands 44 are flat strips that extend vertically, having a width of about 0.020″ and a thickness of 0.006″.
It will be appreciated by those skilled in the art that although the invention is discussed in the context of grill type masks, the invention can be adapted to use formed aperture masks, tensed aperture masks, focus type masks or the like.
FIG. 3 depicts a prior art (U.S. Pat. No. 4,780,641) damper spring arrangement that retains a damper wire across the mask to reduce vibration in the mask. Specifically, a damper spring 50 is attached to a frame 48 of grill type mask 30 . More specifically, each damper spring 50 is comprised of a single metal and is attached to the frame 48 proximate to the two short sides 40 and 42 of grill type mask 30 . A tab 52 is disposed on each damper spring 50 .
A damper wire 54 extends between the damper springs 50 and contacts the surface of the grill type mask 30 . The damper wire 54 is attached to each respective damper spring 50 by sandwiching the damper wire 54 between the spring 50 and a tab 52 welded to the spring 52 .
Damper wire 54 is held under a high tension force of 50 N between each respective damper spring 50 . It is desireable that this tension be maintained to ensure that the damper wire 54 is always contacting the mask. Damper wire 54 is a small diameter wire made of tungsten or the like. Under a normal operating temperature of 70 degrees Celsius, each respective damper spring 50 maintains the proper tension on damper wire 54 . However, during the cathode ray tube manufacturing process, temperatures in the cathode ray tube 10 can reach temperature ranges of between 450 and 480 degrees Celsius. Because the creep threshold of the damper spring and damper wire material at the processing temperature is lower than the creep threshold at normal operating temperature and the thermal expansion of the damper wire 54 causes an increase in wire tension and spring stress at the high processing temperature, such a high temperature can cause creep strain in the damper spring or damper wire which leads to a relaxation of the damper wire tension and a resultant damper wire tension which can only be estimated from initial conditions. For instance, during high temperature processing as shown in FIG. 4 , damper spring 50 moves from Position x to Position y exerting additional direct tension on damper wire 54 and increased bending stress on the damper spring 50 . Creep strain in the damper spring 50 will move the damper spring 50 towards Position x. When normal operating temperatures are reverted to, the permanent creep strain will position the damper spring 50 at Position z, which is inboard of Position x, and the damper wire tension is reduced. The creep threshold is about 27,000 psi at 460 degrees Celsius for a bimetal and a non bimetal spring. However, the bimetal spring has substantially lower stress at this temperature.
FIG. 5 depicts a perspective view of a bimetal damper spring that replaces damper spring 50 in FIG. 3 . Specifically, bimetal damper spring 56 comprises a first metallic layer 58 and a second metallic layer 60 . First metallic layer 58 comprises a metal such as carbon steel and the like disposed on an inner surface 72 of the bimetal damper spring 56 . Second metallic layer 60 comprises a metal such as stainless steel and the like, having a higher thermal expansion characteristic than the first metallic layer, disposed on an outer surface 74 of the bimetal damper spring 56 . Bimetal damper spring 56 has a thickness of between 0.008″ to 0.012″ to ensure flexibility. The first metallic layer 58 and second metallic layer 60 may be coupled with welding which can be achieved with electron beam welding or resistance welding.
Bimetal damper spring 56 has a first end 62 and an opposing second end 64 . Both of the ends 62 and 64 are flat. The second end 64 of each bimetal damper spring 56 is attached to the frame 48 of the grill type mask 30 . Disposed between the first end 62 and second end 64 of each bimetal damper spring 56 is a tab 52 having a first end 68 and an opposing second end 70 . The first end 68 of the tab 52 is attached to bimetal damper spring 56 .
FIG. 6 is a cross sectional view of a bimetal spring depicting positional movement during temperature changes. In a first embodiment of the invention, damper wire 54 is spot welded between the tab 52 and bimetal damper spring 56 at point 600 . During the cathode ray tube manufacturing process, high temperatures are achieved. Since bimetal damper spring 56 has the low expansion metal on the inner surface 74 , the bimetal damper spring 56 curls inward from Position A to Position B. Thus, unloading damper wire 54 during high temperature processing. Thereby, lowering the damper spring and damper wire stress below the creep threshold and allowing damper wire 54 tensions to be fixed before the final cathode ray tube assembly.
FIG. 7 depicts a perspective view of a bimetal spring 57 having a concave first end 76 . Specifically, the bimetal damper spring 57 has a curvature 78 on the first end 76 . The curvature 78 is added to first end 76 so that by aligning the apex 80 of the curvature 78 to the edge of the grill type mask 30 with the spring compressed the proper damper wire angle of elevation 82 can be achieved when the spring is released. The preferred radius of the curvature is 1.875″ degrees. The proper damper wire angle of elevation 82 is one which guarantees a tangential or slightly downward departure of the damper wire 54 from the edge of the grill type mask 30 . Such an angle of elevation guarantees proper contact is maintained with the grill type mask 30 to reduce vibration therein. Factors such as the diameter of the damper wire 54 , the degree of curvature of first end 76 and how close the bimetal damper spring 56 is to the edge of the grill type mask 30 determine the damper wire elevation 82 . Different degrees of curvature of first end 76 can be used to accommodate any type or size of cathode ray tube 10 .
FIG. 8 depicts a perspective view of a bimetal damper spring 86 having a damper wire 54 tied to a respective tab 52 . Tab 52 is coupled to bimetal damper spring 86 at the first end 62 . A crotch 84 exists between tab 52 and bimetal damper spring 86 . The damper wire 54 is looped around the tab 52 . Then the looped portion of damper wire 54 is secured between damper spring 86 and tab 52 by wedging the looped portion of damper wire 54 in the crotch 84 .
It will be appreciated by those skilled in the art that tab 52 can be an integral tab 66 formed from the body of bimetal damper spring 86 .
It will also be appreciated by those skilled in the art that the various embodiments of bimetal damper spring 86 can be combined. For example bimetal damper spring 86 can have a first end 76 having a curvature 78 and have damper wire 54 tied to tab 52 of bimetal damper spring 56 .
In another embodiment, a non-bimetal damper spring has a concave first end similar to the concave first end shown in FIG. 7 . This non-bimetal damper spring benefits from having a damper wire angle of elevation that is adjustable based on the curvature of the first end.
In another embodiment, a non-bimetal damper spring has a damper wire tied to a tab in the same manner as shown in FIG. 8 . As such, the damper wire is looped around the tab and the looped portion of the tab is secured by wedging the looped portion of the damper wire in the crotch.
As the embodiments that incorporate the teachings of the present invention have been shown and described in detail, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings without departing from the spirit of the invention. | An apparatus and method for retaining a damper wire used in a cathode ray tube to reduce vibration in the grill type mask assembly of a cathode ray tube. The damper wire is retained across a grill type mask by a bimetal damper spring having a first end and an opposing second end. The second end is coupled to the frame of the grill type mask assembly. A tab located proximate the first end of the damper spring is adapted to accept the damper wire that traverses the mask. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to an image display device, a direct-view display device, and a projection display device. More particularly, the invention relates to an image display technique capable of controlling the brightness.
[0003] 2. Description of Related Art
[0004] It has recently been considered to control the brightness of the light sources of direct-view and projection display devices depending on the contents of displays in order to increase the apparent dynamic range (gray scale) of a display.
[0005] Known display devices, capable of controlling the brightness of the light source depending on the display contents, include one capable of controlling the light source itself. See, for example, JP-A-03-179886 (pp. 3 to 4, FIG. 1).
SUMMARY OF THE INVENTION
[0006] The above-described method has the problem that the color of the display images has changed because emission spectrum is varied by controlling the brightness of a light source.
[0007] It is an object of the invention to provide a display device, a direct-view display device, and a projection display device in which their apparent dynamic ranges are increased without influence on the color.
[0008] A display device according to the invention can include a light modulation device having a plurality of pixels for displaying an image according to an image signal. The display device includes a light source for illuminating the light modulation device, and light-source driving means for controlling the intensity of light by controlling the period in which the light source is lit at a specified brightness per unit time.
[0009] More specifically, in the display device of the invention, the light emitted from the light source irradiates the display device to form an image based on an image signal. When the display device displays a dark image, the light-source driving device controls the period in which the light source is lit at a specified brightness on the basis of the image signal to thereby control the intensity of light emitted from the light source per unit time.
[0010] Accordingly when a dark image signal is inputted, the period in which the light source is lit at a specified brightness is reduced, decreasing the intensity of light emitted from the light source per unit time, and thus darkening the display image. On the other hand, when a bright image signal is inputted, the period in which the light source is lit at a specified brightness is increased, increasing the intensity of light emitted from the light source per unit time, and thus lightening the display image. Therefore, a displayable gray scale is increased to allow the apparent dynamic range to be increased.
[0011] Since the intensity of the light source during the lighting period is constant, the emission spectrum does not vary and so the color of the display image does not vary. Furthermore, since the lighting period of the light source is controlled within the time width in one unit time, the display is of impulse display system, thus increasing moving-picture viewability.
[0012] In the display device of the invention, preferably, the light-source driving device can have a brightness extraction device for extracting a parameter characterizing the brightness of image from the image signal, and the light-source driving device controls the intensity of light emitted from the light source on the basis of the parameter extracted by the brightness extraction device.
[0013] Since the intensity of the light emitted from the light source is controlled depending on the parameter that characterizes the brightness of the image, the light intensity is controlled to display an image with appropriate brightness. Accordingly, the allowable intensity control range of the light source can be used effectively, and so the dynamic range of the display image can be further increased.
[0014] Preferably, the display device of the invention is controlled so that the image signal displayed by the light modulation device is subjected to image processing on the basis of the parameter characterizing the brightness of the image. In addition to the light-source intensity control, such image-signal processing is performed. Thus, not only the brightness of the image but also the contrast of the display image can be increased, and so the image reproducibility can be further improved.
[0015] In the display device of the invention, preferably, the light-source driving device controls the number of lightings of the light source to one per unit time and controls the lighting period for each one time to thereby control the intensity of light emitted from the light source per unit time.
[0016] In the display device of the invention, the light-source driving device controls the number of lightings of the light source to one per unit time and controls also the lighting period. In other words, the intensity of the light emitted from the light source per unit time can be controlled depending on the length of the light-source lighting period.
[0017] In the display device of the invention, preferably, the light-source driving device controls the number of lightings of the light source to a specified number of two or more per unit time and controls the lighting period for each one time to thereby control the intensity of light emitted from the light source per unit time. Since the number of lightings per unit time is a specific number of two or more, the lighting frequency of the light source is higher than the image frequency. An increase in the light-source lighting frequency makes it difficult for human eyes to perceive the blinking of the light source, thus reducing the flickering (image flickering).
[0018] In the display device of the invention, preferably, the light-source driving means fixes the lighting period of the light source to a specified lighting period and controls the number of lightings per unit time to thereby control the intensity of light emitted from the light source per unit time. More preferably, the specified lighting period is the time from the light source is turned on until the brightness becomes equal to that at steady-state lighting (hereinafter, referred to as a minimum lighting period).
[0019] Since the intensity of light emitted from the light source is controlled by fixing the lighting period at one time to the minimum lighting period and controlling the number of lightings per unit time, the light-source lighting frequency is substantially higher than the image frequency. An increase in the light-source lighting frequency makes it difficult for human eyes to perceive the blinking of the light source, thus reducing the flickering caused by the blinking of the light source.
[0020] In the display device of the invention, preferably, the light-source driving means controls the light source to be lit all the time when the parameter characterizing the brightness of the image is at the maximum. Since the light source is lit all the time when the brightness of the image signal is at the maximum, or the brightness of the image is at the maximum, the flickering of the brightness of the image is completely eliminated. The elimination of the image flickering eliminates the burden on eyes, thus reducing eyestrain.
[0021] In the display device of the invention, preferably, the light-source driving means controls the light source to be lit intermittently when the parameter characterizing the brightness of the image 1 is at the maximum. Since the light source is lit intermittently even when the brightness of the image signal is at the maximum, the display is of impulse display system not only during light-control but also when the brightness of the image is at the maximum; thus, moving-picture viewability is improved.
[0022] In the display device of the invention, preferably, the light-source driving means controls the lighting period in which the light source is lit at a specified brightness per unit time and controls the light source to be turned on at a brightness lower than the specified brightness during the time other than the lighting period. More preferably, the above-mentioned lower brightness is the one at the period in which the light source is lit all the time when the brightness of the image signal is the lowest. Since the light source is turned on at a brightness at the period in which the light source is lit all the time when the brightness of the image signal is the lowest (hereinafter, referred to as the minimum brightness) even during the time other than the lighting time, the difference in the brightness of the light source per unit time is reduced. The decrease of the difference in brightness reduces flickering, thus reducing eyestrain. Particularly, flickering in dark images is reduced.
[0023] The display device of the invention can be applied to a display device including a light modulator and a display device of a projection display device that projects light modulated by a light modulator.
[0024] The use of the display device in the projection display device increases the apparent dynamic range and reduces power consumption.
[0025] Preferably, the projection display device includes three light modulation elements corresponding to the three primary colors, and three light sources capable of emitting the respective color lights, and the light-source driving device shifts the lighting timing of the light-source for each of the different color lights. The shift of lighting timing of the light-source for different color lights allows the peaks of power consumption by the lighting of the light source to be dispersed, reducing the peak power consumption of the projection display device as a whole, and further reducing the power consumption.
[0026] Preferably, the projection display device includes three light modulation elements corresponding to the three primary colors, and three light sources capable of emitting the respective color lights; and the light-source driving device coincides all the lighting timing of the light-source with one another. The conformation of all the lighting timing of the light-source allows the different color lights to be emitted at the same time, thus preventing a color breakup phenomenon, in which the color lights appear to be separated in time on the image.
[0027] The projection display device of the invention may use light-emitting diodes (hereinafter, referred to as LEDs) as light source capable of emitting different color lights. High-output LEDs are provided at present for the color lights of R, G, and B. This type of LEDs can be arranged in planar shape or curved shape in array. The LEDs can be turned on and off relatively easily at a high frequency, thus providing a preferable light source for the projection display device of the invention.
[0028] The display device of the invention may be applied to a direct-view display device including a light source and a display device that modulates the light from the light source. Providing the display device to the direct-view display device increases the apparent dynamic range and reduces power consumption.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention will be described with reference to the accompanying drawings, wherein like numerals reference like elements, and wherein:
[0030] FIG. 1 is a schematic diagram of a projection display device according to a first embodiment of the present invention;
[0031] FIG. 2 is a time chart of the flash timings of LEDs of a first example;
[0032] FIG. 3 is a graph plotting the brightness necessary for images against the percentage of the lighting period in this example;
[0033] FIG. 4 is a time chart of the flash timings of LEDs of a second example;
[0034] FIG. 5 is a time chart of the flash timings of LEDs of a third example;
[0035] FIG. 6 is a time chart of the flash timings of LEDs of a fourth example;
[0036] FIG. 7 is a time chart of the flash timings of LEDs of a fifth example;
[0037] FIG. 8 is a schematic diagram of a direct-view display device according to a second embodiment of the invention;
[0038] FIG. 9 is a time chart of the flash timing of an LED of the second embodiment; and
[0039] FIG. 10 is a graph plotting the brightness necessary for images against the percentage of the lighting period in the second embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Referring to FIGS. 1 to 3 , a first example of a first embodiment will now be described.
[0041] The embodiment describes a three-plate projection liquid-crystal display device by way of example. FIG. 1 is a schematic diagram of the overall structure of a projection display device 10 . Numerals 11 , 12 , and 13 denote LEDs (light sources); numerals 21 , 22 , and 23 denote liquid-crystal light valves (display devices); numeral 25 denotes a cross-dichroic prism; numeral 31 denotes a projector lens (projection device); and numeral 35 denotes a light-source controller (light-source driving device).
[0042] Referring to FIG. 1 , the projection display device 10 of the embodiment can include the LEDs 11 , 12 , and 13 capable of emitting R-, G-, and B-color lights, respectively, the liquid-crystal light valves 21 , 22 , and 23 corresponding to the R, G, and B for modulating the color lights emitted from the LEDs 11 , 12 , and 13 , respectively, the cross-dichroic prism 25 that combines the modulated color lights, the projector lens 31 for projecting the combined light flux to a screen S, and the light-source controller 35 for controlling the blinking of the LEDs 11 , 12 , and 13 . It is also possible to provide for uniformizing the illumination and for arranging the direction of polarization in one direction between the LED light sources and the liquid-crystal light valves, which are not described in this embodiment.
