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CROSS REFERENCE TO RELATED APPLICATIONS
This is a U.S. national stage of application No. PCT/EP2007/056993, filed on 9 Jul. 2007, priority is claimed on Application No. 10 2006 032 100.6, filed 11 Jul. 2006, the contents both of which are incorporated here by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a fuel delivery unit of a motor vehicle, with a swirl pot and with a prefilter which has a filter element and is intended for filtering the fuel flowing into the swirl pot.
2. Description of the Prior Art
Delivery units with swirl pots of this type are frequently used in motor vehicles nowadays and are known from practice. In the case of the known delivery units, the swirl pot is connected to the filter element of the prefilter. If an appropriately sized filter capacity of the prefilter is to be ensured, an appropriately sized filter element of the prefilter is used. A disadvantage of the known fuel delivery unit is that it is highly cost-intensive to keep different filter elements in stock.
SUMMARY OF THE INVENTION
The invention is based on the problem of developing a fuel delivery unit of the type mentioned at the beginning in such a manner that it can be adapted particularly cost-effectively to designated filter capacities.
This problem is solved according to one embodiment of the invention in that the prefilter has a support with at least one connection piece, which is closed in the basic state, for the installation of an additional filter element.
By means of this configuration, the fuel delivery unit according to one embodiment of the invention can be equipped with the additional filter element as well as with the filter element. The filter element preferably has a sufficient filter surface for most applications. If a particularly large filter capacity of the prefilter is to be ensured, the additional filter element can be fitted on the connection piece. Therefore, the fuel delivery unit according to the invention can be adapted particularly cost-effectively to the designated filter capacity.
The fuel delivery unit according to one embodiment of the invention is particularly compact if the support and a base plate closing the swirl pot delimit a collecting chamber for collecting the prefiltered fuel, if an intake connection of a fuel pump is connected to the collecting chamber, and if the connection piece protrudes into the interior of the swirl pot.
The support in one embodiment a closed wall with a plurality of connection pieces. In this case, the filter element is designed as the additional filter element and could be fitted on one of the connection pieces. The fuel delivery unit according to this embodiment of the invention is particularly compact if the filter element is designed as a partial region of the support. By means of this configuration, the swirl pot has at least the filter element which is designed as a partial region of the support. If the filter surface is to be enlarged, one or more other additional filter elements is or are fitted to the corresponding connection piece or connection pieces.
According to another embodiment of the invention, the prefilter has a particularly large filter surface if the filter element is adjacent to the at least one connection piece.
According to another embodiment of the invention, the installation of the prefilter turns out to be particularly simple if the filter element is connected to the swirl pot and/or to the support with a cohesive material joint. By means of this configuration, the swirl pot, in the basic state, has at least a single filter element and, if the need arises, can be provided with a particularly large surface area by the installation of the additional filter element on the connection piece.
The additional filter element to be fitted to the connection piece turns out to be particularly compact, according to another embodiment of the invention, on the additional filter element provided for installation on the connection piece has a connector and a filter fabric protruding from the connector, and if the filter fabric is of bag-shaped design. The bag-shaped filter fabric can be produced, for example, from a tubular filter fabric by the connector being connected to one end of the tubular filter fabric and the other end being closed.
According to another embodiment of the invention, the prefilter which is fitted on the support has a high degree of stability if the connection piece surrounds the connector of the attached additional filter element. Furthermore, the connector of the additional filter element is capable of sealing the opened connection piece.
The installation of the additional filter element is simplified, according to another embodiment of the invention, if the connection piece protrudes in the shape of a tube from the support, and if the support has an at least partially encircling groove as a predetermined breaking point within the connection piece. By means of this configuration, the additional filter element is pressed, upon installation, into the connection piece until the connector can break open the support at the encircling groove. Subsequently, the connector of the additional filter element is inserted in the connection piece and seals the latter. The connector preferably has an end edge for breaking open the predetermined breaking point. The additional filter element can therefore be fitted without a tool.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention permits numerous embodiments. To further clarify its basic principle, one of said embodiments is illustrated in the drawing and is described below. In the drawing
FIG. 1 is a partial section through a fuel delivery unit according to the invention;
FIG. 2 is schematically a longitudinal section through a swirl pot with a prefilter of the fuel delivery unit according to the invention from FIG. 1 ;
FIG. 3 is a greatly enlarged illustration of a partial region of the prefilter from FIG. 2 in the region of an additional filter; and
FIG. 4 is a greatly enlarged illustration of a partial region of the prefilter from FIG. 2 in the region of a closed connection piece.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a delivery unit which is to be arranged in a fuel tank (not illustrated) of a motor vehicle and is intended for delivering fuel to an internal combustion engine (likewise not illustrated) of the motor vehicle. The delivery unit has a fuel pump 2 which is arranged in a swirl pot 1 and is driven by an electric motor, and a fine filter 3 . The fine filter 3 is likewise arranged in the swirl pot 1 and is connected to the fuel pump 2 via a fuel line 4 . Furthermore, the fine filter 3 has a feed connection 5 for a feed line leading to the internal combustion engine of the fuel tank. A line 7 for a suction jet pump (not illustrated) is connected to a connection 6 of the fuel pump 2 . The suction jet pump sucks up fuel from the surroundings of the swirl pot 1 and delivers said fuel into the swirl pot 1 . The swirl pot 1 serves to collect the fuel and has a base plate 8 and a casing 9 connected to the base plate 8 in a sealing manner. An intake connection 10 of the fuel pump 2 protrudes through a prefilter 11 into a collecting chamber 12 arranged between the base plate 8 and the prefilter 11 . The prefilter 11 has a planar filter element 19 which is connected to the casing 9 of the swirl pot 1 with a cohesive material joint and in a sealing manner
and has two connection pieces 13 , 14 . An additional filter element 15 is connected to one of the connection pieces 13 while the other connection piece 14 is sealed.
Fuel flowing into the swirl pot 1 passes via the prefilter 11 into the collecting chamber 12 and therefore to the intake connection 10 of the fuel pump 2 . The fuel pump 2 is therefore capable of sucking up prefiltered fuel from the swirl pot 1 and of delivering said fuel via the fine filter 3 to the feed connection 5 for the feed line. The casing 9 of the swirl pot 1 has an edge 17 which engages over a supporting edge 16 of the base plate 8 . The edge 17 and the supporting edge 16 are connected to each other in a sealing manner.
FIG. 2 shows schematically a sectional illustration through the swirl pot 1 with the prefilter 11 from FIG. 1 . To simplify the drawing, other components, such as the fuel pump 2 and the fine filter 3 , are not illustrated in FIG. 2 . The prefilter 11 has a support 18 for holding the connection pieces 13 , 14 and holds the planar filter element 19 and the additional filter element 15 . Furthermore, the support 18 with the filter element 19 and the additional filter element 15 together with the base plate 8 delimit the collecting chamber 12 .
FIG. 3 shows, on a greatly enlarged scale, the additional filter element 15 attached in one of the connection pieces 13 of the prefilter 11 . The additional filter element 15 has a bag-shaped filter fabric 20 with a connector 21 which is plugged into one of the connection pieces 13 of the support 18 . The connection piece 13 of the support 18 therefore surrounds the connector 21 of the additional filter element 15 . A filter fabric 22 of the filter element 19 arranged on the support 18 is adjacent to the connection piece 13 .
FIG. 4 shows the sealed connection piece 14 with adjacent regions of the prefilter 11 .
In order to enlarge the filter surface of the prefilter 11 , an additional filter element 15 like the one illustrated in FIG. 3 can likewise be attached to said connection piece 14 . The connection piece 14 has an encircling groove 23 as a predetermined breaking point. When the additional filter element 15 is attached, the encircling groove 23 is broken open. The additional filter element 15 is therefore held on the connection piece 13 in a sealed manner, as illustrated in FIG. 3 .
In the basic state after the manufacturing of the prefilter 11 , the connection pieces 13 , 14 , as per the one from FIG. 4 , are sealed. The prefilter 11 therefore exclusively has the filter surface formed by the filter fabric 22 of the planar filter element 19 . If the prefilter 11 is to be provided with an enlarged filter surface, the additional filter element 15 is attached to one or to both connection pieces 13 , 14 . The filter surface can therefore be adapted with a large number of identical parts in a manner corresponding to the number of connection pieces 13 , 14 provided on the support 18 .
Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.
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A fuel delivery unit of a motor vehicle comprises a prefilter arranged inside a swirl pot, said prefilter having a filter element, and at least one connection piece for connecting a supplementary filter element. The at least one connection piece, in its initial condition, is closed, and is opened when the supplementary filter element is attached. The invention allows the fuel delivery unit to be adapted to projected filter surfaces of the prefilter.
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BACKGROUND
The present invention relates generally to laser systems employing phase conjugation processes (phase conjugate lasers), and more particularly to phase conjugate lasers whose output beam is electronically steerable.
Conventional laser systems which provide for a steerable laser beam have generally used conventional optical steering methods such as those employing movable mirrors with servo drives. Such systems are generally limited in scan frequency to about a few thousand hertz. In addition to relatively slow steering speed, the size of the field of view has generally been limited and the efficiency of the laster transmitter has been impaired. Also, time delays required to scan from one part of the field-of-view to another may be longer than milliseconds.
Other beam pointing techniques have involved the use of multiple lasers. However, this approach sacrifices scanning power. Also, a multi-channel conventional laser, such as a scanlaser, does not extract power efficiently from the laser gain medium. Scanlaser systems are described in publication entitled "Fast Electron Beam Scanlaser" by R. A. Myers, IEEE Journal of Quantum Electronics, Vol. QE-4, No. 6, June 1968, and "Electron Beam Scanlaser" by R. V. Pole et al, IEEE Journal of Quantum Electronics, Vol. 2, July 1966.
Therefore, it would be an improvement to the laser art to have a laser system whose output beam is electronically steerable in a random, but controlled, manner at relatively high speeds within a wide field-of-view, while preserving a high-quality, full-power beam.
SUMMARY OF THE INVENTION
In order to overcome the deficiencies in the prior art, the present invention utilizes phase conjugation principles to provide for a steerable laser beam having good beam quality. The present invention employs the use of a phase conjugate reflector which reflects laser energy that is the phase conjugate of energy incident thereupon. The phase conjugate reflector is utilized as one end mirror of a laser resonator. An electronically controlled optical device is employed as the second mirror element of the laser resonator. The optical device provides for a plurality of selectable transverse lasing modes to exist in the laser resonator. Each of the transverse lasing modes have a predetermined wavefront tilt in the near field of the laser resonator. A laser gain medium and its associated pump source are disposed between the optical device and the phase conjugate reflector for providing the laser energy which is reflected inn the resonator. An output coupling device is disposed adjacent to the optical device in the near field for coupling a portion of the laser energy out of the laser system as an output beam.
The optical device may comprise a focusing lens and a mirror located at the focal plane of the lens. The mirror is one whose dimension is approximately one diffraction spot in size, and whose transverse location in the focal plane is electronically controlled to control wavefront tilt. By selectively controlling the position of the reflecting surface, different transverse modes of the laser will lase between the phase conjugate reflector and the mirror in the optical device. Selective control over the transverse mode which is lasing in the resonator results in a steerable output beam whose position in the far field is determined by the location of the mirror in the focal plane of the optical device.
A second embodiment of the optical device contemplates the use of an electronically controllable spatial filter disposed between lenses and a reflective element disposed as the second end mirror of the resonator. The spatial filter is controlled to transmit light to the reflective element in the same manner as the first embodiment controls the reflective surface. The spatial filter transmits light at a plurality of locations along the transverse extent thereof, hence allowing the various transverse lasing modes to exist in the resonator.
The laser beam may be rapidly steered within the field-of-view, typically on the order of 10 megahertz. The use of the phase conjugate reflector preserves high laser beam quality and ensures a high-power, diffraction-limited beam.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 illustrates an agile beam laser in accordance with the principles of the present invention;
FIG. 2 illustrates the laser of FIG. 1 in which an off-axis transverse mode has been selected;
FIGS. 3a and 3b show an embodiment of an optical device for use in the laser of FIG. 1; and
FIG. 4 shows a second embodiment of an agile beam laser in accordance with the principles of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown an agile beam laser 20 in accordance with the principles of the present invention. The laser 20 includes a phase conjugate reflector 21, laser gain medium 22 and its associated pump source 23, an output coupling device 24, and an optical device 25 disposed along an optical path to form a laser resonator.
The phase conjugate reflector 21 may be one of a number of phase conjugate devices which are generally known in the art. For example, the reflector may be a device which employs stimulated Brillouin scattering, or four-wave mixing processes, or the like. The principles of phase conjugation are generally well-known in the art and are discussed in numerous publications. A general discussion of optical phase conjugation may be found in a publication entitled "Applications of Optical Phase Conjugation", by Concetto R. Giuliano, Physics Today, April 1981; U.S. Pat. No. 4,233,571, entitled "Laser Having a Nonlinear Phase Conjugating Reflector"; "Demonstration of the Longitudinal Modes and Aberration-Correction Properties of a Continuous Waveguide Laser With a Phase Conjugate Mirror", R. C. Lind et al, Optics Letters, Vol. 6, No. 11, November 1981; and "Laser with a Stimulated Brillouin Scattering Complex Conjugate Mirror" by S. A. Lesnik et al, Sov. Phys. Tech. Phys., Vol. 24, No. 10, October 1979.
The laser gain medium 22 and its associated pump source 23 may be any conventional lasing medium which is compatible with the phase conjugate reflector 21. For example, the Giuliano publication includes a table listing a variety of lasing media, phase conjugating media and phase conjugation processes which may be utilized in the present invention. The output coupling device 24 may be any conventional device such as a partially reflecting mirror arrangement, or a beamsplitter, or the like.
The optical device 25 comprises a focusing element 26, such as a lens, or the like, and a transverse mode control device 27. The focusing element 26 is designed to focus laser energy at a focal plane 28 where the transverse mode control device 27 is located.
The transverse mode control device 27 in this embodiment is a reflecting surface which conforms to the focal plane of the focusing element 26, and which may be electronically controlled so that a portion, or portions, of the device 27 may be made to reflect at any one time. The transverse mode control device 27 is designed so that a reflective spot on the order of the diffraction limit of the laser 20 is made to reflect laser energy. The device 27 may be electronically controlled so that the position of the reflective spot is moved in the focal plane 28 hence creating a plurality of transverse lasing modes in the laser 20.
FIG. 2 shows the system of FIG. 1 operating in a second transverse lasing mode. Laser light at this second transverse mode is made to lase between the transverse mode control device 27 and the phase conjugate reflector 21. Since the point of focus of the focusing element 26 is off the optical axis of the system, the collimated beam to the right thereof, which is representive of the near field, has a tilt associated therewith. Accordingly the output beam of the laser 20 has substantially the same tilt.
One embodiment of the transverse mode control device 27 is shown in FIG. 3a. A device may be comprised of a potassium dihydrogen phosphate (KDP) slab 35 which has a plurality of transparent electrodes 36 coated on the front surface thereof. These transparent electrodes 36 are in the form of vertical strips and may be comprised of indium tin oxide (ITO), or the like. In addition, the rear surface of the KDP slab 35 is coated with a plurality of reflective electrodes 37. These reflective electrodes 37 may be made of silver, or the like, and are deposited in a horizontal configuration.
The transparent electrodes 36 may be biased at a value of V.sub.π /8 and the reflective electrodes 37 at -V.sub.π /8, where V.sub.π is the voltage necessary for polarization rotation by 180°. By applying a voltage of approximately 375 volts across selected horizontal and vertical electrodes, the KDP slab 35 may be made to transmit polarized light in a localized area. Accordingly, laser light may be transmitted through the transparent electrodes 36 and KDP slab 35 and hence reflected from the reflective electrodes 37. Accordingly, in referring to FIG. 3b, this arrangement may be electronically scanned to produce one or more reflective locations at the focal plane 28 of the system of FIG. 1. Laser light will thus be reflected to create the desired transverse mode operation of the laser 20. Several reflective spots are shown in FIG. 3b identified by the stippled areas.
It is known in the art that a phase conjugate resonator will oscillate off the brightest reflective surface encountered by a reflected wave from the phase conjugate reflector. This information may be found in an article by J. Feinberg et al entitled "Phase Conjugating Mirror with Continuous Wave Gain", Optics Letters, Vol. 5, No. 12, December 1980.
Another mechanism for creating an electronically controlled reflective surface is described in several publications dealing with electron beam scanlaser systems. One publication is entitled "Fast Electron Beam Scanlaser" by R. A. Myers, IEEE Journal of Quantum Electronics, Vol. QE-4 No. 6, June 1968, and another publication is entitled "Electron Beam Scanlaser" by R. V. Pole et al, IEEE Journal of Quantum Electronics, Vol. 2, July 1966. The scanlaser device employs a scanning electron beam, a layer of photo-refractive material, such as KDP, backed by a plane mirror and fronted by a quartz plate and polarizer. The electron beam is used to modify the birefringence of the KDP at a localized spot such that the KDP birefringence at the spot exactly cancels the birefringence of the quartz. This allows polarized light from the resonator to be reflected from the mirror.
One other method of creating an electronically controlled reflective surface is known in the art and involves the use of vanadium dioxide as a mirror. The vanadium dioxide is heated to a temperature just below the semiconductor-metal transition temperature thereof. An electron beam is utilized to illuminate the vanadium dioxide and heat the illuminated area above the transistion temperature. Therefore, it becomes a metal and is reflecting. Although this method is feasible, it is uncertain whether temperature fluctuations in the vanadium dioxide can be controlled in a manner which would make this method practical.
Referring to FIG. 4 there is shown a second embodiment of present invention. In this embodiment the transverse mode control device 27' is one which transmits the laser light instead of reflecting it. Accordingly, a second focusing element 31 and plane mirror reflector 32 are required in order to complete the laser resonator. The output coupling device 24 is shown positioned between the second focusing element 31 and plane mirror reflector 32. However, this is not absolutely necessary, and it need only be placed in the optical path at positions where the laser light is collimated, preferably as shown. For example, it may be placed between the first focusing element 26 and laser gain medium 22 as described with reference to FIG. 1.
The operation of this embodiment is substantially the same as the first embodiment except that the transverse mode control device 27' allows the focused light to be transmitted therethrough and hence acts as a spatial filter. This spatial filter is electronically controllable as in the first embodiment. For example, the device shown in FIG. 3a could be utilized except that the rear reflective electrodes 37 would be replaced by transparent electrodes so that the device is transparent to the laser light passing therethrough. It should be clear that the general operation of this embodiment is substantially the same as the first embodiment and in particular the transverse mode control device 27' may be implemented in a variety of ways, some of which have been described hereinabove.
It is to be understood that the above-described embodiments are merely illustrative of some of the many specific embodiments which represents applications of the principles of the present invention. Clearly, numerous and varied other arrangements may be readily devised by those skilled in the art without departing from the spirit and scope of the invention.
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A laser system for providing a rapidly steerable laser output beam. The laser system includes a phase conjugate reflector, laser gain medium and its associated pump source, an output coupling device, and an optical element which selectably controls the transverse lasing mode of the laser system. The components are arranged to form a laser oscillator between the phase conjugate reflector and the optical device, and is operated in such a manner that each selected transverse mode of laser operation generates an output beam from the system which has a different wavefront tilt. Accordingly, the output beam is steerable and is dependent upon the selected transverse mode which is currently lasing in the oscillator.
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This is a continuation-in-part of United States patent application Ser. Nos. 07/811,093, filed Dec. 20, 1991 abandoned and 07/810,627, filed Dec. 19, 1991, abandoned, which in turn are both divisional applications of United States Patent application Ser. No. 07/590,247, filed Sep. 28, 1990, now U.S. Pat. No. 5,041,234, which is in turn a continuation-in-part application of United States patent application Ser. No. 07/418,757, filed Oct. 5, 1989, now U.S. Pat. No. 5,041,251, which is in turn a continuation-in-part of Ser. No. 256,547, filed Oct. 17, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1.1. Technical Field
The present invention relates to flame retardant thermosetting epoxy molding compounds of the type comprising an epoxy, a hardener, a catalyst, a mold release agent, a filler, optionally a colorant, optionally a coupling agent and a flame retardant system. The flame retardant system comprises an oxidizing refractory metal oxide, particularly an oxidizing metal oxide of an element selected from Group VIA of the Periodic Table, and an organic compound containing halogen. The flame retardant thermosetting epoxy molding compound may be used, for example, to encapsulate a semiconductor device.
The present invention also relates to a method of encapsulating a semiconductor device by heat curing around a semiconductor device an encapsulating compound comprising an epoxy, a hardener, a catalyst, a mold release agent, a filler, optionally a colorant, optionally a coupling agent and a flame retardant system. The flame retardant system comprises an oxidizing refractory metal oxide, particularly an oxidizing metal oxide of an element selected from Group VIA of the Periodic Table, and an organic compound containing halogen.
The present invention also relates to an encapsulated semiconductor device wherein the encapsulant is the flame retardant thermosetting epoxy molding compound described above, the flame-retardant system comprising an oxizidizing refractory metal oxide, particularly an oxidizing metal oxide of an element selected from Group VIA of the Periodic Table, and an organic compound containing halogen.
A flame-retardant system comprising an organic compound containing a halogen and an oxidizing refractory metal oxide, particularly an oxidizing metal oxide of an element selected from Group VIA of the Periodic Table, was unexpectedly found to have flame retardant synergism when incorporated in thermosetting epoxy molding compounds used for encapsulating a semiconductor device.
The halogen-containing organic compound may be a separate ingredient, but is preferably a part of either the epoxy or the hardener. The halogen-containing organic compound can also be a halogen-containing compound which is chemically incorporated into the product of the epoxy resin and the hardener upon setting or part of other ingredients such as the lubricant or the colorant.
The flame retardant system may also comprise, optionally, antimony pentoxide and sodium. The flame retardant system may also comprise, optionally, basic magnesium oxide compound to reduce corrosion of metal conductor lines and pads of the semiconductor device.
The term "epoxy molding compounds" as used herein means epoxy molding compound conventionally known in the art including any material containing two or more reactive oxirane groups. For example, the epoxy molding compound may have two or more epoxy groups in one molecule, including glycidyl ether type such as, phenol novolac type; cresol novolac type and the like; glycidyl-ester type; alicyclic type; heterocyclic type and halogenated epoxy resins, etc. The epoxy resins may be used either singly or as a mixture of two or more resins.
Similarly, the term "hardener" as used herein means an epoxy novolac molding compound including, but not limited to, any phenol-derived and substituted phenol derived novolac hardener and anhydride hardener conventionally used as hardener for epoxy resins. For example, phenolic novolacs, and cresolic novolacs, are most suitable. The epoxy novolac molding compounds may be used either singly or as a mixture of two or more compounds.
The term "catalyst" as used herein means a catalyst appropriate to the hardener used to promote the curing of the present composition. Such catalysts include, but are not limited to, basic and acidic catalysts such as the metal halide Lewis acids, e.g., boron trifluoride, stannic chloride, zinc chloride and the like, metal carboxylate-salts such as stannous octoate and the like; and amines, e.g., triethylamine, imidazole derivatives and the like. The catalysts are used in conventional amounts such as from about 0.1 to 5.0% by weight of the combined weight of epoxy and hardener.
The term "mold release agents" as used herein means chemical agents commonly used to assist the release of the cured epoxy molding compounds from the mold. For example, carnauba wax; montanic acid ester wax; polyethylene wax; polytetrafluoroethylene wax; glyceral monostearate; metallic stearates; paraffin waxes and the like are suitable.
The term "fillers" as used herein means one or more of the conventional fillers such as silica, calcium carbonate, calcium silicate, aluminum oxide, glass fibers, clay, and the like. The preferred filler is silica or a mixture of predominantly silica with other filler(s). The fillers usually are used in at least 50 percent by weight of the molding compound.
The term "colorant" as used herein includes colorant commonly used in epoxy molding compound, such as carbon black, pigments, dyes and the like.
The term "coupling agent," as used herein means a coupling agent known to improve dry electrical properties of the compound. The coupling agents may be of the silane type, characterized by the formula R'Si(OR) 3 ; where R' represents an organo-functional group such as amino, mercapto, vinyl, epoxy or methacryloxy, and OR represents a hydrolyzable alkoxy group attached to the silicon. Preferred coupling agents are described in U.S. Pat Nos. 4,042,550 and 3,849,187, of which the descriptions are incorporated herein by reference.
The term "halogen-containing organic compound" or "organic compound containing halogen", as used herein, includes organic compound in which the halogen is present from any source including halogenation of a component or its precursor (such as a monomer) or by addition of halogen-containing monomers by reactions in which the halogen is not completely removed.
The halogen-containing organic compound used in a is preferably of the reactive type and further preferably has, as halogen, chlorine or bromine. Exemplary halogenated organic compounds are those types of polyglycidyl ether of bromophenolformaldehyde novolac, commercially sold by Nippon Kayaku under the tradename "BREN™," those described in U.S. Pat. Nos. 4,042,550 and 4,282,136, of which the descriptions are incorporated herein by reference and include halogenated bisphenol A and derivatives of bisphenol A such as tetrabromobisphenol A, and glycidyl ethers of halogenated resins such as the diglycidyl ether of tetrabromobisphenol A.
Preferred is meta-brominated cresol epoxy novolac available from the Dow Chemical Co. under the tradename "Stable Bromine Cresol Epoxy Novolac" (71842.00L type or 71970.00 type, production no. R0544-91091-21-1. These are described in U.S. Pat. Nos. 4,727,119 and 4,731,423). The 71842.00L type is of the general formula: ##STR1## The 71970.00 type contains the following ingredients:
______________________________________Diglycidylether of Dibromotetramethylbisphenol 0-8%Diglycidylether of Tribromotetramethylbisphenol 8-40%Cas No. 108935-90-6Diglycidylether of Tetrabromotetramethylbisphenol 0-2%Cas No. 72436-58-9Reaction product of cresol, formaldehyde & 60-90%epichlorohydrinCas No. 064425-89-4______________________________________
The halogen containing organic compound may be a separate additive or may be contained in one or more of the organic components of the molding compound, especially the epoxy or the hardener, or possibly other components such as the lubricant, or the colorant or the filler (if organic).
Exemplary of reactive halogen-containing organic compounds which are part of the epoxy resin are metabrominated phenolics such as meta-brominated cresol epoxy novolac.
The term "oxidizing" means capable of at least partially oxidizing residual reduced sites on integrated circuit components where two different metals are in contact with each other, such as conductor lines, pads and ball-bonds. For example, for an integrated circuit having an Al 2 O 3 surface layer which passivates the metallic aluminum of the integrated circuit, oxidizing of the residual reduced sites thickens and strengthens the passivating surface layer.
The term "refractory metal oxide" means any oxide of any metal or alloy of any metal recognized as a refractory metal in the Manual of Classifiaction of Patents at page 75-1 of the December 1991 edition. These include titanium, zirconium, hafnium, vanadium, niobium, columbium, tantalum, chromium, molybdenum and tungsten.
The term "metal oxide of an element selected from Group VIA of the Periodic Table" means any Group VIA metal or alloy in any oxide form. Preferably, the metal oxide is tungsten or molybdenum. More preferably, the metal oxide is tungsten trioxide or molybdenum trioxide, both sold by Johnson Matthe Chemicals Ltd.
The term "antimony pentoxide" as used herein means antimony pentoxide in any available form. Preferably, antimony pentoxide used is Nyacol A1590 commercially sold by the Nyacol Division of P. Q. Corporation which has a sodium content of 0.03 to 0.06% by weight of the antimony pentoxide.
The term "magnesium oxide compound" as used herein means any magnesium oxide in any available form capable of neutralizing the acidity of the antimony pentoxide and thereby reducing the corrosion of the metal semiconductor device lines and pads, especially in regions where two different metals are in contact with each other. Preferably, the magnesium oxide compound is magnesium aluminum carbonate hydrate commercially sold by Kyowa Chemical Industry Co. under the trade name "DHT-4A".
1.2. Description of Background Art
Epoxy resin compounds have often been used for encapsulation of semiconductor devices such as integrated circuits (IC), large scale integrated circuits (LSI), transistors and diodes, etc., or other electronic components. Such encapsulants generally comprise an epoxy, a hardener, a catalyst, a mold release agent, optionally a filler, optionally a colorant and sometimes a coupling agent.
Exemplary formulations of these ingredients are described in U.S. Pat. No. 4,710,796 to Ikeya et al., U.S. Pat. No. 4,282,136 to Hunt et al., U.S. Pat. No. 4,042,550 to Nussbaum et al. and references cited therein and in Raymond, T. "Avoiding Bond Pad Failure Mechanisms in Au--Al Systems" Semiconductor Int'l. p. 152-158, September 1989. Recently, the electronic industries require these epoxy molding compounds be flame retardant. Additives including halogenated compounds, transition metal oxides and hydrated alumina to improve the flame retardancy, as measured for example by Underwriters Laboratory Test 94V-0 of 1/16" bar, have been reported. However, at high temperatures, these flame retardant additives detract from the compatibility of the encapsulant with semiconductor devices.
U.S. Pat. No. 4,710,796 to Ikeya et al. teaches a resin for encapsulating semiconductor device comprising an epoxy resin, curing agent, organic phosphine compound and at least one antimony oxide.
U.S. Pat. No. 4,042,550 to Nussbaum et al. teaches encapsulating semiconductors using epoxyanhydride molding compounds with secondary fillers including antimony trioxide or antimony tetraoxide and halogenated compounds in flame retardant systems.
Similarly, U.S. Pat. No. 4,282,136 to Hunt et al. describes the use of synergistic flame retardants consisting of halogen-containing organic compounds and antimony pentoxide for encapsulating semiconductors. The reference teaches that an encapsulant employing such a flame retardant system, when used to encapsulate a semiconductor device, has improved high temperature compatibility compared to similar molding compounds with antimony trioxide or antimony tetraoxide. However, the prior art epoxy molding compounds contain a high percent of sodium which is known to cause poor performance in semiconductor devices due to current leakage. See Moltzan et al., "The Evolution of Epoxy Encapsulation Compounds For Integrated Circuits: A User's Perspective, Polymer for High Technology Electronics and Protronics", ACS Sym. Series No. 346, p. 521, Sep. 7-12, 1986.
Raymond describes the necessity of IC manufacturers keeping Br in molding compounds at a low level (around 0.6-0.8%.) based on poor dry heat reliability results with a high Br compound (1.0%).
Prior to the present invention, there has never been suggested or disclosed the use of an epoxy molding compound used to encapsulate semiconductor devices which compound has a flame retardant system comprising an oxidizing refractory metal oxide and a halogen containing organic compound.
Molybdenum compounds have been used with polyvinyl chloride for smoke suppression. See e.g., Moore et al., "Molybdenum Compounds as Smoke Suppressants", Proc. Int. Conf. Fire Saf., Vol. 12, p. 324-339, 1987; Kroenke et al., "Melaminium Molybdate Smoke and Fire Retardants for Poly(vinyl chloride)", Journal of Applied Polymer Science, Vol. 32, no. 3, p. 4155-4168, Aug., 1986; Handa et al., "The Synergistic Effects of Antimony Trioxide and Other Metal Oxide or Hydroxide in Plasticized Flame Retardant Polypropylene and Plasticized PVC", J. Fire Retard Chem., Vol. 8, no. 4, p. 171-192, 1981.
Additionally, molybdenum has been found to be a flameproofing synergist in applications unrelated to epoxy molding compounds for encapsulating electronic devices, such as in flameproofing cotton fabric or unsaturated polyesters See e.g., Trask et al., "A Synergistic Molybdenum-based Fire-Retardant System for Outdoor Cotton Fabric", Proc. Symp. Text. Flammability, Vol. 6, p. 304-316, 1978; Skinner et al., "Flame Retardant Synergism Between Molybdenum and Halogen-containing Compounds in Unsaturated Polyesters", Fire Mater., Vol. 1, no. 4, p. 154-159, 1976.
Ammonium tungstate has been found to improve Integrated Circuit performance, but no flame retardant synergism has been attributed to such compound. See, Ainger et al., "Improvements to Microcircuit Reliability by the Use of Inhibited Encapsulants", A.C.S. Symp. Series, Vol. 242, pp. 313-322, 1984.