[0043] The LEDs 11 , 12 , and 13 are arranged to face the respective surfaces of the cross-dichroic prism 25 and so as to emit the respective color lights toward the cross-dichroic prism 25 . The liquid-crystal light valves 21 , 22 , and 23 are arranged between the LEDs 11 , 12 , and 13 and the cross-dichroic prism 25 , respectively.
[0044] Each of the liquid-crystal light valves 21 , 22 , and 23 can include a liquid-crystal panel, an incident-end polarizing plate (not shown), and an emerging-end polarizing plate (not shown). The liquid-crystal panel uses an active-matrix transmissive liquid-crystal cell in twisted nematic (TN) mode that uses a thin film transistor (hereinafter, referred to as a TFT) as pixel-switching element.
[0045] The cross-dichroic prism 25 is constructed such that four rectangular prisms are bonded together, of which the inner surface has a dielectric multilayer film that reflects red light and a dielectric multilayer film that reflects blue light in cross shape.
[0046] The light-source controller 35 can include a brightness extraction section (brightness extraction device) for extracting the maximum brightness of an image from the inputted image signal and outputting maximum-brightness data to the light-source controller 35 .
[0047] The operation of the projection display device 10 with the above-described structure will now be described.
[0048] Referring to FIG. 1 , the color lights R, G, and B emitted from the LEDs 11 , 12 , and 13 , respectively, are incident to the liquid-crystal light valves 21 , 22 , and 23 corresponding to the respective color lights, respectively. The incident color lights are modulated by the liquid-crystal light valves 21 , 22 , and 23 in accordance with the image signal and are then incident to the cross-dichroic prism 25 . The modulated color lights are combined by the cross-dichroic prism 25 and are then incident to the projector lens 31 . The projector lens 31 projects the combined color lights toward the screen S in magnification.
[0049] The lighting control of the LEDs 11 , 12 , and 13 , which is the feature of the invention, will now be described.
[0050] Referring to FIG. 1 , the image signal is inputted to the brightness extracting section 36 , wherein the maximum brightness of the image in one field, is calculated. The calculated maximum brightness is outputted to the light-source controller 35 .
[0051] FIG. 2 is a time chart of the flash timings of the LEDs 11 , 12 , and 13 of this example.
[0052] The light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness. The light-source controller 35 then determines a lighting period T necessary for emitting the light intensity when the LEDs 11 , 12 , and 13 emit light at a brightness M at the time when a rated current is fed.
[0053] Referring to FIG. 2 , when the lighting period T has been determined, the light-source controller 35 turns on the LEDs 11 , 12 , and 13 one time per one field for the lighting period T at the same time. For example, when the maximum brightness calculated from the image signal is increased, the light intensity required for one field is increased. Since the brightness of the LEDs 11 , 12 , and 13 reaches the upper limit at the time when the rated current is fed, as described above, the lighting period is increased in order to increase the light intensity for one field. Briefly, as indicated by the chain double-dashed line in FIG. 2 , the lighting period of the LEDs 11 , 12 , and 13 in one field is increased.
[0054] FIG. 3 is a graph plotting the necessary brightness calculated from the maximum brightness against the percentage of the lighting period for one field.
[0055] The lighting period of the LEDs 11 , 12 , and 13 in one field is set so as to be increased when the brightness calculated from the maximum brightness becomes stronger (an increase of light intensity), as shown in FIG. 3 . The percentage of the lighting period in one field does not become 100 percent even in maximum-brightness display; the LEDs 11 , 12 , and 13 are being lit intermittently.
[0056] With such a structure, the light intensity applied to the liquid-crystal light valves 21 , 22 , and 23 in one field can be measured depending on the maximum brightness of the image signal, and the lighting period in which the LEDs 11 , 12 , and 13 are lit in one field can be measured from the light intensity.
[0057] In other words, the lower the maximum brightness of the image signal is, the shorter the period in which the LEDs 11 , 12 , and 13 are lit in one field is, and so the display image is darkened; on the other hand, the higher the maximum brightness of the image signal is, the longer the period in which the LEDs 11 , 12 , and 13 are lit in one field is, and so the display image is lightened. Accordingly, the displayable gray scale is increased, so that the apparent dynamic range can be expanded.
[0058] More specifically, the LEDs 11 , 12 , and 13 are turned on one time simultaneously in one field. In other words, the LEDs 11 , 12 , and 13 are turned on and off simultaneously, thus preventing the color of the display image from being viewed separately in time. Since the lighting time of the LEDs 11 , 12 , and 13 is controlled within the time width less than one field, the images are switched by impulse display system, thus improving moving-image viewability.
[0059] The lighting period of the LEDs 11 , 12 , and 13 is set so that only necessary light intensity can be emitted depending on the maximum brightness of the image signal. In this case, the light intensity of the light source is constant during the lighting period; therefore, the emission spectrum does not vary, thus preventing the color of the image from varying.
[0060] Each of the LEDs 11 , 12 , and 13 is controlled to emit light intermittently even when maximum brightness of the image signal is at the maximum, therefore ensuring moving-image viewability even when the brightness of the image is at the maximum.
[0061] Referring now to FIG. 4 , a second example of the invention will be described. Although the principal structure of the projection display device of the example is the same as that of the first example, the flash patterns of the LEDs 11 , 12 , and 13 are different therefrom. Accordingly, in this example, only the description of the flash control of the LEDs 11 , 12 , and 13 will be provided with reference to FIG. 4 and the description of the light sources and so on will be omitted.
[0062] The operation of the projection display device 10 with such a structure will be described.
[0063] FIG. 4 is a time chart of the flash timings of the LEDs 11 , 12 , and 13 of this example.
[0064] As set forth hereinabove, the light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness. The light-source controller 35 then determines a lighting period T necessary for emitting the light intensity. When the lighting period T has been determined, the light-source controller 35 divides the lighting period into two and turns on the LEDs 11 , 12 , and 13 two times per one field for the lighting period of T/2 at the same time, as shown in FIG. 4 .
[0065] When the maximum brightness calculated from the image signal is increased, the light-source controller 35 increases the lighting period to increase the intensity of the light emitted from the LEDs 11 , 12 , and 13 in one field. Briefly, as indicated by the chain double-dashed line in FIG. 4 , the lighting period of the LEDs 11 , 12 , and 13 in each lighting period is increased.
[0066] With the above structure, since the number of lightings of the LEDs 11 , 12 , and 13 for one field is set at two, the lighting frequencies of the LEDs 11 , 12 , and 13 are approximately twice as high as the image frequency. The increase in lighting frequency of the LEDs 11 , 12 , and 13 makes it difficult for human eyes to perceive the blinking of the LEDs 11 , 12 , and 13 , thus reducing flickering (image flickering).
[0067] Referring now to FIG. 5 , a third example of the invention will be described. Although the principal structure of the projection display device of the example is the same as that of the first example, the flash patterns of the LEDs 11 , 12 , and 13 are different therefrom. Accordingly, in this example, only the description of the flash control of the LEDs 11 , 12 , and 13 will be provided with reference to FIG. 5 and the description of the light sources and so on will be omitted.
[0068] The operation of the projection display device 10 with such a structure will be described.
[0069] FIG. 5 is a time chart of the flash timings of the LEDs 11 , 12 , and 13 of this example.
[0070] As set forth hereinabove, the light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness. The light-source controller 35 then determines a lighting period T necessary for emitting the light intensity. When the lighting period T has been determined, the light-source controller 35 divides the light period T by the later-described minimum lighting period t (into four in FIG. 5 ), as shown in FIG. 5 . The LEDs 11 , 12 , and 13 are turned on at the number of times that is obtained by dividing the lighting period T in one field by the minimum lighting period t, for the minimum lighting period t for each lighting at the same time. The minimum lighting period t in this case means the time from the LEDs 11 , 12 , and 13 are turned on until the brightness becomes equal to that at steady-state lighting.
[0071] When the brightness calculated from the image signal is increased, the light-source controller 35 increases the number of lightings to increase the intensity of the light emitted from the LEDs 11 , 12 , and 13 in one field. Briefly, as indicated by the chain double-dashed line in FIG. 5 , the number of lightings of the LEDs 11 , 12 , and 13 in one field is increased.
[0072] With the above structure, the light-source controller 35 controls the intensity of light emitted from the light source by fixing the lighting period of the LEDs 11 , 12 , and 13 at one time to the minimum lighting period t and controlling the number of lightings in one field. Accordingly, the lighting frequencies of the LEDs 11 , 12 , and 13 are substantially higher than the image frequency, making it difficult for human eyes to perceive the blinking of the LEDs 11 , 12 , and 13 , thus reducing the flickering due to the blinking of the LEDs 11 , 12 , and 13 .
[0073] Referring now to FIG. 6 , a fourth example of the invention will be described.
[0074] Although the principal structure of the projection display device of the example is the same as that of the first example, the flash patterns of the LEDs 11 , 12 , and 13 are different therefrom. Accordingly, in this example, only the description of the flash control of the LEDs 11 , 12 , and 13 will be provided with reference to FIG. 6 and the description of the light sources and so on will be omitted.
[0075] The operation of the projection display device 10 with such a structure will be described. FIG. 6 is a time chart of the flash timings of the LEDs 11 , 12 , and 13 of this example.
[0076] As set forth hereinabove, the light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness. At this time, a minimum brightness L is set for the light-intensity control range. The brightness L is obtained by steady-state lighting of the light source. The light-source controller 35 determines a lighting period T 1 necessary for emitting light having necessary light intensity in consideration of that.
[0077] When the lighting period T 1 has been determined, the light-source controller 35 turns on the LEDs 11 , 12 , and 13 at the brightness L all the time and at the brightness M only one time in one field at the time when a rated current is fed, as shown in FIG. 6 . The lighting period at the brightness M is the above-described T 1 . The LEDs 11 , 12 , and 13 are turned on at the brightness M at the same time.
[0078] When the maximum brightness calculated from the image signal is increased, the light-source controller 35 increases the period in which the LEDs 11 , 12 , and 13 are lit at the brightness M to increase the intensity of light emitted from the LEDs 11 , 12 , and 13 in one field. Briefly, as indicated by the chain double-dashed line in FIG. 4 , the lighting period of the LEDs 11 , 12 , and 13 at the brightness M during lighting is increased.
[0079] With such a structure, the LEDs 11 , 12 , and 13 are lit at the brightness L even at the period in which the LEDs 11 , 12 , and 13 are lit out in other examples. Accordingly, the ratio of the brightest display and the darkest display in one field, or the difference in brightness, is decreased. The decrease in the difference in brightness reduces flicker, thus reducing eyestrain and, particularly, flickering in dark images.
[0080] Referring now to FIG. 7 , a fifth example of the invention will be described.
[0081] Although the principal structure of the projection display device of the example is the same as that of the first example, the flash patterns of the LEDs 11 , 12 , and 13 are different therefrom. Accordingly, in this example, only the description of the flash control of the LEDs 11 , 12 , and 13 will be provided with reference to FIG. 7 and the description of the light sources and so on will be omitted.
[0082] As set forth hereinabove, the light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness and then determines the lighting period T necessary for emitting the light intensity. When the lighting period T has been determined, the light-source controller 35 turns on the LEDs 11 , 12 , and 13 one time for one field for the lighting period T, with the timings shifted in the order of the LEDs 11 , 12 , and 13 so that they are not turned on at the same time, as shown in FIG. 7 .
[0083] With the above structure, by shifting the lighting timings of the LEDs 11 , 12 , and 13 for each of the different color lights, the peaks of power consumption by the lighting of the LEDs 11 , 12 , and 13 can be dispersed, and the entire peak power consumption of the projection display device 10 can be reduced. Therfore the power consumption can be further reduced.
[0084] Referring now to FIGS. 8 to 10 , a second embodiment of the invention will be described. This embodiment will be described using a direct-view liquid crystal display device as an example. The same components as those of the first embodiment are given the same numerals and their description will be omitted here. FIG. 8 ( a ) is a schematic front view of the overall structure of a direct-view display device 50 ; and FIG. 8 ( b ) is a schematic side view of the direct-view display device 50 .
[0085] As shown in FIG. 8 , the direct-view display device 50 of the embodiment includes an LED (light source) 51 capable of emitting white light, a liquid-crystal cell (display device) 52 that modulates the white light emitted from the LED 51 , a light guide 53 that guides the white light emitted from the LED 51 to the liquid-crystal cell 52 , and the light-source controller 35 that controls the LED 51 .
[0086] The LED 51 is arranged on the upper end of the light guide 53 so as to emit white light toward the light guide 53 .
[0087] The light guide 53 has approximately the same size as that of the liquid-crystal cell 52 , viewed from the front, such that a rear surface 54 is inclined forwardly from the upper part to the lower part, viewed from the side.
[0088] The liquid-crystal cell 52 includes an incident-end polarizing plate (not shown) and an emerging-end polarizing plate (not shown). The liquid-crystal cell 52 uses an active-matrix transmissive liquid-crystal cell in twisted nematic (TN) mode that uses a thin film transistor (TFT) as pixel-switching element.
[0089] The operation of the direct-view display device 50 with such a structure will be described. Referring to FIG. 8 , the white light emitted from the LED 51 is incident to the light guide 53 through the upper end of the light guide 53 . The white light incident to the light guide 53 propagates in the light guide 53 while being reflected therein, and part of which is reflected by the rear surface 54 having an inclination angle to propagate toward the liquid-crystal cell 52 . The white light incident to the liquid-crystal cell 52 is modulated by the liquid-crystal cell 52 in accordance with the image signal to form an image.
[0090] As shown in FIG. 8 , the image signal is inputted to the brightness extracting section 36 , wherein the maximum tone of the image signal in one field, or the maximum brightness of the image in one field, is calculated. The calculated maximum brightness is outputted to the light-source controller 35 .
[0091] FIG. 9 is a time chart of the flash timing of the LED 51 of this embodiment. The light-source controller 35 first determines a light intensity necessary for one field from the inputted maximum brightness. The light-source controller 35 then determines a lighting period T necessary for emitting the light intensity when the LED 51 emits light at a brightness M at the time when a rated current is fed.
[0092] Referring to FIG. 9 , when the lighting period T has been determined, the light-source controller 35 turns on the LED 51 one time per one field for the lighting period T.
[0093] FIG. 10 is a graph plotting the necessary brightness calculated from a maximum brightness against the percentage of the lighting period for one field. The lighting period of the LED 51 in one field is set so as to be increased when the brightness calculated from the maximum brightness (with increasing light intensity) becomes stronger, as shown in FIG. 10 . The percentage of the lighting period in one field becomes 100 percent in maximum-brightness display, and the LED 51 is being lit all the time.
[0094] With the above structure, the LED 51 is lit all the time when the maximum brightness of the image signal is at the maximum, or the brightness of the image is at the maximum, thus eliminating image flickering. The elimination of the image flickering decreases the burden on eyes, thus reducing eyestrain.
[0095] It is to be understood that the technical scope of the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
[0096] While the above embodiments have been described with reference to an application using a liquid-crystal light valve as display device, the invention is not limited to that, but may be applied to various spatial light modulators such as digital micromirror device (DMD).
[0097] While the above embodiments have been described with reference to an application using LEDs as light source, it should be understood that the invention is not limited to that, but may be applied to various light source such as high-pressure mercury lamps.
[0098] Additionally, while this invention has been described in conjunction with the specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. There are changes that may be made without departing from the spirit and scope of the invention. | The invention provides a display device, a direct-view display device, and a projection display device in which their apparent dynamic ranges are increased with less color change. The display device can include a light modulation device having a plurality of pixels for displaying an image according to an image signal, a light source for illuminating the light modulation device, and a light-source driving device for controlling the intensity of light emitted from the light source by controlling the period in which the light source is lit at a specified brightness per unit time. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to fabrics, and more particularly to a woven fabric having a feature whereby the fabric can be adhesively attached to another fabric or other object, or whereby one portion of the fabric can be adhesively attached to another portion of the same fabric.