While the prior art flame retardant combinations used in epoxy molding compounds that encapsulate semiconductor devices provides reasonable flame retardance and satisfactory compatibility on electronic devices, a need clearly exists for flame retardant epoxy molding compounds of all types with improved high temperature compatibility and performance, and lower cost and toxicity.
Accordingly, it is an object of the present invention to provide a flame retardant thermosetting epoxy molding compound that is compatible with semiconductor devices at high temperatures.
It is yet another object of the present invention to provide an improved method of encapsulating a semiconductor device.
It is yet another object of the present invention to provide an improved encapsulated semiconductor device. These and other objects of the invention, as well as a fuller understanding of the advantage thereof, can be had by reference to the following descriptions and claims.
2. SUMMARY OF THE INVENTION
The foregoing objects are achieved according to the present invention by an improved epoxy molding compound comprising:
(a) about 5-25 percent by weight of compound of an epoxy;
(b) about 4-20 percent by weight of compound of a resin hardener;
(c) an effective amount of a catalyst for the reaction between said epoxy resin and said hardener in an amount of from about 0.1 to 10% by weight of the combined weight of epoxy and hardener;
(d) an effective amount of a mold release agent for the release of the cured molding compound from a mold in an amount of between about 0.01 and about 2 percent by weight of composition;
(e) between about 50 and 85 percent by weight of composition of a filler; and
(f) a flame retardant system of:
(1) a refractory metal oxide; and
(2) a reactive organic compound containing halogen said reactive organic compound being a separate compound or being contained in one or more of said components (a)-(e) of said epoxy molding compound.
The improved epoxy molding compounds of the present invention are suitable for use in encapsulating a semiconductor device.
According to the present invention, the said improved epoxy molding compounds may be prepared by any conventional method. For example, the ingredients may be finely ground, dry blended and then densified on a hot differential roll mill, followed by granulation. Generally, the ingredients (or any portion of them) may be prepared as a fine powder, fed directly into a compounding device such as an extruder prepared as a premix of raw materials. If less than all of the ingredients are present in the initial form, the remainder of the ingredients can be added prior to or during densification.
Densification can be by mechanical compacting using a preformer or a combining mill in the case of a fine powder, or by an extruder or differential roll mill in the case of the fine powders, direct feed or premix. Premixes or densified forms (such as preforms and granular forms), containing less than all of the ingredients can also be fed to the ultimate mold in the system with the remaining ingredients in a similar or different form.
The present invention includes flame retardant molding compounds in any physical form or even as systems of two or more components. Where two or more components are used, one should contain the epoxy, the other the hardener. Preferably, the catalyst is in the hardener component to avoid catalyzed homopolymerization of the epoxy.
In a preferred embodiment, in the laboratory, the dry ingredients of the formula are preground to a fine powder and then mixed in a large plastic bag. The liquid ingredients (i.e., the silane coupling agents) are added to dry ingredients and the mixture is mixed again by hand. The mixture is then treated on a large two-roll mill (one roll heated to about 90° C. and the other cooled with tap water) until a uniform sheet (about 6" wide by 24" long) is obtained. The sheet is allowed to cool and then ground to a fine powder.
In another preferred embodiment, in the pilot plant and during large scale production, the dry ingredients are mixed in a large hopper, the liquid ingredients are added in a homogeneous manner to ensure blending, and mixing continues. This mixture is then extruded (with heating) to give a continuous sheet which is cooled and grounded. The final ground powder can be used as is, or compacted (densified) in a preformer to give tablets (preforms) of desired shape and size.
These compounds may be molded into various articles by application of the appropriate temperature and pressure. For example, molding conditions for the encapsulated semiconductor of the present invention may range from about 300° to 400° F., (about 149°-204° C.), preferably about 350° to about 375° F., (about 177°-191° C.), at 400 to 1,500 psi, (about 28-105 kg/cm 2 ), for a time ranging from about 30 to 120 seconds, preferably 60 to 90 seconds.
The epoxy molding compound obtained may be used to encapsulate semiconductor devices by any conventional method. Any suitable molding apparatus may be employed, such as a transfer press equipped with a multi-cavity mold.
The ratio between the various ingredients may vary widely. In general, the epoxy will be in proportion to a novolac hardener so as to give a mole ratio of oxirane:reactive hydroxy between about 0.8 and 1.25. Similarly, the epoxy will be in proportion to an anhydride hardener so as to give a ratio of oxirane: anhydride equivalent between about 1.0 and 1.7, preferably between about 1.11 and 1.25.
The catalyst employed is generally applied at levels sufficient to harden the epoxy molding compound under anticipated molding conditions. Amounts between about 0.01 and 10 weight percent (by combined weight of epoxy and hardener) are sufficient, preferably between about 0.5 and 2.0 weight percent.
The mold release agent will be employed in amounts sufficient to give good release from the mold and also to improve the dry electrical properties of the encapsulated semiconductor device. Amounts between about 0.01 and 2 percent by weight of total compound, preferably between about 0.02 and 1 percent by weight of total compound can be used.
The total amount of filler may range from 0 up to about 85 percent of the total compound. Preferably, the filler comprises a total of more than 50 weight percent of the total compound and more preferably between about 60 and about 80 weight percent of the total compound. Preferably the filler includes silica.
Colorants, if employed, are generally in amounts sufficient to give encapsulated devices the desired color preferably black. Amounts between about 0.05% -preferably 0.1-0.5% by weight of total compound can be employed.
Coupling agents, and in particular silane coupling agents, are provided in amounts sufficient to give the desired dry electrical properties and preferably between about 0.05 and 2 weight percent by total weight of compound, more preferably between about 0.1 and 1.5 weight percent by total weight of compound.
Preferably, the halogen of the reactive organic compound having halogen is bromine. Preferably, the organic compound having halogen contains about 0.5-1.5% halogen by weight of molding compound.
Preferably, the oxidizing refractory metal oxide is an oxidizing metal oxide of an element selected from Group VIA of the Periodic Table, most preferably tungsten trioxide or molybdenum trioxide. Preferably, the formulation comprises from 0.40-2.0% of the oxidizing refractory metal oxide.
Optionally, the formulation may comprise 0.4-0.8% percentage of antimony pentoxide and 0.03-0.06% sodium content (by weight of antimony pentoxide). Further, optionally, the formulation may comprise 0.02-3.20% by weight of magnesium oxide compound, preferably, basic magnesium aluminum carbonate hydrate.
The use of a lower percentage of antimony pentoxide in the present invention is preferred because antimony compounds are expensive and at least potentially toxic.
Oxidizing refractory metal oxides, particularly oxidizing metal oxides of an element selected from Group VIA of the Periodic Table, and an organic compound containing halogen, when included as part of a flame retardant system of an epoxy molding compound for molding semiconductor devices, were found to be flame retardant synergists based on the test results as shown herein.
In the ball bond degradation test, the encapsulated devices are placed in an autoclave having a moist environment. After a number of hours, the encapsulated devices are removed from the autoclave and a hole drilled in the top thereof. Fuming nitric acid is poured into the hole to expose the bonding wire. The strength of the bond between the gold wire ball and the aluminum bonding pad is measured using a probe. The reduction in strength of the bond from the bond prior to placement in the autoclave is the measure of the % of original ball bond strength. National LF412 operational amplifiers encapsulated with epoxy molding compound comprising MoO 3 retained 95% of their original ball bond strength when stored in an autoclave set at 30 psi steam for 1000 hours. National LF412 operational amplifiers encapsulated with epoxy molding compound comprising WO 3 retained 90% of their original ball bond strength under the same conditions.
The electrical reliability of the encapsulated devices in a moist environment is determined by placing the encapsulated devices with no bias in an autoclave having a moist environment. After a number of hours, the encapsulated devices are dried and tested with an electrical tester. The time that it takes for 50% of the encapsulated devices to show a failure in any one of several electrical parameters is determined. These parameters, set by the manufacturer of the device, include, for example, the net DC input offset current for zero device output, the current from device negative input with zero output, the current from the device positive input terminal with zero output, the average of the two previous parameters, DC input offset voltage for zero device output, etc. National LF412 operational amplifiers encapsulated with epoxy molding compound comprising MoO 3 placed in autoclave set at 15 psi did not show 50% failure until 660 hours.
The high temperature storage life (HTSL) test assesses electrical reliability of the encapsulated devices in a dry environment. In the HTSL test, parametric shifts in voltage output levels are monitored. The temperature at which the semiconductor is stored may be varied. The voltage output levels reflect increased resistance across the ball-bonds of the devices. The improved epoxy molding formulations delay or eliminate the failure due to parameter shifts in voltage output levels of encapsulated semiconductor devices.
When the HTSL test is performed at 200° C., 5420 devices encapsulted with epoxy molding compound comprising WO 3 did not show 50% failure at 400 mV until 930 hours and at 250 mV until 451 hours. When the HTSL test is performed at 190° C., 74LS00 devices encapsulted with epoxy molding compound comprising WO 3 did not show 50% failure at 400/500 mV until more than 3000 hours and at 300/350 mV until 1900 hours. Further, when the HTSL test is set at 190° C., 74LS00 devices encapsulated with the epoxy molding compound comprising WO 3 showed no failure at 400/500 mV and a constant 4.0/8.0 mA current until 902 hours and no failure at 300/350 mV and a constant current of 4.0/8.0 mA until 594 hours. These reults are a significant improvement over the HTSL test results under the same conditions for the 74LS00 devices encapsulated with an epoxy molding compound comprising S 2 O 5 and no oxidizing refractory metal oxide, which was unexpected in view of the fact that Sb 2 O 5 is a flame retardant synergist, as shown in U.S. Pat. No. 5,041,234 of Gallo.
In the high temperature accelerated stress (HAST) test, encapsulated devices with no bias are placed in a HAST chamber set at a constant temperature. After a number of hours the encapsulated devices are dried and tested with an electrical tester. The time that it takes for 50% of the encapsulated devices to show failure in any one of several electrical paramters set by the manufacturer of the device is determined. When National LF412 operational amplifiers encapsulated with epoxy molding compound comprising WO 3 were placed in a HAST chamber set at 148° C./90% RH with no bias, the devices did not show 50% failure until 2650 hours.
In the T-shock cycle test, the encapsulated devices are placed in liquid nitrogen for 5 minutes and then in hot solder for 5 minutes. This cycle is continuously repeated and the parts examined for visual cracks every 5 cycles. When National LF412 operational amplifiers encapsulated with epoxy molding compound comprising WO 3 were tested, the devices did not show 50% failure until 245 cycles, which is a significant improvement over the same devices encapsulated with an epoxy molding compound comprising Sb 2 O 5 and no oxidizing refractory metal oxide.
The results of these tests show that oxidizing refractory metal oxides, particularly oxidizing metal oxides of an element selected from Group VIA of the Periodic Table, and more particularly, WO 3 and MoO 3 , are flame retardant synergists when added to a reactive organic compound containing a halogen in a flame retardant system of an epoxy molding compound for encapsulating semiconductor devices.
Further, the epoxy molding compounds may optionally contain from about 0.40-0.80% antimony pentoxide by weight of molding compound. This is especially surprising in view of the prior art teaching that a higher percent antimony pentoxide (≧1%) will give formulation with better synergistic performance. One skilled in the art of molding compound systems would not be led to use about ≦0.8% antimony pentoxide because prior art teaches use of a halogen containing organic compound with ≧1% of pentoxide is expected to give reduced parametric failures.
In the present invention, the improved epoxy compound obtains superior results with both < and ≧1.0% bromine content. This result is unexpected based on the prior art teachings that high levels of bromine are detrimental to high temperature reliability. One skilled in the art would not be led to use about ≧1.0% bromine content because prior art teaches the use of ≧1.0% bromine content is expected to give poor dry heat reliability results.
The improved epoxy molding compounds may also contain basic magnesium aluminum carbonate hydrate and antimony pentoxide in addition to the oxidizing refractory metal oxides. In particular, test results showed that compounds containing DHT-4A in addition to WO 3 are also flame retardant synergists.
The present invention is not restricted to the above ingredients but may include other ingredients which do not detract from flame retardant properties of the flame retardant agent. Accordingly, other organic or inorganic materials may be added under the above conditions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 describes test results of the ball bond degradation test on Example 4 as a function of time and the estimated bond pull strength at 30 psi.
FIG. 2 describes test results of the ball bond degradation test on Example 4 as a function of time and the estimated hours of 50% occurrence of ball lift at 30 psi.
FIG. 3 describes test results of the ball bond degradation test on Example 7 as a function of time and the estimated bond pull strength at 30 psi.
FIG. 4 describes test results of the ball bond degradation test on Example 7 as a function of time and the estimated hours of 50% occurrence of ball lift at 30 psi.
DESCRIPTION OF PREFERRED EMBODIMENTS
The following nonlimiting examples further illustrate the present invention relating to an improved epoxy molding compound, method and encapsulated device. All parts are by weight unless indicated otherwise.
Examples 1-6
Epoxy encapsulants are prepared from the modified formulation A indicated in Table 1. The six encapsulants differ in the presence/absence of MoO 3 , Sb 2 O 5 , or Bi 2 O 3 :
TABLE 1______________________________________ SamplesDescription 1 2 3 4 5 6molding compound % % % % % %______________________________________Fused silica filler 71.39 71.39 70.19 70.99 70.19 69.79Carbon black coloring 0.20 0.20 0.20 0.20 0.20 0.20Epoxy resin 13.49 13.26 13.49 13.49 13.49 13.49Phenolic Novolac 9.22 9.10 9.22 9.22 9.22 9.22HardenerSilane coupling agent 0.70 0.70 0.70 0.70 0.70 0.70catalyst 0.35 0.35 0.35 0.35 0.35 0.35wax lubricants 0.45 0.45 0.45 0.45 0.45 0.45Brominated Epoxy 3.80 3.80 3.80 3.80 3.80 3.80NovolacMoO.sub.3 -- -- 1.60 0.80 -- --antimony pentoxide 0.40 0.75 -- -- -- 0.40Bi.sub.2 O.sub.3 -- -- -- -- 1.60 1.60______________________________________
3.2 Examples 7-11
The properties of the cured encapsulants of Samples 1-6 are determined by total burn times of 1/16" bar according to the UL-94V-O test. The test results are summarized in Table 2.
TABLE 2______________________________________ 1/16" BarSample # Total Burn Time 94V-O Status______________________________________1 17 sec. pass2 4 sec. pass3 9 sec. pass4 31 sec. pass5 60 sec. fail6 18 sec. pass______________________________________
A review of the data shows that MoO 3 and Sb 2 O 5 are flame retardant synergists while Bi 2 O 3 is not, by itself, a flame retardant synergist.
Examples 12-17
National LF412 operational amplifiers are encapsulated with the epoxy molding compounds of Sample 2, 4, 5 and 6. A ball bond degradation test is performed. In this case, the autoclave is set at 30 psi steam and the encapsulated devices are autoclaved for 1000 hours. The test results of the ball bond degradation test are summarized in Table 3 and FIGS. 1-2.
TABLE 3______________________________________ % of original Ball Bond StrengthSample # After 1000 hrs. at 30 psi______________________________________2 about 954 about 955 676 88______________________________________
A review of the data shows that flame retardant systems with Bi 2 O 3 by itself suffers significant degradation of ball bond strength after 1000 hours at 30 psi, but flame retardant systems with Sb 2 O 5 or MoO 3 do not suffer significant degradation of ball bond strength after 1000 hours at 30 psi.
Examples 18-20
National LF412 operational amplifiers are encapsulated with Samples 1, 4 and 6. The electrical reliability of the encapsulated devices is tested by placing the encapsulated devices with no bias into an autoclave set at 15 psi. The test results are summarized in Table 4.
TABLE 4______________________________________ Hours to 50% Failure 15 psi/Sample # No bias, Parametric Failures______________________________________1 6604 6606 1060______________________________________
A review of the data shows both MoO 3 and Sb 2 O 5 are both flame retardant synergists.
Examples 21-22
Two epoxy encapsulants are prepared from the formulations indicated in Table 5. The two encapsulants differ in the presence/absence of Bi 2 O 3 .
TABLE 5______________________________________ SampleMolding Compound 7 8______________________________________Fused silica filler 70.99 69.39Carbon black coloring 0.20 0.20Epoxy Resin 13.49 13.49Phenol Novolac Hardener 9.22 9.22Silane coupling agent 0.70 0.70Catalyst 0.35 0.35Wax lubricants 0.45 0.45Brominated epoxy Novolac 3.80 3.80WO.sub.3 0.80 0.80Bi.sub.2 O.sub.3 -- 1.60______________________________________
Example 23-26
The properties of the cured encapsulants of Samples 2, 4, 7 and 8 are determined by total burn times of 1/16" and of 1/8" bar according to the UL-94V-O test. The test results are summarized in Table 6.
TABLE 6______________________________________ 1/16" and 1/8" BarsSample # 1/16" 1/8" 1/16" 1/"8______________________________________2 4 sec. -- pass --4 31 sec. -- pass --7 86 sec. 27 sec. fail pass8 73 sec. 40 sec. fail pass______________________________________
Examples 27-30
National LF412 operational amplifiers are encapsulated with Samples 2, 4, 7 and 8 and are subjected to the ball bond degradation test as described in Examples 12-17. The test results are summarized in Table 7 and FIGS. 3-4.
TABLE 7______________________________________ % of original Ball Bond StrengthSample # After 1000 hrs. at 30 psi______________________________________2 about 954 about 957 about 908 --______________________________________
A review of the data shows that like Sb 2 O 5 and MoO 3 , WO 3 was found to be flame retardant synergist and protects against ball bond degradation.
Examples 31-32
Epoxy encapsulants are prepared from the formulation indicated in Table 8.
TABLE 8______________________________________ SamplesMolding Compound 9 10______________________________________Fused silica filler 71.29 70.99Carbon black coloring 0.20 0.20Epoxy Resin 13.49 13.49Phenolic Novolac Hardener 9.22 9.22Silane coupling agent 0.70 0.70Catalyst 0.35 0.35Wax Lubricants 0.45 0.45Brominated Epoxy Novolac 3.80 3.80IXE-600 0.80Sb.sub.2 O.sub.5 0.50 --______________________________________
Examples 33-35
5420 devices are encapsulated with the formulations of samples 7, 9 and 10 and are subjected to high temperature storage life (HTSL) testing at 200° C., highly accelerated stress (HAST) testing at 148° C./90% R.H./no bias and the ball bond degradation test. The test results are shown in the Table 9.
TABLE 9______________________________________ % of HAST (148° C./90% original HTSL (200° C.) RH/ no bias) Ball Bond Hours to 50% Hours to 50% Strength af-Sample failure failure ter 1000 hrs# 250 mV 400 mV parametric at 30 psi______________________________________7 451 930 2650 about 909 540 860 1500-2200 about 9510 180 630 2770 about 60______________________________________
A review of the test data show that the WO 3 sample showed an improvement in live device performance vis-a-vis Sb 2 O 5 , particularly in the HAST test, while the IXE-600 sample showed unacceptable HTSL results, especially at the 250 mV failure limit, and ball bond degradation.
Examples 36-37
Epoxy encapsulants are prepared from the formulations indicated in Table 10.
TABLE 10______________________________________ SamplesMolding Compound 11 12______________________________________Fused silica filler 78.39 78.39DHT-4A 0.70 0.70Carbon black coloring 0.20 0.20Epoxy Resin 8.30 8.30Phenolic Novolac Hardener 6.01 6.01Flexibilizers 1.60 1.60Silane coupling agent 0.75 0.75Catalyst 0.35 0.35Wax Lubricants 0.45 0.45Brominated Epoxy Novolac 2.50 2.50Sb.sub.2 O.sub.5 0.75 --WO.sub.3 -- 0.75______________________________________
Examples 38-39
74L500 devices are encapsulated with samples 11 and 12 and are subjected to the T-shock test, the HAST test and the HTSL test. The results are shown in Table 11.
TABLE 11______________________________________ Sample 11 12______________________________________T-Shock Cycles to 50% failure 200 245Live Device, Hours to 50% failureHAST 148° C. 2,410 2,880HAST 158° C. 1,400 1,110HTSL 190° C.300/350 mV 1,000 1,900400/500 mV 1,300 about 3,000______________________________________
A review of the test data shows that WO 3 gave comparable results to Sb 2 O 5 in the HAST test, a slight improvement in the T-shock test and, unexpectedly, a substantial improvement in the HTSL test.
Examples 40-42
Epoxy encapsulates are prepared from the formulations indicated in Table 12.
TABLE 12______________________________________ SampleMolding Compound 13 14 15______________________________________Fused silica filler 78.29 78.09 77.89Carbon black coloring 0.20 0.20 0.20Epoxy Resin 8.30 8.30 8.30DHT-4A 0.70 0.70 0.70Phenolic Novolac Hardener 6.01 6.01 6.01Flexibilizers 1.60 1.60 1.60Silane coupling agent 0.75 0.75 0.75Catalyst 0.35 0.35 0.35Wax Lubricants 0.45 0.45 0.45Brominated Epoxy Novolac 2.50 2.50 2.50WO.sub.3 0.75 0.75 0.75Sb.sub.2 O.sub.5 0.10 0.30 0.50______________________________________
Examples 43-47
Devices encapsulated with Samples 11-15 are subjected to the UL-94V-O test at total burn times of 1/16" and 1/8" bar. The test results are summarized in Table 13.
TABLE 13______________________________________ Total Burn Time 94V-O StatusSample 1/8" bar/1/16" bar 1/8" bar/1/16" bar______________________________________11 5 13 Pass Pass12 27 62 Pass Fail13 34 67 Pass Fail14 16 25 Pass Pass15 8 20 Pass Pass______________________________________
A review of the test data shows that a system comprising both WO 3 and Sb 2 O 5 is a flame retardant synergist, and the synergistic effect improves as more Sb 2 O 5 is added to the WO 3 .
Examples 48-49
74L500 devices are encapsulated with samples 11 and 12 and are subjected to an HTSL test. The packages were stored for a variable number of hours at 190° C. and the cumulative voltage output/low state level failures are recorded. The results are summarized in Table 14.
TABLE 14______________________________________High Temperature Storage Life Test (190° C.)74LS00 Lead Dual In-Line PartsUsing Copper FramesCumulative VOL Failures 300/350 mV 400/500 mV Samples SamplesHours 11 12 11 12______________________________________ 0 0/35 0/34 0/35 0/34 44 0/35 0/34 0/35 0/34 154 0/35 0/34 0/35 0/34 308 0/35 0/34 0/35 0/34 418 4/35 0/34 0/35 0/34 594 6/35 0/34 0/35 0/34 748 7/35 1/34 1/35 0/34 902 11/35 3/34 2/35 0/341043 20/35 4/34 3/35 1/341197 -- 5/34 7/35 1/341351 -- 14/34 19/35 3/341505 -- 16/34 22/35 6/341659 -- 17/34 -- 6/331870 -- 17/34 -- 7/332046 -- 18/34 -- 7/332178 -- -- -- 7/332332 -- -- -- 7/332486 -- -- -- 8/332640 -- -- -- 9/332794 -- -- -- 10/332948 -- -- -- 10/333102 -- -- -- 13/333256 -- -- -- 13/333410 -- -- -- 16/33______________________________________
A review of the test data shows that WO 3 is more effective as a flame retardant synergist in the HTSL test than is Sb 2 O 5 .
The foregoing examples are intended to illustrate without limitation, the improved flame retardant epoxy molding compound, method and encapsulated device. It is understood that changes and variation can be made therein without departing from the scope of the invention as defined in the following claims.
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A flame retardant epoxy molding compound comprises an epoxy, a hardener preferably of the novolac or anhydride type, a catalyst, a mold release agent, preferably a filler, preferably a colorant, preferably a coupling agent, an organic compound containing a halogen (which can be part of the resin or the hardener), and an oxidizing refractory metal oxide, preferably on oxidizing metal oxide of an element selected from the Group VIA of the Periodic Table. The flame retardant epoxy molding compounds when used to encapsulated semiconductor devices have synergistic flame retardant properties.
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This is a continuation of Ser. No. 07/208,234, now abandoned.
FIELD OF THE INVENTION
This invention relates to supporting and stabilizing structures and, more particularly, this invention relates to portable structures for supporting and stabilizing a utilization area, for example work surfaces, equipment mounting surfaces, food trays and the like.
BACKGROUND OF THE INVENTION
Supporting devices for maintaining trays, work surfaces and the like adjacent to various body members of a user have been heretofore suggested and/or utilized. Examples of such support devices for, at least in part, engaging the outer region of the legs of the user can be found in U.S. Pat. Nos. 1,520,085, 1,546,116, 2,039,922, 2,663,603, 2,750,705, 2,770,514, 2,783,109, and 2,844,429. Examples of such support devices configured to be engaged by the inner region of the legs, and thus held between the thighs of the user, are shown in U.S. Pat. Nos. 2,647,678 and 2,979,990.
Such devices now known and/or utilized have not been found to fully provide stability of the surface to be utilized, particularly when the supporting structure is to be held between the inner thighs of the user, have not proven to be adaptable for a variety of usages thereof, and/or have not provided for adjustment of the surface to accommodate differing modes of utilization. Improvements in such devices are deemed, therefore, to be needed and/or useful.
SUMMARY OF THE INVENTION
This invention provides a supporting and stabilizing structure for securely maintaining a preselected orientation of a utilization area, for example a work surface, adjacent to the thighs of a user which, when held by forces applied by the user's thighs to one portion of the stabilizing structure, resists applied straight line and rotational forces, which is adaptably maintainable adjacent to the inner or outer thigh region of the user, which is lightweight and portable, and/or which provides for adjustment of the position of the work surface relative to a user thereof.
It is therefore an object of this invention to provide a supporting and stabilizing structure for securely maintaining a preselected orientation of a utilization area adjacent to the thighs of a user thereof.
It is another object of this invention to provide a supporting and stabilizing structure securely maintainable adjacent to a user's body by thigh exerted pressure.
It is another object of this invention to provide a utility structure having a stabilizing portion maintainable between the thighs of a seated user thereof.
It is still another object of this invention to provide a utility structure having stabilizing portions which are selectively configurable for stabilization of a utility surface by forces applied by the inner thighs or outer thighs of a seated user against the stabilizing portions depending on the configuration selected.
It is yet another object of this invention to provide a portable utility surface supporting and stabilizing structure securely maintainable between the thighs of a seated user having stabilizing portions which are movable between a surface supporting position extending away from the utility surface and a stored position adjacent to the utility surface.
It is still another object of this invention to provide a utility surface supporting and stabilizing structure having an adjusting mechanism for adjusting the position of the utility surface relative to a user thereof.
It is yet another object of this invention to provide a supporting and stabilizing structure for securely maintaining a utility structure adjacent to the thighs of a user having a stabilizing portion including contoured portions configured to receive different ones of the inner left and right thigh regions of the user, and with the contoured portions having a lower section extending toward the inner thigh region of the user received thereby.
With these and other objects in view, which will become apparent to one skilled in the art as the description proceeds, this invention resides in the novel construction, combination, and arrangement of parts substantially as hereinafter described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiment of the herein disclosed invention are meant to be included as come within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a complete embodiment of the invention according to the best mode so far devised for the practical application of the principles thereof, and in which:
FIG. 1 is a perspective view of a first embodiment of the utility surface supporting and stabilizing structure of this invention;
FIG. 2 is a perspective view of the supporting and stabilizing structure of FIG. 1 illustrated in use by being gripped between the thighs of a user of the utility surface supported and stabilized thereby;
FIG. 3 is a side elevation view of the supporting and stabilizing structure of FIG. 1;
FIG. 4 is an end elevation view of the supporting and stabilizing structure of FIG. 1;
FIG. 5 is a bottom elevation view of the supporting and stabilizing structure of FIG. 1;
FIG. 6 is a partial perspective view of a portion of the supporting and stabilizing structure of FIG. 1 particularly illustrating the section of the structure for securing the position of the utility surface support and stabilizing walls;
FIG. 7 is a sectional view of the section of the structure of FIG. 6 taken along section line 7--7;
FIGS. 8, 9, and 10 are a series of perspective views of the structure of FIG. 1 illustrating movement of the various sections thereof from operable to stored positions;
FIG. 11 is a sectional view of the structure of FIG. 1 in its stored position taken along section line 11--11 of FIG. 10;
FIG. 12 is a perspective view of a second embodiment of the supporting and stabilizing structure of this invention
FIG. 13 is an end elevation view of the structure of FIG. 12;
FIG. 14 is a perspective view of the structure of FIG. 12 illustrating the structure in an upright position and used in association with a tool;
FIG. 15 is a partial perspective view of the structure of FIG. 12 illustrating storage thereof in a bag structure;
FIG. 16 is an end elevation view of the stored structure of FIG. 15;
FIG. 17 is a perspective view of a third embodiment of the supporting and stabilizing structure of this invention;
FIG. 18 is an end elevation view of the structure of FIG. 17 particularly illustrating the mechanism for adjustment of the utility surface thereof;
FIG. 19 is an end elevation view of the structure of FIG. 17 showing the utility surface in a raised position;
FIG. 20 is a perspective view of the structure of FIG. 17 showing the utility surface in a raised position;
FIG. 21 is a perspective view of a fourth embodiment of the supporting and stabilizing structure of this invention;
FIG. 22 is a side elevation view of the structure of FIG. 21 illustrating positioning of the support and stabilizing sections thereof for receipt outwardly of the thighs of a user of the structure;
FIG. 23 is a side elevation view of the structure of FIG. 21 illustrating positioning of the support and stabilizing sections thereof for receipt inwardly of the thighs of a user of the structure;
FIG. 24 is an end elevation view of the structure of FIG. 21; and
FIG. 25 is an end elevation view of the structure of FIG. 21 illustrating positioning of the support and stabilizing sections thereof in a stored position.
DESCRIPTION OF THE INVENTION
Referring to the drawings, the now preferred embodiment of the utility surface supporting and stabilizing structure 29 of this invention is shown in FIGS. 1 through 11. As illustrated in FIG. 1, supporting and stabilizing structure 29 includes support section 31 having utility surface 33 defining a utilization area at the upper portion thereof and stabilizing section 35 attached thereto.
Stabilizing section 35 includes forward stabilizing wall portion 37 (positioned nearer the user's upper thigh region as shown in FIG. 2) and rearward stabilizing wall portion 39 (positioned nearer the lower thigh region as shown in FIG. 2) pivotably attached to side walls 41 and 43 of supporting section 31 utilizing, for example, nut, bolt and washer combinations 45. Wall portions 37 and 39 are maintained in their operable position in a spaced, substantially parallel, relationship to each other by position securing member 49.
As shown in FIGS. 1 through 3, wall portions 37 and 39 each include left and right spaced contoured portions 51, 53, 55 and 57, respectively, which are configured to be comfortably engaged by the thighs of a user so that supporting and stabilizing structure 29 is gripped therebetween thus securely positioning utility surface 33 for use thereof (as illustrated in FIG. 2).
Contoured portions 51 and 53, while facing in opposite directions for receipt of the left and right inner thighs of the user, are substantially identical in configuration, as are contoured portions 55 and 57. Using contoured portion 51 as an example as the description proceeds, and with the understanding that contoured portion 53 is similarly formed, contoured portion 51 is formed by angles 61, 63 and 65 and upper contour section 69, middle contour section 71 and lower contour section 73. Likewise, using contour portion 55 as an example of the formation of contoured sections 55 and 57, contoured section 55 is formed by angles 75, 77 and 79 and upper contour section 81, middle contour section 83 and lower contour section 85.
As suggested by FIG. 2, middle sections 71 and 83 are received adjacent the inner thighs of the user, with middle sections 71 being received adjacent the upper distal medial thigh region of the user's legs, and with middle sections 83 being received adjacent to the lower distal medial thigh region. Lower sections 73 and 85 extend from middle sections 71 and 83, respectively, toward the inner thigh region of the user, while upper sections 69 and 81 extend over the thigh region of the user, so that, in combination with angles 61, 63, 65, 75, 77, and 79, the contoured sections are nested comfortably into the distal medial thigh region of the left and right legs of the user supporting the structure.
All four contoured portions 51, 53, 55 and 57 are similar in that angles 63 and 65, and angles 77 and 79, are approximately at 120° angles with reference to middle sections 71 and 83, thus allowing the thighs of a wide range of morphology to comfortably conform to the contoured portions of any one structure in order to firmly grip the structure and thus stabilize utility surface 33.
The actual lengths of upper sections 69 and 81, middle sections 71 and 83, and lower sections 73 and 85 may, of course, be varied in production to accommodate different thicknesses of thighs of users, and to provide for different relative lengths of middle sections 71 and 83, with middle section 71 being greater in length than middle section 83, if desired, to accommodate the difference in thickness of the upper and lower thigh region of a user (also, thereby, necessitating some variation in the angles utilized to form the contoured portions).
Contoured portions 51 and 53 are separated by wall sections 91 and 93, and contoured portions 55 and 57 are separated by wall sections 95 and 97. The distance between contoured portions 51 and 53, as determined by wall sections 91 and 93 will generally be less than the distance between contoured portions 55 and 57 as determined by wall sections 95 and 97 in order to accommodate the greater distance between the upper thigh region and lower thigh region of the user.
The vertical dimensions of wall sections 91 and 95 are preferably of such a length that wall portions 37 and 39 do not touch the chair or other seating mechanism of the seated user of the structure, and may be of different relative lengths in order for utility surface 33 to remain parallel with the lap of the seated user of the structure.
The structure as above-described is configured for utilization of the bilateral adduction forces generated by the legs of the seated user to grip the structure and thus stabilize the utility surface. However, wall portions 37 and 39 may also include foot sections 100, 102, 104 and 106 for supporting the structure when standing alone (thereby allowing the structure to also be utilized as a stool for example).
The distance between wall portions 37 and 39 effects the degree of rotational stability of the structure as it is gripped between the thighs of the user, and adjusting mechanisms (as shown hereinafter) can be provided for adjustment of the distance between the wall portions.
As shown in FIGS. 1 through 7, the operable positioning of wall portions 37 and 39 is maintained by position securing member 49 which includes forward and rearward tongues 110 and 112 for receipt through apertures 114 and 116 in wall portions 37 and 39, respectively.
Tongues 110 and 112 are firmly, yet releasably, maintained in apertures 114 and 116, thereby maintaining wall portions 37 and 39 in alignment for receipt between the thighs of a user, by resilient cord member 120.
Cord member 120 is threaded at its opposite ends through apertures 124 and 126 in wall portion 39, and ends are knotted at the outward face of wall portion 39 to prevent movement thereof through apertures 124 and 126. Apertures 124 and 126 are positioned directly above and directly below, respectively, aperture 116. Cord member 120 is maintained through apertures 128 and 130 in position securing member 49 adjacent wall portion 39 and through slots 132 and 134 in position securing member 49 adjacent wall portion 37.
When tongues 110 and 112 are positioned through apertures 114 and 116 loop section 136 of cord member 120 is stretched and positioned over ear 138 extending from wall section 140 of wall portion 37. The overall length of cord member 120 is such that when loop section 136 thereof is stretch over ear 138 cord member 120 is taut thus urging tongues 110 and 112 into apertures 114 and 116 and, thereby, wall portions 37 and 39 into firm engagement with position securing member 49.
Turning now to FIGS. 8 through 11, movement of wall sections 37 and 39 and position securing member 49 from their operable, engaged positions (as shown in FIG. 1) to their stored positions is illustrated. Wall portions 37 and 39 each include pivotable angled attachment sections 142 and 144 and 146 and 148, respectively. Angled attachment sections 142 and 144 are formed by sections 150 and 152 and 90° angle 153 and angled attachment sections 146 and 148 are formed by sections 154 and 156 and 90° angle 158. Sections 154 and 156 are of greater length between the point of attachment at bolts 45 and 90° angle 158 than is the length of sections 150 and 152 between the point of attachment at bolt 45 and 90° angle 153 (with the difference in length being approximately equal to the thickness of the material being used to construct wall portions 37 and 39).
As illustrated, loop section 136 is released from ear 138, thus releasing tongue 110 from aperture 114. Wall portion 37 is then pivoted outwardly on nut, bolt and washer combinations 45 until wall portion 37 is resting upon utility surface 33, with the upper edge of side walls 41 and 43 nested in angled sections 142 and 144, respectively.
As shown in FIG. 9, wall section 39 may then be pivoted outwardly around nut, bolt and washer combinations 45 until wall section 39 is resting on wall section 37. As illustrated in FIGS. 10 and 11, position securing member 49 may then be pulled upwardly, thus releasing tongue 112 from aperture 116 so that position securing member 49 may be lain atop wall portion 39, being urged to remain in this position by further contraction of cord member 120.
Turning now to FIGS. 12 through 16, a second embodiment of the supporting and stabilizing structure of this invention 170 is shown which is similar in many regards to the structure shown in FIGS. 1 through 11, particularly with respect to contoured portions 51, 53, 55 and 57.
Structure 170 includes stabilizing wall portions 172 and 174, with stabilizing wall portion 172 being affixed to support portion 176 having work surface 178 positioned at the upper portion thereof. Wall portion 174 is slidably affixed to support section 176, with rail 180, attached to wall portion 174, being slidably attached by nut, bolt and washers arrangements 182 through elongated apertures 184 to support portion 176. By loosening of the nuts in nut, bolt and washer arrangements 182, the distance of wall portion 174 from wall portion 172 may be adjusted for storage and/or for comfort and maximum stability of the structure when in use (as illustrated in FIG. 13).
By providing separate work surface 178, cutout areas thereof, such as cutout area 185, 187 and 189 shown in FIG. 14, may be provided thus creating storage areas for maintaining various items used in association with the structure, as well as providing a firmer, reinforced, work surface for attachment of various utility structures, such as fly tying vise 191 shown in FIG. 14. Cutout portion 193 in wall portion 172 is provided to allow space for attachment of such utility structures. (While a fly tying vise 191 is shown herein, it should be understood that any number of attachment arrangements for utility structures, for example typewriters, computing and/or word processing devices and the like could be provided for at the utility surfaces of the various embodiments of the invention shown in the drawings).
While the embodiment shown in FIGS. 12 through 16 is not collapsible, it is particularly well suited to carriage in a bag structure 200 as illustrated in FIGS. 15 and 16. Pockets 202 and 204 opening toward the bottom of the bag structure are provided on either side thereof, and are of a size to snugly receive wall portions 172 and 174 therein so that bag structure 200 is nested between wall portions 172 and 174 and resting against support section 176 thereby providing a compact portable system.
A third embodiment of the supporting and stabilizing structure 210 is illustrated in FIGS. 17 through 20. Support and stabilizing structure 210 is similar in many regards to the structures shown in FIGS. 1 and 12, again particularly with regard to contoured portions 51, 53, 55, and 57 of stabilizing wall portions 172 and 174 (as shown in FIGS. 18 through 20) or stabilizing wall portions 211 and 212 (shown in FIG. 17 and configured for receipt over the outer thigh region as more fully set forth hereinafter).
However, this embodiment of the device is provided with a mechanism for adjusting work surface 213. Support section 176 and wall portion 174 are provided with height adjustment mechanisms 214 and 216. Adjustment mechanisms 214 and 216 are similar in many regards, and using height adjustment mechanism 214 as an example, include slide rail assembly 220 mounted to work surface 213, lift bar 222 pivotably attached to rail 220 at pivot pins 224 and having ratchet teeth 226 thereon, guide rail 228, and biased pawl 230. Slide rail 220 includes elongated aperture 232 for movement therethrough of shaft 234 maintained adjacent to support section 176 through mounting rail 238.
Shaft 234 includes nuts 240 and 242 firmly affixed to the shaft adjacent to one side of each slide rail 220 and clamping mechanism 244 affixed to one end thereof. Spring retaining nuts 246 and 247 are firmly affixed on the opposite sides of mounting rails 238 on shaft 234 from slide rail 220. Springs 248 and 249 are positioned on shaft 234 between retaining nuts 246 and 247 and mounting rails 238. By moving clamping mechanism 244 to its downward, or locked, position, slide rails 220 are clamped between mounting rails 238 and nuts 240 and 242 thereby stabilizing work surface 213. Movement of mechanism 244 to its upward position releases rails 220 for adjustment of surface 213.
Pawls 230 include biasing springs 250 for manual release of engaging finger 252 from ratchet teeth 226 for raising or lowering of work surface 213. Work surface 213 may desirably include a lip 254 for maintaining work utensils thereat.
While height adjusting mechanisms 214 and 216 are shown, many other such devices for adjusting height and/or tilt of surfaces could be utilized as are well known in the art, and height adjustment mechanisms could be provided at both wall portions 172 and 174 for adjustment of the overall height of the work surface 213 and/or for leveling the work surface.
FIGS. 21 through 25 illustrate a fourth embodiment of supporting and stabilizing structure 260. Structure 260 includes support section 262 having a retaining wall 264 around the edges thereof. Independently movable supporting portions 266, 268, 270 and 272 are mounted on mounting shafts 274, 276, 278 and 280 mounted on mounting brackets 282 (shafts 274 and 278) and 284 (shafts 276 and 280). Support portions 266 through 272 include contour portions 51, 53, 55 and 57 as heretofore described.
Stabilizing portions 266 through 272 are removable from shafts 274 through 280 for positioning thereon so that contoured portions 51 through 57 face either inwardly (for receipt in the contoured portions of the outer thigh regions of a user of the device for stabilizing structure 260 by adduction forces generated by the legs of a seated person, as shown in FIG. 22), or for outward positioning of the contoured portions (as shown in FIG. 23) for use as heretofore described.
The stabilizing portions are slidably secured on shafts 274 through 280 by mounting barrels 285 which are slidably mounted over rods 274 through 280 (as illustrated in FIG. 24). Barrels 285 are attached to legs 287 and 289, with legs 287 being shorter than legs 289 to accommodate storage of the legs in a collapsed position as illustrated in FIG. 25.
The position of barrels 285 on rods 274 through 280 is adjustable (both for purposes of adjusting spacing for receipt by the outer thighs of the user or the inner thighs of the user, and for adjusting the separation of the contoured portions for increased comfort and maximum efficiency) by provision of spring clips 295 mounted by pins 297 in retainers 298 in legs 287 and 289 (only mounting on legs 287 is illustrated herein in FIGS. 22 and 23, similar structure being employed for mounting hereof on legs 289). The clips are arranged on legs 287 and 289 so that pawl 300 is urged into the selected one of detents 302 and retractable therefrom (for adjustment or removal of stabilizing portions 266 through 272) by depression of spring-biased lever arms 305.
As illustrated in FIGS. 24 and 25 stabilizing portions 266 through 272 may be rotated on rods 274 through 280 (by depression of levers 305) between operable and stored positions.
All portions of the structure herein disclosed may be made of a variety of materials including wood, plastic, metal and the like, and some of the structures herein disclosed may be appropriately constructed of disposable materials, such as paper, cardboard, compressed paper board and the like.
As may be appreciated from the foregoing, a supporting and stabilizing structure for securely maintaining a utility surface adjacent to a user of the utility surface is provided wherein the structure is stabilized by forces applied by the legs of the user of the device, wherein the utility surface may be maintained in a selected attitude for use thereof and which may be collapsed for storage and portability of the structure.
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A portable supporting and stabilizing structure is disclosed that is particularly well suited for securely maintaining a preselected orientation of a utility surface, such as, for example, a work surface, an equipment mounting surface, or a food tray by, and adjacent to, the thighs of a seated user of the utility surface. The structure includes a supporting section for support of the utility surface and a stabilizing section connected with the supporting section and receivable adjacent to the thighs of a user of the structure so that, when force is exerted by the user's thighs against the stabilizing section of the structure, changes in orientation of the surface are resisted thus securely maintaining the position of the utility surface during use thereof. Structures are disclosed which are collapsible and which are selectively configurable for employing inward or outward exertion of the thighs by the user against the stabilizing section of the structure to stabilize the utility surface.
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FIELD OF INVENTION
[0001] This invention relates to direct response e-mail.
BACKGROUND OF THE INVENTION
[0002] In direct response e-mail, a vendor, for example, can sell a product to a customer by sending an e-mail message to the customer that describes the product and its price. The customer can order the product by returning an e-mail (sometimes called a direct response e-mail) that gives appropriate order information. The vendor can confirm the order by a return e-mail. The order information returned by the customer can sometimes be determined automatically using software that analyses the customer's reply e-mail.
SUMMARY OF THE INVENTION
[0003] In general, in one aspect of the invention, an e-mail message is analyzed to derive response information concerning a commercial transaction. Based on the derived information, commercial transaction data are automatically generated in a format that is usable to automatically complete the commercial transaction.
[0004] In general, in another aspect of the invention, an e-mail message is sent to a customer offering a product or service for sale. The e-mail message includes locations for response by the customer to indicate his intention to order the product or service. The customer returns an e-mail message that includes the response. Based on the received e-mail, order information is automatically generated in a format usable automatically by an order fulfillment system to cause the order to be filled.
[0005] In general, another aspect of the invention includes automatically identifying response information which requires resolution of an issue with the source of the e-mail message and automatically managing an e-mail dialog with the source to resolve the issue.
[0006] In general, in another aspect, the invention features automatically sorting e-mail messages, based on response information contained in the messages, into e-mail messages that can be processed automatically to generate commercial transactions, e-mail messages in which the response information is inadequate to permit generation of commercial transactions, and e-mail messages that may be subjected to exception handling to yield information that is sufficient to generate commercial transactions.
[0007] In general, in another aspect, the invention features automatically generating a confirmatory e-mail message to the source of the e-mail message confirming that a commercial transaction has been or will be completed.
[0008] In general, in another aspect, the invention features receiving inbound e-mail messages that result from corresponding outbound e-mail messages associated with a marketing program, the inbound messages containing response information, each of the outbound messages being associated with a distinct piece of the marketing program. The response information in each of the inbound messages is automatically associated with the corresponding distinct piece of the marketing program.
[0009] In general, in another aspect, the invention features automatically merging response information with corresponding information in a database for use in completing transactions.
[0010] In general, in another aspect, the invention features identifying inbound e-mail messages that cannot be processed automatically to generate commercial transactions, and using the database information to assist in exception handling of the identified inbound messages.
[0011] Other advantages and features will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
[0012] [0012]FIGS. 1A through 1C and 2 A through 2 B show e-mail messages.
[0013] [0013]FIG. 3 is a block diagram of a direct response e-mail system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Outbound E-Mail Messages
[0015] The two e-mail messages shown in FIGS. 1A through 1C and 2 A through 2 B are examples of outbound messages associated with commercial transactions.
[0016] The example message 10 shown in FIG. 1 offers Harvard Business Review products. Message 10 includes basic copy 12 that is similar to basic direct marketing copy of the kind that is commonly used in e-mail marketing. Message 10 also contains a section 14 giving instructions on how to order the products.
[0017] Inbound E-Mail Messages
[0018] To take advantage of the-offer shown in FIG. 1, the recipient creates a reply e-mail message (the direct response message) and types the letters of the items that he wants to order in the first line of the body of the message. In other examples, the letters could be typed in the subject line or the last line of the body of the message. The user is also asked to correct and complete shipping and e-mail address information that has been merged into the outbound e-mail message in a section 16 . In section 16 , each of the entries is bounded by brackets. Another section could contain merged billing information, not shown. The person who replies to the e-mail (the customer) is meant to include the corrections or additions within the indicated brackets.
[0019] By allowing the recipient to take advantage of the offer simply by replying to the e-mail, rather than requiring the recipient to place an order by linking to a related web-site or to print the e-mail message and FAX it back, or to call an 800 number, a much higher return rate can be achieved. For conventional outbound e-mail messages that require the recipient to click on an embedded URL to go to a web site, the returns may be on the order of several hundred percent on investment (the fee charged for delivering the outbound messages). By enabling the recipient to provide direct response e-mail messages as in FIG. 1, the return on investment can be as high as several thousand percent.
[0020] [0020]FIGS. 2A and 2B illustrate a similar outbound e-mail message in which there is no choice of products but only a single offer to be accepted or rejected. To take advantage of the offer, the recipient types “yes” in the subject line. In FIG. 2B, a shipping block 18 of the kind mentioned above is shown. (In this case, the shipping block contains no information because the shipping address is the same as the billing address.)
[0021] One reason for including differential billing and shipping blocks is to acquire information in the return e-mail message that is similar to information captured in orders placed on a related web site. In a system in which web-site orders generate fields that can be fed directly to an automated order fulfillment process, it is useful to make the e-mail message information field-wise consistent to permit the information to be delivered automatically to the same order fulfillment process.
[0022] Exception Processing
[0023] Processing the inbound e-mails (the ones with responses concerning commercial transactions from the recipients of the outbound e-mails) may require custom interaction with the recipients. For example, the wording of the outbound messages may be confusing to the recipients.
[0024] As shown in FIG. 3, the system 40 enables the transactional e-mail message processor 42 to determine when a dialog with the recipient 44 is needed and then assists a human service representative 46 to conduct an effective dialog 48 . The dialog can be conducted on behalf of the vendor 50 but without involving the vendor. Alternatively, the vendor's fulfillment process 52 can be notified electronically 54 of interaction that may be required. Easing the processing of responses that include customer orders is important because the orders-typically come back quickly, e.g., within 36-48 hours, and in large volume. The ability to deal with questions that arise as a result of the contact from a customer service point of view keeps the vendor's customer service organization from being overwhelmed by the responses that come back.
[0025] The ability to process exceptions without involving the customer service organization of the vendor is based partly on knowing how the outbound e-mail messages were constructed. As a simple example, a recipient may ask an unnecessary question that could have been answered by reading the outbound e-mail message. The e-mail message processor can pull out the relevant portion of the message and send it back to the recipient to answer the question.
[0026] ProcOrder Process
[0027] The inbound e-mail messages 60 are batch processed by a script called ProcOrder 62 . ProcOrder parses the elements of the inbound e-mail messages in accordance with the original set up and instructions of the outbound e-mail messages 64 . ProcOrder determines if all of the items that are required for an order to be completely processed automatically appear in the inbound e-mail message. For example, the script would look for the ordering token, such as the word “yes” or a series of letters depending on whether it is a single or multiple offer. The script would also look for footer information in the e-mail message, including a code that identifies the given campaign and the given offer, as seen in block 66 of FIG. 2B. In that example, there are four components in the footer, but only two are represented because the other two are not required in this instance. The first element is a customer identifier 68 , e.g. 861270. Then there is a space 70 between two pipes that would contain the list identifier if there were one. There may be multiple recipient lists for a given marketing campaign. In the example, there is only one list, and there is no list identifier. A list number 243 might refer to a list of people who made a purchase at the ‘vendor’s web site or who subscribed at the web-site for a listserv.
[0028] The third footer item could be a source of awareness code 72 , e.g., 3275, which identifies a particular marketing campaign. For example, in the case of FIG. 2, the code could refer to a Benchmarking Three-part Video Series offer.
[0029] The last item in the footer, located between the final pipe and the first right bracket would be a flight identification code 74 . A given campaign could have multiple flights of e-mail messages.
[0030] After looking for the footer information, the ProcOrder parser looks for fields in the billing and shipping address blocks that are required to complete the order. What is required may vary with the type of campaign but typically the minimum requirements are a name and a physical address. If the information is not completely available in the response e-mail message, the script checks to see if it is available in the database 76 . If not available in either place, the script generates an exception entry for an exception list. The exception list is provided to a service representative 46 who can then act on it (without involving the vendor's customer service organization), e.g., by sending back an e-mail message asking for the shipping address.
[0031] If all required information is available, the script generates a fully fielded valid order in a format required by the fulfillment system of the vendor and adds it to a batch of valid orders 78 which are sent electronically to the fulfillment process.
[0032] Confirmation E-Mail Message
[0033] As a result of running the ProcOrder script, an e-mail message 80 is returned to each customer either to confirm an order or to request more information. In the latter case, a dialog ensues and is managed by software and through an exception handling service as explained earlier. For example, the customer's response could say something like “sure, send”; or “send it and I'll take a look.” Shortly thereafter the customer would receive a confirmation “Thank you for your order; you can expect the CD-ROM in about seven business days. Please let us know if there is anything else we can do to help simply by replying to this e-mail.”
[0034] One-Click Ordering
[0035] Another feature of the e-mail dialog with a customer involves simplifying and optimizing the presentation of content. In the examples of FIGS. 1 and 2, the information is presented in a simple text format. It is useful also to provide in-line HTML code in the outbound e-mail message in a manner similar to the one-click ordering that Amazon.com offers in a web-site context. In one-click ordering, the customer sets up an account by providing credit card and shipping information. On subsequent visits to the web site, the customer can pick a product with one click, place an order, and have it shipped. A similar technique could be adapted to e-mail message interchange by embedding one-click ordering into e-mail.
[0036] An advantage of in-line HTML code is the opportunity for a much higher response rate because of the higher graphical contact and higher level of engagement normally achieved by a graphical message.
[0037] Template
[0038] The outbound e-mail messages are set up in a standard format using templates 90 . The templates enable either a single-offer message or a multiple-offer message. Other templates are also possible, including one that embeds in-line HTML into the message as mentioned above, either for the single-offer or multiple-offer cases.
[0039] In addition, a set-up tool 92 permits the parameters of a given campaign to be defined, including the source of awareness code, the flight identification code, the campaign identification code, and similar information. The set-up tool also permits defining the tokens that are to be used in a given campaign (for example, the letters assigned to different products being offered). The set-up tool also allows a definition of the required fields that must appear in a given campaign to enable automated generation of orders to an existing fulfillment system.
[0040] The set-up tool also provides a user interface that enables a vendor to help in entering the set-up information.
[0041] The result of applying the tool to the templates is a set of outbound message forms 94 that are ready for use.
[0042] Reporting Tool
[0043] After the template is set up and the system is ready to launch a flight, address 108 and other information 110 . 112 stored in the target list of customers is merged with the message forms, and the e-mail messages are automatically generated and sent by an outbound e-mail delivery engine 96 . Customers then begin to respond. The ProcOrder script generates automatic orders to the fulfillment system and exception information for additional processing.
[0044] A reporting tool 104 aggregates-information about the responses for a given campaign according to source of awareness code and flight. The information is made available on-line to the vendor and can be used for a variety of marketing purposes. The information could be generated as an Excel file attached to an e-mail, or as a paper-based report, or as an electronic file that is transferred on a batch basis.
[0045] Gathering Additional Information from Database
[0046] There may be an intermediate step between the parsing engine's (ProcOrder) extraction of information from an e-mail message and the generation of the valid order. The intermediate step could be a querying process 112 to gather additional information from an existing database. The additional information may not have been included in the outbound e-mail messages but may be needed to generate a valid order. For example, product codes 112 may be stored in the database but not included in the outbound e-mail message. The letters entered by the customer can be mapped to the actual product codes by reference to the tables of the database based upon the source of awareness code.
[0047] The resulting valid order is a fully-fielded record that has the fields required by the client's order fulfillment system to process an order.
[0048] Exception Treatment
[0049] Exception handling can be treated in different ways depending on the circumstances. For example, an exception might occur when a customer responds from an e-mail client that does not quote the original text of the outbound e-mail message. The inbound e-mail message then has the customer's e-mail address, a subject line that says “Iyes”, and the original subject line from the campaign, but does not have the required information for the shipping address or the footer information. ProcOrder would kick that out as an exception, but the exception handling system-would allow a response management representative 46 , based on the e-mail address, to confirm, from the database 76 , that all of the required information is available. Use of the subject line allows the system to tie back to the appropriate campaign and to figure out who is ordering and what he is ordering. A valid order can be created without further interaction with the customer other than to send him a confirmation that the system has been able to enter a valid order on his behalf.
[0050] The system thus recognizes that it is not likely to be possible to automate every interaction with the customer, but it may be possible to complete a dialog with essentially all of the customers from whom inbound e-mail messages are received by automatically identifying messages that will require custom human handling and providing information and tools that enable the human handlers to complete the exception transactions in an efficient manner.
[0051] Non-Order Response Processing
[0052] Not every inbound e-mail message is an order. Non-order messages include undeliverable bounced messages to ad hoc customer service responses. Non-order inbound e-mail messages must be identified by the parsing engine.
[0053] Undeliverable e-mail messages 114 are automatically separated from the inbound e-mail stream and stored for offline handling by a human response handling professional, who operates a script on the files of undeliverable messages. The script classifies them as “soft” and “hard,” parses e-mail addresses and footer data from the messages, matches the parsed records to the database, and flags appropriate records as “undeliverable”.
[0054] Other non-order messages also are handled manually as explained earlier.
[0055] Vendor Creation of E-Mail Campaigns.
[0056] A campaign creation tool 126 is provided to a vendor to enable simple entry of all information needed to create an e-mail campaign, including all the parameters, the text of the messages, and the tables of data needed in the database. The vendor delivers the campaign electronically to the transactional e-mail processor which then delivers the e-mail messages, receive the responses, processes all exceptions, and returns to the fulfillment system the vendor orders in a proper format.
[0057] A web-based vendor interface 128 enables on-line viewing by the vendor of the status of all campaigns, including the state of those that are in development and the results of those that are “live”. The information is hosted by the transactional e-mail processor in part based on the database 76 . The interface also gives the vendor a mechanism to check text and other content into the database.
[0058] Alternatively, instead of automatically permitting the vendor to fully create a finished campaign, the vendor may be enabled to download and check into the database a proposed campaign. Then an account executive of the e-mail handler process would review it and work with the vendor to complete it before it is finally queued for distribution.
[0059] Appendices A, B, and C contain more detailed descriptions of aspects of implementations of the invention. Appendix D contains source code written of an example of the ProcOrder process.
[0060] Other implementations are within the scope of the following claims.
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An e-mail message is analyzed to derive response information concerning a commercial transaction. Based on the derived information, commercial transaction data are automatically generated in a format that is usable to automatically complete the commercial transaction.
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BACKGROUND OF THE INVENTION
The present invention relates to the preparing of sewing data for an embroidery sewing machine. More specifically, the present invention relates to a sewing machine that forms an embroidery pattern on a work by causing the relative movement between a vertically movable needle and the work based on needle location data showing the relative position of the needle and the work or based on block data that is related to the needle location.
A data preparing apparatus is disclosed in Japan Published Unexamined Patent Application No. 58-198375. In this related art, a drawing showing an embroidery design is adhered on a tablet board. An operator defines multiple closed areas for dividing the design. When the operator designates multiple points on the outlines of the defined closed areas with a cursor, the outlines of the closed areas are stored as defined. The needle location data for embroidering each stored closed area can thus be computed.
The needle location data is computed by moving a predetermined straight line parallel with a stitch-forming direction, sequentially obtaining intersections where the closed area outline and the straight line meet, and selectively storing the intersections as the needle location data.
Another data preparing apparatus is disclosed in Japan Published Unexamined Patent Application No. 63-132690. In this related art, the image of an embroidery design is picked up with a TV camera and displayed on a CRT. An operator designates given points on the outline of the displayed image on the CRT and sets the outline. Subsequently, the operator designates a dividing line for dividing the outline. When designating given points and dividing lines, the operator may use, for example, a light pen. The image of the embroidery design is thus divided into polygonal closed areas. Vertexes of the closed areas and other location data are sequentially computed and prepared as block data that is related to the needle location (hereinafter referred to as the block data). The needle location data indicating actual needle locations is then computed based on the block data and a predetermined stitch density data.
In these related arts, the operator must define the closed areas dividing the embroidery pattern and designate coordinate data such as vertexes of the closed areas with the cursor, the light pen or the like so that the defined closed areas are set and stored. When the closed areas are set, the data preparing apparatus computes and prepares the needle location data.
In the related arts, however, the operator must manually set the closed areas according to the configuration of the embroidery pattern. The setting of the closed areas is a troublesome and time-consuming operation. At the same time, the operator must set the closed areas having a configuration such that the computation of the needle locations is possible. The operator must be experienced in setting the closed areas. In the related art disclosed in Japan Published Unexamined Patent Application No. 58-198375, for example, when the operator sets an almost U-shaped closed area the closed-area outline and the straight line might meet at three or more intersections. Therefore, the needle location cannot be computed.
SUMMARY OF THE INVENTION
One object of this invention is to provide a data preparing apparatus for an embroidery sewing machine that can automatically prepare needle location data or the data related with needle location for forming embroidery stitches within an embroidery pattern surrounded with a continuous outline of a given configuration.
To attain this object, this invention provides a control data preparing apparatus for an embroidery sewing machine that stitches an embroidery pattern on a workpiece under the control of control data. The control data preparing apparatus comprises a first memory means for storing outline data representing an outline of the embroidery pattern; a first computing means for dividing the outline of the embroidery pattern into divided outlines based on the outline data and a predetermined stick-forming direction and for computing divided outline data representing the outlines of the divided outlines; a second computing means for computing control data from the divided outline data; and a second memory means for storing the control data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an electric structure of a data preparing apparatus constructed in accordance with the present invention.
FIG. 2 is a perspective view of a multi-needle embroidery sewing machine to which the data preparing apparatus is mounted.
FIGS. 3A through 3C are flowcharts showing main operations of a CPU.
FIGS. 4A, 4B and 4C are flowcharts showing a closed-area dividing subroutine.
FIG. 5 is a flowchart showing a needle location data preparing subroutine.
FIG. 6 is a flowchart showing a block data preparing subroutine.
FIG. 7 is an explanatory drawing of a closed area Ao to embroider.
FIGS. 8 and 9 are explanatory drawings showing the dividing of the closed area Ao.
FIGS. 10 and 11 are explanatory drawings showing the dividing of a closed area Bo to embroider.
FIGS. 12 and 13 are explanatory drawings showing the dividing of a closed area Co to embroider.
FIG. 14 is an explanatory drawing showing the preparing of needle location data.
FIGS. 15 through 19 are explanatory drawings showing the preparing of block data.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In this embodiment, data preparing apparatus of this invention is mounted on a multi-needle embroidery sewing machine shown in FIG. 2.
As shown in FIG. 2, an arm 1 is positioned on a table 2. A needle-bar support case 3 is supported on the front end of the arm 1 so that the needle-bar support case 3 can be moved in the direction shown by an arrow X. Five needle bars 4 are respectively supported by the needle-bar support case 3 so that the needle bars 4 are vertically movable. Needles 5 are detachably attached to the lower ends of each of the needle bars 4. Different kinds of thread are supplied from a not-shown thread source via thread tension guides 6 and needle thread take-ups 7 on the needle-bar support case 3 to the needles 5, respectively. A needle-selecting motor 8 is provided on the arm 1 and is connected to the needle-bar support case 3. When a predetermined needle bar selecting signal is sent to the needle-selecting motor 8, the needle-selecting motor 8 moves the needle-bar support case 3 and selectively positions one of the needles 5 at a predetermined application location.
A sewing-machine motor 9 is provided at the rear of the arm 1. The drive power of the sewing-machine motor 9 is transmitted through a not-shown transmission mechanism in the arm 1 to the positioned needle tar 4, thereby moving the needle bar 4 vertically. A bed 10 projects from the table 2, and is opposed to the positioned needle bar 4. The bed 10 has therein a not-shown thread-loop catcher for forming stitches on work W in cooperation with the needle 5. The needles 5 and the thread-loop catcher compose a stitch-forming means.
A pair of Y-direction moving brackets 11 are provided at both sides of the table 2 so that the moving brackets 11 can reciprocate in the direction shown by arrow Y. The Y-direction moving brackets 11 are driven by a not-shown Y-direction drive motor. FIG. 2 shows only the bracket 11 at one side of the table 2. A support beam 12 is provided between the pair of the Y-direction moving brackets 11. The end of an X-direction moving member 13 is supported so that the X-direction moving member 13 can move in the direction shown by arrow X along the support beam 12. The X-direction moving member 13 is driven by a not-shown X-direction drive motor. A support ring 14 as a support means is provided on the X-direction moving member 13. The support ring 14 can be detachably attached to the work W, thus supporting the work W.
The Y-direction moving brackets 11, the X-direction moving member 13, the support beam 12, and the X and Y-direction drive motors compose a feeder 15 for changing the relative position of the support ring 14 and the needle 5. The relative movement of the support ring 14 and the needle 5 results in the formation of embroidery stitches on the work W.
The electric structure of the embroidery sewing machine for this embodiment will now be explained.