BACKGROUND OF THE INVENTION
[0002] An example of a woven fabric having an adhesive feature is the narrow woven fabric commonly used as edging for a metal sifting screen. A typical screen edging fabric is in the form of a narrow woven strip composed of cotton yarns. A coating of low-melting adhesive is provided on one side of the woven strip. The coating can be in the form of two parallel stripes extending lengthwise along the woven strip, separated from each other by an intermediate space located midway between the long edges of the strip. The strip can be bent around an edge of a metal screen, so that the intermediate space is located along the edge of the screen, and the two adhesive stripes are positioned against the screen on opposite sides thereof. By applying heat to the bent strip of fabric using a heating tool, e.g., an iron, the adhesive layers can be made to adhere to the screen and to each other by the formation of adhesive bridges that extend through the apertures of the screen. At the same time, if the adhesive coating is limited to one side of the tube, the adhesive can be melted by the application of heat to the uncoated side of the tube, and exposure of the melted material on the uncoated side can be avoided. Consequently, the melting of the adhesive will neither impair the appearance of the finished article nor cause adhesive to come into direct contact with the heating tool.
[0003] Adhesives have many other applications in fabric products, taking the place of stitching where stitching is not essential, to simplify manufacture and reduce costs. Examples of hot melt adhesives used as coatings on woven fabrics include ethylene-vinyl acetate (EVA), polyolefins (PO), and polyamides (PA).
[0004] In applying stripes of low-melting adhesive to a woven fabric, it is necessary to control the temperature of the adhesive carefully in order to ensure that the adhesive flows properly and is applied uniformly. Other difficulties are encountered in the manufacture of adhesive-coated woven fabrics, including difficulties in feeding and collecting the fabric strip while the adhesive is hot and still in a semi-liquid state.
[0005] This invention addresses problems encountered in the manufacture of adhesive-coated woven fabrics by incorporating yarns composed of a hot-melt adhesive material into the weave. By weaving the fabric as a tube, and limiting the hot-melting yarns to one side of the tube, the woven fabric in accordance with the invention can exhibit many of the same advantages as the conventional adhesive-coated tubular fabrics: avoidance of exposure of melted adhesive, and avoidance of direct contact between the heating tool and the melted adhesive.
SUMMARY OF THE INVENTION
[0006] The term “tubular woven fabric” as used herein refers to a woven fabric that is the form of a tube, which has a hollow internal passage extending in the direction of the warp yarn. The tube can be flattened so that it takes the form of two face-to-face layers of fabric connected to each other by folds along opposite side edges. The layers can be connected by interlocking the weft yarn of one layer with one or more warp yarns of the other layer at one or more intermediate locations between the side edges, and if these connections are made, the internal passage is divided into two or more passages. The term “tubular woven fabric” also includes woven fabrics that have, not only one or more tubular woven portions, but an additional woven portion that is in the form of a single, i.e., non-tubular, woven layer.
[0007] The tubular woven fabric in accordance with the invention is composed of at least one continuous weft yarn, and multiple warp yarns. The warp yarns include a first group of fusible yarns composed of a material that melts upon the application of heat at a predetermined temperature, and a second group of yarns composed of a material that is substantially unaffected when raised to the predetermined temperature at which the fusible yarns melt.
[0008] The fusible yarns can be positioned so that they can be melted by heat applied by a heating element to, and conducted through, a layer composed of yarns of the second group. In this way, the melting of the fusible yarns can be utilized to attach the fabric to an object, to another fabric, or to another portion of itself, without exposure of the fusible yarns in such a way that they impair the appearance or function of the fabric, and without having the fusible yarns come into direct contact with the heating element.
[0009] Thus, in a useful embodiment of the invention suitable for applications such as edging for a particle classification screen, if the fusible yarns in the fabric are limited to a area of the fabric having a weft-wise dimension not exceeding one-half the perimeter of the tubular fabric, the tubular fabric can be folded upon itself while in a flattened condition to form a fabric edging having interior and exterior parts. The fusible yarns are opposed to one another in the interior part of the edging, and substantially all of the yarns exposed on the exterior part of the edging are yarns of the second group.
[0010] The tubular woven fabric can be produced so that it is in the form of a tape having opposite flat sides, in which exposure of the fusible yarns is substantially limited to one of the flat sides.
[0011] In a preferred embodiment in which the fabric is in the form of a tape and the fusible yarns are exposed only on one of the flat sides, the fusible yarns are composed of two sets of yarns respectively on opposite sides of a longitudinal centerline, parallel to and located between longitudinal edges of the tape. These two sets of fusible yarns can be spaced from each other so that the tape is formed with a longitudinal hinge along the centerline, about which the tubular woven fabric can be folded.
[0012] In a preferred embodiment, warp yarns on both of the opposite flat sides of the hinged tape can be connected in close relationship to one another by a weft yarn at an intermediate location between the two longitudinal edges, so that the tubular woven fabric is composed of two parallel tubes, ensuring that the tape folds properly so that the fusible yarns are on the inside of the folded tape.
[0013] While the principal advantages of the invention lie in the simplification of manufacture of the fabric, other advantages of the invention will be apparent from the following description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic cross-sectional view of a tubular woven fabric according to a first embodiment of the invention;
[0015] FIG. 2 is a schematic cross-sectional view showing an application of the tubular woven fabric of FIG. 1 ;
[0016] FIG. 3 is a schematic cross-sectional view illustrating a modification of the tubular woven fabric of FIG. 1 ;
[0017] FIG. 4 is a schematic cross-sectional view showing a second embodiment of the invention;
[0018] FIG. 5 is a schematic cross-sectional view showing an application of the tubular woven fabric of FIG. 4 ; and
[0019] FIG. 6 is a schematic cross-sectional view showing an application of a third embodiment of the tubular woven fabric.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The tubular woven fabric is shown schematically in FIG. 1 with a very limited number of warp yarns for clarity of illustration, and will ordinarily have many more warp yarns than the limited number shown. The fabric is composed of an upper layer 10 and a lower layer 12 , connected to each other by folds along longitudinal side edges 14 and 16 . The warp yarns consist of two groups. The warp yarns 18 , shown as black dots, located in the lower layer 12 , the folded edges 14 and 16 , and along the right and left sides of the upper layer 10 , can be composed of any conventional yarn material, cotton, polyester, etc. The weft yarn 20 can likewise be composed of any conventional yarn material.
[0021] The warp yarns 22 , shown as circles, which are in the upper layer 10 and not in the folded edges or the lower layer, are fusible yarns composed of a material that melts upon application of heat at a temperature that does not affect the warp yarns 18 or the weft yarn 20 . Preferably, the warp yarns are composed of a low-melting PET (poly (ethylene terephthalate)), which has a melting temperature of approximately 130° C., well below the 218° C. melting temperature of ordinary polyester yarns. Various alternative low-melting warp yarn can be used, such as polypropylene (PP) monofilament yarns, which have a melting temperature of approximately 160° C. The cotton warp yarns do not melt, and can withstand temperatures considerably higher than the melting temperatures of the low-melting warp yarns without deterioration.
[0022] In the process of weaving the fabric shown in FIG. 1 , the weft yarn 20 is shuttled back and forth while the warp yarns are controlled by the heddles of a loom in such a way that as the shuttle passes weftwise in a first direction, the weft yarn is interlaced with the warp yarns the become part of the upper layer 10 , and as the shuttle passes weftwise in the opposite direction, the weft yarn is interlaced with the warp yarns that ultimately become the lower layer 12 of the fabric. The weft yarn, therefore essentially takes the form of a helix in the final product.
[0023] The fusible warp yarns 22 should be limited to a particular area of the fabric, and preferably to one of the two layers of the tubular fabric when flattened. In this way, heat can be applied to the fusible yarns indirectly, through the yarns of the other layer, the heating element is protected from direct contact with the fusible yarns, and the melted yarn material is not exposed on the side of the fabric opposite from the side having the fusible yarns.
[0024] The weaving pattern can be a plain weave, or any of various other patterns, such as a twill weave, or a herringbone weave. Optionally, the weft can be composed of plural yarns rather than a single weft yarn.
[0025] As shown in FIG. 1 , the innermost fusible warp yarns 24 and 26 , along a centerline (not shown) midway between the edges of the fabric, are preferably spaced from each other so that the fusible yarns are in two distinct groups on opposite sides of the centerline. When the fabric is folded on itself, the amount of fusible material does not become excessive at the location of the fold.
[0026] In one of its applications, the tubular fabric of the invention is used to form fabric edging for a particle classification screen 28 as shown schematically in FIG. 2 . The particle classification screen, which can be composed of metal, is typically a rectangular array of evenly spaced, mutually perpendicular elements 26 and 28 , forming a set of openings of uniform size though which only particles smaller than a given size can pass. Grommets (not shown), which are punched through the fabric edging, are used to secure the screen in a machine that causes the screen to vibrate. As the screen vibrates, larger particles are retained on the top of the screen and smaller particles pass through the openings in the screen. The fabric edging defines a rectangular open area of the screen, supports the grommets, and serves as a seal in the vibrating machine.
[0027] The tubular fabric of FIG. 1 is folded on itself along the centerline so that what was the upper layer 10 in FIG. 1 becomes two opposed layers 30 and 32 in direct contact respectively with the upper and lower sides of the screen. What was the lower layer 12 then becomes outer layers 34 and 36 . By applying heat to the outer layers using a heating element, the fusible warp yarns 22 ( FIG. 1 ) are melted, and the melted material flows through the apertures of the screen forming bridges 38 of resin which harden when cooled, extending through apertures and securing the layers 30 and 32 to each other and to the screen. Edging fabric can be applied to all four edges of the screen in this manner.
[0028] In weaving the modified tubular fabric shown in FIG. 3 , the heddles are controlled to cause the weft yarn 40 to become interlaced with one or more warp yarns 42 located midway between the side edges of the fabric, thereby forming a tubular fabric having two, side-by-side openings 44 and 46 instead of a single opening as in FIG. 1 . Connecting the upper and lower layers at a central location ensures that, when the fabric is folded, it is folded along a central hinge line so that all the fusible yarns are on the mutually opposed inside layers.
[0029] It is also possible, of course, to interlace the weft yarn with warp yarns at two or more intermediate location to form a tubular woven fabric with three or more longitudinally extending openings.
[0030] Advantages of the invention can be realized in various other embodiments such as the second embodiment, shown in FIGS. 4 and 5 . In this embodiment, the tubular fabric is woven so that a tubular portion 50 , comprising upper layer 52 and lower layer 54 , extends weftwise only part-way across the width of the fabric, the remainder being in the form of a single layer or “flag” 56 . Fusible warp yarns 58 are limited to the upper layer 52 of the tubular part, which preferably includes non-fusible yarns along its side edges.
[0031] As shown in FIG. 5 , the fabric can be folded over on itself along a fold line 58 at an intermediate location on layer 56 , and formed into a tube by applying heat to the fusible yarns in layer 52 by means of a heating element (not shown) in contact with layer 54 , thereby connecting layer 52 to an opposing part 60 of layer 56 by a layer of resin 62 formed when the melted yarns 58 harden. The final product is a fabric tube having a longitudinally extending opening 64 .
[0032] The fabric tube can have various uses, for example, as a cathodic protector for a pipeline. The cathodic pipe protector can be manufactured using a continuous process in which so the material of FIG. 4 is fed into a machine in a flat condition and formed into a tube as it enters the machine. A copper wire is fed into the center of the tube and then the tube is filled with a ground carbon material. The adhesive strip formed by the fusible yarns is activated by a heating bar and then cooled, to make the tube permanent. The finished tube is laid into the ground with one or more gas pipes or other pipe lines, and a low current is sent through the copper wire to prevent rusting of the pipes. The cathodic protector can be produced using various materials, depending on the requirements of the end user. For example, a polyester fabric can be used where the end user wants the carbon to remain wrapped within the fabric sheath. A cotton fabric version can be used where the end user wants the material to decay, leaving only the carbon and the copper wire.
[0033] In a third embodiment, shown in FIG. 6 , the tubular woven fabric is formed with two tubular parts 64 and 66 along opposite edges of a connecting layer 68 . The tubular parts, each of which has upper and lower layers, and the connecting layer, which is a single layer, can be formed by weaving, in a manner similar to the manner in which the fabric of FIG. 3 is woven. However, the intermediate layer in FIG. 6 is wider than the central part of the fabric in FIG. 3 . In this embodiment, the fusible warp yarns on the layers 70 and 72 of the tubular parts, can be used to secure the tubular parts to another fabric layer 74 by means of resin layers 76 and 78 forming a tube having a longitudinal opening 80 , which can receive an object such as a curtain rod, for example. In this embodiment, the use of the tubular woven fabric having fusible warp yarns, can obviate expensive and time-consuming sewing steps while resulting in a durable product having an acceptable appearance.
[0034] The tubular woven fabric of the invention can, of course, have various configurations other than those exemplified by the three embodiments specifically described, and the materials utilized for the yarns can vary, depending on the intended application. For example, in the embodiment shown in FIGS. 4 , the fusible fibers can be located in layer 54 instead of in layer 52 . Accordingly, the scope of the invention should be understood as limited only by the following claims. | A tubular woven fabric includes fusible warp yarns along with other warp yarns that are substantially unaffected at the temperature at which the fusible yarns melt. The fusible warp yarns are disposed at selected locations in the fabric such that they can be melted by applying heat to them indirectly by a heating element brought into direct contact with the other yarns. | 3 |
[0001] Provisional application Serial No. 60/303,195 filed Jul. 5, 2001 is hereby cited for purposes of priority and such is hereby claimed.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention generally relates to the precise correction of imbalance of rotating work pieces and more particularly to new and improved self-calibrating work piece balancing machines having the capability to automatically determine and correct the imbalance of rotating parts and to automatically self-calibrate under predetermined operating conditions and further to new and improved processes for the automatic calibration of work piece balancing machines.
[0004] 2. Description of the Prior Art
[0005] Production equipment such as automatic work piece balancing machines for rotating metallic work pieces at high rotational speeds and effecting the dynamic balancing thereof by adding balancing weights in appropriate locations thereon or by removal of mass therefrom have been successfully employed for many years. Highly developed machines in this category have balance computers that calculate the amount of weight adjustment needed for dynamically balancing different work pieces and control the balancing speeds and many other machine operations. More particularly these balance computers function with the machine hardware to precisely locate the positions in selected balancing planes on the work piece where weight correction is needed for work piece balancing and for activating the tools to accomplish the actual weight correction. These precisioned operations are required for an effective single balancing operation or for the repeated rotational balancing of a quantity of unbalanced work pieces in mass production operations.
[0006] For such work, the balancing machines need to be precisely calibrated so that the exact location on each individual work piece for weight-adjustment can be quickly and precisely determined and the appropriate balance weight adjustment quickly made. Prior to the present invention, work piece balancing machines required a time consuming and tedious manual process of stopping and starting the rotating machine to manually add and remove calibration weights to a master or selected standard work piece for calibrating the machine. Such prior calibrating procedures were prone to various human errors and required great skill and care to avoid calibration mistakes. Personal care also had to be taken by the operator since it was generally necessary to physically handle, add, and remove calibration weights with respect to the standard or master and the starting and stopping of the machine for the calibration thereof.
SUMMARY OF THE INVENTION
[0007] In contrast to the prior machines and calibration processes, the new and improved self-calibrating work piece balancing equipment and processes of this invention reduces machine down-time for calibration and to a large extent eliminates the labor and skill including attention to precise detail previously required of the operator to manually calibrate a balancing machine. This advancement is achieved in this invention by the unique incorporation of one or more automatic load or force injecting units, hereinafter referenced as unbalance injector devices, into a new and improved dynamic balancing machine featuring automatic self calibration. These on-board devices provide hands free selection and changing of calibration loads and along with other machine equipment cooperate to form and complete a new and improved self-calibrating work piece balancing machine. These unbalance injection devices are uniquely operative in this invention in that known unbalancing loads are automatically injected into the rotating chucks or other workpiece mountings of the machine to establish inertia axes offset from the rotational axis of a standard or master work piece rotatably driven therein. Known moments are resultantly established at predetermined correction planes that extend through the work piece whose values are fed to a balance computer of the machine for the automatic calibration thereof. Such calibration can be readily and quickly accomplished with minimal operator input and in many cases, while the master is being continuously rotatably driven. Moreover, these unbalance injector devices are generally arranged into the machine construction so that they are offset to one or both ends or extremities of a calibrating master or known standard workpiece operatively mounted for rotation in the machine. The physical characteristics of the calibrating work piece are not changed such as in prior calibration procedures and the calibrating workpiece are not physically handled or touched by the calibrating operator except for machine loading and unloading.
[0008] For single plane calibration, base line imbalance measurements are taken from the rotating master or known standard and fed to a balance computer incorporated into the balancing machine where the data is registered. The unbalance injection device is then automatically activated to inject known imbalance loads into a base injection plane of the machine. This plane may transversely extend through the unbalance injector device and the spindle or other machine component securing the calibrating work piece and operatively mounting the injector device for rotation of these components about a spin axis. This injected force is, in effect, linearly translated as an unbalancing load to the master in a predetermined correction or calibration plane parallel to the base plane and transverse of the work piece spin axis. The cradle supporting the work piece mounting and spinning equipment is usually mounted by suspension spring construction and is subject to vibratory excitation from the rotational imbalance of the master or standard during machine calibration, as well as from unbalanced workpieces subsequently balanced by the machine.
[0009] Vibratory and positional signals reflecting these known imbalance loads and the location of the eccentricity as applied to the standard or master by the unbalance injector device are received by synchronizer and vibration pick up units. Data from these pick-ups are fed to the balance computer in a first calibration thereof. The machine is stopped and the part rotated relative to the work piece holding chuck or other securement a predetermined number of degrees, 180 degrees for example. Known imbalance loads from the imbalance injection device are again injected into the machine and translated to the standard or masterwork piece in the correction plane and the final calibration readings are taken. With known calibration imbalance loads applied in specific locations in known correction planes, the balance computer will identify and store the known imbalance data and calibrate with reference thereto.
[0010] With such calibration, the computer will subsequently recognize imbalance loads and eccentricities in unbalanced work pieces being processed with the machine and effect the accurate weight correction and location to effect the dynamic balancing of such work pieces.
[0011] For double plane calibration at least two unbalance injecting devices and associated controller are integrated the balancing machine and the balance computer thereof so that known unbalancing loads injected into a rotating portion of the machine are translated from the injection planes through the machine into calibration planes through a calibrating master or known standard workpiece operatively mounted in the machine. These calibrating planes are spaced apart from one another and the unbalancing loads cause the inertia axis of the master or standard to misalign with respect to the spin axis thereof. The magnitude of the resulting dynamic unbalance is used to calculate the moment or couple generated at a predetermined spin rpm. The injected unbalances generate vibrations, which are picked up by spaced pick up devices and generate data supplied to the balance computer to effect the calibration thereof.
[0012] This new and improved self-calibrating machine can be easily calibrated by different machine operators of varying skills including those that are mechanically oriented and can follow prescribed procedures but have little calibration experience. The machine may be conditioned for the automatic calibration mode after a known standard work piece or master is operatively mounted therein by operator initiative in simply starting the machine. Under computer control the known standard part is brought to a balancing speed and the unbalance injection device or devices under command from the balance computer are automatically actuated by the controller thereof so that the machine quickly and automatically calibrates the balance computer to the known imbalance injected into the master without human intervention.
[0013] This invention is further drawn to new and improved self-calibrating balancing machines for rotating and determining balancing points on work pieces and to the physical balancing of work pieces and to new and improved machine calibration methods. With these machines and methods, work pieces such as propeller shafts, crankshafts and road wheels for vehicles can be quickly loaded into the machine and balanced with extraordinary and repeatable accuracy. In this invention, known and predetermined forces are automatically applied to a rotating standard or master calibrating work piece and are effective in a predetermined calibrating plane thereof to achieve the rotational imbalance thereof. Data directly resulting from these imbalance loads is fed to a balance computer of the machine to effect the calibration of the machine computer. This imbalance data is supplied from a synchronizer or positional pick up and from vibration pick-ups associated with the balancing machine and stored in the memory of the balance computer for subsequent reference in calculating the rotational imbalance and correction of unbalanced work pieces subsequently processed in the machine.
[0014] These self-calibrating balancing machines are generally equipped with specialized tooling that quickly makes the balancing adjustment by adding or subtracting work piece balancing weight in predetermined balancing planes thereof. With such equipment, unbalanced parts can be loaded and spun to predetermined speeds and then automatically balanced to provide improved quantity production. The machines of this invention require only minimal down-time for automatic calibration purposes and with improved accuracy to further improve operating efficiency particularly as compared to the prior manual calibration of balancing machines.
[0015] A general feature, object and advantage of this invention is to provide (1) new improved work piece balancing machines capable automatic self calibration and without stopping once a calibrating work piece is installed in the machine and (2) new and improved methods of calibrating such machines with at least one onboard unbalance injector device which can be operated to automatically inject predetermined imbalance forces to a known standard work piece and in at least one predetermined calibration plane thereof while it is being rotatably driven at predetermined speeds to effect calibration of a balance computer associated with the machine.
[0016] Another feature, object and advantage of this invention to provide a new and improved automated work piece balancing machine having a balance computer as part thereof that is functional to: (1) serially spin and determine the rotational imbalance of work pieces each generally having a principal inertia axis that is not parallel to the axis of rotation thereof and operatively mounted therein and the weight variances necessary to correct such imbalance to physically effect the correction of such imbalance and (2) self-calibrate by effecting the injection of known loads of imbalance into predetermined points in at least two calibration planes of a calibrating standard work piece and then to feed data detailing such imbalances into a balance computer to teach the computer to recognize such imbalances and calibrate relative thereto. This allows the balance machine to be subsequently employed in the accurate dynamic balancing of interchangeable and unbalanced work pieces.
[0017] Another feature, object and advantage of this invention is to provide a new and improved process for automatically calibrating a work piece balancing machine in which a master or known standard work piece is continuously rotating during the calibration of the machine and in which the master or standard is rotatably driven and at least one unbalance force injecting device is utilized to inject known imbalance loads to the rotating workpiece to produce the rotational imbalance of the master and the feeding of resulting and exact imbalance data to an associated balance computer so that the balance computer is precisely calibrated and the machine can be subsequently employed with great accuracy to spin and detect imbalances in other work pieces and effect the accurate rotational balancing thereof.
[0018] Another feature object and advantage of this invention is to provide a new and improved self calibrating work piece balancing machine and method of calibration in which known imbalance loads are injected into a master or other calibrating work piece being rotatably driven in the balancing machine without physically changing the master such as by adding calibrating weights thereto.
[0019] These and other features, objects and advantages of this invention will become more apparent and understood from the following specifications including the detailed description and drawings in which:
DETAILED DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a side view of a balancing machine along with a diagram of a balance computer operatively connected thereto illustrating one embodiment of the invention;
[0021] [0021]FIG. 1 a is an enlargement of the encircled portion 1 a of FIG. 1 illustrating parts of an unbalance injector device utilized in this invention;
[0022] [0022]FIG. 1 b is a pictorial view of part of the balancing machine of FIG. 1
[0023] [0023]FIG. 2 is a front view of the balancing machine of FIG. 1;
[0024] [0024]FIG. 3 is a schematic diagram of the embodiment of the invention illustrated n FIGS. 1 and 2;
[0025] [0025]FIG. 4 is a front view of another preferred embodiment of the invention;
[0026] [0026]FIG. 5 is a schematic diagram illustrative of the embodiment of the invention of FIG. 4;
[0027] [0027]FIGS. 6 a , 6 b and 6 c are interrelated curves illustrating self calibration operations of a work piece balancing machine according to this invention;
[0028] [0028]FIGS. 7 a , 7 b and 7 c are interrelated curves illustrating a prior art process of manually calibrating of a work piece balancing machine;
[0029] [0029]FIG. 8 is a side view of another preferred embodiment of this invention;
[0030] [0030]FIG. 8 a is a pictorial view of the FIG. 8 embodiment of the invention;
[0031] [0031]FIG. 8 b is a pictorial view of one pair of balancing rings used in the FIG. 8 embodiment of this invention;
[0032] [0032]FIG. 9 is a front view of still another preferred embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Turning now in detail to the drawings there is illustrated in FIGS. 1 through 3, a single plane balancing machine 10 for spinning and dynamically balancing a rotatable drum or other work piece 12 . The work piece 12 is securely mounted on a work piece holding unit or chuck 14 operatively mounted to and forming an extension of a cylindrical spindle 16 . For machine calibration, the workpiece 12 is a known standard work piece or a balanced master into which a known unbalancing force is injected as will be further explained below.
[0034] The spindle, work piece holding unit, and any master or work piece mounted thereon are accordingly supported for unitized rotation about a spin axis 18 by upper and lower spindle mounting brackets or plates 20 , 22 vertically spaced from one another. The upper plate may be fixed to a stationary support 21 and have a centralized annular hole 23 therein through which the spindle extends. The lower plate is operatively connected mounted to the upper plate by a pair of flat supporting suspension springs 24 , 26 , laterally spaced from each other. The spindle mounting is accordingly resilient and the work piece 12 and the spindle and mount exhibit significant vibration when the unbalanced work piece is rotatable driven.
[0035] Torque for the rotational drive of the spindle and the components mounted thereon is provided by a selectively energizable electric motor 28 that is secured to the plate 22 or other suitable mounting. The motor has an upwardly extending and rotatable output shaft 30 . This shaft has a drive pulley 32 fixed thereto that operatively receives an endless drive belt 34 which extends laterally and around a driven pulley 36 . Pulley 36 is fixed to the lower end of the cylindrical spindle 16 just below the lower support plate 22 . With this arrangement, power is readily transferred from the motor to the spindle for the rotational drive of the work piece 12 about spin axis 18 .
[0036] In addition to the work piece holder, the spindle operatively mounts an unbalance injector device 42 operatively associated with the machine which can be set to inject predetermined unbalancing loads into the rotating standard or master work piece 12 for calibrating the work piece balancing machine 10 . The unbalance injector device 42 may be a balancing unit such as one capable of injecting balancing loads into rotating tools for tool balancing purposes, a milling or drilling tool for example.
[0037] Among the commercial units, that can be utilized in this invention to inject loads into the work piece 12 are balancing units such as the EM 2000 high speed balancer or others supplied by BalaDyne Corporation, 1665 Highland Drive, Ann Arbor, Mich. 48108. and the automatic balancing system SBS or the SB-4500 balancer supplied by Schmitt Industries, Inc. 2765 NW Nicolai St Portland Oreg. 95210. U.S. Pat. No. 5,757,662 issued May 26, 1998 to S. W. Dyer et al for Electromagnetically Actuated Rotating Machine Unbalance Compensator, hereby incorporated by reference, discloses a balancing unit and electronic controls that may be readily integrated into the balancing machine and methods of this invention.
[0038] In any event, the unbalance injector device 42 may have a pair of interior counter-weight rings 44 , 46 see FIG. 1 a, operatively mounted to a rotatable upper, axially-extending shaft portion of the spindle or to the rotatable workpiece holding unit 14 of the spindle. The unbalance force injection unit further comprises a driver 48 having a coil assembly 50 gapped from and disposed outwardly of the rings 44 , 46 that mounts to a housing of the spindle or other stationary component 52 .
[0039] As applied to the present invention when a predetermined unbalancing load is required for calibrating purposes, electronic controller 54 best diagrammatically illustrated in FIG. 3 and operatively connected to the coil assembly by line 56 are activated by the balance computer to initiate load injections on signals transmitted from a balance computer 60 through line 59 connecting the controller to the balance computer. The controls 54 are accordingly operative to send power pulses to the coil assembly of the driver 48 of the unbalance injector device and effect the electromagnetic rotational stepping of the counter-weight rings 44 , 46 to different predetermined rotary positions. Rotation of the rings to different preestablished positions results in the application or injection of a predetermined imbalance load into a base or injection plane IP extending through the work piece holding end of the spindle.
[0040] For machine calibration, the known unbalancing load is translated from the rotating spindle of the machine to the attached rotating master work piece 12 and particularly to a location on the master that is in a predetermined calibration or correction plane CP. This calibration plane extends thorough the master at a set distance from the base or injection plane and is parallel thereto.
[0041] The unbalance injector device 42 of the embodiment of FIGS. 1 - 3 is adjusted and set by the controller to automatically inject the predetermined unbalancing load into the spindle or chuck of the machine when the machine drives the work piece to a predetermined rpm. This unbalancing load is subsequently injected into the work piece 12 as a transversely oriented load and in the transverse calibration or correction plane extending therethrough for calibration proposes. This known unbalancing load is physically applied to the rotating workpiece holding component of the machine by the displaced rings 44 , 46 of the rotating components of the unbalance injection device and by translation to the workpiece 12 in the predetermined correction plane CP thereof.
[0042] While the unbalancing load is physically applied to the spindle and work piece holding device through base or injection plane IP extending therethrough, the calculated resulting imbalance force from unit 42 is linearly displaced to the predetermined calibrating or correction plane CP extending through the work piece at an offset location outboard of the injection or base plane IP. In a single plane balancing operation, the applied unbalancing load and the resulting injector force are equal.
[0043] As diagrammatically illustrated in FIGS. 1 and 3, the work piece balancing machine 10 has a balance computer 60 associated therewith which is programmed to effect the calculations necessary to effect the balancing of work pieces being processed by the machine 10 . The balancing computer is calibrated with the functional work piece imbalance positional signals from a synchronizer pick up 62 positioned adjacent the work piece holder unit 14 or the work piece itself. Additionally electrical signals generated by unbalanced work piece vibrations are fed into the balance computer 60 from a vibration pick up 66 that is operatively connected to one of the support springs such as spring 24 or other suitable vibrating support forming part of the machine and connected to the balance computer 60 by lead 67 as diagrammatically illustrated in FIG. 3.
[0044] For machine startup operation, an operator preferably calibrates the machine by installing a known standard or masterwork piece on the machine 10 and energizes the balance computer and controller for automatic calibration. The machine rotatably drives the standard to a predetermined balancing speed and a minimized unbalance load, programmed into the controller, is injected into the standard work piece. Positional and known unbalance data resulting from the minimized load injection into the rotating master or other work piece mounting unit are recorded by the synchronizer and vibration pick ups and fed to the balance computer where such data is stored in the memory to calibrate to such imbalance. In the next run, the unbalance injection device is ordered to apply a predetermined unbalancing calibration load into the system and the results are again fed to the balance computer. The difference between the two readings taken from the unbalance pickups is the gain of the system.
[0045] Optionally for further calibration to compensate for the unbalance in the spindle and eccentricity of the part relative to the rotational axis of the spindle, additional steps are taken. This includes the stopping of the machine so that the operator can disengage the work piece and rotate the work piece on its rotational axis and relative to the workpiece holding chuck 14 a predetermined number of degrees, 180 for example. The work piece is then reattached to the machine chuck for the rotational drive thereby and ramped to a predetermined speed The unbalancing injection device is activated to again inject a minimized unbalancing load into the work piece as previously described. The calibration load is then injected and the final reading are taken and sent to the balancing computer for finalizing the calibration thereof.
[0046] After such calibration is completed, unbalanced work pieces can be quickly loaded one after the other and spun to balancing speeds whereby the calibrated balance computer can calculate the particular imbalance of the work piece being processed and effect the precise correction thereof with appropriate weight position and the quantity of weight adjustment in the balancing planes thereof.
[0047] Double Plane Balancing
[0048] FIGS. 4 - 6 illustrate another preferred embodiment of the invention that carries forward principles of the embodiment of FIGS. 1 - 3 . Primarily they share in the aspect directed to the automated injection of predetermined unbalancing loads into a load injection plane utilizing unbalance injector device while the workpiece holding device is spinning a known standard or master work piece at a predetermined rotational speed. This injection of known unbalancing force into the machine such as the work piece holding chuck thereof results in a corresponding unbalancing force being injected into the master work piece being driven by the machine and in a predetermined correction plane thereof. Data from the resulting workpiece imbalance vibrations and the corresponding eccentricity the unbalanced master or standard is supplied to the balancing computer for the calibration thereof.