As shown in FIG. 1, an operation keyboard 18 is connected to an interface 36 of a CPU 17. The operation keyboard 18 comprises a data-forming key 20, a needle location data key 21, a block data key 22, a stitching-order set mode key 23, an outline point input key 24, a closed area dividing command key 25, and a stitching start key 26. The needle-selecting motor 8, the sewing machine motor 9, and the feeder 15 are connected via drive circuits 39, 40, and 41, respectively, to the interface 36. A CRT 35 is also connected via a CRT drive circuit 34 to the interface 36. A light pen 37 for designating points on the image on the screen of the CRT 35 is connected via a position-detecting circuit 38 to the interface 36. A TV camera 30 for projecting the image of embroidery design and an image sensor 31 are respectively connected via a video interface 33 to the CPU 17. A program memory 42, an operation memory 43, an external memory 16, and an image memory 44 are connected to the CPU 17. The operation program of the CPU 17 is stored in the program memory 42. The operation memory 43 mainly composing first and second memory means is readable and writable. The external memory 16 stores needle location data or block data that is related to the needle location (hereinafter referred to as the block data). The image memory 44 stores the embroidery image picked up by the TV camera 30, and the position data of the designated points are displayed on the screen of the CRT 35.
The operation of the CPU 17 for preparing the needle location data or the block data so as to embroider a pattern shown in FIG. 7 will now be explained referring to flowcharts in FIGS. 3A through 3C, 4A, 4B and 4C.
First, a given embroidery pattern consists of one continuous outline forming a given configuration. The data preparing apparatus of this invention automatically prepares the needle location data or the block data for forming embroidery stitches along a predetermined stitch-forming direction. In this embodiment, the stitch-forming direction is set along a vertical Y-axis of the displayed image of the embroidery design picked up by the TV camera 30. The embroidery advancing direction corresponds to an X-axis.
After the operator sets the embroidery design, a detection signal from the TV camera 30 or the image sensor 31 is transmitted to the CPU 17. After the needle location data key 21 or the block data key 22 is turned on, the dataforming key 20 is turned on. The CPU 17 thus starts operation according to the flowcharts in FIGS. 3A through 3C. When the needle location data key 21 is turned on, the needle location data preparing flag is set to one.
At step S100 the CPU 17 displays the image of the embroidery design from the TV camera 30 or the image sensor 31 on the CRT 35 and stores image data into the image memory 44. Subsequently, the operator designates a given point Ti on the outline of the image displayed on the CRT 35 by using the light pen 37 and presses the outline point input key 24. At step S102, the CPU 17 obtains the location data of the point Ti designated by the light pen 37, stores Ti as outline-point data into the operation memory 43, and stores the location data into the image memory 44. When the operator repeats this operation along the outline, the outline-point data is sequentially stored. A sequence of points To, . . . Ti, . . . Tn, . . . ,Tm shown in FIG. 7 is stored as the outline data of embroidery closed area Ao into the operation memory 43. Respective points are connected with a straight line or a curved line and are displayed on the CRT 35.
At step S104, the CPU 17 determines whether the closed-area dividing command key 25 is turned on. When the closed-area dividing command key 25 is turned on, the process goes to step S106. At step S106, the CPU 17 sequentially reads the outline-point data of the closed area Ao To, . . . Tm, and obtains a MAX. point Tn having the maximum X-axis value and a MIN. point To having the minimum X-axis value.
Next, at step S108, based on outline data To, . . . Tm, the CPU 17 sets a line connecting the MIN. and MAX. points and composed of the points To, . . . ,Ti, . . . ,Tn as upper outline point sequence Ui. At step S110, the CPU 17 sets the other line connecting the MIN. and MAX. points and composed of the points To,Tm, . . . Tn as lower outline point sequence di. The process of the CPU 17 goes to step S200 which is a closed-area dividing subroutine described later. When the closed area is divided into two in the subroutine, the process goes to step S112. At step S112 it is determined whether the closed area is divided. When the CPU 17 cannot divide the given closed area into two at step S200, the outline-point data of the closed area and the closed-area dividing end flag are stored in the operation memory 43.
Until the answer at step S112 becomes affirmative, thereby storing the closed-area dividing end flag into the operation memory 43, the CPU 17 repeats steps S106 through S110 and S200. After finishing the dividing of the closed area, at step S114 the image of the divided closed areas is displayed on the CRT 35.
The closed-area dividing subroutine at step S200 will now be explained. The purpose of the closed-area dividing subroutine is to divide the closed area to make possible the operation of a needle location data preparing subroutine at step S122 and of a block data preparing subroutine at step S124 described later.
In general, the closed area is divided based on the existence of expected dividing points among the outline data To, . . . ,Tm. Referring to FIGS. 7 through 13, expected dividing points are determined according to the following rules: a point Ui is an expected dividing point if (1) Uxi>Uxi-1, Uxi>Uxi+1, and Uxi+1 is above a line defined by Ux and Ux-1; or (2) Uxi<Uxi-1, Uxi<Uxi+1, and Ux+1 is below a line defined by Ux and Ux-1.
For each expected dividing point, a line segment UiP or dip between the expected dividing point and a point p is determined. The line segments UiP and dip are part of a line parallel to the Y-axis containing the expected dividing point. When an expected dividing point Ui is along an upper outline point sequence composed of points To, . . . ,Ti, . . . ,Tn, point P is at the intersection of the line parallel to the Y-axis and containing the expected dividing point Ui and the outline above and nearest to the expected dividing point. However, when an expected dividing point di is along a lower outline point sequence composed of points To, . . . ,Tm, . . . ,Tn, point p is at the intersection of the line parallel to the Y-axis containing the expected dividing point di and the outline below and nearest to the expected dividing point.
Each line segment UiP or dip divides the closed area into smaller closed areas.
The closed-area dividing subroutine will be explained in detail below referring to the flowcharts in FIGS. 4A, 4B and 4C.
At step S210, the CPU 17 compares X-axis values Uxi of adjoining points in the upper outline point sequence sequentially from the MIN. through the MAX. point. The CPU 17 thus searches the upper outline point sequence for an expected dividing point having the relationship in X-axis value of Uxi>Uxi+1. Specifically, for the closed area Ao in FIG. 7, a point Ui shown in FIG. 8 is obtained as the expected dividing point. When no other expected dividing points exist on the upper outline point sequence, the process goes to step S230. At step S230 the CPU 17 compares X-axis values dxi of adjoining points in the lower outline point sequence sequentially from the MIN. through the MAX. point. The CPU 17 thus searches the lower outline point sequence for an expected dividing point having the relationship in X-axis value of dxi>dxi+1. If no further expected dividing points exist on the lower outline point sequence, either, the CPU 17 determines that the given closed area cannot be divided further. The CPU 17 thus determines that the operations of the needle location data preparing subroutine and the block data preparing subroutine can be executed. At step S240 the CPU 17 stores the closed-area dividing end flag as well as the outline-point data into the operation memory 43, and the program goes to step S114.
When the expected dividing point exists on the upper outline point sequence at step S210, it is determined at step S211 whether a point Uxi+1 subsequent to the expected dividing point Ui is above a straight line X comprising the expected dividing point Ui and its preceding point Ui-1 along Y-axis, as shown in FIG. 8. When the answer at step S211 is affirmative, step S212 obtains an intersection P above and nearest to the expected dividing point Ui from intersections where the straight line and the closed-area outline meet. The straight line r is represented by equation of X=Uxi and extends past the expected dividing point Ui and parallel with Y-axis as shown in FIG. 8. Subsequently, at step S213, the CPU 17 divides the closed area Ao into A1 and A2, as shown in FIG. 9, by segment UiP connecting the expected dividing point Ui in FIG. 8 and the intersection P. At step S214, the CUP 17 stores respective outline-point data of the divided closed areas A1 and A2 into the operation memory 43. For example, as shown in FIG. 9, the outline-point data To, . . . Ti,P, . . . Tn of the closed area A 1 and the outline-point data Ti, Ti+1, Ti+2, . . . P of the closed area A 2 are obtained.
On the other hand, when the answer at step S211 is negative, as occurs in FIG. 10, the CPU 17 cancels the designation of the expected dividing point from a point Ui of a closed area Bo obtained at step S210, because the closed area Bo cannot be divided by a straight line represented by equation X=Uxi. Subsequently, at step S215, the CPU 17 compares X-axis values Uxk of adjoining point in the upper outline point sequence from the point Ui+1 to a MAX. point, and obtains an expected dividing point Uk where decreased X-axis value begins to increase. Specifically, the point Uk has a relationship in X-axis value of Uxk<Uxk+1. Subsequently, it is determined at step S216 whether a point Uk+1 subsequent to the expected dividing point Uk is below a straight line f passing the expected dividing point Uk and its preceding point Uk-1 along Y-axis. when the point Uk+1 is below the straight line f, at step S217, an intersection q above and nearest to the expected dividing point Uk is obtained from intersections where the straight line extending past the expected dividing point Uk parallel with Y-axis and the closed area outline meet. The straight line is represented by equation of X=Uxk. Subsequently, at step S218, the CPU 17 divides the closed area Bo in FIG. 10 into two areas B.sub. 1 and B 2 in FIG. 11 by segment Ukq connecting the expected dividing point Uk and the intersection q. At step S219, the CPU 17 stores respective outline-point data of the divided closed areas B1 and B2 into the operation memory 43.
On the other hand, if the answer at step S216 is negative, the CPU 17 cancels the designation of the expected dividing point from the point Uk obtained at step S215. The process returns to step S210 where the CPU 17 distinguishes the X-axis values from an upper outline point Uk+1 subsequent to the point Uk obtained at step S215. For example, a closed area C o in FIG. 12 results in the negative determination at step S216. after step S210 obtains an expected dividing point Ue of the closed area C o , the answer at step S211 is negative. Subsequently, after step S215 obtains an expected dividing point Um, the answer at step S216 is negative. Subsequently, step S210 obtains an expected dividing point Us, and the answer at step S211 is affirmative for the first time. As a result, at step S213, as shown in FIG. 13, the closed area C o is divided into two closed areas C 1 and C 2 by a segment UsP passing the expected dividing point Us and an intersection P.
Through steps S210 through S219, the upper outline of any configuration can be divided.
On the other hand, when the answer at step S210 is negative, the process goes to step S230. Specifically, the CPU 17 searches the upper outline of a given closed area from the MIN. to the MAX. point, but cannot find a point of Uxi>Uxi+1 where the increasing X-axis value starts decreasing. The CPU 17 then carries out the operation of steps S231 through S239 regarding the lower outline obtained at step S110. The operation of steps S231 through S239 corresponds to that of the aforementioned steps S210 through S219. However, the operation of steps S231, S232, S236 and S237 is different from that of steps S211, S212, S216 and S217. Only the different operation will now be explained, referring to the flowchart in FIG. 4C.
At step S231, as shown in FIG. 11, the CPU 17 determines whether a point di+1 subsequent to the expected dividing point di obtained at step S230 is below a straight line passing the point di and its preceding point di-1 along Y-axis. When the answer at step S231 is affirmative, at step S232 the CPU 17 obtains an intersection p below and nearest to the expected dividing point di from intersections where a straight line extending past the expected dividing point di parallel with Y-axis and the closed area outline meet. The straight line can be represented by the equation of X=dxi. This operation can be applied to the closed area B 1 shown in FIG. 11, for example. The closed area B 1 is divided into two areas B 3 and B 4 by a segment dip.
On the other hand, when the answer at step S231 is negative, the CPU 17 searches the lower outline point sequence from lower-outline point di+1 through the MAX. point for an expected dividing point dk where decreasing X-value starts increasing. Subsequently, at step S236 the CPU 17 determines whether a point dk+1 subsequent to the expected dividing point dk is above a straight line comprising the expected dividing point dk and its preceding point dk-1 along Y-axis. When the answer at step S236 is negative, the CPU 17 returns to step S230. When the answer at step S236 is affirmative, the CPU 17 obtains an intersection q below and nearest to the expected dividing point dk from intersections where a straight line extending past the expected dividing point dk parallel with Y-axis and a closed area outline meet. The straight line is represented by equation of X=dxk.
Through steps S230 through S239, the lower outline with any configuration can thus be divided.
By repeating steps S106 through S110 and S200, for example, the closed area A o is divided into A 1 and A 2 , and the closed area B 0 is divided into B 2 , B 3 and B 4 .
After finishing the dividing of the closed area, at step S114 the CPU 17 displays the image of all the obtained closed areas on the CRT 35. The process then goes to a stitching-order determining routine S115. At step S115 the operator presses the stitching-order set mode key 23, and selects the closed area with the light pen 37. The stitching order of each closed area is thus stored in the operation memory 43.
Subsequently, at step S120 the CPU 17 determines whether the needle location data preparing flag is set to one or not. When the answer at step S120 is affirmative, the process goes to the needle location data preparing subroutine at step S122. On the other hand, when the answer at step S120 is negative, the process goes to the block data preparing subroutine at step S124.
The needle location data preparing subroutine will now be explained, referring to FIGS. 5 and 14. First, the CPU 17 reads the outline-point data of each closed area according to the determined stitching order at step S300, and obtains MIN. and MAX. points from the outline-point data at step S301. Subsequently, at step S302 the CPU 17 obtains upper and lower outlines extending from the MIN. to the MAX. point. At step S303 the CPU 17 obtains a straight line V extending past the MIN. point parallel with Y-axis. The straight line V is represented by equation of X=Ux 0 . At step S304 the CPU 17 obtains as needle location data intersections where the straight line V and the upper outline meet and where the straight line V and the lower outline meet. Subsequently, at step S305 the CPU 17 stores the needle location data into the operation memory 43. At step S306 the CPU 17 moves the straight line V by pitch α corresponding to the predetermined stitching density toward the MAX. point. It is determined at step S307 whether the straight line V exceeds the MAX. point.
The straight line V is moved by the predetermined pitch α from the MIN. to the MAX. point until the answer at step S307 becomes affirmative. Every time the straight line V moves, the intersections are sequentially stored as the needle location data into the operation memory 43. It is determined at step S308 whether there is any other closed area or not. By repeating steps S300 through S307 until the answer at step S308 becomes negative, the needle location data for stitching each closed area can be prepared.
The block data preparing subroutine will now be explained, referring to FIGS. 6, 15 through 19. First, at step S350 the CPU 17 reads the outline-point data of the closed area from the operation memory 43 according to the stitching order. At step S351, as shown in FIG. 15, the CPU 17 obtains a point To having a minimum X-axis value as a MIN. point and a point Tn having a maximum X-axis value as a MAX. point. At step S352, as shown in FIG. 16, the CPU 17 obtains two paths extending from the MIN. to MAX. point as upper outline point sequence U0, U1, . . . Ui, . . . Un, and lower outline point sequence do, dm, . . . dn.
Subsequently, at step S353, as shown in FIG. 17, the CPU 17 sets straight lines passing respective points of the upper outline point sequence U 0 , U 1 , . . . Ui, . . . Un parallel with Y-axis, obtains intersections where the respective straight lines and the lower outline meet, and adds the intersections to the lower outline point sequence. Subsequently, at step S354, as shown in FIG. 18, the CPU 17 sets straight lines passing the respective points of the lower outline point sequence do, dm, . . . dn parallel with Y-axis, obtains intersections where the respective straight lines and the upper outline meet, and adds the intersections to the upper outline point sequence. The number of the data in the upper outline point sequence thus equals that of the data in the lower outline point sequence.
At step S355, as shown in FIG. 19, the CPU 17 forms multiple blocks Go through Gn from the MIN. toward the MAX. point by connecting the upper and lower outline points having the same sequence numbers. At step S356 the CPU 17 alternately stores upper and lower outline points representing a vertex of each block as block data into the operation memory 43. For example, the CPU 17 stores points Ui, di ,Ui+1, then di+1 as the block data of a block Gi into the operation memory 43. It is determined at step S357 whether the closed area has been blocked, and at step S358 whether there exists any other closed area. The closed area is divided into multiple blocks Go through Gn until the answer at step S357 becomes affirmative. The vertexes of each block are thus prepared as the block data until the answer at step S358 becomes negative.
After the needle location data preparing subroutine at step S122 has been finished, at step S123 the CPU 17 displays simulated stitching pattern on the CRT 35. After the block data preparing subroutine at step S124 has finished, at step S123 the CPU 17 displays all the blocks on the CRT 35. Subsequently, it is determined at step S125 whether a correction signal is sent from the operation keyboard 18. When the correction signal is sent, the process goes to step S126 which carries out a predetermined correction such as the modification of the block data. When no correction signal is sent, the process goes to a needle-thread code selecting routine at step S128 where the CRT 35 indicates that the CPU 17 is in a needle-thread selecting mode, and the CPU 17 waits for the input of needle bar number of each closed area.
Consequently, the CPU 17 prepares the stitching data consisting of the block data, the stitching-order data and the needle-thread code, or the stitching data consisting of the needle location data, the stitching-order data and the needle-thread code.
STITCHING MODE
A stitching mode will now be explained, referring to FIG. 3C. It is determined at step S150 in FIG. 3B whether the stitching start key 26 is turned on. When the stitching start key 26 is turned on, the CPU 17 reads the stitching data from the operation memory 43. First, at step S151 the CPU 17 reads the needle-bar number data from the operation memory 43. At step S152, the CPU 17 drives the needle-selecting motor 8 according to the needle-bar number data. After selecting the needle bar, at step S153 the CPU 17 lets out a sewing-machine motor drive signal, thereby driving the sewing-machine motor 9.
Subsequently, at step S154 the CPU 17 determines whether the needle location data preparing flag is set to one or not. When the answer at step S154 is affirmative, at step S155 the CPU 17 reads the needle location data of each needle, and drives and controls the X,Y pulse motor of the feeder 15, thereby finishing the stitching of the closed area. The sewing-machine motor 9 is then stopped and the thread is cut. It is determined at step S157 whether there is any other stitching data for the closed area. When there is more stitching data, the process returns to step S151. On the other hand, when there is no more stitching data, the process ends.
When the needle location data preparing flag is not set to one, at step S156 the CPU 17 reads the X,Y-axis value of the vertex of each block as the block data and calculates the needle location data from the predetermined stitching density data and the block data in a known method. The CPU 17 drives and controls the X,Y pulse motor of the feeder 15 based on the needle location data of each needle, finishing the stitching of the block. When there is more stitching data, the process returns to step S151. On the other hand, when there is no more stitching data, the process ends. The stitching of the closed area is thus finished.
From the above description of a preferred embodiment of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims. For example, in the embodiment the stitch-forming direction is set parallel with Y-axis of X,Y coordinate plane which defines the outline data of the closed area. However, the stitch-forming direction can be set parallel with the X-axis. When the stitch-forming direction is parallel with the X-axis, X-axis values are exchanged for Y-axis values of each outline data. After the process in the embodiment is carried out, X-axis values are exchanged for Y-axis values again. The CPU 17 searches for the expected dividing point along the Y-axis.
In the embodiment the CPU 17 searches for the expected dividing point from the MIN. point to the MAX. point of the closed area along X-axis. However, the CPU 17 can search for the expected dividing point from the MAX. point to the MIN. point. In the embodiment, to input the closed area surrounded with the continuous line with any configuration, the operator designates points on the outline. An automatic program can be used, instead. In the automatic program, the original design drawn on a recording sheet is picked up with an image pick-up means, and outline data is extracted from the image.
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In this invention, a first memory means stores outline data of an embroidery pattern to embroider. Based on the outline data and a predetermined stitch-forming direction, a first computing means divides the outline of the embroidery pattern into multiple closed areas by a segment extending parallel with the stitch-forming direction and computes outline data of the divided closed areas. Subsequently, based on the closed-area outline data computed by the first computing means and the stitch-forming direction, a second computing means computes needle location data or block data that is related to needle location. The needle location data or the block data is stored in a second memory means. Each of the closed areas is thus embroidered in the stitch-forming direction. By providing the closed-area outline data, the needle location data or the block data can automatically be prepared. This automatic data preparing apparatus saves the manual designation of the closed areas by an operator, and reduces time required for preparing the data. Even an inexperienced operator can easily prepare the data.
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RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/969,904, filed Sep. 4, 2007, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a radiation therapy imaging and treatment system. More specifically, the invention relates to a patient support device for use with such a system having improved motion control.
BACKGROUND
Medical equipment for radiation therapy treats tumorous tissue with high energy radiation. The dose and the placement of the dose must be accurately controlled to ensure both that the tumor receives sufficient radiation to be destroyed, and that damage to the surrounding and adjacent non-tumorous tissue is minimized. Intensity modulated radiation therapy (IMRT) treats a patient with multiple rays of radiation each of which may be independently controlled in intensity and/or energy. The rays are directed from different angles about the patient and combine to provide a desired dose pattern. In external source radiation therapy, a radiation source external to the patient treats internal tumors. The external source is normally collimated to direct a beam only to the tumorous site. Typically, the radiation source consists of either high-energy X-rays, electrons from certain linear accelerators, or gamma rays from highly focused radioisotopes, though other types of radiation sources are possible.
One way to control the position of the radiation delivery to the patient is through the use of a patient support device, such as a couch, that is adjustable in one or more directions. The use of a patient support device is well known in the medical field, with similar patient support devices being used in CT scanning devices and Magnetic Resonances Imagers (MRIs). The patient support device allows the patient to be moved into and out of the field of the radiation to be delivered and in some cases, allow for adjustments of patient position during a radiation treatment.
SUMMARY
When a patient support device such as a couch is used in this manner, there are many variables that need to be accounted for. For example construction materials and configuration of suitable electronics necessary to operate the couch must be carefully selected to ensure smooth operation of the couch, and precise measurement of couch position (when the couch has multiple movable parts). When these features are thoughtfully considered in the environment of radiation delivery, the patient support device can be a key tool in improving patient outcomes.
In one embodiment, the present invention provides a patient support device including a base, a table assembly, a controller, and a lateral motion control system. The table assembly is configured to support a patient and includes a lower support, and an upper support movable with respect to the lower support, the upper support including a first end and a second end. The controller is electrically coupled to the table assembly and is configured to instruct the table assembly to move in a first direction along an axis, in a lateral direction with respect to the axis, and in a vertical direction with respect to the axis. The lateral motion control system is electrically coupled to the table assembly and includes a first motor including a shaft coupled to the first end of the upper support, a first encoder coupled to the shaft and configured to detect a first position of the shaft of the first motor, a second motor including a shaft coupled to the second end of the upper support, and a second encoder coupled to the shaft and configured to detect a second position of the shaft of the second motor, the controller configured to receive and compare the first position and the second position, the controller configured to communicate instructions to the first motor and the second motor to substantially synchronize the first position and the second position.
In another embodiment, the invention provides a radiation therapy treatment system comprising a gantry, a table assembly configured to support a patient, a controller, and a lateral motion control system. The table assembly includes a lower support, and an upper support movable with respect to the lower support, the upper support including a first end and a second end. The controller is electrically coupled to the table assembly and is configured to instruct the table assembly to move in a first direction into the gantry, in a lateral direction with respect to the first direction, and in a vertical direction with respect to the first direction. The lateral motion control system is electrically coupled to the table assembly and is configured to detect a position of the first end of the upper support and a position of the second end of the upper support and output the positions of the first end and the second end.
In another aspect of the invention, the present invention provides a method including the acts of detecting a position of a first end of a table assembly for a radiation therapy treatment system, detecting a position of a second end of the table assembly, comparing the position of the first end with the position of the second end, and substantially synchronizing the position of the first end with the position of the second end.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a radiation therapy treatment system.
FIG. 2 is a perspective view of a multi-leaf collimator that can be used in the radiation therapy treatment system illustrated in FIG. 1 .
FIG. 3 is a perspective view of a patient support device for use with the system of FIG. 1 .
FIG. 4 is an exploded view of a table assembly of the patient support device of FIG. 3 .
FIG. 5 is a perspective view of an upper support of the table assembly of FIG. 4 .
FIG. 6 is a perspective view of a lower support of the table assembly of FIG. 4 .
FIG. 7 is an assortment of views of a control keypad for use with the patient support device of FIG. 1 .
FIG. 8 is an exploded view of the keypad of FIG. 7 .
FIG. 9 is a front view of the keypad of FIG. 7 , illustrating the control buttons in greater detail
FIG. 10 is a perspective view of the keypad of FIG. 7 , illustrating operation of the buttons by the operator of the patient support device
FIG. 11 is a perspective view of the patient support device of FIG. 3 , shown in the lowered position.
FIG. 12 illustrates a riser of the patient support device of FIG. 3 .
FIG. 13 is a diagram of a lateral motion control system according to one embodiment of the present invention.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.
Although directional references, such as upper, lower, downward, upward, rearward, bottom, front, rear, etc., may be made herein in describing the drawings, these references are made relative to the drawings (as normally viewed) for convenience. These directions are not intended to be taken literally or limit the present invention in any form. In addition, terms such as “first,” “second,” and “third” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
In addition, it should be understood that embodiments of the invention include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic based aspects of the invention may be implemented in software. As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components may be utilized to implement the invention. Furthermore, and as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention and that other alternative mechanical configurations are possible.
FIG. 1 illustrates a radiation therapy treatment system 10 that can provide radiation therapy to a patient 14 . The radiation therapy treatment can include photon-based radiation therapy, brachytherapy, electron beam therapy, proton, neutron, or particle therapy, or other types of treatment therapy. The radiation therapy treatment system 10 includes a gantry 18 . The gantry 18 can support a radiation module 22 , which can include a radiation source 24 and a linear accelerator 26 (a.k.a. “a linac”) operable to generate a beam 30 of radiation. Though the gantry 18 shown in the drawings is a ring gantry, i.e., it extends through a full 360° arc to create a complete ring or circle, other types of mounting arrangements may also be employed. For example, a C-type, partial ring gantry, or robotic arm could be used. Any other framework capable of positioning the radiation module 22 at various rotational and/or axial positions relative to the patient 14 may also be employed. In addition, the radiation source 24 may travel in path that does not follow the shape of the gantry 18 . For example, the radiation source 24 may travel in a non-circular path even though the illustrated gantry 18 is generally circular-shaped. The gantry 18 of the illustrated embodiment defines a gantry aperture 32 into which the patient 14 moves during treatment.
The radiation module 22 can also include a modulation device 34 operable to modify or modulate the radiation beam 30 . The modulation device 34 provides the modulation of the radiation beam 30 and directs the radiation beam 30 toward the patient 14 . Specifically, the radiation beam 30 is directed toward a portion 38 of the patient. Broadly speaking, the portion may include the entire body, but is generally smaller than the entire body and can be defined by a two-dimensional area and/or a three-dimensional volume. A portion or area desired to receive the radiation, which may be referred to as a target or target region, is an example of a region of interest. Another type of region of interest is a region at risk. If a portion includes a region at risk, the radiation beam is preferably diverted from the region at risk. Such modulation is sometimes referred to as intensity modulated radiation therapy (“IMRT”).
The modulation device 34 can include a collimation device 42 as illustrated in FIG. 2 . The collimation device 42 includes a set of jaws 46 that define and adjust the size of an aperture 50 through which the radiation beam 30 may pass. The jaws 46 include an upper jaw 54 and a lower jaw 58 . The upper jaw 54 and the lower jaw 58 are moveable to adjust the size of the aperture 50 . The position of the jaws 46 regulates the shape of the beam 30 that is delivered to the patient 14 .
In one embodiment, and illustrated in FIG. 2 , the modulation device 34 can comprise a multi-leaf collimator 62 (a.k.a. “MLC”), which includes a plurality of interlaced leaves 66 operable to move from position to position, to provide intensity modulation. It is also noted that the leaves 66 can be moved to a position anywhere between a minimally and maximally-open position. The plurality of interlaced leaves 66 modulate the strength, size, and shape of the radiation beam 30 before the radiation beam 30 reaches the portion 38 on the patient 14 . Each of the leaves 66 is independently controlled by an actuator 70 , such as a motor or an air valve so that the leaf 66 can open and close quickly to permit or block the passage of radiation. The actuators 70 can be controlled by a computer 74 and/or controller.
The radiation therapy treatment system 10 can also include a detector 78 , e.g., a kilovoltage or a megavoltage detector, operable to receive the radiation beam 30 , as illustrated in FIG. 1 . The linear accelerator 26 and the detector 78 can also operate as a computed tomography (CT) system to generate CT images of the patient 14 . The linear accelerator 26 emits the radiation beam 30 toward the portion 38 in the patient 14 . The portion 38 absorbs some of the radiation. The detector 78 detects or measures the amount of radiation absorbed by the portion 38 . The detector 78 collects the absorption data from different angles as the linear accelerator 26 rotates around and emits radiation toward the patient 14 . The collected absorption data is transmitted to the computer 74 to process the absorption data and to generate images of the patient's body tissues and organs. The images can also illustrate bone, soft tissues, and blood vessels. The system 10 can also include a patient support device, shown as a couch 82 , operable to support at least a portion of the patient 14 during treatment. While the illustrated couch 82 is designed to support the entire body of the patient 14 , in other embodiments of the invention the patient support need not support the entire body, but rather can be designed to support only a portion of the patient 14 during treatment. The couch 82 moves into and out of the field of radiation along an axis 84 (i.e., Y axis). The couch 82 is also capable of moving along the X and Z axes as illustrated in FIG. 1 .
With reference to FIGS. 3-6 , the couch 82 includes a table assembly 92 coupled to a base 93 via a platform 95 . The table assembly 92 includes an upper support 94 movably coupled to a lower support 98 . With particular reference to FIG. 5 , the upper support 94 is a substantially flat, rectangular support member on which the patient is supported during treatment. The upper support 94 is movable with respect to the lower support 98 to move the patient into and out of the radiation beam 30 during treatment. In the illustrated embodiment, the upper and lower supports 94 , 98 are composed of a carbon fiber composite, though other compositions of the supports are possible.
The upper support 94 has an upper surface 102 and a lower surface 106 that contacts an upper surface 110 of the lower support 98 . As shown in the illustrated embodiment, the lower surface 106 includes a bearing layer 114 that is intended to reduce friction between the lower surface 106 and the upper surface 110 of the lower support 98 when the upper support 94 is moved with respect to the lower support 98 . In the illustrated embodiment, the bearing layer 114 is a polyimide laminate that is coupled to the lower surface 106 using a pressure sensitive adhesive. In the illustrated embodiment, the laminate is Kapton™, available from DuPont. When the upper support 94 moves with respect to the lower support 98 , any friction that builds up between the supports can interrupt the operation of the electronics that control the operation of the couch 82 and thus minimizing the friction is one of the goals of the invention. Further, when the supports are composed of the carbon fiber composite, the friction can cause the creation and build-up of carbon dust, which can cause problems with couch operation. Additionally, if the surfaces of the upper and lower supports 94 , 98 were to contact each other directly, the contact would result in additional wear and possible warping of the supports themselves, which may not only reduce the precision with which the couch can operate to position a patient, but can also cause couch failure.
With reference to FIG. 4 , the lower support 98 includes two channels 118 that are designed to receive and house wiring necessary for the operation of the couch 82 . In some embodiments, a retaining member 122 is placed over the wiring within the channels 118 to hold the wiring in place and force the wiring to lie straight within the channels 118 to reduce the possibility of the wiring being pinched between the upper support 94 and the lower support 98 . Furthermore, it is desirable to hold the wires in a straight and constant position for image reproducibility. Both the retaining member 122 and the outer sheathing of the wiring itself are composed of radiation resistant material to provide for the protection and proper functioning of the wiring in the high radiation environment of the couch 82 . The spacing and design of the channels 118 is selected to separate the power lines from the data lines to prevent interference problems that occur when the two lines are not sufficiently spaced.
The table assembly 92 is movable in the X, Y, and Z directions, as illustrated in FIG. 1 . Positioning of the table assembly 92 , and thus the position of the patient, with respect to the gantry 18 and the radiation beam 30 must be precise to ensure that the radiation is delivered to the proper areas of the patient. The movement of the table assembly 92 is controlled by the couch operator using a control keypad 140 , illustrated in FIGS. 7-10 . Once the user actuates the buttons 144 of the keypad 140 , the table assembly 92 will move at the direction of the user.
Another feature of the couch 82 according to the present invention is that lateral motion (i.e., motion in the X direction) is automatically controlled, and the lateral motion of both ends of the table assembly 92 is synchronized. In conventional patient support tables, lateral motion adjustment is accomplished using a knob or screw that is manually turned to adjust position in the lateral direction. Not only is this adjustment manual, but also the adjustment of each end of the support table must be done separately and there is no mechanism that synchronizes the position of the table ends. This can cause patient positioning errors as one end may be moved to a more extreme lateral position than the other and obtaining a true, synchronized position of both ends in the lateral direction is very difficult.