[0049] However, the machine of FIGS. 1 - 3 can not precisely balance elongated work pieces, such as mass produced propeller or crank shafts or other units, whose principal inertia axes are not parallel to their associated axes of rotation. This non-parallel relationship of the inertia and rotational axes in such parts is known as dynamic unbalance. Correction of unbalances such as dynamic unbalance in an elongated work piece requires the addition of two weights to the work piece and in two separate and spaced-apart correction planes so that other machines and process steps are needed and their associated balancing computers need to be calibrated.
[0050] In the construction of FIGS. 4 - 5 , a balancing machine 100 capable of balancing such elongated work pieces provided. This machine has an electric or otherwise powered drive motor 102 which is operatively mounted in a housing 104 supported on a generally rectilinear lower base plate 106 in turn secured to a floor or other fixed support 108 . The machine has a cradle 110 resiliently supported by four vertically extending corner suspension spring units 112 extending upwardly from attachment with the base plate 106 . The upper ends of these spring units adjustably mount into threaded adjustment fittings 114 secured to the sides of the cradle, for cradle leveling or positioning purposes. Moreover, with this resilient suspension spring construction the cradle, the work piece-spinning sub-assembly 116 operatively mounted thereon as well as the work piece, here in the form of a master or known standard engine crank shaft 118 operatively mounted therein experience significant vibrations from work piece imbalances.
[0051] As in the embodiment of FIGS. 1 - 3 , data from such vibrations and the location of injected imbalance loads are supplied to the balance computer 120 of the machine for calibration purposes as will be explained hereinafter.
[0052] The work piece spinning equipment or sub-assembly 116 equipment includes a horizontally extending spindle 122 having its cylindrical outboard end 123 mounted for rotation in a bearing assembly 124 secured in a supporting end housing 126 that extends upwardly from attachment with the cradle 110 . The inboard end 127 of the spindle mounts a hook drive 128 , which drivingly fits onto the adjacent end of the crankshaft 118 , which for calibrating purposes is a master or known standard crankshaft as previously indicated. As shown the master crankshaft 118 is supported for rotation in the machine about a horizontal spin axis 130 by suitable bearings such as a front roller bearing 132 secured to a stationary part of the spindle or other component and by a rear roller bearing operatively mounted on upright 136 . Additional support is provided by upright 138 . The uprights 136 and 138 are securely attached by their bases to cradle 110 by appropriate fastener devices that provide for the adjustment of the uprights to accommodate work pieces of different lengths and other configurations Upper clamping retainers 140 , 142 operatively mounted on the stationary uprights 136 and 138 have bottom rollers which contact main bearing surfaces of the crankshaft to operatively retain it in the spinning equipment of the machine.
[0053] The crank shaft 118 is rotatably driven about the axis 130 by the motor 102 which has a rotatable output shaft 144 having a pulley 146 operatively mounted on the end thereof which accommodates and drives an endless drive belt 148 which loops around a spindle drive pulley 150 that is drivingly secured at its inner diameter to the spindle 122 .
[0054] In addition to the drive pulley 150 , the spindle 122 operatively mounts left and right side unbalance injection devices 152 , and 154 . Each of these devices is substantially the same in construction as the unbalance injection device 42 of the machine of FIGS. 1 - 3 . Each device 152 , 154 may comprise a pair of interior counterweight rings operatively mounted in side by side relationship. These rings have known imbalance loads so that they can be rotated to different angular positions to effect the loading of the spindle with predetermined imbalancing loads for calibration purposes.
[0055] Moreover, as in the previous embodiment the counterweight rings are actuated by a driver such as a surrounding coil disposed outwardly of the pair of rings. The coil is secured in an outer housing that may be fastened to a stationary housing or other component of the machine. The unbalancing injector devices 152 , 154 are supplied with injector command signals from a controller 160 through lines 162 and 164 diagrammatically shown in FIG. 5. The controller 160 operates automatically on command signals from the balance computer through signal line 165 . Accordingly, the unbalance injector devices are selectively operative on computer command to serially inject unbalance loads into the machine driving the master workpiece in the laterally spaced injection planes IP-1 and IP-2. These unbalancing loads are translated to the correction planes CP-1 and CP-2 of the workpiece respectively to effect the establishment of inertia axis that is not parallel to the spin axis of the crankshaft. A known imbalance is created in the master, which will be used for calibration of the machine
[0056] As in the previous embodiment, the balance computer 120 is operationally utilized to determine the specifics of the imbalance in unbalanced work pieces to be processed in the machine 100 . The balance computer 120 is supplied with imbalance positional data of a workpiece from the synchronizer pickup 162 communicating with the balance computer 120 by data line 163 . However, because the master being used for calibration purposes is eccentrically loaded by the imbalance injector device in the two correction planes its inertia axis does not align with the centerline or rotational axis 130 . Consequently, a known dynamic imbalance is created in the master. This imbalance generates vibrations of particular amplitudes recorded by left and right side unbalance vibration pick-ups 166 and 168 . These pick-ups are operatively mounted with respect to the reiliently sprung cradle to receive vibration inputs therefrom. Picks up signals resulting from these vibrations are sent to the input/output board 170 of the balance computer 120 .
[0057] For calibrating purposes, the rotationally balanced master or a standard work piece 118 with known imbalances and other physical measurements and characteristics, which is operatively loaded into the machine as by the machine operator or an automatic loader so that the hook drive 128 drivingly engages the drive end of the master crankshaft. Then the operator simply starts the calibration drive by a suitable control such as a push button. Base line reading with minimized load injections are taken and stored in the computer memory as in the previous embodiment of FIGS. 1 - 3 . After this the machine accelerates the part to a balancing speed and without stopping serially injects the unbalancing loads into the master or standard in the two horizontally spaced correction planes thereof and the data reflective of these unbalancing loads are automatically sent by operation of the synchronizer and vibration pick ups to the balance computer for the self-calibration thereof.
[0058] [0058]FIGS. 6 a , 6 b and 6 c depict the known load injection and self-calibration operation of the balancing machine and methods of the embodiments of FIGS. 4 and 5. More particularly FIG. 6 a shows the continuous and constant rotational speed of the motor and the master or standard work piece 118 driven by the machine. As an example during the initial third of the operation, both of the unbalance injector devices 152 and 154 are in a return or home position. FIG. 6 b illustrates the calibrating position of the unbalance injector device 152 at time T-1 by signals from the controller 160 as required by the balance computer 120 . This first load injection into the injection plane IP-1 and translated to calibrating plane CP-1 results in increased amplitude of plane 1 or calibrating plane CP-1 vibrations “a” which are picked up by the vibration sensor 166 . At a subsequent time T-2 for example, the balancing computer 120 directs the unbalance device controller 160 to return the unbalance injection device 152 to home and simultaneously effect the calibration operation of unbalancing injection device 154 . As shown in FIGS. 6 c this results in the reduction of plane 1 vibration amplitude and an increase in the plane 2 amplitude of the vibrations “b” from the injection of the calibrating load into the work piece in plane 2 or calibrating plane CP-2.
[0059] This staged increased amplitude of vibrations in planes 1 and 2 resulting from the serial injection of known calibration loads into the spindle of the machine is translated to the workpiece in calibrating planes CP-1 and CP-2. These timed injections are diagrammatically represented by the large amplitude signals “a” and “b” for each revolution. Data representative of the known unbalances and their sites of insertion are supplied to the balance computer for the initial calibration thereof. These calibrating load injections take place without machine stoppage as previously described,
[0060] [0060]FIGS. 7 a , 7 b and 7 c are graphical representation of the calibration operation of a prior art workpiece-balancing machine that requires manual calibration and are presented for comparison with the corresponding calibration of the machine of this invention, FIGS. 6 a , 6 b and 6 c . The time intervals DT-1 and DT-2 shown as dashed lines between the curves of FIGS. 7 a represent prior art machine down times for stopping and starting the machine and for the hands on activity of the operator for manually adding and subtracting calibration weights to the master or standard. Such down times are eliminated in automatic two-plane calibration of the present invention. This demonstrates the material improvement in the machine and efficiency of this invention over the prior art. Moreover, these new processes and machines sharply eliminate the opportunity for operator error and materially reduces calibration burden.
[0061] Turning now to FIG. 8, there is illustrated another two plane dynamic balancing machine 300 that features self-calibration similar to that of the machines and processes of FIGS. 1 - 3 and 4 - 6 . The machine 300 has a pair of laterally spaced support walls 304 and 306 that extend upwardly from base plate 308 that securely mounts to the floor 309 or other stationary support. The walls 304 and 306 have enlarged and upstanding rear portions 310 and 312 that provide end support for a pair of laterally spaced and forwardly extending, spring suspension arms 314 and 316 . The forward ends of these spring suspension arms attach to a cradle unit 318 operatively mounted thereto which has suitable bearings such as ball races 319 that support a spindle assembly 320 therein for rotation about a vertical spin axis 322 . Additionally the base plate 308 supports a servo unit such as an electric or hydraulic drive motor 326 thereon which has an upwardly extending output shaft 328 that rotatably drives a pulley 330 on the distal end thereof that receives and drives an endless drive belt 332 which loops around and drives a chuck drive pulley 334 . The pulley 334 is drivingly secured by threaded fasteners 336 to a chuck assembly 338 supported by the spindle assembly. More particularly the chuck assembly 338 extends upwardly from attachment with the upper end of the spindle assembly 320 by threaded fasteners 340 so that it rotates about the spin axis 322 . The chuck further has a pneumatically actuated collet 343 that is operable in the releasable attachment of a road wheel assembly 344 to the chuck 338 .
[0062] The chuck assembly 338 further operatively carries a pair of spaced unbalancing injector devices, 342 and 344 which have construction such as described about the embodiments of FIGS. 1 - 3 and FIGS. 4 - 6 . More particularly these unbalance injector devices 342 , 344 may each have a pair of weighted rings 346 , 348 pictorially illustrated in FIGS. 8 b operatively mounted to the spindle. As in the previous embodiments these devices may have an outer driver such as a selectively energized coil separated by an air gap and outwardly of the rings. The driver as in prior embodiments is attached to a fixed housing not shown. This coil is operatively connected to a controller 352 through leads 354 and 356 that is operable to effect energization of the coil to step the rings to different predetermined positions on the chuck 338 and relative to one another to effect the injection of different and predetermined unbalancing loads to the spindle for calibration purposes.
[0063] The wheel assembly 344 although a master for calibration purposes has two vertically spaced correction planes CP-1 and CP-2 assigned there to since its inertia axis will be changed by known weight application in each of these planes so as to be out of parallel with respect to the spin axis 322 .
[0064] As in the preceding embodiments, this embodiment of the invention has a balance computer 360 associated therewith which is employed to receive data from vibration pick up units 364 and 366 whose housings are mounted to the walls 304 of the frame 302 . These units receive vibration signals from the elongated pick-up rods 367 , 369 extending from the pick-up devices into operative engagement with the spindle 320 or other suitable vibrating component of the machine. In addition to the vibration pick-up units 364 , 366 , a synchronizer or once-per-turn pick up 368 is mounted to a fixed housing or wall 370 adjacent to the chuck 338 and is operative to deliver signals to the balance computer 360 with positional data regarding the imbalance loads so that effective balancing weight can be applied to precise positions in the correction planes of the wheel assembly to effect the balancing thereof The balance computer communicates with the controller 352 through signal line 372 so that the controller timely injects the predetermined unbalancing loads into the injection planes extending through the spindle of the balancing machine.
[0065] The balance computer 360 of the machine is precisely and efficiently calibrated relative to known imbalances for the optimized dynamic balancing of unbalanced parts. This is accomplished by the employment of programmed unbalancing load injector devices, 342 and 344 , which may be substantially the same as the pair of units of the FIGS. 4, 5 and 6 . The load injectors, operatively mounted to the spindle assembly, are signaled by controller 352 to serially inject unbalancing loads into the spindle assembly in injection planes IP-1 and IP-2 for calibration purposes. These planes respectively extend transversely though the load injector units and the spin axis 322 and are parallel to the correction planes CP-1 and CP-2 to which these loads are translated as described in connection with the two plane balancing of FIGS. 4, 5 and 6 . As with the other two plane balancing embodiment of this invention, signals from the known imbalance loads and their locations are picked up by the vibration sensors or velocity transducers 364 , 366 and synchronizer 368 and sent to the balance computer 360 . This calibrating data recognized by the balancing computer is stored in memory thereof so that subsequent unbalanced wheel assemblies can be balanced by machine 300 with optimized accuracy
[0066] [0066]FIG. 9 depicts a propeller or prop shaft balancing machine 400 that is self-calibrating as in the other embodiments. The machine 400 has a base 402 mounted to a support such as floor 404 . The machine further comprises pairs of horizontally spaced suspension spring units 406 and 408 that extend upward from connection with the base into connection with left and right side cradles 410 and 412 . The left side cradle supports an outer housing fixed thereto that operatively mounts a cylindrical spindle 414 therein for rotation about a horizontal spin axis 416 . The spindle is rotatably driven by an electric or hydraulic motor 420 supported on a base 422 . The motor has a rotatable output connected by coupling 424 to the outer end of the spindle 414 . The inboard end of the spindle has a chuck 426 operatively mounted thereto which is adjustable to operatively receive the end of an elongated master or known propshaft 428 thereto for the rotational drive of the propshaft about axis 416 . The aft end of the propshaft is secured into a right side chuck 430 that in turn is mounted to the end of a spindle 432 supported by a housing 436 secured on cradle 408 of the right side suspension.
[0067] Importantly the chucks have unbalance injection devices 440 and 442 operatively mounted thereon which like the embodiment of FIGS. 4 - 6 and 8 are operable under command of a controller 444 to be selectively energizable to inject unbalance loads into the propshaft for calibration purposes as in the previous embodiments. Vibration pickups 446 and 448 are operatively mounted to the left and right side spring suspensions 406 and 408 which are subjected to the vibratory energy of left and right side imbalance loads as in the previous embodiments. Data from the injected loads are delivered to a balance computer 450 by feeds from the vibration pick-ups 446 and 448 . A once per turn pick up or synchronizer 452 provides the positional data of the imbalance loads which are fed to the balance computer 450 for calibration thereof.
[0068] The prop shaft of FIG. 9 has a universal, constant velocity, or other connector-joint 460 therein. With such constructions, the injection plane of the unbalance injector device 434 will be in plane IP-1 and transversely through the joint 460 , which is translated to correction plane through the master workpiece and calibration plane CP-1 for calibration purposes. In contrast, the imbalance load injection of the unbalance injector device 440 will be through the IP-2 extending through the device 440 and the chuck 426 which is translated from the machine spindle to correction plane CP-2 that extends through the prop shaft for purposes of calibration as in the preceding embodiments.
[0069] Diagrammatically illustrated are weight welding units 470 which are operatively supported by overhead gantry 472 for welding balancing weights to the prop shaft in accordance with dynamic balancing data from the balancing computer. The weight welder provision may however be automated in manner disclosed in U.S. copending application Ser. No. 10/121,583 filed Apr. 12, 2002 by P. Loetzner, P Hemingray and C. Maas for Rotatable Shaft Balancing Machine and Method assigned to the assignee of this invention and hereby incorporated by reference
[0070] In the FIG. 9 embodiment of this invention, an unbalanced production part can be used for the calibration of the machine 400 with some modification of the above process or method that involves stopping of the machine. For such variation, the machine is stopped once to reorient the part in the machine. No down time is required for changing the calibration weights. To begin such modified calibration, a normal production part such as those formed by process machines is randomly selected and placed into the machine 400 for the rotational drive thereby. The machine is started and the selected workpiece is rotationally accelerated to a calibrating speed. At this time, the known imbalance loads are serially inject into the rotating workplace in the separate correction planes and the machine automatically calibrates itself as previously described.
[0071] The operator then stops the machine 400 , rotates the production part 180 degrees on its spin axis, and reconnects the part to the drive chuck or other drive. The machine is again started and to rotatably drive the selected part to a balancing speed. The calibration weights are again automatically and serially injected into the two correction planes. Again the vibrations resulting from these subsequent known unbalancing loads and positional signals from the synchronizer are picked up and the calibration data therefrom are directed to and stored in the associated computer so that subsequent unbalanced propshafts can be accurately balanced by the machine 400 .
[0072] While this invention has been described in terms of certain preferred embodiments and methods thereof, it will be appreciated that other forms and methods could readily be adapted by one skilled in the art. Accordingly, the scope of this invention is to be considered limited only by the following claims. | In this system an unbalancing force, as set by an unbalance load injection device integrated into a work piece balancing machine and its balance computer, is injected into an injection planethrough an operating portion of the machine. This injected load is in effect transferred by computation to a calibrating plane of a known standard or a masterwork part loaded into and rotatably driven by the balancing machine. The values of the unbalancing force as generated by the unbalance injecting device and by calculation into the rotating master are sensed by synchronizer and vibration pick-ups. Data reflective of the injected imbalance are furnished to the balance computer for the calibration thereof. The principle of this self-calibration is to use a workpiece drive spindle and unbalance injector device that can introduce a known unbalance, set by adjusting the unbalance injector device to inject a predetermined load at a known angle into the master to effect master unbalance. This induced unbalance is picked up by synchronizer units and used as the parameters in the calibration process of the balance compute. This allows the machine to accurately determining the imbalance in other work pieces. Subsequently conventional unbalanced work parts processed by the calibrated machine can be balanced by the machine with a higher-level of accuracy in accordance with balancing data of the calibrated balance computer. | 6 |
FIELD OF THE INVENTION
This invention relates to an electrically conductive plastic molding using an ethylene copolymer and a process for producing the same. More particularly, it relates to an ionically conductive plastic molding comprising a molding of an ethylene-dialkylaminoalkylacrylamide copolymer having impregnated therein an aqueous solution of at least one of inorganic acids, organic acids, and inorganic metal salts, and to a process for producing the same.
The electrically conductive plastic moldings of this invention can be obtained easily and exhibit excellent conductivity. They are useful as electromagnetic wave shields, antistatic materials, electrically heating elements for plane heater, etc. They can also be applied, for example, to fixation of an electrolyte liquor of a portable lead accumulator by taking advantage of their ionic conductivity.
BACKGROUND OF THE INVENTION
Conductive plastic moldings obtained by imparting electrical conductivity to plastic moldings have advantages of moldability, light weight, and the like and have recently been utilized in a broad range of application, such as electromagnetic wave shields, antistatic materials, plane heaters for room heating, etc. The application range tends to be further broadened.
Known techniques for imparting conductivity to plastic moldings include compounding of a conductive substance, e.g., carbon black, metal powders, metallic fibers, etc. into a resin molding material, application of a coating containing a conductive substance to a resin molding, adhesion of a metal atom to a resin molding by ion plating or sputtering, and the like. In addition, various attempts have been made to render the resin per se electrically conductive.
However, these conventional techniques have their respective disadvantages as described below, and the resulting products are not always satisfactory depending on use.
According to the method of dispersing a conductive substance in a resin before molding to obtain a conductive resin molding material, achievement of satisfactory conductivity requires a large quantity of the conductive substance to be compounded, which leads to adverse influences on molding properties of the resulting mixture and physical properties of the resin.
The method comprising applying a coating having incorporated therein a conductive substance onto a resin molding encounters difficulty in uniformly applying the coating particularly on a molding of complicated shape. Besides, the conductive layer formed on the surface of the molding is apt to fall off during long-term use.
The method comprising adhesion of a metal atom to the surface of a resin molding requires a special apparatus to carry out to thereby increase the cost.
Further, none of the so-far proposed resins showing conductivity by themselves have been put into practical use due to their poor molding properties.
On the other hand, in the filed of portable storage batteries including lead accumulators which are utilized as auto batteries, there are many problems in handling and transportation because a fluid, such as dilute sulfuric acid, is employed as an electrolyte liquor.
In order to solve these problems, various attempts have been made to fix the electrolyte liquor. For example, there have been proposed a method of impregnating an electrolyte liquor into voids of glass cloth and a method of incorporating a gelling agent to an electrolyte liquor. These proposals, however, are still unsatisfactory as fixation or retention of the electrolyte liquor is insufficient and also the cell to be used is limited in shape and volume. Therefore, it has been keenly demanded to develop an effective method for fixation of an electrolyte liquor for portable storage batteries.
SUMMARY OF THE INVENTION
One object of this invention is to eliminate various problems associated with the state-of-the-art conductive plastic moldings and to provide a ionically conductive plastic molding having excellent conductivity which can be obtained by molding with ease and can be fabricated into a complicated shape.
Another object of this invention is to provide a process for producing the above-described conductive plastic molding easily and at low cost.
In the light of the above objects, the inventors have conducted intensive and extensive researches on molding resins having excellent molding properties as well as excellent receptivity to an organic or inorganic acid aqueous solution, an inorganic metal salt aqueous solution or a mixture thereof upon contact therewith to provide a conductive molding. As a result, it has now been found that a copolymer comprising ethylene and a dialkylaminoalkylacrylamide comonomer effectively meets the purposes.
The present invention relates to a conductive plastic molding which is obtained by melt molding an ethylene copolymer comprising from 40 to 90% by weight of an ethylene unit, from 10 to 60% by weight of at least one dialkylaminoalkylacrylamide comonomer unit represented by formula (I): ##STR2## wherein R 1 represents a hydrogen atom or a methyl group; R 2 and R 3 each represents an alkyl group haVing from 1 to 4 carbon atoms; and n represents an integer of from 2 to 5, and up to 20% by weight of one or more ethylenically unsaturated comonomer units, and having a number average molecular weight of from 5,000 to 50,000 and impregnating at least 10 parts by weight of an aqueous solution of at least one of an organic acid, an inorganic acid, and an inorganic metal salt into 100 parts by weight of the resulting melt molded.
The present invention further relates to a process for producing the above-described conductive plastic molding.
DETAILED DESCRIPTION OF THE INVENTION
The ethylene copolymer which can be used as a molding resin in the present invention may be prepared by any process, but is generally prepared by a high-pressure polymerization process, in which ethylene and a dialkylaminoalkylacrylamide are copolymerized in the presence of a radical polymerization initiator at a temperature of from 100° to 300° C. under a pressure of from 500 to 3,000 kg/cm 2 . The polymerization may be carried out in a batch system, a semi-continuous system, or a continuous system. The continuous system is industrially advantageous.
Specific examples of the dialkylaminoalkylacrylamide comonomer are dimethylaminoethylacrylamide, dimethylaminopropylacrylamide, dimethylaminobutylacrylamide, diethylaminoethylacrylamide, diethylaminopropylacrylamide, diethylaminobutylacrylamide, dipropylaminoethylacrylamide, dipropylaminopropylacrylamide, dipropylaminobutylacrylamide, N-(1,1-dimethyl-3-dimethylaminopropyl)acrylamide, N-(2-methyl-3-dimethylaminopropyl)acrylamide, etc. and methacrylamide derivatives corresponding to these acrylamides. Of these preferred are dimethylaminopropylacrylamide, dimethylaminopropylmethacrylamide, dimethylaminoethylacrylamide, and dimethylaminoethylmethacrylamide.
The content of the dialkylaminoalkylacrylamide comonomer unit in the ethylene copolymer ranges from 10 to 60%, and preferably from 10 to 50%, by weight. If it is less than 10% by weight, the resulting molding cannot be sufficiently impregnated with an aqueous solution of an organic acid and/or an inorganic acid, and/or an inorganic metal salt, thus failing to manifest excellent conductivity.
On the other hand, if the content of the dialkylaminoalkylacrylamide comonomer unit exceeds 60% by weight, the ethylene copolymer has so high hydrophilic properties that the resulting molding may have reduced mechanical strength when immersed in the aqueous solution of an organic acid and/or an inorganic acid, and/or an inorganic metal salt and, in some cases, ultimately dissolved in the aqueous solution.
Specific and preferred examples of other ethylenically unsaturated comonomer which may be used in this invention include methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, n-butyl acrylate, n-butyl methacrylate, glycidyl acrylate, glycidyl methacrylate, vinyl acetate, vinyl propionate, dimethylaminoethyl methacrylate, dimethylaminoethyl acrylate, etc. Particularly preferred of them are methyl acrylate, methyl methacrylate, ethyl acrylate, vinyl acetate, dimethylaminoethyl methacrylate, and dimethylaminoethyl acrylate.
The content of the ethylenically unsaturated comonomer unit in the ethylene copolymer should not exceed 20% by weight, and preferably not exceed 15% by weight.
The ethylene copolymer of this invention has a number average molecular weight of from 5,000 to 50,000 ([η]=0.29-1.23), and preferably from 8,000 to 40,000 ([η]=0.39-1.07) as calculated from the intrinsic viscosity [η] measured at 135° C. in a tetralin solution according to the following equation:
[η]=1.35×10.sup.-3 Mn.sup.0.63
wherein [η] is an intrinsic viscosity; and M is a number average molecular weight [cf. I. Harris, Journal of Polymer Science, Vol. 8 (4), 353-364 (1952)].
If the M of the ethylene copolymer exceeds 50,000, the molding cannot be sufficiently impregnated with the aqueous solution of an inorganic acid and/or an organic acid, and/or an inorganic metal salt, failing to attain excellent conductivity. If it is less than 5,000, the resulting molding suffers from not only shortage of mechanical strength but also lack of shape retention when impregnated with the aqueous solution.
The terminology "plastic molding" or "resin molding" as used herein means molded products obtained by molding the above-described ethylene copolymer by commonly employed molding processes, such as extrusion molding, injection molding, blow molding, vacuum molding, and the like, in which are included tubing, sheeting, filming, and spinning. The form of the molding is not particularly limited and includes, for example, films, sheets, tubes, rods, fibers (inclusive of hollow fibers), nonwoven fabric, woven fabric, etc. The fibers may be conjugate fibers with other resins, e.g., polypropylene, polyester, polyamide, polyethylene, etc., and the nonwoven and woven fabric may be those obtained from such conjugate fibers.
Further, the resin molding according to the present invention embraces composites or laminates composed of the above-recited moldings and other materials, such as metals (e.g., stainless steel, lead, etc.), other resins or rubbers (e.g., polyethylene, polypropylene, ethylene-propylene rubber, etc.), glass, and the like.
In the present invention, the resin molding can be rendered electrically conductive by contacting it with an impregnating aqueous solution containing at least one of inorganic acids, organic acids, and inorganic metal salts by immersion or the like impregnation technique.
The inorganic acids to be used include, for example, hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, pyrophosphoric acid, polyphosphoric acid, perchloric acid, hydrofluoric acid, hydrobromic acid, and hydroiodic acid.
The organic acids include carboxylic acids, e.g., formic acid, acetic acid, oxalic acid, tartaric acid, benzoic acid, lactic acid, acrylic acid, maleic acid, etc., and sulfonic acids, e.g., methanesulfonic acid, benzenesulfonic acid, etc.
The inorganic metal salts to be used are selected from those easily soluble in water or an acidic aqueous solution and include ferrous chloride, ferric chloride, nickel chloride, ferrous sulfate, ferric sulfate, nickel sulfate, ferrous nitrate, ferric nitrate, nickel nitrate, etc.
The concentration of the inorganic metal salt in the aqueous solution is arbitrary so long as within its solubility in water or an inorganic acid aqueous solution. The concentration of the inorganic acid may be either low as in a 0.01N sulfuric acid or high as in a 70% by weight sulfuric acid. The concentration of the organic acid aqueous solution may be optionally chosen within the range of solubility of the organic acid.
The upper limit of the amount of the abovedescribed aqueous solution to be impregnated in the molding is necessarily determined by the content of the dialkylaminoalkylacrylamide comonomer unit in the ethylene copolymer and the molecular weight of the copolymer, while the lower limit is 10 parts by weight per 100 parts by weight of the molding. If the impregnated amount is less than 10 parts, sufficient conductivity cannot be attained.
The temperature and time for the contact between the molding and the impregnating aqueous solution, for example, immersion, can be selected according to the desired conductivity, the desired pick-up of the impregnating liquor, and the shape of the molding. For instance, treatment for a molding having a relatively large surface area, such as films, fibers, nonwoven fabric, woven fabric, etc., can be completed at a relatively low temperature for a short period of time, e.g., at 25° C. for 1 hour or less. With a molding having a relatively small surface area, such as thick sheets, tubes, rods, etc., the contact temperature may be raised, e.g., to 60° C., to complete the treatment in a short period of time, e.g., 1 hour or less.
The plastic molding prepared from the ethylene copolymer of the present invention which can be applied to the treatment for rendering electrically conductive according to the present invention is not limited in shape and has excellent receptivity to the above-described aqueous solution upon contact therewith to provide a plastic molding exhibiting superior electrical conductivity. In addition, the conductive plastic molding of the present invention is flame retardant and self-extinguishing. It is possible to dye the conductive plastic molding in an arbitrary color with an acid dye or a metallized acid dye.
As described above, the conductive plastic molding according to the present invention enjoys many advantages over those obtained by conventional techniques and, therefore, can be used in a wider range of application such as electromagnetic wave shields, antistatic materials, electrically heating elements for plane heater, and for fixation of an electrolyte liquor of a portable lead accumulator.
The present invention is now illustrated in greater detail with reference to Examples and Comparative Examples, but it should be understood that the present invention is not deemed to be limited thereto. In these examples all the percents are by weight unless otherwise indicated.
EXAMPLE 1
An ethylene copolymer containing 57% of an ethylene unit and 43% of a dimethylaminopropylacrylamide unit and having a number average molecular weight of 1,000 ([η]=0.91) and a melt index of 5 g/10 min as measured by a melt indexer at 125° C. was extrusion molded in a T-die extruder having a diameter of 20 mm at a resin temperature of 155° C. to prepare a continuous sheeting of 7.3 cm in width and 2.1 mm in thickness. A sample piece (4 cm×4.5 cm) was cut out from the sheeting and immersed in 200 ml of a 0.1N hydrochloric acid aqueous solution at 60° C. for 2 hours to obtain an impregnated resin sheet having a pick-up (based on the weight of the resin before impregnation) of 174%.
The conductivity of the impregnated resin was found to be 3×10 -4 siemens/cm as measured by the use of a four-point probe resistivity meter (manufactured by Mitsubishi Petrochemical Company, Ltd.).
EXAMPLES 2 TO 13
Extruded sheetings having a thickness of 2.1 mm or 1.0 mm were prepared in the same manner as in Example 1, and a cut piece of each sheeting was immersed in an aqueous solution containing at least one of an organic acid, an inorganic acid, and an inorganic metal salt as shown in Table 1 to obtain a conductive resin sheet.
The pick-up and conductivity of the resulting impregnated resin sheet were determined in the same manner as in Example 1, and the results obtained are shown in Table 1.
EXAMPLES 14 AND 15
An ethylene copolymer containing 64% of an ethylene unit and 36% of a dimethylaminopropylacrylamide unit and having a number average molecular weight of 12,000 ([η]=0.50) and a melt index of 20 g/10 min at 125° C. was molded in a T-die extruder having a diameter of 20 mm at a resin temperature of 155° C. to prepare a continuous sheeting of 7.3 cm in wedth and 2.1 mm in thickness. A sample piece (4 cm×4.5 cm) was cut out of the sheeting and immersed in an inorganic acid aqueous solution as shown in Table 1. The pick-up and conductivity of the resulting sheet are shown in Table 1.
EXAMPLES 16 AND 17
An ethylene copolymer containing 61% of an ethylene unit, 25% of a dimethylaminopropylmethacrylamide unit, and 14% of a dimethylaminoethyl methacrylate unit and having a number average molecular weight of 24,200 ([η]=0.78) and a melt index of 8 g/10 min at 125° C. was extrusion molded in the same manner as in Example 1 to prepare a sheeting. The resulting sheeting was immersed in an inorganic acid aqueous solution as shown in Table 1 to obtain a conductive sheet. The pick-up and conductivity of the resulting impregnated sheet are shown in Table 1.