In addition, synchronization of the ends is also useful in assuring reliable and reproducible imaging results. In a system such as the system of the present invention where a patient on the couch 82 is subject to radiation for the purposes of taking an image of that patient, anything in the path between the radiation source and the detector that feeds data to the system to produce the image can impact the quality of the images. The wiring that runs underneath the table assembly 92 as discussed above can interfere with the quality of the images taken, and may result in an artifact on the resulting images that a therapist or physician will want to take into consideration when reviewing the resulting images. The channels 118 in the lower support 98 discussed above function to keep the wiring separated and contained. By synchronizing the motion of the ends of the table assembly 92 in addition to knowing the position of the channels 118 , the physician/therapist has predictable artifacts that can be effectively eliminated by the physician/therapist when viewing the images because those artifacts will be in predictable locations, will be correctable, and the images will be reproducible. Without the synchronization, the artifacts would be more of a distraction to the user.
The couch 82 includes a lateral motion control system 200 according to one embodiment of the present invention as illustrated in FIG. 13 . The lateral motion control system 200 includes a controller 204 electrically coupled to a first motor 208 positioned near a first end 212 of the table assembly 92 and electrically coupled to a second motor 216 positioned near a second end 220 of the table assembly 92 . The first motor 208 includes a shaft 224 and an encoder 228 coupled to the shaft 224 . The second motor 216 includes a shaft 232 and an encoder 236 coupled to the shaft 232 . The encoders 228 , 236 communicate with the controller 204 to transmit position data of the respective motor shaft. The controller 204 receives motion instructions from the keypad 140 . The controller 204 includes computer code that compares the position data from the encoders 228 , 236 to ensure that the shafts 224 , 232 of the respective motors 208 , 216 at both ends of the table assembly 92 are synchronized. The controller 204 moves the table assembly 92 in both axes (X and Y) at the same time and looks for yaw at the same time as the motion. The encoders 228 , 236 are absolute encoders that incorporate feedback, such as SSI or other appropriate types of feedback, to make the synchronicity possible.
The use of motors 208 , 216 in conjunction with the linear absolute feedback of the encoders 228 , 236 allow the system to be able to detect yawing and crab motion of the table assembly 92 and display that information for the operator. The fact that the feedback is linear allows the user to see what is happening on the load side as well. All of this feedback information is possible due to the separation of the feedback lines (data wires) from those supplying power in the channels 118 as described above.
Y axis motion is controlled using a stepper motor. While the table assembly 92 is moving, absolute linear feedback is used to servo the table assembly 92 to keep it within tolerance limits, thereby improving the accuracy with which couch motion can be controlled. Furthermore, the Y axis motion control has the benefit of being able to detect obstructions or impending couch collisions (such as with the gantry), causing the couch to stop prior to the collision. Collision detection occurs dynamically with continuous double-checking on couch position. Any error propagation is displayed to the end user on the PCP.
Additional features of the invention can be found in the following claims.
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A method and system configured to substantially synchronize two opposite ends of a table assembly of a radiation therapy treatment system. The system includes a lateral motion control system coupled to the table assembly and configured to detect positions of the two opposite ends of the table assembly and to substantially synchronize the positions as the table assembly is laterally moved with respect to a gantry of the radiation therapy treatment system.
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BACKGROUND OF THE INVENTION
The present invention deals with the field of devices utilized in the health care field generally for receiving bodily fluids. Devices for this purpose have been used primarily in hospitals but also in doctors' facilities and smaller clinics and the like. Currently, it is common to use basins, which are open, shallow, kidney-shaped, plastic pans for collection of bodily fluids, such as sputum and emesis. The present device is specifically usable for collecting of emesis. This is particularly important in view of disease control considerations, such as the likelihood that emesis might contain blood, which may present a risk of contamination by HIV, Hepatitis B, and/or pathogens not carried in the blood. As such, the present invention provides a unique configuration solely utilized for the purposes of safe and efficient gathering and containment of potentially dangerous spewed emesis.
OBJECT OF THE PRESENT INVENTION
An object of the present invention is to provide a container for receiving and retaining emesis.
Another object of the present invention is to provide such a container wherein the chance of emesis escape or spillage is minimized if not eliminated.
A further object of the present invention is to provide such a container which is easy to use.
Yet another object of the present invention is to provide such a container which is easily emptied.
It is an additional object of the present invention to provide such a container which is easily secured, for example, to hospital beds.
These and other objects of the present invention will be apparent from the drawings and descriptions herein.
SUMMARY OF THE INVENTION
A portable receptacle for receiving and containing emesis comprises, in accordance with one embodiment of the present invention, a main body member defining an emesis containment chamber, a neck connected to the main body member, and a mouthpiece attached to the neck at an end thereof opposite the main body member. The neck defines a conduit communicating with the chamber. A baffle structure is positioned substantially within the conduit to allow emesis to move therethrough into the chamber and to minimize spillage and leakage outwardly through the conduit from the chamber.
In accordance with a specific feature of the present invention, the baffle structure includes a plurality of baffle plates positioned in the conduit. The baffle plates may be angularly oriented with respect to the conduit such as to extend downstream therealong. The baffle plates are preferably fixed to the neck.
A portable receptacle for receiving and containing emesis comprises, in accordance with another embodiment of the present invention, a main body member defining an emesis containment chamber, a neck connected to the main body member, and a mouthpiece attached to the neck at an end thereof opposite the main body member. The neck defines a conduit communicating with the chamber. A one-way valve is positioned substantially within the conduit to allow emesis to move therethrough into the chamber and to minimize spillage and leakage outwardly through the conduit from the chamber.
In accordance with another feature of the present invention, applicable in either embodiment, the mouthpiece has a form substantially conforming to a face of a user about the user's mouth, thereby facilitating a substantial seal or closure between the user's face and the neck. The mouthpiece may be rotatably movably mounted with respect to the neck to facilitate engagement thereof with respect to the mouth of a patient.
Pursuant to another feature of the present invention, the neck and the conduit are oriented obliquely with respect to the main body member to facilitate flow of emesis through the conduit into the chamber.
A handle is advantageously secured to the main body member to facilitate holding and stabilizing of the main body member during usage of the portable emesis receptacle. The handle may cooperate with the main body member to define a least one vertically extending slot to facilitate a mounting of the portable receptacle.
According to furthers feature of the present invention, measurement indicia markings are provided on the main body member to facilitate measurement of the amount of material within the chamber, the main body member defines an exit opening therein in fluid flow communication with the chamber to facilitate removal of material therefrom, and a mouthpiece cap is detachably positionable selectively in engagement with the mouthpiece and extending thereover for closing thereof to facilitate retaining of emesis within the chamber of the main body member. The mouthpiece cap is adapted to extend over the mouthpiece for selectively closing the mouthpiece to prevent emesis passing outwardly through the mouthpiece. Also a mouthpiece cap attachment line may be secured to the mouth piece cap and attached to the neck in order to facilitate retainment of the mouthpiece cap with respect to the portable receptacle and minimize the chance of loss thereof during any extended time of non use.
The main body member of a portable receptacle in accordance with the present invention is mostly opaque but includes a translucent section which includes a plurality of measurement indicia markings to facilitate the measurement of the amount of total fluid volume within the emesis containment chamber at a given time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective illustration of an embodiment of the portable receptacle for receiving and containing emesis made in accordance with the present invention shown in usage by a patient or user.
FIG. 2 is a side view of embodiment shown in FIG. 1 taken from the right.
FIG. 3 is a side plan view of the neck piece and the mouth area of an embodiment of the present invention showing the mouthpiece cap in position extending over the mouthpiece area.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a new and useful improvement in gathering and disposing of emesis for use in hospitals, doctors' offices, clinics or even home environments. Numerous precautions are being published especially for use by health care workers as dictated by the Center for Disease Control to aid in the collection of various body fluids including emesis. Current disease control requirements, including preventative measures, have been significantly made more important by the significant presence of highly communicable diseases in society, such as HIV and Hepatitis B.
The present invention provides a portable receptacle 10 designed to accumulate emesis 12. Receptacle 10 includes a main body member 14 which defines an emesis containment chamber 16 therein. This emesis containment chamber 16 is designed to receive and contain emesis 12 and facilitate disposal thereof.
Main body member 14 defines a channel opening 18 preferably defined in a sidewall 46 thereof. This chamber opening 18 is in fluid flow communication with the emesis containment chamber 16 to facilitate the flow of emesis therein. A neck member 20 which preferably includes a neck conduit 26 extending therethrough from a neck inlet 22 to a neck outlet 24 is included in the apparatus of the receptacle 10. Neck member 20 is preferably at an angular orientation 28 of, preferably 30 to 60 degrees with respect to the main body member 14 and in particular with respect to the sidewall 46 thereof.
A mouthpiece 30 may be positioned over the neck inlet 22 to facilitate engagement thereof with respect to the mouth of a patient or user 62. Furthermore the mouthpiece 30 will preferably include an arcuate mouth engaging edge 44 adapted to contact the mouth area of the patient or user 62 in surrounding relationship to the user's mouth in order to facilitate receiving and containing of emesis 12 spewed therefrom.
The neck conduit 22 will preferably include therein a rigid differential flow control structure in the form of baffle plates 32 which are angularly oriented with respect to the neck conduit 26 such as to extend downstream therealong. The baffle plates 32 are designed preferably to allow emesis to be spewed from the neck inlet 22 through the neck conduit 26 to the neck outlet 24 and on into the emesis containment chamber 16 but to prevent similar reverse flow and thereby minimize spillage as well as minimizing any possibility of splashing. To further facilitate containment and prevent spillage and splashing a one-way valve 38 can optionally be included in the apparatus of the present invention. The one-way valve 38 is designed to allow emesis spewed through the neck conduit 26 at high speed to pass therethrough but to prevent reverse flow or reverse spillage outwardly through the neck conduit 26 from the outlet 24 to the inlet 22.
As an additional element of protection, a mouthpiece cap 48 may be positionable in engagement with the mouthpiece 30 to extend over the neck inlet 22 for closing thereof to prevent spillage of emesis 12 after usage of the portable receptacle 10. In order to prevent loss of the mouthpiece cap 48, a mouthpiece cap attachment line 50 may optionally be included which is attached with respect to the receptacle 10 and also with respect to the mouthpiece cap 48.
To facilitate holding of the receptacle 10 during usage, a handle means 34 may be included which may take the form of a first handle member 40 positioned on one side of the main body member 14 and a second handle member 42 positioned on the other opposite side of the main body member 14. In this manner a user can put his hands on both handles and rest the main body member 14 on his lap or abdomen for fixed holding thereof during the spewing of emesis 12.
Preferably the main body member 14 is generally opaque throughout in order to prevent direct viewing of the emesis 12 contained therein to make usage of the device more aesthetically pleasing. However, it is important under many circumstances that a doctor have an accurate measurement of the fluid volume of spewed emesis 12. For this reason the opaque areas 54 of the main body member 14 will preferably not include a section thereof positioned along the measurement indicia markings 52. This marking section 56 of the main body member 14 will preferably be defined as a translucent marking section to facilitate the viewing of the level of liquid within the emesis containment chamber 16 immediately adjacent the measurement indicia marking 52 to thereby determine the total fluid volume of spewed emesis 12.
The emptying of the emesis from the emesis containment chamber 16 can be achieved through the neck conduit 26 if desired. However, to further facilitate emptying of the containment chamber 16 an additional exit opening 58 may be optionally included with an exit cap member 60 engageable therewith for closing of the exit during usage and opening of the exit 58 whenever it is desired to empty the emesis containment chamber.
One of the unique aspects of the present invention is the orientation of the neck 20 and particularly the neck conduit 26 at an angle of 30 to 60 degrees with respect to the main body 14 and particularly with respect to the sidewall 46 thereof. This angular orientation when used in combination with the universal mouthpiece 30 allows usage by virtually any patient. Also, the downwardly extending baffle plates 32 allow movement of fluid into the emesis containment chamber 16 and prevent movement outwardly therefrom during the spewing of emesis 12 and thereafter during movement of the portable receptacle 10 to a disposal location. The transport of any filled container other than the receptacle 10 of the present invention to a location where it can be emptied is often difficult and risks contaminating because of the numerous types of body fluids which are often contained with emesis 12 and therefore contained within the containment device. The apparatus of the present invention is small enough to be used in households as well as in ambulances and clinics and is certainly capable of being used in hospital and other similar environments.
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A portable receptacle for receiving and containing emesis has a main body member defining an emesis containment chamber, a neck connected to the main body member, and a mouthpiece attached to the neck at an end thereof opposite the main body member. The neck defines a conduit communicating with the chamber. A baffle structure and/or one-way valve is positioned substantially within the conduit to allow emesis to move therethrough into the chamber and to minimize spillage and leakage outwardly through the conduit from the chamber.
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RELATED APPLICATION
[0001] This application is a divisional of an application filed on Nov. 18, 2003, having Ser. No. 10/716,945.
BACKGROUND
[0002] Background of the Invention
[0003] FIG. 1 a is a cross sectional side view of a heating assembly 100 to attach a die 106 to a substrate 112 . A heating block 102 generates heat. A heat nozzle 104 transmits heat from the heating block 102 to a die 106 . The die 106 is positioned above a substrate 112 . Solder bumps 110 , once melted by the heat applied to the die 106 and then cooled, attach the die 106 to the substrate 112 . Underfill material 108 , such as epoxy resin, substantially fills the areas between the die 106 and the substrate 112 .
[0004] FIG. 1 b is a graph that shows the heat generated by different areas of the heating block 102 . The heating block 102 generates heat in a substantially uniform manner, as shown by the graph in FIG. 1 b . Heat put out at one point of the heating block's 102 surface is about equal to heat put out at another point of the heating block's 102 surface. FIG. 1 c is a graph that shows the thermal conductivity of the heat nozzle 104 . As shown in the graph of FIG. 1 c , the thermal conductivity of the heat nozzle 104 is substantially the same from the left edge 114 of the die to the right edge 116 of the die. FIG. 1 d illustrates a graph that shows the temperature of the solder bump 110 and the underfill material 108 beneath the die 106 that results from the heat generated by the heating block 102 as shown by the graph in FIG. 1 b and transmitted from the heating block 102 to the die 106 by the heat nozzle 104 as shown by the graph in FIG. 1 c . The graph in FIG. 1 d shows that the temperature at the die 106 is lower at the left 114 and right 116 edges of the die 106 , and has a higher temperature peak 118 approximately in the center.
[0005] Since heat may be exchanged between the edges 114 , 116 of the die 106 and the surrounding environment, some heat at the edges of the die is dispersed, leaving the center of the die 106 hotter. Applying enough heat to ensure that the temperature near the edges 114 , 116 of the die 106 is hot enough to melt the solder bumps 110 to attach the die 106 to the substrate 112 may result in a higher peak 118 temperature near the center of the die 106 that may be too high and result in overheating the underfill material 108 and causing voids in the underfill 108 to occur.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 a is a cross sectional side view of a heating assembly.
[0007] FIG. 1 b is a graph that shows the heat generated by different areas of the heating block.
[0008] FIG. 1 c is a graph that shows the thermal conductivity of the heat nozzle.
[0009] FIG. 1 d illustrates a graph that shows the temperature of the underfill material beneath the die.
[0010] FIG. 2 illustrates a graph that shows the temperature of underfill material between a die and a substrate from a left die edge to a right die edge according to one embodiment of the present invention.
[0011] FIG. 3 a is a cross sectional side view of one embodiment of a heating assembly that may provide more heat to the edges of a die than to the center of a die.
[0012] FIG. 3 b illustrates a graph that shows the heat generated by the heating block.
[0013] FIG. 3 c illustrates a graph that shows the thermal conductivity of the heat nozzle.
[0014] FIG. 3 d illustrates a graph that shows the temperature of the underfill material beneath the die.
[0015] FIG. 3 e is a cross sectional top view of a heating block that generates uneven heat according to one embodiment of the present invention.
[0016] FIG. 3 f is a cross sectional side view of one embodiment of a heating assembly that may provide more heat to the edges of a die than to the center of a die.
[0017] FIG. 4 a is a cross sectional side view of another embodiment of a heating assembly that may provide more heat to the edges of a die than to the center of a die.
[0018] FIG. 4 b illustrates a graph that shows the heat generated by the heating block.
[0019] FIG. 4 c illustrates a graph that shows the thermal conductivity of the heat nozzle.
[0020] FIG. 4 d illustrates a graph that shows the temperature of the underfill material beneath the die.
[0021] FIG. 4 e is a cross sectional top view of a heat nozzle that has a varying thermal conductivity according to one embodiment of the present invention.
[0022] FIG. 4 f is a cross sectional side view of one embodiment of a heating assembly that may provide more heat to the edges of a die than to the center of a die.
DETAILED DESCRIPTION
[0023] FIG. 2 illustrates a graph 200 that shows the temperature of solder bumps (or other connectors) and underfill material between a die and a substrate from a left die edge 214 to a right die edge 216 according to one embodiment of the present invention. According to an embodiment, the underfill temperature may be substantially the same from the left die edge 214 through the middle of the die to the right die edge 216 . Since more heat is lost through the edges of a die than the center of the die, this temperature distribution may be achieved by applying more heat to the edges of the die than to the center of the die.
[0024] In some embodiments, the graph 200 may not be flat as that shown in FIG. 2 , and the temperature may vary some at various points along the die, but the highest temperature may still remain below a temperature that would cause voids in underfill to occur. For example, in one embodiment, the underfill material may comprise an epoxy resin. The temperature of the underfill may be hotter in the middle of the die than at the edges 214 , 216 , but the temperature at the middle may remain lower than a temperature that would vaporize the underfill material to form voids. Various other embodiments may have a temperature that is cooler in the middle of the die than at the edges 214 , 216 , temperatures that are coolest at the edges 214 , 216 , hotter at a distance from the edges 214 , 216 , and cooler again in the middle of the die, or other temperature distributions.
[0025] FIG. 3 a is a cross sectional side view of one embodiment of a heating assembly 300 that may provide more heat to the edges of a die than to the center of a die. The heating assembly 300 may include a heating block 202 and a heat nozzle 204 . The heating block 202 may be anything that can generate heat and transfer it to the heat nozzle 204 . In various embodiments, the heating block 202 may produce heat by passing through a conductive element that has resistance, by generating microwaves, through infrared radiation, or other methods. In an embodiment, the heating block 202 may be capable of heating itself, the heat nozzle 202 , and a die 206 to a temperature in a range from about 200 degrees Celsius to about 340 degrees Celsius at a rate in a range from about 10 degrees Celsius per second to about 50 degrees Celsius per second or higher. The heat nozzle 204 may receive heat generated by the heating block 202 and transmit that heat to a die 206 . In an embodiment, the heating block 202 and heat nozzle 204 may be two components that are coupled so that the heat nozzle 204 may receive the heat generated by the heating block 202 and transmit that heat to the die 206 . In another embodiment, the heating block 202 and heat nozzle 204 may comprise a single component. For example, the heating block 202 may be the part of the component that generates heat, and the heat nozzle 204 may be an area of the component adapted to transmit the heat to the die 206 . Together, the heating block 202 and the heat nozzle may be considered to comprise a heater.
[0026] The die 206 may be an integrated circuit die such as a microprocessor. The die 206 may be positioned above a substrate 212 . Connectors, such as solder bumps 210 or other connectors, may be between the die 206 and the substrate 212 . The heater may operate to apply heat to the die 206 . This heat may melt the solder bumps 210 . When cooled, the solder bumps 210 may couple the die 206 to the substrate 212 . Underfill material 208 may substantially fill the areas between the die 206 and the substrate 212 . In an embodiment, the underfill material 208 may comprise an epoxy material.
[0027] In the embodiment illustrated in FIG. 3 a , the heating block 202 may generate heat unevenly. FIG. 3 b illustrates a graph 350 that shows the heat generated by the heating block 202 in an embodiment. As shown in the graph 350 , the heating block 202 may generate more heat toward the edges 214 , 216 of the die 206 than in the middle. The heat nozzle 204 may have a substantially uniform thermal conductivity, as shown by the graph 352 in FIG. 3 c . Since the heating block 202 may generate less heat in the middle of the die 206 , as shown by graph 350 in FIG. 3 b , the temperature of the underfill 208 may be substantially uniform from the left die edge 214 to the right die edge 216 as shown in graph 354 in FIG. 3 d . In other embodiments, the temperature of the solder bumps 210 (or other connectors) and the underfill 208 may not be substantially uniform as shown in graph 354 , but may vary somewhat between the left die edge 214 and the right die edge 216 . However, in an embodiment where the heating block 202 generates less heat in the middle of the die 206 as shown in graph 350 of FIG. 3 b , this variation may be less than in prior art systems, such as shown in FIG. 1 d . Generating less heat in the middle of the die 206 may result in the maximum underfill 208 temperature being low enough to substantially prevent formation of underfill voids.
[0028] FIG. 3 e is a cross sectional top view of a heating block 202 that generates uneven heat according to one embodiment of the present invention. In an embodiment, the heating block 202 may include a middle section 322 and a peripheral section 320 . The heating block 202 may generate more heat in the peripheral section 320 than in the middle section 322 . The die 206 may be positioned so that the middle section 322 is positioned over the middle of the die 206 . This may result in the heat generation graph 350 as shown in FIG. 3 b , and result in a more even solder bump 210 (or other connector) and underfill 208 temperature, as shown in the graph 354 of FIG. 3 d . The graph 354 indicates that the temperature of the solder bumps 210 (or other connectors) and the underfill 208 may be substantially uniform from the left die edge 214 to the right die edge 216 in an embodiment. In other embodiments, the temperature of the solder bumps 210 (or other connectors) and the underfill 208 may not be substantially uniform as shown in graph 354 , but may vary somewhat between the left die edge 214 and the right die edge 216 . However, this variation may be less than in prior art systems, such as shown in FIG. 1 d . While the illustrated embodiment includes a sharp boundary between the middle section 322 and the peripheral section 320 , in other embodiments there may be a gradual transition rather than a boundary. There may be progressively less heat generated at points closer to the middle of the heating block 202 .
[0029] FIG. 3 f is a cross sectional side view of one embodiment of a heating assembly 300 that may provide more heat to the edges of a die 206 than to the center of a die 206 . In the embodiment illustrated in FIG. 3 f , at least some heat that is generated by the heating block 202 is generated by heating elements 318 , which may comprise conductive or semi-conductive elements wherein heat is generated by the resistance of the heating element 318 as a current passes through it, within a matrix material of the heating block 202 . In an embodiment, there are more heating elements 318 per unit volume in the peripheral section 320 of the heating block 202 than in the middle section 322 of the heating block 202 . Since there are more heating elements 318 in the peripheral section 320 , the heating block 202 produces more heat in the peripheral section 320 than in the middle section 322 .
[0030] FIG. 4 a is a cross sectional side view of another embodiment of a heating assembly 400 that may provide more heat to the edges of a die 206 than to the center of a die 206 . The heating assembly 400 may be similar in most respects to the heating assembly 300 described above, and may include a heating block 402 , a heat nozzle 404 , a die 206 , a substrate 212 , solder bumps 210 or other connectors, and underfill material 208 . The heating block 402 may generate heat in a uniform manner, or in a non-uniform manner as described with respect to FIG. 3 a . The shape, size, and material of the heat nozzle 404 may vary. In an embodiment, the heat nozzle 404 may comprise a thermally conductive material such as silicon nitride, aluminum nitride, copper carbide, tungsten carbide, steel, or another material.
[0031] In the embodiment illustrated in FIG. 4 a , the heat nozzle 404 may have a non-uniform thermal conductivity. FIG. 4 b illustrates a graph 450 that shows the heat generated by the heating block 402 in an embodiment. As shown in the graph 450 , the heating block 402 may generate heat in a substantially uniform manner. However, the heat nozzle 404 may have a non-uniform thermal conductivity, as shown by the graph 452 in FIG. 4 c . As shown by the graph 452 of FIG. 4 c , the heat nozzle 404 may have a higher thermal conductivity toward the edges 214 , 216 of the die 206 , and a lower thermal conductivity toward the center of the die 206 . Less heat will be transmitted by the center of the heat nozzle 404 than the periphery. Such differences in thermal conductivity may mean that the temperature of the solder bumps 210 (or other connectors) and the underfill 208 may be substantially uniform from the left die edge 214 to the right die edge 216 as shown in graph 454 in FIG. 4 d ; more heat is transmitted to the die 206 edges 214 , 216 than to the die middle. In other embodiments, the temperature of the solder bumps 210 (or other connectors) and the underfill 208 may not be substantially uniform as shown in graph 454 , but may vary somewhat between the left die edge 214 and the right die edge 216 . However, in an embodiment where the heat nozzle 404 has a lower thermal conductivity in the middle, and therefore transmits less heat to the middle of the die 206 , this variation may be less than in prior art systems, such as shown in FIG. 1 d . Transmitting less heat to the middle of the die 206 may result in the maximum underfill 208 temperature being low enough to substantially prevent formation of underfill voids.
[0032] FIG. 4 e is a cross sectional top view of a heat nozzle 404 that has a varying thermal conductivity according to one embodiment of the present invention. In an embodiment, the heat nozzle 404 may include a middle section 422 and a peripheral section 420 . The heat nozzle 404 may have a higher thermal conductivity in the peripheral section 420 than in the middle section 422 . The die 206 may be positioned so that the middle section 422 is positioned over the middle of the die 206 . This may result in less heat being transmitted to the middle of the die 206 , and result in a more even underfill temperature, as shown in the graph 454 of FIG. 4 d . While the illustrated embodiment includes a sharp boundary between the middle section 422 and the peripheral section 420 , in other embodiments there may be a gradual transition rather than a boundary. There may be a progressively lower thermal conductivity at points closer to the middle of the heat nozzle 404 .
[0033] FIG. 4 f is a cross sectional side view of one embodiment of a heating assembly 400 that may provide more heat to the edges of a die 206 than to the center of a die 206 . In the embodiment illustrated in FIG. 4 f , there may be a cavity 424 in the middle section of the heat nozzle 404 . Such a cavity 424 means that the middle of the heat nozzle 404 is not in direct contact with the die 206 surface, creating an air gap that reduces the conduction of heat from the heat nozzle 404 to the die 206 . In an embodiment, this cavity 424 may be a portion of a spherical shape. The maximum distance from the die to the surface of the heat nozzle 404 , at the center of the spherical cavity 424 , may be in a range from about several microns to about 100 microns. The cavity may extend to about two-thirds of the surface of the heat nozzle 404 in an embodiment. Since the presence of the cavity 424 reduces conduction of heat to the center of the die 206 , the heat nozzle 404 transmits more heat in the peripheral section 420 than in the middle section 422 . This may result in a more uniform temperature in the solder bump 210 (or other connector) and the underfill material 208 , as illustrated in FIGS. 2, 3 d , and 4 d . In other embodiments, the peripheral section 420 of the heat nozzle 404 may comprise different materials than the middle section 422 . For example, different materials in the peripheral section 420 and the middle section 422 may be deposited, laminated, or sintered together to form the heat nozzle 404 with varying thermal conductivities.
[0034] In other embodiments, various combinations of heating blocks 202 that produce different amounts of heat in different areas and heat nozzles 404 that have non-uniform thermal conductivities may be used in a heating assembly. These different combinations can be used to ensure a more uniform temperature in the solder bumps 210 (or other connectors) and the underfill material 208 , as illustrated in FIGS. 2, 3 d , and 4 d.
[0035] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. This description and the claims following include terms, such as left, right, top, bottom, over, under, upper, lower, first, second, etc. that are used for descriptive purposes only and are not to be construed as limiting. The embodiments of a device or article described herein can be manufactured, used, or shipped in a number of positions and orientations. Persons skilled in the relevant art can appreciate that many modifications and variations are possible in light of the above teaching. Persons skilled in the art will recognize various equivalent combinations and substitutions for various components shown in the Figures. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
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The invention provides a heater for flip chip bonding. The heater transfers more heat to the periphery of a die than to the center. This results in a more even temperature profile along the die and helps prevent epoxy voiding problems.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Patent Application is a Divisional of, and claims priority to under 35 U.S.C. §120, co-pending U.S. patent application Ser. No. 11/141,900, filed on Jun. 1, 2005, entitled, “Minimum Till Seeding Knife” and having Terry Emerson Summach and Bradley T. Summach as the Inventors. The full disclosure of U.S. patent application Ser. No. 11/141,900 is hereby fully incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of farming, a farm implement and a knife or knife assembly which may be used as part of no-till or minimum-till farming practices primarily for placement in the ground of seed and/or fertilizer and other materials. The invention works in all field conditions, and in particular it operates with minimum soil disturbance in minimum till and zero till farming practices, better allows passage of trash in such practices, and does not cause the hair-pinning of crop residue as is often caused by disc-type openers. As a result, the method provides a simple, reliable and inexpensive procedure and tool which can be used in all farming practices so that multiple types of equipment are not required by farms for various soil conditions.
BACKGROUND OF THE INVENTION
[0003] Important advantages have been found in soil preparation, and seed and fertilizer delivery in employing no-tilling or minimum tilling methods which cause minimum disturbance to the soil. This is particularly important in dry land conditions where the soil is subject to moisture and topsoil loss if conventional tilling methods are used.
[0004] It is usually desirable when employing no-till farming practices to disturb the soil surface as little as possible. The surface will be covered with the residue from previous crops, and the surface layer will contain old root structure. This plant material can serve to retain moisture below the surface and to assist in securing the soil against runoff and erosion. Particularly in dry land conditions it is beneficial to retain this covering. Tools available to seed into zero till or minimum till conditions have encountered problems.
[0005] Fertilizing prior to seeding is a method utilized by some farmers. While broadcasting the fertilizer on the surface is a method that does not disturb the surface, it is very inefficient, as much of the fertilizer can be lost due to runoff surface water. Placement of fertilizer at a level well below the level that seed will be place has been utilized. Tilling and fertilizing is disclosed in Great Britain patent No. 1,574,412 issued to Ede in 1980. In that prior art device an angled tilling blade for deeply penetrating the soil is shown with a central duct and a number of separated orifices for providing fertilizer in vertically separated bands. To maintain those desirable characteristics of the surface structure in zero till conditions major surface disturbance is not acceptable.
[0006] Zero till devices have been developed to deposit high concentration bands of fertilizer in furrows. If the seed is placed in close proximity to a high concentration of fertilizer, burning of the newly germinated plant will result. To avoid this one technique has been to separate the seeds by a soil layer from the fertilizer.
[0007] In the U.S. Pat. No. 5,396,851 issued to Beau jot in 1995 fertilizer is deposited by a first vertical blade which cuts a deeper furrow. A second blade cuts a second furrow in which to deposit seed. Other devices such as disclosed in U.S. Pat. No. 4,798,151 issued to Rodrigues in 1989 form a deep fertilizer furrow, and a shallower shelf above the fertilizer on which to plant the seed. In both cases, to minimize soil disturbance only a narrow furrow is cut. It is grown to prepare soil when using traditional tilling methods to cut out weed growth prior to or at the time of a seeding operation.
[0008] U.S. Pat. No. 1,085,825 issued in 1914 to Rubarth discloses a subsurface tilling blade for use with a traditional turning plowshare. The tilling blade its curved to angle the cut and includes a horizontal blade on the opposite side. The blades are shown to include an arrangement in overlapping fashion to cut the full width of the subsurface to remove weeds and old growth. Seeding and fertilizing are separate operations.
[0009] U.S. Pat. No. 5,005,497 issued in 1991 to Kolskog discloses a deep banding knife for delivering seed and fertilizer with an additional transverse rod for disrupting weed growth. The banding knife makes a substantially vertical cut in the soil. The rod disrupts the subsoil to loosen soil and cut weeds. The transverse rods can be arranged in parallel to remove weeds completely.
[0010] Adaptations of these concepts have been used for deep placement of fertilizer in fully tilled row-crop situations.
[0011] In traditional zero till farming practice, no till furrows are separated by undisturbed areas of soil and weeds. Typically a herbicide application is necessary to control weeds which would otherwise compete with the crop growth and possibly contaminate the harvest. Herbicide is an expensive additional operation.
[0012] A further problem encountered by seeding implements particularly in zero till conditions is the accumulation of trash during seeding which impairs their operation. Many devices for seeding in zero till conditions provide a blade which penetrates the soil substantially vertically. Trash gathers around the blade and is dragged with the device. This can impair operation. It also removes the desired moisture retaining cover. In an effort to combat this problem the Beau jot discussed above is adapted to lift over obstacles, such as crop stubble, interrupting seeding. Such a technique reduces trash accumulation, but reduces seeding efficiency.