TABLE 1__________________________________________________________________________Resin Sample Immersion Condition Result Thick- Temper- Conduct-Example Content ness Concent- ature Time Pick-up ivityNo. Comonomer (wt %) -- Mn (mm) solution ration (°C.) (hr) (wt %) (siemens/cm)__________________________________________________________________________ 1 Dimethylamino- 43 31000 2.1 hydrochloric 0.1N 60 2 174 3 × 10.sup.-4propylacrylamide acid (137)* 2 Dimethylamino- " " " hydrochloric 0.1N " " 125 1 × 10.sup.-4propylacrylamide acid (98) ferric 0.2 mol/l chloride 3 Dimethylamino- " " " hydrochloric 0.1N 25 24 147 4 × 10.sup.-4propylacrylamide acid (129) 4 Dimethylamino- " " 1.0 hydrochloric " " 4 138 4 × 10.sup.-4propylacrylamide acid (131) 5 Dimethylamino- " " 2.1 nitric acid 0.1N 60 2 125 2 × 10.sup.-4propylacrylamide (95) 6 Dimethylamino- " " " sulfuric acid 0.1N 60 2 86 3 × 10.sup.-4propylacrylamide (71) 7 Dimethylamino- " " 2.1 " 50% " " 173 2 × 10.sup.-2propylacrylamide (102) 8 Dimethylamino- " " " " 70% " " 152 5 × 10.sup.-2propylacrylamide (84) 9 Dimethylamino- " " 1.0 " 50% " 1 225 2 × 10.sup.-2propylacrylamide (135)10 Dimethylamino- 43 31000 2.1 phosphoric 0.1N 60 2 135 3 × 10.sup.-4propylacrylamide acid (110)*11 Dimethylamino- " " " acetic acid 0.05N " 0.5 265 7 × 10.sup.-3propylacrylamide (257)12 Dimethylamino- " " " acrylic acid 0.05N " " 236 5 × 10.sup.-3propylacrylamide (227)13 Dimethylamino- " " " ferric 2 mol/l " 4 70 5 × 10.sup.-4propylacrylamide sulfate (58)14 Dimethylamino- 36 12000 " hydrochloric 0.1N " " 69 2 × 10.sup.-4propylacrylamide acid (54)15 Dimethylamino- " " " sulfuric acid 50% " " 115 8 × 10.sup.-2propylacrylamide (72)16 Dimethylamino- 20/15 24200 " hydrochloric 0.1N " " 55 5 × 10.sup.-4propylmeth- acid (46)acrylamide/di-methylaminoethylmethacrylate17 Dimethylamino- " " " sulfuric acid 50% " " 103 2 × 10.sup.-2propylmeth- (69)acrylamide/di-methylaminoethylmethacrylate__________________________________________________________________________ Note: *Values in the parentheses each indicates a degree of swelling (% by volume)
EXAMPLE 18
The same ethylene copolymer as used in Example 1 (ethylene unit content: 57%; dimethylaminopropylacrylamide unit content: 43%) was spun in a simplified spinning apparatus composed of a melt indexer combined with a winding machine to prepare a filament yarn having an average diameter of 60 μm. The filaments were gathered and heat-pressed at 75° C. to prepare a porous sheet having a density of 0.35 g/cm 3 and a void of 62% by volume. The porous sheet was immersed in a 50% sulfuric acid aqueous solution at 25° C. for 30 minutes.
The resulting impregnated sheet was found to have absorbed in its resinous portion the 50% sulfuric acid aqueous solution in an amount of 2.2 times the weight of the resin before impregnation while stably retaining the 50% sulfuric acid aqueous solution in an amount of 2.3 times the weight of the resin before impregnation in its voids. The electrical conductivity of the impregnated sheet was 5×10 -1 siemens/cm.
COMPARATIVE EXAMPLES 1 TO 3
Each of the sample pieces as prepared in Examples 1, 14, and 16 was immersed in pure water at 60° C. for 2 hours. The resulting impregnated sheets were found to have a pick-up of 2.7%, 1.7%, and 1.5%, respectively, and a conductivity of 10 -7 siemens/cm or less as measured by means of a four-point probe resistivity meter in each case or a conductivity of 8×10 -10 , 6×10 -10 , and 3×10 -10 siemens/cm, respectively, as measured by means of an ultra-megohm meter (manufactured by Toa Denpa Kogyo K.K.). These results are tabulated in Table 2 below.
TABLE 2__________________________________________________________________________ Resin Sample Immersion Condition ResultComparative Thick- Temper- Conduct-Example Content ness ature Time Pick-up ivity*No. Comonomer (wt %) -- Mn (mm) solution (°C.) (hr) (wt %) (siemens/cm)__________________________________________________________________________1 Dimethylamino- 43 31000 2.1 pure water 60 2 2.7 8 × 10.sup.-10 propylacrylamide (2.2)**2 Dimethylamino- 36 12000 " " " " 1.7 6 × 10.sup.-10 propylacrylamide (1.4)3 Dimethylamino- 20/15 24200 " " " " 1.5 3 × 10.sup.-10 propyl meth- (1.3) acrylamide/di- methylaminoethyl methacrylate__________________________________________________________________________ Note: *Measures by the use of a super insulation tester (manufactured by Toa Denpa Kogyo K. K.) **Values in the parentheses each indicates a degree of swelling (% by volume)
As described above, the present invention provides an ionically conductive plastic molding which has excellent electrical conductivity and can be fabricated in any complicated shape, being free from various disadvantages attending the conventional conductive plastic moldings. The present invention further provides a process for producing such a conductive plastic molding, in which a resin molding material can be molded easily and at low cost.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A conductive plastic molding obtained by melt molding an ethylene copolymer comprising from 40 to 90% by weight of an ethylene unit, from 10 to 60% by weight of at least one dialkylaminoalkylacrylamide comonomer unit represented by formula ##STR1## wherein R 1 represents a hydrogen atom or a methyl group; R 2 and R 3 each represents an alkyl group having from 1 to 4 carbon atoms; and n represents an integer of from 2 to 5, and up to 20% by weight of one or more ethylenically unsaturated comonomer units and having a number average molecular weight of from 5,000 to 50,000 and impregnating at least 10 parts by weight of an aqueous solution of at least one of an organic acid, an inorganic acid, and an inorganic metal salt into 100 parts by weight of the resulting melt molded. The molding exhibits excellent conductivity and can be obtained easily and at low cost without any limitation on shape. | 7 |
TECHNICAL FIELD
[0001] The present invention relates to reliability improvement of the whole of electronic devices. In particular, the present invention relates to a programmable device, a method for reconfiguring a programmable device, and an electronic device.
BACKGROUND ART
[0002] With size shrinking of semiconductor devices, the problem of soft errors caused by environmental radiations is actualized especially for SRAMs (non patent literature 1), logic gates (non patent literature 2), clock systems (non patent literature 3), and the like. If a neutron having extremely high energy rushes into an atomic nucleus included in a device, nucleons (neutrons, protons) in the nucleus repeat collision and nucleons having especially high energy are emitted to the outside of the nucleus. If a state in which nucleons cannot have kinetic energy enough to fly out to the outside of the nucleus is brought about, a process in which protons, neutrons, deuterons, and leptons such as alpha particles evaporate from a remaining atomic nucleus in an excited state continues. Finally, the remaining nucleus also has recoil energy. Therefore, all of these secondary particles fly in the device by distances corresponding to their ranges.
[0003] If alpha rays generated from radioisotope included in a semiconductor package or the like or secondary ions having charge generated as a result of a nuclear reaction pass through a vacancy layer in a storage node, electrons are absorbed by the node and holes flow in an opposite direction and a charge collection area spreads along a track of ions. Charges are collected into the storage node by this funneling mechanism. If charges of a critical charge amount or more are collected, a “high” state shifts to a “low” state, resulting in a soft error (Single Event Upset; SEU).
[0004] This is a typical mechanism which has been considered as a mechanism of an environmental radiation soft error, and it is called SEU (Single Event Upset). As for the SEU of a memory device, a case where a plurality of cells become erroneous at the same time is called MCU (Multi Cell Upset), and it is distinguished from SBU (Single Bit Upset; single bit error). In a case where MCU occurs in the same word, it is called MBU (Multiple Bit Upset) and it cannot be restored by using an ordinary ECC (Error Correction Code), resulting in a cause of system down.
[0005] As for soft errors including the SEU, update to new data is conducted even after occurrence of an error and restoration to a normal state is performed by restart or the like, unlike a hard error (a fixed failure in hardware). This results in a problem that it is difficult to find a cause of the error. In this way, influence of a soft error occurring in a logic circuit means that false operations are caused in a processor in a computer, an ASIC, a digital circuit for control, or the like. There is a fear that the soft error will cause a false operation in an electronic system.
[0006] In recent years, programmable devices have been frequently used as control logic circuits in various electronic system devices. Especially among the programmable devices, utilization of FPGA (Field Programmable Gate Array) is increasing. In the FPGA, logic circuit information is stored in a memory (configuration memory: configuration will be “config” for short) within a device and arithmetic operation circuits or control circuits are constructed. There is a possibility that a false operation of an electronic system device will be caused due to destruction of data stored in the memory by a soft error. It is becoming regarded as a problem. Usually, consideration is given to prevent the system from being affected by a false operation. However, this becomes a cause of an increase in power dissipation, development work, verification work, and cost.
[0007] As attempts to improve tolerance of the FPGA to environmental radiations, there are a technique using reconfiguration (“reconfig” for short) to write proper circuit information again into a configuration memory rewritten by a soft error, and a technique using internal circuits provided with redundancy and a majority decision circuit. Patent literature 1 (JP-A-2011-13829) discloses improvement of tolerance by reconfiguring a circuit region where a soft error has occurred, and shortening of time from occurrence of a soft error to completion of reconfiguration by storing circuit information using fixed length blocks, conducting soft error detection by taking a fixed length block as the unit, and providing a means for reconfiguring only the circuit region. Patent literature 2 (JP-B-4422596) discloses an attempt to achieve high reliability by disposing at least two reconfigurable signal processing systems dispersedly in various signal processing units connected by a network and substituting a different reconfigurable signal processing system which can perform a normal operation for a signal processing unit in which a failure (including a soft error) has occurred. Furthermore, non patent literature 4 describes a tolerant circuit technique. According to the tolerant circuit technique, triplication (TMR: Triple Modular Redundant) is performed for a processor circuit in a FPGA. In a case where a configuration memory is rewritten because of a soft error, operation of the whole inclusive of a normally operating processor circuit is stopped once and an internal register of a normal circuit is stored in an internal memory. Then, only the processor circuit is reconfigured. After the reconfiguration is finished, the stored register values are loaded into the reconfigured processor circuit. Thereafter, restoration is performed by conducting restart.
CITATION LIST
Patent Literature
[0000]
PATENT LITERATURE 1: JP-A-2011-13829
PATENT LITERATURE 2: JP-B-4422596
Non Patent Literature
[0000]
NON PATENT LITERATURE 1: E. Ibe, “Current and Future trend on Cosmic-Ray-Neutron Induced Single Event Upset at the Ground down to 0.1-Micron-Devices,” The Svedberg Laboratory Workshop on Applied Physics, Uppsala, May 3, No. 1 (2001).
NON PATENT LITERATURE 2: P. Shivakumar (University of Texas at Austin), W. Kistler, W. Keckler. S, DougBurger, Lorenzo. A., “Modeling the Effect of Technology Trends on the Soft Error Rate of Combinational Logic,” Int'l Conf. on Dependable Systems and Networks, pp. 389-398 (2002).
NON PATENT LITERATURE 3: Seifert, N., Shipley, Pant, M. D., Ambrose, V, and Gill, B., “Radiation-Induced Clock Jitter and Race,” 2005 IEEE International Reliability Physics Symposium Proceedings, April 17-21, San Jose, Apr. 17-21, 2005, Vol. 43rd Annual, pp. 215-222 (2005).
NON PATENT LITERATURE 4: Improving the Robustness of a Softcore Processor against SEUs by using TMR and Partial Reconfiguration, author name: Yoshihiro Ichinomiya, Shiro Tanoue (Kumamoto University), document name: 2010 18th Annual International Symposium on Field-Programmable Custom Computing Machines.
SUMMARY OF INVENTION
Technical Problem
[0014] As sizes of semiconductor devices shrink and reliability of the semiconductor devices becomes high, influence of soft errors caused by environmental radiations (such as alpha rays and neutron rays) spreads and soft error frequencies in programmable devices (mainly FPGAs) increase rapidly. As a result, soft errors in electronic system products are posing a problem. However, it is difficult to shield neutron rays which are a main cause of soft errors, and it is difficult to provide a countermeasure against soft errors.
[0015] As a method for improving tolerance against soft errors in programmable devices, it is general to make a circuit redundant. If a part of a redundant circuit is rewritten by neutrons, however, an error remains as long as the region is not rewritten with correct data, resulting in hampered redundancy. In this case, restoration is possible by partially rewriting the whole programmable device or a region where an error has occurred. Unless operation is stopped inclusive of a normal circuit while rewriting is performed, a difference occurs in processing speed between processing in the normal circuit and processing in a circuit in which the error has occurred. In a case where a configuration memory is rewritten when a soft error has occurred in a programmable device, therefore, the operation must be stopped during that time. In a system, such as a communication device, in which device stopping exerts great influence, it is important to perform restoration without stopping the operation of the system. When using a programmable device, therefore, the soft error was coped with formerly by making the whole product or a part of the product (such as a substrate unit) redundant.
[0016] An object of the present invention is to improve tolerance of a programmable device used in an electronic system product to environmental radiation soft errors and provide a programmable device, a method for reconfiguring a programmable device, and an electronic device capable of contributing to implementation of high reliability and a non-stopping system required of a social infrastructure system.
Solution to Problem
[0017] Among aspects of the invention disclosed in the present application, an outline of a representative aspect will now be described briefly.
[0000] (1) A programmable device includes a plurality of control circuits, a comparison unit for comparing outputs from the plurality of control circuits and inspecting occurrence of an error, a storage unit responsive to determination that an error has occurred therein conducted by the comparison unit to store an internal state of a control circuit in which an error has not occurred among the plurality of control circuits, a reconfiguration unit for reconfiguring a control circuit determined that an error has occurred therein by the comparison unit, and a control unit for inputting the internal state of the control circuit in which an error has not occurred, stored in the storage unit, to the control circuit determined that an error has occurred therein by the comparison unit.
Advantageous Effects of Invention
[0018] According to the present invention, it is possible to improve tolerance of a programmable device used in an electronic system product to environmental radiation soft errors and provide a programmable device, a method for reconfiguring a programmable device, and an electronic device capable of contributing to implementation of high reliability and a non-stopping system required of a social infrastructure system.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a configuration diagram of a programmable device according to an embodiment of the present invention;
[0020] FIG. 2 is another configuration diagram of a programmable device according to an embodiment of the present invention;
[0021] FIG. 3 shows an operation sequence example according to an embodiment of the present invention;
[0022] FIG. 4 is a diagram showing a timing chart example of control on a redundant region exercised by a programmable device according to an embodiment of the present invention;
[0023] FIG. 5 is a diagram showing a means used to record an internal state of a redundant region by a programmable device according to an embodiment of the present invention;
[0024] FIG. 6 is a diagram showing an input screen example in a case where design is conducted on the basis of a programmable device according to an embodiment of the present invention;
[0025] FIG. 7 is a diagram showing a means for forcibly inserting a soft error when conducting verification on design including a region configured by a programmable device according to an embodiment of the present invention;
[0026] FIG. 8 is a diagram showing a means for outputting an internal state to the outside at time of environmental radiation irradiation test on an electronic system device using a programmable device according to an embodiment of the present invention;
[0027] FIG. 9 shows an example of a screen that displays an output result obtained in FIG. 8 ;
[0028] FIG. 10 shows a configuration example of a reconfiguration control unit formed by a programmable device according to an embodiment of the present invention and a high order system; and
[0029] FIG. 11 shows an example in which a communication device according to an embodiment of the present invention is configured.
DESCRIPTION OF EMBODIMENTS
[0030] An example of a circuit and a device tolerant to a soft error caused by environmental radiations in a programmable device according to the present invention will now be described with reference to the drawings.
[0031] FIG. 1 is a configuration diagram of a programmable device programmable device according to an embodiment of the present invention.
[0032] A programmable device 1 shown in FIG. 1 includes a reconfiguration control unit 2 , a redundant circuit unit 3 (control circuit units 4 , 5 and 6 ), a majority decision circuit unit 7 , a clock control unit 8 , input recording units 9 , selectors 10 , a tracking control unit 11 , a recording data selection unit 12 , and a state recording unit 13 .