[0013] A deep sowing tool has been disclosed for rice seeding in relatively wet conditions in USSR patent No. 372,962 issued in 1973 using a tilling blade and deep seed delivery to cover seeds and to reduce the need to water. This is not suitable for zero tilling, as tilling using this tool is deep in order to cause deep soil aeration. The blade of this prior art design penetrates the soil essentially vertically, with an angled blade portion cutting more deeply. The blade portion of this design would also be subject to accumulation of trash.
[0014] Significant soil disruption occurs as vertical furrow parting tools are drawn through surface soils at relatively high velocity, especially in high trash conditions or with unprepared soils. Additional energy is imparted to the soil, throwing and turning the soil.
[0015] It is desired for minimum soil disruption to pass through the soil surface and any trash cleanly without undue lifting or turning of the soil. While disk openers have the ability to cut through most trash, some straw will not cut easily, and is pushed into the furrow, a result commonly called hairpinning. This can displace seeds, as well as drying out the seed bed. As well, effective no-till disc opener designs are relatively expensive.
[0016] The prior art fails to provide teaching to or a suggestion of any method or device for operation in zero or min-till conditions which provides tilling and/or seeding, fertilizing or weed clearing in a single pass without significantly disrupting the soil or the order of the soil structure and avoid hairpinning. It is desired to provide the advantages of tilling seeding and weed clearing without trash accumulation.
SUMMARY OF THE INVENTION
[0017] The invention provides a ground opening knife for use in no-till or minimum-till farming operations primarily in conjunction with seed and/or fertilizer placement adjacent a soil cut-line generally in the direction of travel comprising connection mechanism adapted to mount the knife on a farm implement, and a blade comprising a lower portion, said lower portion adapted to open soils along the direction of travel, said lower portion adapted to extend into the soil but no more than 6 inches measured vertically, said lower portion adapted to be oriented in a direction having a 1 st component of between 30 and 60 degrees below horizontal in a plane transverse to the said direction of travel, and a 2 nd component forward in the direction of travel.
[0018] The knife may include an upper portion adjacent said lower portion adapted to extend away from the surface of the soil and is adapted to pass through materials or residue on the surface of the soil or associated with the passage of the knife though the soil.
[0019] The knife may also include an extension extending substantially laterally from said lower portion and provides support for material delivery tubes at various locations along the blade and extension.
[0020] The knife may also include in extension to form a secondary furrow adjacent the said lower portion intermediate the surface of the soil and the lowermost end of the said blade and may include an extension of said leading edge generally forward in the direction of travel.
[0021] The invention also provides a method of no-till or minimum-till farming operation primarily in conjunction with seed and/or fertilizer placement adjacent a soil cut-line aligned generally in the direction of travel comprising forming a furrow in the soil extending from said soil cut-line no more than 6″ into the soil measured vertically, and forming the said furrow by cutting the soil along a direction having a 1 st component of between 30 and 60 degrees below the horizontal in a plane transverse to the said direction of travel, and a 2 nd component forward in the direction of travel.
[0022] The method substantially minimizes any disturbance of the cut soil either above the said furrow or below it or both whether distribution or particulate or other materials is included at the same time within the furrow being formed.
[0023] The invention also provides a no-till or minimum-till farm implement primarily for use in conjunction with cultivation or materials placement adjacent a plurality of soil cut-lines generally parallel and in the direction of travel comprising a support frame structure, a plurality of around opening knives attached to said support structure, spaced from each other in a direction transverse to the direction of travel of the implement and each adapted to cut the soil along adjacent ones of said cut-lines, each said knife having a blade comprising a lower portion, said lower portion adapted to extend into the soil but no more than 6 inches measured vertically between the surface of the soil and the lowermost extremity of the said blade, said lower portion adapted to be oriented in a direction having a 1 st component of between 30 and 60 degrees below horizontal in a plane transverse to the said direction of travel, and a 2 nd substantial component forward in the direction of travel.
[0024] The farm implement may include an extension of the blade extending laterally across a substantial portion of said spacing between adjacent said cut-lines when viewed in a plan view.
[0025] The invention will be more clearly understood to those skilled in the art with the following detailed description of preferred embodiments with reference of the following drafting's in which:
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIG. 1 is a plan view of a single knife according to the present invention;
[0027] FIG. 2 is a side view of the embodiment of FIG. 1 ;
[0028] FIG. 3 is a front view of the embodiment of FIG. 1 ;
[0029] FIG. 4 is a plan view of a further embodiment according to the present invention;
[0030] FIG. 5 is a side view of the embodiment of FIG. 4 ;
[0031] FIG. 6 is a front view of the embodiment of FIG. 4 ;
[0032] FIG. 7 is an isometric view of the embodiment of FIG. 4 arranged on an implement for operation; and
[0033] FIGS. 8-1 through 8 - 3 are front, top and side elevations respectively of another embodiment of the invention adapted for double shooting of materials in seeding. Like references are used throughout to designate like elements.
[0034] FIG. 9 is a plan view of an agricultural implement for planting seeds. Which incorporates the seeding knives of the invention;
[0035] FIG. 10 is a horizontal front elevation of an angled seeding knife, in use;
[0036] FIG. 11 is a side elevation of the knife of FIG. 10 , from the left side of FIG. 10 , and FIG. 11 includes a cross-section on the line X-X of FIG. 10 ;
[0037] FIG. 12 is a rear elevation of knife of FIG. 10 ;
[0038] FIG. 13 is a right side elevation of the knife of FIG. 10 ;
[0039] FIG. 14 is a cross-section of a blade of the knife of FIG. 10 , the cross-section being taken in a plane at right angles to a knife-edge of the blade;
[0040] FIG. 15 is a front elevation corresponding to FIG. 10 of another angled seeding knife;
[0041] FIGS. 16, 17 , 18 are further elevations of the knife of FIG. 15 ;
[0042] FIG. 19 is a pictorial elevation of a replaceable tip, of the knife of FIG. 15 ;
[0043] FIG. 20 is an elevation of the body of the knife of FIG. 15 , and is shaded to show the configuration thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The preferred embodiment of the single knife of the present invention is as shown generally at 10 in FIGS. 1-3 . In FIG. 1 , arrow designated 1 shows the direction of travel of the knife 10 through the soil when working.
[0045] As shown in FIG. 7 , the knife 10 is typically attached to a cultivator-type frame or implement generally indicated at 2 to be towed by a tractor in a direction of travel 1 primarily in cooperation with a tow-between or tow-behind seed supply carrier (not shown) having a repository of seed, fertilizer or other material and fluid passages for connection with the knife 10 . The frame 2 is shown in general outline only.
[0046] The knife 10 includes a shank 12 which serves as a connection for mounting the knife 10 selectively on the implement in a known fashion (as at 3 in FIG. 7 ). As shown in FIG. 7 , an appropriate spacing 4 for seeding or tilling operations will be selected, determining the number and spacing of knives 10 mounted across the width of the implement. The shank 12 preferably has a pair of holes 13 (See FIG. 1 ) for mounting bolts or the mounting could be provided in any conventional manner such as a knock-on taper mounting system or other known mounting mechanism.
[0047] Knife 10 includes a blade 14 formed to penetrate the soil along a soil-cut line 11 oriented in the direction of travel. Penetration of the soil occurs at an angle A which has both substantial lateral (A 1 ) and forward (A 2 ) components as shown in FIGS. 3 and 1 , respectively, of approximately 35-55 degrees to the surface 5 of the soil to be tilled. Preferably each of lateral and forward components A 1 and A 2 respectively is 45 degrees. Soil penetration (d) is by the lower portion of the blade 14 as at 6 in FIG. 3 and is no more than 6 inches, consistent with minimum till or no till farming practices.
[0048] The lateral component A 1 of angle A determines the final angle of the furrow cut into the soil. The angled furrow allows seed to be planted ensuring soil cover.
[0049] The blade is also angled significantly forwardly by component A 2 of angle A. Preferably, a lower end 17 of a cutting edge 16 is significantly in advance of the upper end 15 of the cutting edge 16 . Deeper soil is cut and lifted in advance of cutting the surface soil allowing the surface to be cut along cut-line 11 more easily and without undue lateral disruption. Vertical motion is limited. The forward component of angle A of the blade cuts through the surface and trash layers last without accumulating trash on the knife 10 . Leading edge 16 is preferably continuous from its lower end 17 to its upper end 15 .
[0050] The blade 14 had a leading cutting edge 16 and a pair of opposing angled surfaces 18 a and 18 b which form a wedge shaped profile. The profile shape is determined by the furrow opening required. Edge 16 may be in 2 parts, one below the surface and another above, but preferably extends continuously above the surface sufficient to move trash and other materials aside without accumulation. Also preferably it is formed aligned with the leading edge of the lower portion of the blade 14 .
[0051] Preferably surface 18 b is inclined slightly from the horizontal to avoid sliding contact with the soil below the blade 14 and minimize soil disturbance below the cut.
[0052] Also preferably, the rear surface of blade 14 is also angled forwardly and downwardly so as to assist in the creation of a small temporary cavity behind the blade as it travels through the soil.
[0053] The overall effect is to provide a method and knife whereby primarily vertical motion is imparted to the soil to permit the blade 14 passage and then a return substantially vertical motion is permitted whereby the soil may return to its approximate original location.
[0054] Adjacent the trailing surface 20 of the blade 14 , a conduit 22 may be secured for delivering seeds or other material.
[0055] The conduit 22 may have an outlet 24 near the lower end 17 of the blade 14 as shown in FIGS. 1 and 2 , and as a result the outlet 24 is adjacent the lowest area of the furrow cut by the blade 14 . The seed delivery conduit 22 is protected from damage as the blade 14 is advanced through the soil by the blade body 14 . The outlet 24 is also shielded from becoming clogged with earth by this arrangement.
[0056] Additional conduits along the blade for fertilizer, herbicide or other materials may be similarly located (not shown in FIGS. 1-3 )
[0057] The preferred method provides the steps of forming an angled no-till or minimum till furrow by a knife 10 which furrow cutting motion has both a substantial forward and a substantial lateral component both above and below the ground to a depth (d) of 6 inches.
[0058] In a preferred method, seed and fertilizer are scattered from adjacent outlets in a pattern across the width of the furrow. The outlets may be spaced apart to appropriate depths and separation, for example, placing fertilizer outlet at the lowest end of the blade for the deepest application and a seed outlet spaced above it on the angled blade 14 .
[0059] Another preferred embodiment is shown in FIGS. 8 in which FIG. 8-1 shows the embodiment in a front view, FIG. 8-2 in a plan view and FIG. 8-3 is a side elevation.
[0060] In FIGS. 8-1 through 8 - 3 , the embodiment is shown in conjunction with the knife and method shown in FIGS. 1 to 3 with an additional double shoot extension 8 . Leading edge 16 of the lower portion 7 is extended further forward and downward as best depicted in FIG. 8-3 . As seen in the front view of FIG. 8-1 , this will provide a secondary furrow or ledge intermediate the surface of the soil 5 and the lower end 17 . FIGS. 8-1 through 8 - 3 show this embodiment as forming a v-shaped furrow particularly suited to the deposit of particulate material such as seed which would be retained in this groove. The extension 8 could have other shapes to form a ledge or other shape as required.
[0061] An extension 8 depends from the leading edge 16 and may be provided with a delivery conduit 19 .
[0062] This double shoot method forms a seed or other material positioning shelf or secondary furrow within the angled furrow with a specific spacing from the lowermost extremity.
[0063] An alternate embodiment of the invention is shown in FIGS. 4-6 . The knife 10 includes a blade 14 as described above. The knife 10 further includes an extension blade 30 that extends substantially horizontally form the blade 14 preferably at its lowermost end 17 . The extension blade 30 has a leading cutting edge 36 , which preferable forms a continuation of or a 3 rd part if also the leading ledge 16 . Edge 36 is substantially horizontal and is preferably oriented transverse to the direction of travel. The cutting edge 36 is formed between an upper surface 32 angled upwardly and rearwardly and a lower surface 33 which is substantially horizontal. The lower blade surface 33 may preferably be angled to the rear, upwardly about 2 degrees, or notched, to reduce drag.
[0064] The extension blade 30 increases the width of the knife 10 as shown in FIG. 7 . This extends the cultivating and/or planting area for greater seed bed utilization, or may be selected for greater spacing between seed planting while still effectively cutting existing plant roots to condition more of the width of soil. The extension blade 30 may be varying in width for different spacing considerations.
[0065] Outlets for seed, fertilizer and other addictives may be spaced apart in or on the extension blade 30 to form distinct rows (not shown) and are preferably adjacent the rear surface thereof or may provide for broadcast across the width of extension 30 .
[0066] Outlets 24 may also be placed at the corner between the angled blade 14 and the extension 30 as shown in FIGS. 4 and 5 , or higher on the angled blade 14 for vertical separation such as for herbicide application nearer the soil surface.
[0067] As seen in FIG. 7 , a plurality if knives shown including extension 30 on an implement frame in outline may be arranged spaced in continuous or overlapping arrangement on the implement 2 so that the full width of soil is conditioned. The number and spacing will depend on the crop and planting conditions. Suitable placement of outlets along extension 30 would result in a generally scattered seed and fertilizer delivery in behind each knife 10 . In this case the complete width of the soil may also be cut by the blade extension without being dragged and fouling the knife 10 .
[0068] The extension blade 30 may be positioned to travel under the path of the angled blade 14 of the adjacent knife 10 .
[0069] Knives 10 are mounted to an implement or cultivator frame 2 as in FIG. 7 . A wing section of the frame 2 is illustrated in outline form. Additional central and wing sections are not shown. The frame 2 is carried on loads bearing wheels (not shown) which support the frame 2 in a raised position for travel and in operative position.
[0070] Adjustment of the height if the frame 2 in a known fashion accurately controls furrow depth (d). Depths (d) may typically range from ½ inch to 4 inches or up to 6 inches. Alternatively, a ground following linkage may be used to attach each knife 10 to the frame 2 , with the depth being controlled by a wheel attached to each knife assembly.
[0071] In use, the knifes 10 arranged in parallel fashion on an implement or overlapping arrangement on an angled draw bar are drawn by a tractor together with a seed carrier provided with reservoirs of seed and fertilizer material and a fluid delivery system operatively connected with the conduits 22 on the knives 10 . The frame 2 is advanced with the leading cutting edges 16 and, optionally, edge 36 facing in the direction of travel 1 . The deposit of material is controlled by the speed of advance of the tractor in a known fashion.
[0072] The knife 10 will not normally produce overlapping furrows without the blade extension 30 being present, or being long enough to result in an overlapped cut with adjacent rows as the placement would be too close. Weed control with herbicides is necessary in those circumstances.
[0073] As seeding occurs, fertilizer can be added simultaneously in controlled concentration, or at a desired depth or spacing from the seed. Fertilizer is more efficiently used without loss from runoff. Further fertilizer is placed to be available to the crop and not at the surface for weeds. A substance delivery of fertilizer is particularly effective if gaseous fertilizer, such as ammonia, is used. The knife provides a variety of options for placement with minimum adjustment and cost.
[0074] It may be desired to seed an area progressively in time for continuous harvest. Or with different additives, or with different crop. Since the process is a complete single pass operation, each seeding will include complete weeding and fertilizing more accurately than if separate steps are made which might leave areas untouched.
[0075] The invention may also be used as a light tilling tool for minimum soil disturbance without seeding or fertilizer outlets. This would cut weeds and provide minimum soil aeration. The knife advantageously does not turn the soil which would incorporate weed seeds from the surface into the soil to germinate.
[0076] Additional embodiments of the present invention will be apparent to persons of skill in the art.
[0077] FIG. 9 is a plan-view diagram of an implement 120 which carries thirty-five angled-knife seeders 123 in four rows. The implement 120 has a centre section 124 , and two hinged wings 125 . The wings 125 can be folded upwards for road-transport and storage of the implement. The centre section 124 includes a hitching mechanism 126 whereby the implement can be towed by a tractor.
[0078] It will be noted that some of the angled-knife seeders 123 slope to the left, and some to the right. Thus, there is no, or only a small, net sideways force on the implement. The left seeders and the right seeders are kept separate. In banks, since the configuration of the seeders is not suitable for close-pitched left-right mountings thereof.
[0079] Press-wheels 127 are provided. One in-line behind each seeder to roll over. And to close the ground. After the seeds have been deposited by the seeders.
[0080] The seeders are attached each to a respective mounting bar 128 , which is suspended from the frame 129 of the implement, the suspension mechanism including the usual break-back-spring mountings 130 .
[0081] FIG. 10 is front view of one of the angled-knife seeders 123 . FIG. 10 shows the seeder being dragged forwards, i.e. out of the paper, as indicated by the arrow 132 . FIG. 11 is a lateral or side elevation, showing the seeder being drawn through the ground, and moving to the left as indicated by arrow 132 . FIG. 11 includes an inset cross-section, taken on line +-+ of FIG. 10 . It is emphasized that line +-+ is vertical, i.e. the inset cross-section in FIG. 11 lies in a vertical plane.
[0082] As shown from the front view, FIG. 10 , the seeder or knife 123 has an angled blade 134 which extends down into the ground to a depth, typically of about 10 cm. The depth is determined by the needs of the type of seeds being planted; planting seeds deeper than 10 cm would be unusual, and 15 cm can be regarded as a maximum planting depth.
[0083] The angled knife cuts an angled slit-opening in the ground, and the seeds are deposited therein. The seeds to be planted are sullied from a hopper on the implement, and are blown along a hose by mechanism of a fan which forces an air flow in the hose. The hoses are of flexible plastic tubing, one for each seeder (the hoses are not shown in FIG. 9 ).
[0084] Each flexible hose is clipped to a respective conduit 135 , which is built into the seeder 123 . The conduit is structurally integrated into the back-side of the angled-knife-blade 134 , and runs down the back-side 136 of the blade. The conduit ends in a discharge mouth 137 , from which the seeds emerge, and fall down into the slit-opening. The discharge mouth 137 is near the bottom of the knife blade, whereby the seeds are deposited more or less at the bottom of the slit opening.
[0085] The conduit 135 is shown in the rear view of the seeder, FIG. 12 , and in the opposite side-elevational view to FIG. 11 , FIG. 13 . The upper end of the conduit terminates at a port 138 , into which the flexible hose can be secured.
[0086] The knife blade has an over-surface 139 and an under-surface 140 . These surfaces are respective flat planes which meet at a line, that line being the knife-edge 142 . The blade is generally triangular in cross-section. In that the surfaces 139 , 140 slope back from the knife edge, to a maximum thickness of the blade at the back-side 136 thereof. The conduit 135 is accommodated within the thickness of the back-side of the blade.
[0087] FIG. 14 is a cross-section of the blade 134 and shows the dimensions thereof. The FIG. 14 cross-section is taken in a plane at right angles to the knife-edge. The dimension 143 is the distance between the over-surface 139 and the under-surface 140 at the back-side if the blade, which in this case is 32 mm; and dimension 145 is the distance from the knife-edge 142 to the mid-point of the conduit 135 , which in this case is 70 mm. The conduit 135 has an internal diameter if 24 mm. The angle between the over-surface 139 and the under-surface 140 , in the cross-section at right-angles to the knife-edge, is called the wedge angle 146 , which in this case is 25 degrees.
[0088] Not only is the angled blade 134 angled to the side, at a side-slope-angle 147 , as shown in FIGS. 10 and 12 , but the blade is also given a forward pitch angle 148 , as shown in FIGS. 11 and 13 . In this case, the side-slope angle 147 is 45 degrees, and the forward pitch angle is also 45 degrees.
[0089] The leading knife-edge 142 is positioned such that when the blade is viewed from in front. Only the over-surface 139 can be seen. The under-surface 140 is invisible. That is to say, the knife edge is at the lowermost point of every vertical cross-section taken through the blade 134 . Thus, the portion of soil that lies in the path of the blade lies in the path of the over-surface 139 of the blade. The over-surface has the wedge angle 146 , and the soil is therefore driven upwards, by the wedge angle. The uplift travel of the soil is determined by the vertical height 149 of the over-surface 139 , as presented to the oncoming soil, which in this case is about 8 cm.
[0090] FIG. 15 is a front elevation of another design of angled-knife seeder 150 . In this case, the above-ground portion of the seed conduit 152 is positioned to one side of the above-ground shank 153 . This location of the conduit provides access for the nuts and bolts which are used at 154 to fix the seeder to the mounting bar 128 . However, although access for the nuts and bolts is good, the extra width of the shank 153 can be obtrusive, and can cause soil debris created by the passing of the angled blade to hang up such that the wide shank 153 can act like a bulldozer blade.
[0091] A deflector surface 156 is provided, for deflecting soil debris away from the front face of the shank 153 . The deflector surface 156 is angled to deflect the debris downwards, and to the side. The nub 157 serves also to break the upward flow of the debris, and to keep the shank 153 clear.
[0092] It may be noted that in FIG. 1 , the triangular gusset-surface 159 was disposed at an angle that included a downwards component, and so the gusset-surface 159 also served to deflect up-flowing debris downwards, and sideways, away from the shank 12 of the knife. Thus, the deflector-surface can be on the outside ( FIG. 15 ) or the inside ( FIG. 1 ) of the angle between the shank and the blade. Providing downward-facing deflector surfaces on both the inside and the outside also is possible, except that the designer should take care that the knife is not weakened thereby, at the transition 160 ( FIG. 15 ), 162 ( FIG. 1 ), between the shank 12 and the angled blade 14 .
[0093] FIGS. 16, 17 , 18 are other views of the knife of FIG. 15 . It will be noted that this knife includes a separable and replaceable tip 163 . The tip shown separately in FIG. 19 . FIG. 20 is a shaded view of the back of the body 164 of the knife, and shows not only how the conduit in this design is molded into the shape of the knife, but shows also a spline 165 on the body, which forms the mounting base for the replaceable tip 163 . The tip 163 is held to the spline 165 by mechanism of a pin which engages the pin-receiving-hole 167 . The spline 165 is prism-shaped, having a triangular cross-section like that of the blade itself, but smaller, and the tip 163 includes a socket that is complementary to the conduit 152 . Once pinned in place, the tip 163 is very securely constrained against all modes of movement relative to the body 164 . The pin serves only to keep the tip from falling down the spline, but the force tending to make the tip 163 move in that mode minimal: all the heavy forces between the tip 163 and the body 164 are supported by the chunky spline 165 .
[0094] The conduit 152 continues inside the spline 165 . It is important that the seeds are deposited close to the bottom of the cut opening; with the conduit inside the spline, even though the bottom part of the knife comprises the tip, the conduit goes to the bottom of the opening. (It would be inefficient to cut the opening deeper that the planting depths of the seed, so the discharge mouth of the conduit should be as near the bottom of the knife as possible.) On the other hand, the prudent designer would seek to avoid calling for the manufacture of a (tubular) extension of the conduit in the tip casting. Putting the conduit in the spline puts the discharge mouth of the conduit more or less at the bottom of the trench, even though the knife has a replaceable tip.
[0095] It will be noted that the lower extremity 168 of the knife edge 169 on the body 164 is rounded convexly, whereas the upper extremity 172 of the knife edge 170 on the tip 163 includes a tag 173 which is rounded concavely. Thus, debris traveling up the knife edge can readily pass smoothly over the transition between the two knife edges 169 , 170 . The designer should see to it that the knife edges do not contain interruptions, upon which soil-debris could be snagged. Forming the body 164 with a large convex radius is easy from the casting-manufacture standpoint; it is much easier to control the quality of a concavely-curved tag on the tip casting than on the body casting.
[0096] The knife edge 170 in the tip 163 can be blunter than the knife edge 169 on the body 164 . The tip 163 operated more deeply, where debris, even if imperfectly cut, tends to be brushed off the knife edge 170 by the pressing passing soil. On the body 164 , the knife edge 169 itself has to do all the cutting of debris and vegetation, with little assistance from the passing soil, since, being shallower, the passing soil might more easily be deflected. It is noted that, if it happened, a hang-up of imperfectly cut material on the knife edge would be a quite serious problem, as it would quickly lead to disruption and disturbance of a large area of soil around the slit opening.
[0097] Conventionally, when seeding has been done with seeding knives (as opposed to discs, etc) the seeding knife has been held vertically. When the seeding knife is held at a side-slope-angle, as described herein, the manner in which the soil is opened for receiving the seeds is considerably changed.
[0098] When the knife is at a side-slope-angle of about 45 degrees to the horizontal, what happens is that a flap 174 of soil is lifted temporarily by the passing blade 134 , and then the flap is lowered gently back after the seeder knife 123 has passed. As a result, the layers of the soil are preserved, during seeding. In other words, it is possible for a farmer to plant seed without disturbing the stratification of the soil. It may be noted that the press wheels 127 serve to press the flap 174 back down, and assist in the maintenance of stratification: thus the function of the press wheel is more in harmony with the action of the angled blade, than in the case of a press when linked with, for example, a non-angled (vertical) seeding knife.
[0099] Maintenance of soil stratification is important in currently-favored minimum-till farming regimes, because moisture in the layers a few centimeters down is not dissipated; weed seeds on the surface remain on the surface and do not germinate; and stalks and vegetation at the surface remain intact, providing cover and moisture retention. On the other hand, the angled knife, especially when a wing extension is provided below ground, cuts and severs the roots of any vegetation that might be present, whereby weeds and unwanted plant growth are destroyed simply by mechanical action. Using herbicide to destroy weeds is expensive and can be dangerous, and has to be done as “reach” of the angled knife can be enough to sever the roots of weeds and other growth not only around the seed openings, but over the whole area of ground between the openings.
[0100] The fact that the flap of soil is pushed upwards by the angled blade does not mean that the soil is compressed: if the soil were pushed downwards or sideways, it would become compressed and perhaps smeared, since there is no where for the deflected soil to go; but when the soil is urged upwards, the soil simply moves upwards. Of course, lifting deeper soild would involve lifting the weight of all the soil above, so lifting without compression only works down to shallow depths. Thus, it would not be possible to lift a flap of soil without compressing it if the soil were more than 10 or 15 cm deep. But it is recognized that seed planting is done predominantly at shallower depths than that; and it is recognized that the depths down to which an angled blade can cause the soil to simply lift without being compressed is a suitable depth to enable planting of nearly all types of seeds.
[0101] If the knife were nearly vertical, i.e. if the knife were angled over at more than about 60 degrees to the horizontal, the lifting action that occurs with the angled knife would become negligible. With the 45-degree angle, most of the movement of the soil that occurs is a riding up of the soil over the front edge of the knife. At an angle of 60 degrees, the soil tends to be bulldozed, or chiseled, rather than slit or cut. Insofar as the soil is pushed to the side by the knife, the soil is compressed, and smeared, rather than gently lifted.
[0102] Of course, the knife must emerge from the ground surface, and the very shallow soil around the point of emergence inevitably is lifted too much, and tends to fly away. However, this effect is less disturbing than inserting a vertical chisel into the ground.
[0103] If the knife were more nearly horizontal, this fly-away lifting of the shallow soil might be too much. Besides, if the knife were nearly horizontal, although the knife would still lift the flap of soil, the knife blade would need to be too long in order to get down to the seed planting depth, which would mean that too much soil was being moved for a given planting depth, and which would be poor mechanically.
[0104] Tests have shown that the slap-lifting, stratification-maintaining, advantageous effects of the angles blade are largely lost if the blade is angled (i.e. the side-slope-angle) more than about 55 degrees or less than about 35 degrees. 60 degrees and 30 degrees can be regarded as the practical limits. It has been found that the force required to draw the angles blade through the ground is at a minimum when the blade is at about 45 degrees. It may be noted that the minimum draw force is an indication of minimum ground disturbance, which is what makes for minimum-till agriculture.
[0105] The leading knife-edge of the angled blade should be lowermost into the ground. That is to say, the soil approaching the blade should “see” only the over-surface of the blade. Thus, all the soil that is deflected is deflected upwards. If some of the soil were driven downwards, or horizontally sideways, it would be compressed or smeared, and seeding is most effective and efficient when the seeds are placed on and in soil that has not just been compressed.
[0106] The effective but gentle lifting as desired has been obtained with angled blades where the blade has been so presented that the over-surface has been about 7 cm high, measured in a vertical sense, from the leading knife edge to the back of the over surface. (The thickness of the blade, measured in a plane at right angled to the leading edge, preferably is between 25 and 45 mm.) The angle between the over-surface of the blade and the under-surface, called the wedge angle, is a key factor in determining the lift of the blade, and good results have been obtained when the wedge angle lies between 20 and 30 degrees.
[0107] Preferably, the over-surface should be a single flat plane over its whole area, but it is recognized that it id the front of the over-surface of the blade that is key to the performance, i.e. the front 4 cm of the over-surface contiguous with the knife edge.
[0108] Preferably, the blade is generally triangular as to its cross-sectional shape, the three sides of the triangle being the over-surface, the under-surface, and the back-side of the blade. (The back-side is not, as shown, a flat plane.) It is recognized that the triangular is a good shape, in that it leads to a suitable angle for the over-surface of the blade, in order for the over-surface to deflect soil dynamically; also, the bottom face can be easily set to not touch the soil passing-by underneath the blade; also, the bottom face can easily be set to not touch the soil passing-by underneath the blade; also, the thick back-side has to be thick to accommodate the conduit. In short, the triangular shape is a highly efficient shape for performing the soil-moving operations required for seeding, for accommodating the seed conduit, and (not least) is a food shape for providing mechanical strength and rigidity in just the right amounts for the task.
[0109] The designer should see to it that the knife is reasonably short, in the travel direction. Length would just lead to extra drag, and perhaps smearing of the soil, the aim should be to combine efficient use of surfaces and angles to give smooth lift-then-fall-back movement of the soil, without disturbing the soil, and while maintaining stratification. The designer should see to it that the surfaces are angled enough, and are long enough for that, and of course the knife has to be strong and rigid enough to be struck occasionally by stones etc without being damaged. It is recognized that the angled blasé as described herein is a design that handles these conflicting requirements very advantageously.
[0110] The conduit preferably should be in the size range of 15 to 25 mm diameter, for proper seed conveyance. It is recognized that such a size of conduit is wee-suited to being located behind the triangular angled blade, as described. The blade surfaces, i.e. the over-surface and the under-surface, slope towards the conduit as two simple flat planes, straight from the knife edge.
[0111] As mentioned, the functions of the blade require that the blade be wide enough for its surfaces to be so angled as to be effective; and the blade must also be strong enough; beyond that, the blade should preferably be short. Good results have been obtained when the blade is about 7 cm, or at least between 5 cm and 10 cm, in width, from the knife-edge to a mid-point inside the conduit.
[0112] The blade should have forward pitch to ensure the soil debris can clear, by riding upwards along the knife edge, and out of the soil. It will happen sometimes that some material are not cut, or not cut immediately, by the knife edge, and will be piled up ahead of the knife edge, thereby blunting the knife edge. The angled knife should have forward pitch to counteract this. Of course, conventional vertical seeding knives have had forward pitch.
[0113] Preferably, the seed conduit should be integral with the knife unit. If separate, the conduit has to be attached to the knife unit. The conduit should not get in the way, not least above ground, where the conduit can contribute to snagging of soil debris. Therefore, the conduit should lie in line behind the knife. Whilst this is clearly achievable below the ground, above ground putting the conduit in line with the knife structure is not so good, because the shank of the knife is attached to the mounting bar by bolts passing through from front to back, and putting the conduit behind the shank would deny access to the bolts/nuts.
[0114] The designer also want the point of attachment of the flexible seed hose to be high, out of harm's way, and also wants to provide room for a clip for attaching the hose into the conduit. The designer either can put the conduit on a stalk that protrudes out behind the shank (which suits fabricated construction ( FIG. 2 )), or can put the conduit to one side of the shank (which suits casting ( FIG. 16 )). Or, the conduit may be finished lower down, below where the shank is bolted to the mounting bar ( FIG. 11 ), although now the flexible hose might be vulnerably close to the ground. Putting the conduit to one side of the shank ( FIG. 16 ) gives access to the fixing bolts, but now the front face of shank is thereby widened, so it is even more important to take measures against snagging of the above-ground soil debris on the shank.
[0115] One of the benefits of the angles blade configuration lies in the ability to deposit two types of items simultaneously, e.g. seeds and fertilizer, which preferably should be kept spaced apart, upon planting. Simultaneous deposition of both seeds and fertilizer ( FIG. 8 ) is simplified by the fact that the knife is at an angle, while ensuring same are kept spaced apart. If the knife were vertical, both items would fall to the bottom of the trench, and it would be difficult to keep the items apart. On vertical knife seeders, it is conventional to provide side ledges; for fertilizer, however, the protrusions on the vertical knifes that produce such side ledges have also compressed the soil.
[0116] Generally, the farmer wishes to plant as many rows of seeds as possible in a single pass if the seeder implement. In one of the machines described herein, thirty-five seeders are provided on a single implement. The smallest number that might practically be contemplated would be about eighteen seeders per implement. The large number of seeders is appropriate for single-pass seeding operations at shallow depth, in that a tractor can easily provide the force necessary to draw a large number of shallow seeders through the ground. This may be contrasted with the conventional usage of angled cutters to break up hard-pan sub-soil, i.e. caked clay and soil some 50 cm or more below ground. Sometimes, these deep angled-cutters have been used to prepare ground for seeding, but in that case the seeding has been done separately, as a follow-up seeding operation, using conventional seed drills. (Breaking up hard-pan also can be done for other purposes, e.g. to improve drainage.) The conventional large, deep, hard-pan angled-cutters were angled simply in order to cover more ground. They were constructed so as to cause maximum disturbance to the soil, at a large depth; they required large forces to draw them through the ground, so that only a small number, say four to five, could be pulled by a tractor. The use of an angled blade as described herein to lift shallow flaps of soil with minimum disruption, and to lower the soil flap back down without disturbing stratification, makes a clear contrast with the use of deep angled cutters to break up hard-pan. It is emphasized that the gentle, minimum-till, operations described can take place only at shallow depths.
[0117] In the above aspects, the invention is defined by reference to an implement, in which the angled blades are mounted for operation, In another aspect, the invention can be defined with respect only to the knife unit itself, independently of the implement. In this case, the definition makes use of the shank of the knife, and of the axis of the shank. When the shank is provided with two bolts, one above the other, for attachment to the mounting bar, the shank axis (in a frontal view of the shank) is the line that runs through the bolts. However, even if the shank is mounted by mechanism other than two bolts vertically in-line, the shank still has an axis, which can be determined by the geometry of the shank in a particular case. The major features of the invention, the blade lies at an angle to the shank in front view, and the shallow depth of the blade, are present in this definition.
[0118] As mentioned above, sometimes the conventional vertical knife seeders have included, as an accessory, a mechanism for providing a side ledge to the vertical trench. As mentioned, grains of fertilizer are deposited on or in this side ledge, whereby the fertilizer can be kept spaced apart from the seeds. The fertilizer rests on the ledge, while the seeds fall down to the bottom of the vertical trench.
[0119] An example of such vertical-knife-with-side-ledge structure is depicted in Canadian patent publication CA-2,099,555 (Henry, 1995). Henry's structure includes a first conventional vertical knife-blade, for cutting a vertical slit in the ground, with the associated delivery pipe for depositing seeds at the bottom of the vertical slit. Henry also shows a ledge-cutting accessory. The accessory is fixed to the back of the vertical knife-blade. Thus, in the design of Henry, two injectors are shown: one for injecting seeds, and the other for injecting fertilizer.
[0120] Regarding Henry's vertical knife-blade cutter/fertilizer-injector: when viewed from the side, Henry's knife blade is angled, such that the bottom extremity of the knife-blade leads the rest of the knife-blade as the knife-blade travels through the ground. It is conventional, and very common, for vertical seeding-trench knife-blades to be angled forwards, i.e. bottom-edge leading. In the front view, Henry's knife-blade is not angled at all.
[0121] Regarding Henry's side-ledge cutter/fertilizer-injector: when viewed from the side Henry's ledge-cutter is so angled as to be “bottom-edge-trailing”. That is to say, the bottom extremity of the ledge-cutter lags, or trails, as the ledge-cutter travels through the ground. In the front view, Henry's ledge-cutter makes an angle to the horizontal of about 45 degrees.
[0122] Neither of the blades or cutters of Henry will achieve the “gentle up-and-over” effect, which is the aim of the present invention. This is because neither of the blades or cutters of Henry has an over-surface and an under-surface, which meet at a line, where the line defines the leading knife edge of the blade, and where the knife edge, thus defined, has a side-slope angle of between 30 degrees and 60 degrees.
[0123] Defined with the respect only to the knife unit itself, independently of the implement. In this case, the definition makes use of the shank of the knife, and of the axis of the shank. When the shank is provided with two bolts, one above the other, for attachment to the mounting bar, the shank axis (in a frontal view of the shank) is the line that runs through the bolts. However, even if the shank is mounted by mechanism other than two bolts vertically in-line, the shank still has an axis, which can be determined by the geometry of the shank in a particular case. The major features of the invention, that the blade lies at an angle to the shank in front view, and the shallow depth of the blade, are present in this definition.
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The present invention relates to a knife for and a method of zero till or minimum till seeding and fertilizing. The knife is particularly adapted for dry land conditions producing minimum solid disturbance and very shallow operation. The knife has a high penetration angle preferably of 45 degrees which permits the blade to enter high trash surface cover with little tendency to plug due to trash accumulation. The blade has a forward angle of attack, the lower cutting edge advancing before the upper cutting edge, serving to make a clean cut in the soil surface without accumulating trash. Seed and/or fertilizer conduits are attached to or incorporated in the trailing face of the blade in which the outlets may be spaced for controlled placement of the materials. By the method a furrow is cut having a substantial transverse component in an operation with a substantial forward component. A preferred embodiment includes a horizontal extension blade for cutting a horizontal swath at a shallow depth through weed growth. Conduits may be secured to the extension to allow greater separation and control of material placement. The knives may be arranged in overlapping configuration on the draw bar to affect weed cutting, seeding and fertilizing of a complete with of soil in a single pass.
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RELATED APPLICATIONS
This application claims priority to Taiwan Application Serial Number 96151466, filed Dec. 31, 2007, which is herein incorporated by reference.
BACKGROUND
1. Field of Invention
The present invention relates to an electrode and a method for manufacturing the same. More particularly, the present invention relates to an electrode of a supercapacitor and a method for manufacturing the same.
2. Description of Related Art
As the technology advances, there are stringent demands for the performance of all sorts of electronic products such as computers, communication devices, and programmable consumer electronics. In order to improve the performance of these and other electronic products, the capacitors used in the electronic products must have greater capacity and higher stability. Hence, the supercapacitor has been considered as a favorable candidate.
The most common supercapacitor has a pair of electrodes and an electrolyte filled between the pair of electrodes. The capacity of the supercapacitor depends on the characteristics of the electrodes. Thus, in respect of improving the capacity, there is an urgent need to enhance the manufacturing process of the electrode.
SUMMARY
In the embodiments of the present invention, an electrode of a supercapacitor and a method for manufacturing the same are provided.
According to one embodiment of the present invention, a method for manufacturing an electrode of a supercapacitor comprises the following steps. First, a poly(acrylonitrile) (PAN) fabric is provided. The PAN fabric includes a plurality of PAN fibers each having a diameter of about 50-500 nm. Then, the PAN fabric undergoes a heat treatment so that the PAN fibers are carbonized to form a carbon fiber textile. The carbon fiber fabric includes a plurality of carbon fibers each having a diameter of about 50-500 nm. The surface of each carbon fiber is nano-porous having a plurality of nano pores of about 1-50 nm in diameter. The total surface area of the nano pores account for about 85-95% of the total surface area of the carbon fibers. The carbon fiber fabric is then cut to acquire the electrode of the supercapacitor.
According to another embodiment of the present invention, an electrode of a supercapacitor has a plurality of carbon fibers each having a diameter of about 50-500 nm. The surface of each carbon fiber is nano-porous having a plurality of nano pores of about 1-50 nm in diameter. The total surface area of the nano pores account for about 85-95% of the total surface area of the carbon fibers.
The electrode of the supercapacitor of the embodiments of the present invention has excellent specific capacity thereby improving the capacity of the supercapacitor employing the electrode.
It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows:
FIG. 1 is a flow chart illustrating a method for manufacturing an electrode of a supercapacitor according to one embodiment of the present invention.
FIG. 2 is a cross-sectional view illustrating an electrode having a carbon fiber fabric and a metal current collector according to one embodiment of the present invention.
FIG. 3 is a diagram illustrating the results of the galvanostatic charge and discharge analysis of the electrode of one example of the present invention.
DETAILED DESCRIPTION
Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.
Method for Manufacturing the Electrode of the Supercapacitor
FIG. 1 is a flow chart illustrating a method for manufacturing an electrode of a supercapacitor according to one embodiment of the present invention. First, at step 110 , a PAN fabric was provided. The PAN fabric is made from PAN fibers. The PAN fibers each has a diameter of about 50-500 nm. The PAN fiber could be made by electrospinning.
Then, at step 120 , the PAN fabric was heat treated to carbonize the PAN fibers to produce carbon fibers thereby obtaining a carbon fiber fabric. The carbon fiber fabric comprises carbon fibers each having a diameter of about 50-500 nm. The surface of the carbon fiber has nano pores of about 1-50 nm in diameter, and a total surface area of the nano pores accounts for 85-95% of a total surface area of the carbon fibers.
Specifically, the step 120 for heat treating the PAN fabric comprises two heating stages. In the first heating stage, the PAN fabric was heated to a first heating temperature of about 200-300° C., and the first heating temperature was maintained for about 60-120 minutes to oxidize the PAN fabric. Afterward, in the second heating stage, the PAN fabric was heated to a second heating temperature of about 800-1000° C., and the second heating temperature was maintained for about 3-9 minutes to form the carbon fiber fabric. In this application, the duration of the time used for maintaining specific heating temperature is also referred as “retention time”.
After the carbon fiber fabric has been made, the carbon fiber fabric itself could be cut into electrodes for use in a supercapacitor. Alternatively, at step 130 shown in FIG. 1 , a metal current collector could be formed on the carbon fiber fabric so as to obtain an electrode material with lower impedance.
FIG. 2 is a cross-sectional view illustrating an electrode having a carbon fiber fabric and a metal current collector according to one embodiment of the present invention. In FIG. 2 , the electrode 200 has a carbon fiber fabric 240 and a metal current collector 250 . The material of the metal current collector 250 can be platinum, titanium, gold, silver, copper, aluminum, chromium, iron, or an alloy thereof. The metal current collector 250 can be formed by suitable technique known in the related art such as adhering or sputtering techniques. If the metal current collector 250 were formed by the adhering technique, an adhering layer (not shown) would exist between the metal current collector 250 and the carbon fiber fabric 240 .
Manufacturing Examples
In examples E1 to E3, the carbon fiber fabrics to be used as the electrode of the supercapacitor were manufactured according to the above-mentioned embodiments. The fibers of the PAN fabric used in these examples have a diameter less than 500 nm. In the first heating stage, the PAN fabric was heated at a rate of about 2° C./minute to about 260° C. (first heating temperature). In the second heating stage, the PAN fabric was further heated to a second heating temperature of about 1000° C., and the retention time of the second heating stage is 3 minutes (in example E1), 6 minutes (in example E2), and 9 minutes (in example E3), respectively.
Analysis of Specific Surface Area
The carbon fiber fabrics of the examples E1-E3 were subjected to absorption experiment to determine the specific surface area of the carbon fiber fabrics. The results are listed in table 1.
TABLE 1
Analysis of Specific Surface Area
E1
E2
E3
Specific surface
343
494
1104
area (m 2 /g)
In table 1, it could be seen that as the retention time of the second heating stage increases, so did the specific surface area of the carbon fiber fabric. For example, the carbon fiber fabric of example E3 had the greatest specific surface area (1104 m 2 /g) among the examples shown in table 1. Base on this finding, it's possible to enhance the capacity of the supercapacitor manufactured according to the embodiments of the present invention.
The surface of the carbon fiber fabric of example E3 was further analyzed to demonstrate the pore distribution of the surface. For the carbon fiber fabric of the example E3 (having a specific surface area of 1104 m 2 /g), the total surface area of bigger pores (those with diameter greater than 50 nm) was about 110.092 m 2 /g, which accounted for about 10% of the surface area of the carbon fiber fabric of example E3. Thus, the nano pores (those with diameter no greater than 50 nm) responsible for the surface area of carbon fiber fabric of example E3 accounted for about 90% of the surface area.
Analysis of Capacity
The carbon fiber fabrics of examples E1-E3 were further cut into electrodes, and the capacities of the electrodes were determined. The electrodes were disposed in a three-electrode electrochemical system and the capacities were measured by galvanostatic charge and discharge method and cyclic voltammetric method.
In the three-electrode electrochemical system, the reference electrode was a saturated calomel electrode, the working electrode was the electrode of the carbon fiber fabric of example E1-E3, and the counter electrode was a graphite electrode. The electrolyte was 1M sulfuric acid.
Galvanostatic Charge and Discharge Analysis
In galvanostatic charge and discharge analysis, the electrodes of examples E1-E3 were charged at a current of 1 mA and a charge and discharge voltage of 0-0.75 V.
FIG. 3 is a diagram illustrating the results of the galvanostatic charge and discharge analysis of the electrode of example E1. From the data shown in FIG. 3 , the specific capacity of the electrode was calculated from equation 1:
C = ( I × Δ T ) Δ V × m Equation 1
where C is the specific capacity (F/g), I is the current used for charge/discharge, ΔT is the time elapsed for the discharge cycle, ΔV is the voltage interval of the discharge, and m is the mass of the active electrode.
The specific capacities of the electrodes made from the carbon fiber fabrics of examples E1-E3 were calculated from equation 1. Each fabric of examples E1-E3 was cut into three electrodes and each electrode was analyzed individually. The result shown in table 2 is the mean value of the three repetitions.
TABLE 2
Galvanostatic Charge and Discharge Analysis
Charge Specific
Discharge Specific
Electrode Mass (mg)
Capacity (F/g)
Capacity (F/g)
E1-1
9.7
161
168
E1-2
9.7
174
183
E1-3
13.1
188
209
E1 (mean)
174
187
E2-1
12.1
222
242
E2-2
5.5
256
296
E2-3
7.5
266
291
E2 (mean)
248
276
E3-1
7.5
267
288
E3-2
6.8
292
314
E3-3
5.9
264
292
E3 (mean)
274
298
Commercial active carbon
—
110
fiber 1*
Commercial active carbon
—
130
fiber 2*
*Commercial active carbon fiber 1 was acquired from Taiwan Carbon Technology Co., Ltd., Taiwan; Commercial active carbon fiber 2 was acquired from Challenge Carbon CO., Ltd., Taiwan.
As can be seen in table 2, electrodes made from the fiber fabrics of examples E1-E3 had a mean charge specific capacities of about 174-274 F/g and a mean discharge specific capacities of about 187-298 F/g. As compared with the commercially available electrodes, the discharge specific capacities of which were about 110-130 F/g, the electrodes made from the carbon fiber fabrics of examples E1-E3 had much higher specific capacity. Specifically, the specific capacity of the electrode according to examples of the present invention increases by 70-170 percents. Hence, the supercapacitor manufactured from the electrode of the examples of the present invention could have higher capacity.
Cyclic Voltammetric Analysis
Cyclic voltammetric analysis was performed to confirm the capacity of the electrodes of examples E1-E3. The scanning rate of cyclic voltammetric analysis was 6 mV/s and the voltage was 0-0.75 V.
The specific capacities of the electrodes made from the carbon fiber fabrics of examples E1-E3 obtained from cyclic voltammetric analysis were listed in table 3. Each fabric of examples E1-E3 was cut into three electrodes and each electrode was analyzed individually. The result shown in table 3 is the mean value of the three repetitions.
TABLE 3
Cyclic Voltammetric Analysis
Discharge Specific
Electrode Mass (mg)
Capacity (F)
Capacity (F/g)
E1-1
10.41
1.965
189
E1-2
8.67
1.733
200
E1-3
8.27
1.308
158
E1 (mean)
182
E2-1
13.35
3.245
243
E2-2
14.44
4.563
316
E2-3
9.75
2.552
262
E2 (mean)
274
E3-1
2.89
0.957
331
E3-2
9.4
2.548
271
E3-3
2.91
0.755
259
E3 (mean)
287
As can be seen in table 3, the specific capacities of the electrodes made from the carbon fiber fabrics of the examples E1-E3 were 182 F/g, 274 F/g, and 287 F/g, respectively. The specific capacity measured by cyclic voltammetric analysis was similar to that measured by galvanostatic charge and discharge analysis. Thus, it's confirmed that the electrodes made from the E3 carbon fiber fabrics of the examples E1-E3 of the present invention had higher specific capacity.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims.
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A method for manufacturing an electrode of a supercapacitor is provided. First, a poly(acrylonitrile) (PAN) fabric is provided. The PAN fabric includes a plurality of PAN fibers each having a diameter of about 50-500 nm. Then, the PAN fabric undergoes a heat treatment so that the PAN fibers are carbonized to form a carbon fiber textile. The carbon fiber fabric includes a plurality of carbon fibers each having a diameter of about 50-500 nm. The surface of each carbon fiber is nano-porous having a plurality of nano pores of about 1-50 nm in diameter. The total surface area of the nano pores account for about 85-95% of the total surface area of the carbon fibers. The carbon fiber fabric is then cut to acquire the electrode of the supercapacitor.
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PRIORITY INFORMATION
[0001] This application claims priority from DE 103 47 259.2 filed Oct. 8, 2003.
BACKGROUND OF THE INVENTION
[0002] The invention relates to synchronizing a circuit during reception of a modulated signal that has been mixed in the multidimensional complex signal space.
[0003] In a conventional receiver designed to receive digital signals that have undergone two-dimensional modulation by a quadrature-amplitude-modulation (QAM) or a phase shift keying (PSK) method, a complex multiplier or mixer, driven by a local oscillator, mixes in a correct frequency and phase relation the received signal, which has been modulated on a carrier, into the baseband of the circuit. A phase-locked loop (PLL) ensures the correct frequency and phase of the local oscillator for mixing. In the case of digital processing, mixing may occur either before or after an analog-to-digital conversion. The signal is either sampled and digitized at the symbol clock rate or a multiple thereof, or the digitization clock rate is left free-running relative to the required symbol clock rate. In this case the signal is converted to the symbol clock rate or a multiple thereof through a purely digital sampling rate conversion. Gain controls ensure that the specific modulation range is utilized and that the received signals are correctly mapped to the symbol decision element stage. An adaptive equalizer prevents any inter-symbol interference originating in distortions of the transmitter, transmission path, or receiver.
[0004] In many demodulators for QAM signals or PSK signals, in order to achieve frequency and phase control the control circuits need both the received signals and those elements of the predetermined symbol alphabet viewed as the most probable by the decision element stage for the purpose of gain control, for recovering the symbol clock rate, and/or for the adaptive equalizer. These types of control using differences between the received and decision-based symbol current are called decision-feedback controls. Their use presupposes essentially correct decisions.
[0005] The conventional approach has been to use a decision that in the complex I/Q plane assigns the received signals to target symbols based on the least distance. If the target symbols are located on a uniform grid or matrix, a grid or box pattern for decisions is produced.
[0006] Since the decision-feedback controls are interlinked in prior art demodulators, locking is difficult as long as the control for the carrier of the local oscillator that mixes the received signal into the baseband is not yet stable in terms of frequency and phase, and faulty decisions occur as a result. Often locking is successful only when the frequency and phase are located relatively close to their target values.
[0007] If the carrier phase, particularly in the case of higher-order modulation procedures, is only a few degrees distant from the target phase, the symbols are often decided incorrectly. With 256 QAM, a deviation of only approximately 3 degrees is sufficient for faulty decisions to be made.
[0008] The difference in the phase of the received signal and the phase of the decision-based symbol is employed as the control voltage for carrier control.
[0009] FIG. 11 shows the time-averaged control voltage as a function of the deviation of the phase position of the received signal relative to the phase position of the local oscillator. It is readily evident that correct individual decisions, which lead to the rising lines, are made only in the central region. Outside of the central region, it is assumed that there are faulty individual decisions which, however, when averaged over time nevertheless lead at least to the correct sign.
[0010] FIG. 12 shows this control voltage on a different scale together with a line that would correspond to an ideal control voltage. This ideal control voltage is proportional to the phase deviation over the entire range.
[0011] EP 0571788 A2 discloses a carrier and phase control in which only the inner four symbols of the I/Q plane with an additional hysteresis are used in connection with a reduced constellation. However, in higher-order modulation methods having a uniform symbol distribution, the frequency of these symbols is only a very small component (e.g., only about 1.6% for uniformly distributed 256 QAM).
[0012] U.S. Pat. No. 5,471,508 discloses an operational mode of tracking by which the control operates using a reduced symbol alphabet in the I/Q plane wherein only large radii are taken into account.
[0013] DE 199 28 206 A1 discloses a method in which the complex I/Q plane is divided into smaller squares, thereby allowing an essentially unique average control voltage to be obtained. However, this method requires the use of large tables, and still does not solve the fundamental problem.
[0014] In a method disclosed in DE 41 00 099 C1, only the corners of the I/Q symbol alphabet are utilized, and again many symbols are lost as a result.
[0015] EP 0249045 B1 (U.S. Pat. No. 4,811,363, DE 36 19 744 A1) proposes a method in which a two-step decision is implemented. In a first step, a target radius is decided on then, in a second step, the most probable target phase point is assumed on this decision-based target radius. For 16-QAM constellations, such a method works to an acceptable degree. When a 64-QAM plane is used, however, 9 radii must be taken into account, some of which are very closely adjacent to each other. With 64 QAM, the radii boundaries and phase boundaries for a symbol are already located so closely together that effective radii decisions are almost impossible to obtain, especially in the event of additive noise. In the case of 256 QAM, the radii are so close together that very few radii decisions can be obtained at a sufficiently useful level.
[0016] The problem of correctly determining the phase deviation would not exist if the maximum phase deviation at each point in time were as large as the central region of FIG. 11 in which the phase deviations are always measured correctly. For stability reasons, it is almost impossible to have a quickly locking control that when given a frequency offset immediately detects and tracks the first passing correct phase position. That is particularly true considering the fact that practical implementations of the circuit have delays of multiple symbol clock pulses between the frequency/phase correction of the PLL-controlled oscillator with complex mixing of the input signal into the baseband and the symbol decision element. In addition, control filters are also located in the loop, and together cause significant signal delays that produce instabilities in the event of high loop gain.
[0017] Therefore, there is a need for an improved method and circuit for generating a symbol during reception of a modulated signal, specifically, for generating control signals, and to provide a receiving circuit which, in response to a large offset of the carrier frequency or carrier phase, quickly locks in without thereby affecting the overall stability of the system.
SUMMARY OF THE INVENTION
[0018] A basis of the invention is a method for synchronizing a circuit during reception of a modulated signal that is mixed into the multidimensional complex signal space, wherein the decision is made by a decision element by analyzing a received signal within a complex coordinate space using control parameters and, depending on at least one decision-based symbol, the control parameters are adjusted for subsequent decisions. The demodulation here preferably takes place within a two-dimensional complex phase space, that is, in the baseband with the complex I and Q components. The method is also applicable to a one-dimensional signal, for example, a BPSK signal with points on the real axis when a merging or transformation into the multidimensional complex signal space or phase space is implemented for processing.
[0019] The especially preferred solution includes assigning a separate rotation device to the decision element, which device can perform an instantaneous rotation with a preliminary correction angle, specifically an estimated one, before the decision without taking into account the control of the local oscillator. The estimated correction angle is generated by an evaluation device coupled to the decision element. Analogous to this process is a procedure in which, instead of the signal, target symbols are rotated, or a combination of the two rotations is implemented. The preliminary or estimated rotation angle is checked by subsequent symbol decisions, then iteratively improved by integration of the aforementioned phase error until the actual rotation of the received signal relative to the reference coordinate system is recognized. In the case of a frequency offset, the rotation angle follows the increasing phase error. Control of this rotation, which depends on the phase error detected by the decision, may have an extremely high loop gain to ensure reliable locking into the phase position of the received signal. Since the control gain is limited to this circuit component, the stability of the actual carrier control, which may have a much lower loop gain, is not affected. Either the estimated rotation angle or a quantity derived therefrom is suitable as the input signal. In addition, the symbol decided upon can be advantageously supplied to the controls for gain, sampling time, and the equalizer. If the received signal has been rotated before the decision, the decision-based symbol must be back-rotated by the appropriate angle in these controls before use. This action enables this symbol, subsequently usually called the control symbol, to determine correction parameters for the aforementioned controls so as to enable the fastest possible synchronization of the circuit. The difference in the radii of the received signal and the decision-based symbol also enables gain control. The output data for additional processing steps can be obtained either from this decision element as well, or from a separate data decision element, the input data of which or the target symbols of which do not experience this additional rotation about the estimated value.
[0020] Accordingly, the rotation device and/or evaluation device preferably have a separate decision element that will be called an additional decision element or auxiliary decision element hereinafter. This additional decision element preferably has the function of a known decision element, although as an option a modified signal may be supplied to it.
[0021] Lacking a plausible estimate, the tilting action is effected in a first step by an angle of less than 360°, and preferably, taking into account the modulo of the quadrants, less than 90°.
[0022] Preferably, a tap of the signal components, especially the phase signal components, before and after the decision element may be used to determine a difference which indicates a deviation value that can be compared with the previously determined tilting angle. A filter device implements a plausibility check wherein diverse control parameters are used to specify as needed a wider or less wide tolerance range within which an adequate signal quality is detected so as to enable the circuit to lock in.
[0023] The decision element can preferably be operated both in the domain of the polar coordinate space and in the domain of the Cartesian coordinate space.
[0024] Preferably, a control device for the carrier frequency and carrier phase has a direct branch for controlling a phase deviation, and an integrator for controlling a frequency deviation, wherein for purposes of frequency control the integrator is supplied with the time derivative of the preliminary or estimated rotation angle, or with a signal formed therefrom. For purposes of phase control, a direct branch and the integrator are supplied with the estimated rotation angle or a signal formed therefrom.
[0025] Accordingly, a method has been developed in which the instantaneous rotation of the received coordinate system relative to the coordinate system of the circuit is estimated in the decision element itself and is tracked from symbol to symbol. The loop gain of the main control can still be very small. Occasional faulty decisions by assuming the incorrect tilt angle of the received signal have essentially no effect on the actual frequency and phase control since the real phase position is quickly detected again and locked in.
[0026] One specific application provided by the method, or the corresponding circuit, is in binary or complex digital modulation methods such as phase shift keying (PSK) and QAM. Modulation methods of this type are employed in current radio, television, and data operations using cable, satellite, and sometimes terrestrial means.
[0027] These and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of preferred embodiments thereof, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 illustrates a basic circuit for a decoder used to decide on a symbol;
[0029] FIGS. 2A-2 c illustrate the position of a signal received in a tilted or rotated receiving coordinate system, and a fundamental principle for adjusting the coordinate system of the circuit by rotating a received signal and by oppositely rotating a decision-based auxiliary symbol;
[0030] FIGS. 3A-3B schematically illustrate the position of a signal received in a rotated receiving coordinate system, and the adjustment of a decision grid of the circuit by rotation;
[0031] FIG. 4 illustrates a section of a circuit to show an embodiment of a decision element in which the symbols and decision limits are rotated;
[0032] FIG. 5 illustrates a general embodiment of a decision element in which signals and symbols are rotated;
[0033] FIG. 6 shows details of the rotation control device controlling the process sequences that specifically affect the generation of a rotation control signal and amplitude error signal;
[0034] FIG. 7 illustrates another embodiment using a decision element in which rotation and counter-rotation, as well as the decision for a symbol, occur in a polar coordinate space;
[0035] FIG. 8 illustrates an embodiment of a carrier frequency device and phase control device;
[0036] FIGS. 9A, 9B illustrate an example of a measured phase error with 64 QAM ( FIG. 9A ) and the derivative of this signal, that is, the determination of a frequency offset, ( FIG. 9B ), while
[0037] FIGS. 10A-10C , for purposes of comparison, illustrate an example of the measured phase error with 64 QAM for the described method ( FIG. 10A ) and the derivation of this signal, that is, a determination of the frequency offset, for an open ( FIG. 10B ) or a closed ( 10 C) control loop;
[0038] FIG. 11 illustrates averaged control voltages as a function of an angular deviation of −45° to +45° according to the prior art using a modulation according to 256 QAM; and
[0039] FIG. 12 is a diagram, as is FIG. 13 , on a different scale, illustrating the ideal, theoretical control voltage function.
DETAILED DESCRIPTION OF THE INVENTION
[0040] FIG. 1 illustrates a demodulator 1 that includes a plurality of individual components and represents one example of a circuit for determining and deciding on symbols S from a digitized signal sd that is coupled to a quadrature signal pair of a modulation method, for example, using the a QAM standard. These components may all or individually also be part of an integrated circuit. In particular, the components described below may be omitted or augmented by additional components, depending on the purpose of the application. In addition, the continuation of signals in the form of real signals, complex signals, or individual complex signal components may be appropriately adapted, depending on the purpose of the application and the specific circuit.
[0041] The demodulator 1 receives an analog signal sa from a signal source 2 , for example, a tuner. This analog signal sa, which is usually present in a bandwidth-limited intermediate frequency position, is supplied to an analog-to-digital converter (ADC) 3 for conversion to a digital signal sd. The digital signal sd is supplied by the ADC 3 to a bandpass filter 5 that removes steady components and disturbing harmonics from the digital signal.
[0042] The signal outputted by the bandpass filter 5 is supplied to a quadrature converter 6 that converts digital or digitized signal sd to the baseband. The baseband matches the requirements of the demodulator 1 and the modulation method used. In analogous fashion, the quadrature converter outputs digitized signal sd that has been split up into the two quadrature signal components I, Q of the Cartesian coordinate system. To implement frequency conversion, the quadrature converter 6 is usually supplied with two carriers offset by 90° from a local oscillator 7 , the frequency and phase of which is controlled by a carrier control device 8 .
[0043] Quadrature signal components I, Q are outputted by quadrature converter 6 and supplied to a circuit for sampling conversion composed of a low-pass filter 9 and a symbol sampling device 10 . Control of the symbol sampling device 10 is effected through an input to which a sampling signal t i is supplied from a clock control device 21 . In the normal operational state, the symbol sampling times for sampling signal t i are governed by the symbol rate 1/T of the modulation method employed, or by an integral multiple thereof, and by the exact phase position of the received digital symbols. The output signal from the sampling device 10 is filtered by a low-pass filter 11 using a Nyquist characteristic, then supplied to a gain control device 12 . The gain control device 12 serves to optimally cover the control range of a data or symbol decision element 15 . The output signal from the gain control device 12 is supplied to an equalizer 14 . The equalizer 14 removes interfering distortions from the two components of the quadrature signal pair I, Q and supplies a corrected signal I, Q or A at its output.
[0044] The complex received signal A available after the equalizer 14 is thus supplied in the conventional manner to the data decision element 15 that extracts the digital data S. These symbols S are then supplied to another digital signal processing device 16 . This decision element 15 is not, however, integrated into the decision feedback controls of carrier frequency/carrier phase (carrier/phase recovery), sampling time (timing recovery, clock recovery), gain control, or equalizer. Instead, these control branches are controlled by a special auxiliary circuit 50 with an additional decision element—also called control decision element 15 ′ for purposes of differentiation—which has a modified input signal A′ supplied to it.
[0045] To this end, signal A outputted by the equalizer 14 is supplied to a system of components 30 - 32 to determine control parameters (D, D′, ΔR, ρ), either some or all of which may also be implemented integrally within a signal semiconductor module as hardware, software, or in mixed form. These control parameters are then supplied directly or indirectly to the decision-feedback control circuit or components in the demodulator 1 . Specifically, the equalizer 14 , the gain control device 12 , the carrier control device 8 , and a control device, particularly a clock control device 21 for the symbol sampling device 10 , are supplied in this way with auxiliary symbols D′ from the decision element 15 ′, or with control symbols D, or symbol components R, α, or other signals ΔR, ρ generated therefrom.