[0033] The control circuit units 4 , 5 and 6 are circuits for implementing desired functions such as various arithmetic operations, external memory control, communication packet analysis processing, and external I/F control. The control circuit units 4 , 5 and 6 receive signals selected by the selectors 10 , and output data of the control circuit units 4 , 5 and 6 are output to the majority decision circuit unit 7 . The control circuit units 5 and 6 are duplicates of the control circuit unit 4 , and the control circuit units 5 and 6 have redundancy. Here, the control circuit units 4 , 5 and 6 are collectively referred to as redundant circuit unit 3 .
[0034] The clock control unit 8 receives a clock signal 15 from the outside and outputs a clock signal 18 having a frequency used in a steady state or a clock signal 19 changed in frequency to regions such as the control circuit units 4 , 5 and 6 , the reconfiguration unit 2 , the majority decision circuit unit 7 , the input recording units 9 , the tracking control unit 11 , the recording data selection unit 12 , and the state recording unit 13 .
[0035] The majority decision circuit unit 7 conducts majority decision processing on the output data of the control circuit units 4 , 5 and 6 in order to improve the tolerance to environmental radiations, determines whether a soft error occurs, or identifies a control circuit unit in which a soft error occurs. Upon determining that an error occurs in one of the control circuit units 4 , 5 and 6 , the majority decision circuit unit 7 sends signals 20 , 21 and 23 informing that an error has occurred to the tracking control unit 11 , the reconfiguration control unit 2 and the recording data selection unit 12 , respectively. Furthermore, the majority decision circuit unit 7 outputs a result of the decision to the outside as an output signal 17 .
[0036] The recording data selection unit 12 selects normal control circuit units in which an error does not occur at the time when the soft error has occurred, on the basis of the decision result in the majority decision circuit unit 7 as to whether a soft error has occurred, and exchanges a signal 22 informing of internal state data with the selected control circuit units 4 , 5 and 6 .
[0037] The state recording unit 13 conducts data exchange with the recording data selection unit 12 , and stores an internal state of the normal control circuit unit in which an error has not occurred and which is selected by the recording data selection unit 12 .
[0038] The reconfiguration control unit 2 receives the signal 21 informing of error occurrence from the majority decision circuit unit 7 , and exchanges a configuration control signal 14 with the outside. As a result, the reconfiguration control unit 2 exercises write control into a configuration memory (not disclosed) provided in the programmable device to store circuit information for implementing a desired function. The configuration memory is a memory indispensable to implement the programmable device, and it is used generally. All regions disclosed in FIG. 1 are stored in the configuration memory to implement the circuit function.
[0039] The input recording units 9 temporarily record an input signal 16 sent from the outside to be input to the control circuit units 4 , 5 and 6 , and outputs the input signal 16 to the selectors 10 .
[0040] The selectors 10 select either the input signal 16 or the output signal from the input recording unit 9 , and input the selected signal to the control circuit units 4 to 6 .
[0041] On the basis of the signal 20 sent from the majority decision circuit unit 7 to inform that an error has occurred in a part of a control circuit and an output signal from the reconfiguration control unit 3 , the tracking control unit 11 outputs a clock signal quickened temporarily and inputs the clock signal to the clock control unit 8 in order to make partial processing fast. Furthermore, the tracking control unit 11 outputs a signal which orders selection of an output signal to the selectors 10 .
[0042] By the way, the redundant circuit unit 3 includes three control circuit units 4 to 6 . However, a redundant configuration of at least triplication may be used. Redundancy becomes high by increasing the number of control circuit units. Furthermore, the clock control unit 8 has a means for changing the frequency and a means for distributing to a plurality of clock signals.
[0043] In the configuration of the programmable device 1 shown in FIG. 1 , the configuration control signal 14 includes a signal for controlling circuit information data and writing, a signal informing that reconfiguration has finished, and a signal informing that the data is data in a region in the redundant circuit unit 3 where a soft error has occurred.
[0044] Furthermore, relating control units are informed that a soft error has occurred in a part of the control circuit by using the signal 20 sent from the majority decision circuit unit 7 to the tracking control unit 11 to inform that an error has occurred in a part of the control circuit, the signal 21 sent from the majority decision circuit unit 7 to the reconfiguration control unit 2 to inform that an error has occurred in a part of the control circuit, and the signal 23 sent from the majority decision circuit unit 7 to the recording data selection unit 12 to inform that an error has occurred in a part of the control circuit. Furthermore, after receiving the signal 20 , the tracking control unit 11 informs the clock control unit 8 of occurrence of an error in the same way, and delivers information specifying a region for which the frequency should be changed among clock signals distributed within the programmable device 1 , to the clock control unit 8 .
[0045] By the way, a configuration in which this signal is input to the clock control unit 8 directly from the majority decision circuit unit 7 may be used. Although connections of clock signals are not shown in FIG. 1 , the clock signal is connected to respective regions and the clock signal 19 is connected to the redundant circuit unit 3 and the input recording unit 9 . Furthermore, since unnecessary data are sent to the majority decision circuit 7 at the time of reconfiguration, a function of masking inputs from the control circuit units to the majority decision circuit unit 7 may be provided in the majority decision circuit unit 7 .
[0046] FIG. 2 shows another configuration example of a programmable device according to an embodiment of the present invention. The programmable device shown in FIG. 2 differs from the programmable device shown in FIG. 1 in that the input recording units 9 which are separate configurations in the programmable device shown in FIG. 1 are collected to one configuration. In FIG. 1 , as many input recording units 9 as the number of redundant control circuit units in the redundant circuit unit 3 (three input recording units 9 ) are included. In the configuration shown in FIG. 2 , data of the input signal 16 is always stored in the input recording unit 9 as well. In a case where a soft error has occurred, a bus selector 29 selects a signal that is not passed through the input recording unit 9 , for normal control circuit units in which the soft error has not occurred. As an input signal to a control circuit unit in which reconfiguration is finished, the bus selector 29 selects a signal passed through the input recording unit 9 . Owing to this configuration, the volume of the input recording unit 9 can be reduced.
[0047] FIG. 3 shows an operation sequence example according to an embodiment of the present invention.
[0048] The control circuit units 4 , 5 and 6 are formed by circuits having a desired function. After the control circuit starts a steady state operation, the majority decision circuit unit 7 starts soft error monitoring processing on the basis of outputs of the control circuit units 4 to 6 (step 31 ). By the way, the soft error may be detected not only by the majority decision circuit unit 7 but also by a means for monitoring data inversion in the configuration memory in the programmable device.
[0049] In a case where a soft error is detected at the step 31 (Yes at step 32 ), the recording data selection unit 12 selects a normal control circuit unit on the basis of a detection result in the majority decision circuit unit 7 and stores an internal state of the normal control circuit unit into the state recording unit 13 (step 33 ). The internal state means a status register, for example, in a case where the control circuit unit is a processor. Unless a soft error is detected at the step 31 (No at the step 32 ), the error monitoring processing is continued successively until an error is detected.
[0050] Subsequently, a signal that is input to a control circuit block in which a soft error is detected is stored in the input recording unit 9 (step 34 ).
[0051] Subsequently, a reconfiguration operation in the control circuit unit in which a soft error is detected is started (step 35 ). After the reconfiguration is finished, state data at the time when operation is stopped is loaded from the state recording unit 13 (step 43 ).
[0052] Thereafter, the input to the reconfigured control circuit is switched to the input side from the input recording unit 9 (step 36 ). The clock control unit 8 switches an operation frequency of the reconfigured control circuit unit (step 37 ).
[0053] The reconfigured control circuit unit continues operation by using the input signal from the input recording unit 9 until the reconfigured control circuit unit catches up with a processing phase in the normal control circuit unit (step 39 , step 40 ).
[0054] In a case where it is determined that the reconfigured control circuit unit catches up with a processing phase in the normal control circuit unit, the selector 10 switches to the input signal from the outside (step 38 ).
[0055] FIG. 4 is a diagram showing a timing chart example of control on a redundant region exercised by a programmable device according to an embodiment of the present invention.
[0056] An example in FIG. 4 shows a case where a soft error has occurred in the control circuit unit 4 . When a soft error has occurred in the control circuit unit 4 , the recording data selection unit 13 issues an operation start (illustrated enable state). Upon receiving this signal, the state recording unit 13 stores the internal state of the normal control circuit unit 5 or 6 . At the same time, recording of the input signal 16 into the input recording units 9 is started. After the recording in the state recording unit 13 is completed, reconfiguration in the control circuit unit 4 is started. After the reconfiguration is completed, the operation frequency of the control circuit unit 4 is quickened as compared with the control circuit unit 5 and the control circuit unit 6 . By the way, the control circuit units 5 and 6 may be made slow as compared with the control circuit unit 4 .
[0057] FIG. 5 is a diagram showing a means used to record an internal state of a redundant region by a programmable device according to an embodiment of the present invention. In an example shown in FIG. 5 , the majority decision circuit unit 7 detects a soft error which has occurred in the control circuit 4 , and conveys soft error detection information and a soft error occurrence region to the recording data selection unit 12 . The recording data selection unit 12 duplicates data in a register 51 which retains an internal state of a normal control circuit unit (in FIG. 5 , the control circuit unit 5 or 6 ), into the state recording unit 13 collectively. In a case where there are a plurality of normal control circuit units, a priority determination method for the selection does not matter especially.
[0058] FIG. 6 is a diagram showing an example of an input (GUI) 61 in a case where design is conducted on the basis of a programmable device according to an embodiment of the present invention.
[0059] In a program having a function of adding a circuit configuration according to the present invention to the control circuit units 4 to 6 to form a desired function in the programmable device 1 , it is possible to input on its input screen, redundancy which represents the number of redundant control circuit units, an operation frequency ratio between a control circuit unit in which a soft error has occurred and control circuit units in which a soft error has not occurred, a state register size which represents a recording storage size in the state recording unit 13 , and a buffer depth which represents a size for recording the input signal of the input recording units 9 . This GUI screen has a function of generating the input recording units 9 , the selectors 10 , the tracking control unit 11 , the recording data selection unit 12 , the state recording unit 13 , and connection information among them.
[0060] FIG. 7 is a diagram showing a means for forcibly inserting a soft error when conducting verification on design including a region configured by a programmable device according to an embodiment of the present invention. The programmable device shown in FIG. 7 differs from the programmable devices shown in FIG. 1 and FIG. 2 in that an error insertion control unit 72 is provided to forcibly cause a soft error at the time of verification on design of a programmable device according to the present invention and confirm operation from soft error detection to restoration. After receiving an error insertion signal 71 from the outside of the programmable device 1 , the error insertion control unit 72 inserts an error to the control circuit units 4 to 6 . An error insertion region is determined on the basis of the error insertion signal 71 . By the way, as for the designation of the error insertion region, the error insertion region may be predetermined and incorporated when designing the circuit of the programmable device 1 . Furthermore, the error insertion control unit 72 may invert data stored in a configuration memory in a control circuit unit that becomes an object.
[0061] FIG. 8 is a diagram showing a means for outputting an internal state to the outside at time of environmental radiation irradiation test on an electronic system device using a programmable device according to an embodiment of the present invention. In the programmable device 1 according to the present invention, a monitoring control unit 81 and a means 85 for reading out stored data from the state recording unit 13 are provided. A soft error detection signal 84 from the majority decision circuit unit 7 is input to the monitoring control unit 81 . Furthermore, a signal 82 which indicates a reconfiguration end state from the reconfiguration control unit 2 is input to the monitoring control unit 81 at the time of start of reconfiguration and during the reconfiguration. Upon receiving these inputs, the monitoring control unit 81 outputs a soft error detection state and a reconfiguration state by outputting a monitoring signal 83 to the outside at an environmental radiation tolerance test.
[0062] FIG. 9 shows an example 91 of a screen that displays an output result obtained in FIG. 8 . An example in which information output by the monitoring means shown in FIG. 8 is displayed (GUI) by using an external computer or the like is shown in FIG. 9 . As for displayed information, an error block representing a region in which a soft error has been detected, a buffer use quantity representing a use quantity of the input signal recording units 9 , a configuration state representing a reconfiguration state, and the number of times of reconfiguration are displayed. Furthermore, an address representing a storage location at the time when reading out data stored in the state recording unit 13 , and a data display part representing a result which is read out are included. Owing to this display screen, tolerance evaluation and operation confirmation can be performed easily at the time of a test in which environmental radiations are forcibly given. As for the buffer use quantity, the internal monitoring state is displayed immediately in some cases and a maximum use quantity of the buffer is displayed in other cases. By the way, the present configuration can also cope with a false operation cause analysis in ordinary product use state.
[0063] FIG. 10 shows a configuration example of a reconfiguration control unit formed by a programmable device according to an embodiment of the present invention and a high order system. Reconfiguration control in the programmable device 1 is exercised by an external processor 101 . Upon detecting occurrence of a soft error, the reconfiguration control unit 2 conveys the error detection to the processor 101 . The processor 101 reads out configuration data which is normal circuit information from the configuration data memory 102 storing configuration data, and reconfigures the programmable device 1 . The reconfiguration control unit 2 monitors the reconfiguration state. After the reconfiguration is completed, the reconfiguration control unit 2 outputs a reconfiguration end signal to the processor 101 . Furthermore, a configuration in which the configuration data 104 is input not from the configuration data memory 102 but from a high order system 103 (such as a computer) connected via a network or the like to conduct reconfiguration may be used.
[0064] FIG. 11 shows an example in which a communication device according to an embodiment of the present invention is configured. In FIG. 11 , an example in which a packet control unit 111 on a control substrate 117 mounted on a communication apparatus is implemented by using a programmable device according to the present invention is shown. In a network in which servers 113 and 114 are connected to client devices such as personal computers via network switches 112 having the packet control unit 111 , the packet control unit 111 which conducts a path change for communication packets in the communication apparatus needs to let fast flowing packets flow continuously and is not allowed to stop.
[0065] By the way, an error detection means for the configuration memory also monitors units other than the control circuit units made redundant because there is a fear that a soft error will be caused by environmental radiations.
[0066] Furthermore, the present invention can cope with not only a soft error caused by environmental radiations but also a soft error caused by electric or magnetic external disturbance noise or noise generated within a device.
[0067] According to the present embodiment, reconfiguration on a soft error occurrence region can be implemented without stopping a system at the time of restoration of a programmable device used in an electronic system product from a soft error caused by environmental radiations as described heretofore. As a result, reliability of systems supporting social infrastructures such as communication devices can be made high.
REFERENCE SIGNS LIST
[0000]
1 : Programmable device
2 : Reconfiguration control unit
3 : Redundant circuit unit
4 : Control circuit unit
5 : Control circuit unit (duplicate of control circuit unit 4 )
6 : Control circuit unit (duplicate of control circuit unit 4 )
7 : Majority decision circuit unit
8 : Clock control unit
10 : Input signal selection unit
11 : Tracking control unit
12 : Recording data selection unit
13 : State recording unit
14 : Configuration control signal
15 : Clock signal
16 : Input signal (input signal to control circuit unit)
17 : Output signal (output signal of control circuit unit)
18 : Steady state clock signal
19 : Clock signal used at the time of restoration from reconfiguration
20 : Soft error detection signal sent from majority decision circuit to tracking control unit
21 : Soft error detection signal sent from majority decision circuit to reconfiguration control unit
22 : Internal state data signal sent from control circuit unit to recording data selection unit
23 : Soft error detection signal sent from majority decision circuit to recording data selection unit | In the event of a software error, operations of a programmable device must be suspended while a configuration memory is being rewritten; however, with a system such as a communication device that will be significantly affected if the device is shut down, the system needs to be restored without suspending the operations. This programmable device is provided with: multiple control circuits; a comparison unit that compares outputs of the multiple control circuits so as to inspect for an occurrence of an error; a storage unit that stores internal states of error-free control circuits among the multiple control circuits when an occurrence of an error is determined by the comparison unit; a reconfiguration unit that reconfigures the control circuit in which the occurrence of the error has been determined by the comparison unit; and a control unit that inputs the internal states of the error-free control circuits, which are stored in the storage unit, to the control circuit in which the occurrence of the error has been determined by the comparison unit. | 6 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.