[0046] Depending on the circuit, these control circuits are supplied with the two quadrature signal components of the symbol D or D′, and of signal A or A′ in Cartesian coordinates I, Q, or in polar coordinates R, α. Depending on the circuit, another possible technique is to supply individual components with only one of the quadrature signal components, or quantities derived therefrom, for example to supply the carrier control device 8 with a value ρ derived from the angle α of the preliminary symbol A and the angle of control symbol D, and the gain control device 12 with the difference ΔR of the radii of the signal A, A′ and of symbol D, D′.
[0047] In FIG. 1 , a special circuit 50 for determining the control parameters is composed of a rotation device 30 , a control decision element 15 ′, an additional rotation device 31 , and a rotation control device 32 .
[0048] The rotation device 30 rotates signal A outputted by the equalizer 14 about a predetermined quantity ρ and supplies the resulting complex signal A′ to control the decision element 15 ′ that generates an auxiliary symbol D′. To implement the rotation, a rotation control signal ρ is supplied to the rotation device 30 . Rotation control signal ρ matches an estimated instantaneous rotation angle or tilting angle ρ between the coordinate system of received signal sa, sd, and the coordinate system of the circuit 1 . Rotation control signal ρ is determined within the rotation control device 32 to which output signal A′ of the rotation device 30 and output signal D′ of the control decision element 15 ′ are supplied.
[0049] Output signal D′ of the control decision element 15 ′ is also supplied to the counter-rotation device 31 to implement an opposite rotation. Rotation control signal ρ from the rotation control device 32 is supplied to the counter-rotation device 31 in order to back-rotate auxiliary symbol D′ decided upon within the system of the circuit into the coordinate system of the received signal. The output signal D from the counter-rotation device 31 is used for the control circuits and, for example, supplied to clock control device 21 and the equalizer 14 . The two rotation devices 30 , 31 , generate unitary rotations and are formed, for example, using known complex multiplications with sine and cosine.
[0050] Rotation control device ρ is appropriately generated by the rotation control device 32 from the angles of signal sequence A′ and the angles of auxiliary signals D′.
[0051] The clock control device 21 outputs sampling signal t i which is based on the symbol rate 1/T of the modulation method employed, or a multiple thereof.
[0052] To implement control of the clock control device 21 , the carrier control device 8 , the equalizer 14 , the rotation control device 32 , the control device 43 for the gain control device 12 , and the additional components of the demodulator 1 , these components are connected to control device C. Control device C implements the proper sequence and controls the individual components and sequences of corresponding hardware- and software-based instructions. Preferably, the control device may also have the functions of some or all of the above components integrated within it.
[0053] The specific purpose of the circuit is to generate a control voltage or control voltage function, utilizing modulo-90′, as shown in FIG. 12 .
[0054] It is assumed that at a first time t1 at which the phase and frequency of the receiver have not yet locked in, the coordinate system of input signal A is still tilted by angle ρ relative to the reference coordinate system, and may even have to be rotated due to a frequency offset, as shown in FIG. 2A . Accordingly, a received signal is not immediately decided upon in the indicated grid of the circuit 1 since a rotation of the received coordinate system about angle ρ is assumed.
[0055] Input signal A outputted by the equalizer 14 is now rotated within the rotation device 30 by this tilting angle ρ into the circuit system so that in a first approximation a phase error is no longer present. After the rotation shown in FIG. 2B into the circuit system, this rotated signal A′ is then supplied to an auxiliary decision element 15 ′ that makes a decision within the fixed circuit system. Here rotated input signal A′ is assigned in the conventional manner to a target symbol. The counter-rotation device 31 rotates decision-based symbol D′ in the opposite direction by angle ρ from the coordinate system of the circuit 1 back into the presumed coordinate system of the received signal. After this opposite rotation, input signal A has a decision-based control symbol D, although the actual carrier control device—composed specifically of the carrier control device 8 , the local oscillator 7 , and the quadrature converter 6 —has not yet locked in. A target point and a complex error voltage are thus available, as is shown in FIG. 2C .
[0056] Input signal A into circuit 50 and control symbol D generated therein can be employed for the decision-feedback controls of the sampling time recovery and of the equalizer 14 . The presumed rotation angle ρ of input signal A—determined from input signal A and symbol D, or A′ and D′—can be employed for the decision-feedback carrier control within the carrier control device 8 ; and similarly within the circuit 32 an amplitude deviation ΔR—derived from input signal A and symbol D, or A′ and D′, and obtained by subtracting the radius of auxiliary symbol D, D′ from the radius of input signal A, A′—can be employed for the purpose of decision-feedback amplitude control within the amplitude control device 43 .
[0057] In an alternative approach to rotating the coordinates of the received signal into the system of the circuit and back-rotating the decision-based symbol into the coordinate system of the received signal as the control symbol for the purpose of decision-feedback controls, it is also possible, as shown in FIG. 3B , to rotate the decision grid relative to the original ( FIG. 3A ) so that its coordinate system matches the coordinate system of received signal A.
[0058] FIG. 4 illustrates a section of such a circuit 1 wherein the specific rotation 50 * corresponds to the block 50 shown in FIG. 1 with the rotation, decision element, and control components. In regard to additional components, reference is thus made to FIG. 1 and the associated description. To implement the above-outlined method, circuit 50 * shown employs decision limits E which are provided, for example, from a table in memory 15 a *. In a computing unit 15 b * acting as the rotation unit, the decision limits E′ are rotated so that the estimated rotation of the received signal sa, sd, A is achieved relative to the coordinate system of the circuit. These thus rotated decision limits E′ are supplied to the decision element 15 c *. The decision then occurs directly in the estimated coordinate system of received signal A without the prior rotation of the received signal and subsequent opposite rotation of the symbol generated thereby.
[0059] In this and other embodiments, methodological steps and components already described with reference to the above descriptions for the same or analogously functioning methodological steps and components are not repeated.
[0060] Specifically, the two methods—rotation of the received signal and counter-rotation or back-rotation of the decision-based symbol, or rotation of the decision limits—are equivalent and interchangeable. One of these two methods is preferably implementable depending on the given technical means of implementation. The following discussion explains additional details specifically of the first embodiment, although equivalent implementations are also possible for the second embodiment.
[0061] FIG. 5 illustrates a more general embodiment of the circuit block of the circuit 50 . In this block, the preliminary symbol A is supplied to the rotation device 30 that outputs a rotated symbol A′ after rotation. This symbol is supplied both to the decision element 15 ′ and to the rotation control device 32 ′. The decision-based auxiliary symbol D′ outputted from the control decision element 15 ′ is supplied both to the counter-rotation device 31 and the rotation control device 32 ′. The rotation control device 32 ′ generates a control signal ρ for the rotation device 30 and the counter-rotation device 31 which is supplied to these devices. In addition, original symbol A of the equalizer 14 is supplied directly to the carrier control device 8 ′ and the amplitude control device 43 ′. These devices additionally have supplied to them control symbol D which is outputted by the counter-rotation device 31 . This control symbol D is appropriately also supplied to the clock control device 21 and the equalizer 14 . In addition, the clock control device 21 has supplied to it symbol A outputted by the equalizer 14 .
[0062] An example of the rotation control device 32 is illustrated in FIG. 6 . The rotated symbol A′ as the input signal and the decision-based auxiliary symbol D′ outputted by the decision element 15 ′ are supplied to the rotation control device 32 . These two signals or symbols A′, D′ are each supplied to one coordinate converter 20 or 20 ′ which convert these to polar coordinates. An example of what can be used here is a known Cordic circuit. Each of these outputs a radius component R and an angle component or phase α. Alternative methods of coordinate conversion are usable, specifically, mathematical approximation techniques or the use of tables. The amplitude difference ΔR is determined by subtracting the radius components R(A′), R(D′), which difference is outputted as the control signal for the amplitude control device 43 . The phase or angular difference Δρ is determined by corresponding subtraction of the phase of symbol D′ outputted by decision element 15 ′ from the phase of input signal A′ and represents the phase estimation error. This phase difference Δρ is supplied to a circuit composed of an adder, a filter device 33 , and a delay element (z −1 ), whereby the output signal ρ of this arrangement sequence is returned to the second input of the adder. The sum generated from the phase component ρ and the phase difference Δρ represents the most probable current coordinate rotation angle ρ+Δρ found of the signal entered into the decision element 15 ′ relative to the system of the circuit. This sum ρ+Δρ is checked in filter 33 for plausibility. The output from filter 33 simultaneously provides the rotation angle ρ for the next decision to be made. Rotation angle ρ is supplied specifically to the rotation device 30 , the counter-rotation device 31 , and the carrier control device 8 .
[0063] The embodiments described above represent examples of a preferred QAM receiver or decoder with decision-making of the control or auxiliary decision-making in the Cartesian coordinate system I/Q.
[0064] FIG. 7 represents an embodiment in which the decision-making is implemented in the decision element 15 ′ within the polar coordinate system. Rotation and counter-rotation are effected by prior conversion of the signal to polar coordinates and simple subtraction or addition of the rotation control signal or tilting angle from or to the phase component. In addition, the decision-making also occurs within the polar coordinate system.
[0065] This embodiment advantageously also has an optional switch 39 by means of which the integration of the phase difference can be preserved after synchronization of the carrier control circuit has occurred.
[0066] To generate the next rotation control signal ρ, the phases of the input signal and output signal A′ or D′ are tapped before or after the decision element 15 ′, then supplied to a subtraction element. This element determines the phase difference Δρ which is supplied to another addition element. This addition element adds the phase difference and the current rotation control angle ρ. The sum is then supplied to the filter device 33 .
[0067] The switch 39 here is connected within the return branch of the prior adder, filter device 33 , and delay element (z −1 ). In the nonconducting position of the switch 39 , the rotation angle ρ determined is supplied as the rotation control signal only to the carrier control device 8 .
[0068] Additional parameter values m, n, and a tolerance value u are supplied to the filter device 33 . These may, for example, be supplied from a memory device or from an external central control device.
[0069] After delay element z −1 , the output signal from the filter 33 is available as the new rotation control signal ρ for the next decision at the next time point. The filter device within this rotation control checks the found current rotation angle ρ+Δρ for plausibility and adjusts rotation control signal ρ for the next time point.
[0070] The filter device 33 outputs an arbitrary value for rotation control signal ρ. An offset Δρ thereby determined can then be attributed to a still insufficient estimation of rotation control signal ρ. In the event of an extremely insufficient estimation of rotation control signal ρ at the start, many decisions will be incorrect due to incorrect symbol assignment within the decision element 15 ′. There are angle offsets, however, for which most or even all decisions are correct, that is, rotation control signal ρ has been correctly estimated and angular difference Δρ is approximately 0°. If the input signal A rotates due to a frequency offset—a condition that can be assumed in the case of carrier control loops that have not locked in—then sooner or later the system will pass through one such “good” angle offset region. All or many of the found successive rotation angles ρ+Δρ will have identical or similar values. The filter device 33 now recognizes that at least m of n, for example, 4 of 8, of the last found rotation angles ρ+Δρ match the present rotation control signal ρ up to a tolerance u, for example, 0.1 rad, and considers the present found rotation angle ρ+Δρ to be plausible so as to be able to use this as the next value for rotation control signal ρ. Parameters n, m, u, may be advantageously adapted to the reception conditions or the progress of synchronization.
[0071] The simplest implementation of the filter device 33 is an identity stage which corresponds to a short between input and output. The next rotation control signal ρ is then the currently found rotation angle ρ+Δρ.
[0072] If the actual phase control has locked in, rotation control signal ρ can be limited to the found angle deviation Δρ by causing the switch 39 shown in FIG. 7 to prevent the angle integration.
[0073] FIG. 8 shows details of the carrier control device 8 . The carrier frequency and carrier phase control device 8 is preferably composed of a differentiator 36 , three multiplication elements 82 , 83 , 84 , a double-pole two-way switch 37 , an integration element 38 , and an adder 85 .
[0074] The tilting angle or rotation control signal ρ is supplied as the first quantity to the two multiplication elements 82 , 83 , and a P-coefficient or an I-coefficient is supplied to these elements as the second quantity. In addition, rotation control signal ρ is supplied to a differentiator 36 (dρ/dt), the output signal of which is supplied to another, third multiplication element 84 . An F-coefficient for frequency control is supplied as a second signal to this element. A double-pole switch 37 , on the one hand, switches the output of I-multiplier 83 or the output of F-multiplier 84 to integrator 38 , the output of which is supplied to adder 85 . On the other hand, double-pole switch 37 switches between the output of P-multiplier 82 and an unassigned input, the output signal of the switch also being supplied to adder 85 . The output of adder 85 supplies an error signal to local oscillator 7 .
[0075] At the start of the synchronization process, the switch 37 is in the position in which the upper switching element supplies a zero signal, while the lower switching element supplies the signal mixed with coefficient F. As a result, the modulo-correct derivative of rotation control signal dρ/dt, which represents a possible frequency offset Δf, is weighted with the F-coefficient and accumulated in integrator 38 . Once the oscillator 7 finally has approximately reached the target frequency due to the control voltage coming from the integrator 38 , dρ/dt will become very small. Under this condition, dρ/dt≈0, the switch 37 is moved to the other switching position by the central control device C of the circuit 1 , thus obtaining the usual PI control (proportional/integral control) of the phase. The integral component in the integrator 38 obtained through the prior frequency control remains intact. A principal advantage consists is the fact that coefficients F, P and I in the carrier control device 8 , and thus the loop gain of the main control for carrier frequency and carrier phase, can be very small since fast phase tracking occurs in the circuit 50 and is limited to the circuit 50 .
[0076] Whereas a control voltage, such as that illustrated in FIG. 12 , would ideally run from a normalized value −1 at −45° in a straight line through the origin to a normalized value of +1, this is not the case with actual phase control voltages. FIG. 9A illustrates a conventional phase control voltage for 64 QAM as a function of time. Regions are clearly evident in which the phase offset repeatedly passes through zero such that a control may lock in whenever its gain is able to be large enough. In connection with this example of an open control loop, FIG. 9B shows the frequency control voltage obtained from a derivative of the signal on a time axis which is compressed relative to FIG. 9A . In this example, the frequency offset is approximately 2,000 ppm of the symbol rate.
[0077] A corresponding curve of a phase control voltage with a measured rotation control signal ρ using 64 QAM in accordance with the method here proposed is presented in FIG. 10A . What is significant is not only the segment-wise almost linear pattern similar to that of FIG. 12 , but also the fact that, after individual outliers, filter 33 or circuit 1 are able to very quickly recapture the correct phase. In this example, the frequency offset is again approximately 2,000 ppm of the symbol rate, while the signal/noise ratio is the same as in FIG. 9 . In this example with an open control loop, FIG. 10B illustrates the measured frequency offset dρ/dt for the signal, but on a compressed time axis. FIG. 10C shows the corresponding frequency offset dρ/dt for the case with a closed control loop. The scale for FIGS. 10B and 10C is matched to that of FIG. 9B .
[0078] The method and circuit 1 preferably function to synchronize a QAM receiver. In circuit 1 , there is a circuit 50 in which a found angular difference between received signal A′ and decision-based symbol D′ is integrated and checked for plausibility. This angular difference Δρ, integrated and checked in the rotation control device 32 , serves as rotation control signal ρ. As a result, subsequently received signals A are rotated immediately before decision element 15 ′ and thus corrected. Alternatively, the coordinate system of the decision element can be rotated by the opposite angle. The actual control signal for the local oscillator 7 is thus formed from this rotation control signal ρ in a control circuit 8 . The carrier control locks in even in the event of a very small loop gain. The decision-based symbol D′, or possibly the back-rotated symbol D or its difference relative to input signal A, A′ can continue to be employed for the sampling rate 21 , the gain 43 , and the equalizer 14 . The subsequent processing steps contain either the symbol D thus decided upon, or a symbol S from an additional decision stage 15 that does not participate in the described rotations of the circuit 50 .
[0079] Although the present invention has been shown and described with respect to several preferred embodiments thereof, various changes, omissions and additions to the form and detail thereof, may be made therein, without departing from the spirit and scope of the invention.
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The invention relates to a method for synchronizing a circuit ( 1 ) during reception of a modulated signal (sa, sd, A) that has been mixed in the multidimensional complex signal space, specifically, in a QAM-receiver, wherein a decision element ( 15, 15′, 15 *) is employed to analyze the received signal within a complex coordinate space (I, Q) using control parameters (ΔR, ρ, t i ) so as to make a decision on a symbol (S), and to adjust at least one of the control parameters (ΔR, ρ, t i ) for subsequent decisions.
In order to improve the method, specifically, to enable the components of the control loop to provide a decision-based symbol more quickly without long delays, it is proposed that a preliminary, specifically an estimated, correction angle for an instantaneous rotation be supplied as a control parameter (ρ) to the decision element ( 15′, 15 *) independently of a control for a local oscillator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a reservoir in a hydraulic pressure actuating apparatus which requires an accumulator, and more particularly to a reservoir which incorporates an accumulator therein.
2. Description of the Prior Art
In the conventional reservoir, the height of the fluid surface within the reservoir is varied in response to the change of the fluid quantity reserved within the accumulator, so that when the hydraculic fluid is supplied and the fluid quantity is inspected, the hydraulic fluid within the accumulator must be discharged.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved reservoir adapted for obviating the aforementioned drawbacks of conventional systems.
Another object of the present invention is to provide a new and simplified reservoir incorporating an accumulator which is capable of keeping at a certain height the fluid surface within the reservoir regardless of the change of the fluid quantity reserved within the accumulator.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the several views, and wherein:
FIG. 1 is a sectional view of a reservoir incorporating an accumulator and utilized in the fluid pressure circuit constructed according to the present invention; and
FIG. 2 is a similar view to FIG. 1, however, showing another embodiment according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and more particularly to FIG. 1 thereof, the reference numeral 10 denotes a stepped cylindrical casing of a reservoir and a plug 12 having a cylindrical projection 11 is sealingly inserted into a lower portion of the casing 10 by means of an O-ring 13. The lower end portion of the casing 10 is caulked at the outer end surface of the plug 12, thereby, the plug 12 is prevented to break away from the casing 10. A slidable cylindrical member 15 having a flange portion 14 at the lower end portion thereof is sealingly and slidably mounted over the projection 11 of the plug 12 by means of an O-ring 16. A recessed groove 18 is formed by a hollow portion 17 disposed on the top end portion of the projection 11 of the plug 12 and the inner peripheral surface of the cylindrical member 15. The cylindrical member 15 is always urged in the direction of the plug 12 by means of a spring 19 interposed between the upper inner peripheral surface of the casing 10 and the flange portion 14 of the cylindrical member 15. A cylindrical filter 22 disposed between an annular plate spring 21 sealingly contacted with the inner peripheral portion of the casing 10 by means of an O-ring 20 and the inner peripheral surface of the plug 12 is urged into the direction of the plug 12 by the annular plate spring 21. The casing 10 is divided into a chamber 23 and a chamber 24 incorporated with the spring 19 by the plate spring 21 and the filter 22. When the filter 22 is closed by dust and dirt etc. the plate spring 21 is upwardly moved and released from the filter 22, namely, the plate spring 21 acts as a relief valve.
A cap 55 is detachably attached to an annular flange portion 25 extended from the casing 10 and a cap 26 is attached to the top end portion of the cap 55. An air communicating hole 27 is provided on the top end portion of the cap 55 and a passage 28 is formed between the cap 55 and the cap 26. A retainer 34 is mounted on the inner stepped portion of the flange portion 25 of the casing 10 and a strainer 36 is fixed to the lower portion of the retainer 34. A switch body 35 is fixed to the inner peripheral portion of the cap 55 at the top end portion thereof and a fixed member 29 is inserted into the inner top end portion of the switch body 35 through a holding member 30. A lead line 32 is connected to the fixed member 29 and a connecting member 85 is connected to the lead line 32 and to a resistance 33. A switch 37 is connected to the resistance 33, and a float member 39 and a magnet 38 are contacted to the lower end portion of the switch body 35. A holding member 40 is provided at the lower portion of the float member 39.
The chamber 24 within the casing 10 is fluidically communicated to a pump 43 via an outlet portion 41 provided in the plug 12 and a conduit 42 connected to the outlet portion 41. The pump 43 is fluidically communicated with the groove 18 through a conduit 44, a changeover valve 45 cannected to the conduit 44, a conduit 46, a check valve 47, a conduit 48 connected to the check valve 47, a port 84, and a passage 49 formed in the plug 12. A conduit 50 branched from the conduit 48 is connected to the chamber 23 through a conduit 50, an actuator 51 provided with a well-known closed type control valve, a conduit 52 connected to the actuator 51, and an inlet portion 53 connected to the conduit 52. A conduit 54 branched from the conduit 52 is fluidically communicated with the change-over valve 45.
The operation of FIG. 1 will now be described hereinbelow in detail;
When the pump 43 is activated the oil within the chamber 24 of the casing 10 will be sucked in the pump 43 through the outlet portion 41 and the conduit 42. Further when the oil sucked in the pump 43 is transmitted into the groove 18 via the conduit 44, the change-over valve 45, the conduit 46, the check valve 47, the conduit 48, the port 84, and the passage 49, the cylindrical member 15 is upwardly and slidably moved on the outer peripheral surface of the projection 11 of the plug 12 against the downwardly urging force of the spring 19 and then the volume associated with the groove 18 is increased and the oil pressure within the groove 18 is increased to a pre-set pressure P 1 . When the oil pressure within the groove 18 reaches the pre-set pressure P 1 the change-over valve 45 is changed by a sensing means (not shown) for sensing the oil pressure within the groove 18, the oil transmitted from the pump 43 to the change-over valve 45 via the conduit 44 is transmitted into the chamber 23 through the conduit 54 and the inlet portion 53. Accordingly, the oil transmitted to the chamber 23 is filtered by the filter 22 and the filtered oil by the filter 22 is restored to the chamber 24.
The highly pressurized oil within the groove 18 is transmitted to the actuator 51 via the passage 49, the conduit 48 and the conduit 50 and then the actuator 51 is activated by the high pressurized oil. Consequently, when the oil pressure within the groove 18 is reduced to a pre-set pressure P 2 (P 1 >P 2 ) the change-over valve 45 is changed and the oil transmitted from the pump 43 to the change-over valve 45 via the conduit 44 is transmitted to the groove 18 through the conduit 46, the check valve 47, the conduit 48, the port 84 and the passage 49 and therefore the oil is transmitted to the groove 18 until the oil pressure within the groove 18 reaches the pre-set pressure P 1 .
The oil discharged from the actuator 51 is transmitted to the chamber 23 via the conduit 52 and the inlet portion 53. The oil transmitted to the chamber 23 is filtered by the filter 22 and then the filtered oil by the filter 22 is restored to the chamber 24. At this time, the oil quantity pumped out from the chamber 24 by the pump 43 and the oil quantity stored within the groove 18 are the same as each other, so that the height of the fluid surface within the chamber 24 is not changed.
Assuming that the oil quantity within the chamber 24 is decreased the change of the oil quantity is sensed by the float member 39 and then the float member 39 is lowered. When the float member 39 is lowered the switch 37 is switched through the magnet 38 and then it is noticed to a vehicle driver through the resistance 33 and the lead line 32 that the oil quantity within the chamber 24 has decreased.
Now referring to FIG. 2, the different construction from FIG. 1 will now be described hereinbelow in detail, however, the same numeral to FIG. 1 is utilized in the corresponding parts of FIG. 2;
A cover 81 is sealingly attached to the top end portion of the casing 10 through a seal member 71. One end of a rod 64 is fixed to the upper surface of the cover 81 by a bolt 62, a nut 65 and a washer 66 and further a bolt 63 of the rod 64 is fixed to a retainer 69 through a nut 67, a washer 68 and the holder 70. One end of the spring 19 is contacted with the retainer 69 and the other end thereof is contacted with the flange portion 14 of the cylindrical member 15. The other end of the rod 64 is sealingly inserted into the cylindrical member 15 and the projection 11 of the plug 12 by means of a seal ring 72. A poppet valve body 57 is mounted on the plate spring 21 for controlling the oil within the chamber 23 upon closing state of the filter 22. The poppet valve body 57 includes a top end portion 56, a plate portion 59, a valve member 60, a seat portion 83 formed on the plate spring 21, a lower end portion 58 connected to the body 57 and a spring 61 disposed between the lower portion of the seat portion 83 and the lower end portion 58. A flange member 77 is fixedly attached to the cover 81 and a cap 73 is air-tightly covered to the flange member 77. A retainer member 74 is provided between the cap 73 and the flange member 77. A seal member 75 is sealingly disposed between the flange member 77 and the retainer member 74 and a plurality of holes 80 is provided in the retainer member 74. An air cleaner 79 is mounted on the top portion of the retainer 74, and a spring 78 is interposed between the cap 73 and the air cleaner 79. A holder 76 is provided at the lower portion of the retainer member 74 and an oil level gauge 82 is provided at the lower portion of the holder 76.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is to be understood therefore, that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.
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A reservoir fluidically connected to a fluid pressure source and comprising, a casing, a projection projected from one end of the casing into the casing and fixedly connected with the casing, a cylindrical member sealed hermetically and slidably mounted on the projection, a groove formed between a peripheral surface of the cylindrical member and an end portion of the projection and fluidically connected with the fluid pressure source, a chamber formed between the other end of the casing and an outer peripheral surface of the cylindrical member, and a spring interposed between the other end of the casing and the outer peripheral surface of the cylindrical member so as to constantly urge the cylindrical member, thereby keeping at a certain height the fluid surface within the reservoir regardless of the change of the fluid quantity reserved within an accumulator.
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FIELD OF THE INVENTION
[0001] The present invention relates to a hands-free telephone system for a vehicle, and more particularly, to a hands-free telephone system for a vehicle that has improved convenience and is readily adaptable to a next generation communication environment.
BACKGROUND OF THE INVENTION
[0002] A typical hands-free system is composed of a hands-free kit that is connectable to an earphone jack of the portable phone, the microphone, an amplifier, speaker, and a traffic switch, etc. In this conventional hands-free system, the driver must usually use keys on the portable phone to access functions, other than when answering a phone call or re-dialing a recently dialed phone number. In addition, every time they enter the vehicle the driver must connect the portable phone to the hands-free system, and attach a transmitter to the earphone jack even where wireless earphones are provided.
[0003] Entries are registered in a typical hands-free system according to a method where the system first checks to see whether the portable phone is connected to the system. The method then continues to determine whether hands-free system needs to be updated with entries, based on how many entries are in the system versus the number detected in the portable phone. These entries are updated by the hands-free system using voice commends to guide the user through a series of steps and responding to voice commands from the user that verify the entry and register it into the hands-free system. A registry entry management method for a portable phone and a hands-free kit, as described above, for registering names using voice recognition is disclosed in Korean Laid-open Patent Publication No. 1999-018665.
SUMMARY OF THE INVENTION
[0004] The present invention makes it unnecessary to connect a portable phone to the hands-free system. A preferred embodiment of the hands-free system of the present invention enhances mobile communication using a portable phone, and includes: a memory for storing telephone numbers; a voice recognition module for receiving a name and recognizing it; a voice synthesizing module for outputting a name according to an instruction of the voice recognition module or according to character information displayed on said portable phone; a microprocessor for controlling the hands-free system based on signals received from the memory and the voice recognition module; an input/output (I/O) module for inputting or displaying a telephone number of the portable phone; and a communication module for enabling voice and character data transmission through wireless communication so as to enable making a phone call through verbal commands and outputting voice and character information through verbal commands according to an input of the voice and character information.
[0005] An additional preferred embodiment of a hands-free system for a portable phone according to the invention, comprises: a microprocessor with a computer program embedded therein; a communication module configured to detect the presence of at least one portable phone and to facilitate the wireless exchange of information between the microprocessor and the at least one portable phone; a voice recognition module configured to: receive a data packet representing a spoken word from the microprocessor; create a second data packet representing said spoken word using signals from a microphone; determine whether the first and second data packets match; and output the result of whether the first and second data packets match to the microprocessor; a memory for storing the data packets and the information; a voice synthesizing module configured to translate the data packets and the information into signals that upon conversion into sound are understood to be spoken words; an amplifier and speaker for converting said data packets and the information into sound; a keypad; a display; and an input/output module configured to: relay input from the keypad to the microprocessor; and relay output from the microprocessor to the display; wherein said hands-free system automatically recognizes the presence of at least one portable telephone, interfaces with the at least one portable telephone, and allows the operation of the at least one portable telephone through voice commands through the microphone and input from the keypad.
[0006] An additional preferred embodiment of a method for operating a hands-free system for a portable, comprises: having the hands-free system automatically recognize the presence of at least one portable phone; wirelessly interfacing the hands-free system with the at least one portable phone; transferring information from the at least one portable phone to the hands free system, wherein the hands-free system receives at least one data packet with a corresponding phone number from said at least one portable phone; constructing voice commands for the hands-free system that are specific for the at least one portable phone recognized, the constructing comprising: prompting a user to repeat a spoken name, wherein the spoken name was generated using a data packet; creating a second data packet representing the repeated spoken name using signals from a microphone; determining whether the first and second data packets match; and storing the first and second data packets as names if they match; and operating in response to commands input by the user to the hands-free system, said operating comprising: responding to voice commands from the user; and responding to commands input by the user through a keypad.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Preferred embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings, in which:
[0008] [0008]FIG. 1 is a flow chart of a registry entry management method in a voice recognition module of a hands-free system;
[0009] [0009]FIG. 2 is a flow chart of a process for registering names in the memory of the hands-free system shown in FIG. 1;
[0010] [0010]FIG. 3 is a block diagram of a hands-free system of a vehicle according to a preferred embodiment of the present invention; and
[0011] [0011]FIG. 4 is a front view of a front panel of the hands-free system according to a preferred embodiment of the present invention.
[0012] Like numerals refer to similar elements throughout the several drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] Referring to FIGS. 3 and 4, a hands-free system 10 according to a preferred embodiment of the present invention enhances communication using a portable phone in a vehicle. System 10 may comprise: a memory 11 for storing various telephone numbers and related information from the portable phone; a voice recognition module 12 for receiving a name (through a microphone, for example) and recognizing it, thereby facilitating placing a telephone call; a voice synthesizing module 16 for outputting a name according to an instruction from said voice recognition module 12 , or according to an instruction from character information displayed on said portable phone; a microprocessor 13 for controlling said hands-free system based on signals received from said memory 11 and said voice recognition module 12 ; an I/O module 14 for inputting or displaying a telephone number of said portable phone; and a communication module 15 for enabling voice and character data transmission through wireless communication.
[0014] Communication module 15 enables making a phone call and outputting voice and character information using verbal commands. In a preferred embodiment, communication module 15 is a Bluetooth™ communication module, which is now well understood by persons of ordinary skill in the art. The specification for Bluetooth™ technology is developed, published and promoted by the Bluetooth™ Special Interest Group (Bluetooth™ SIG), Inc. Bluetooth™ technology is described in: Dee Baker, Diane Gilster, and Roy Gilster, Bluetooth™ End to End , John Wiley & Sons, Jan. 15, 2002; and Robert Morrow, Bluetooth™ Operation and Use , McGraw-Hill Professional, Jun. 14, 2002.
[0015] The I/O module 14 comprises: an interface (I/F) module 14 a that enables the hands-free system to communicate with the vehicle; an LCD display module 14 b for displaying telephone numbers; and a keypad or key input module 14 c for inputting the telephone number of the portable phone to the memory 11 . The keypad and display functions could be performed by one user interface. In another preferred embodiment of the invention, system 10 is modified for use, resulting in the elimination of I/F module 14 a.
[0016] When the system is started, if two or more portable phones in the vicinity are detected by the Bluetooth™ communication modules, their telephone numbers are displayed on the LCD display module 14 b of the I/O module. The voice synthesizing module 16 synthesizes the voice of the portable phone user, and is connected to an amplification module 17 that amplifies the voice and outputs it through a speaker. During the output of the voice, the vehicle's audio system is muted by commands transmitted through the vehicle I/F module 14 a . The portable phone used with the hands-free system of the present invention should be a portable phone having a built-in Bluetooth™ module or a portable phone enabling Bluetooth™ communication by having a Bluetooth™ adapter attached to it.
[0017] The system is used in the following manner. Referring to FIG. 1, in step 410 , a microprocessor checks the hands-free kit connection part to verify that the jack of the hands-free kit and the portable phone are connected to each other and that the portable phone is mounted on the holder. If so, the microprocessor recognizes that they are in hands-free mode, and, in step 420 , calculates an entry difference value by subtracting the number of registered entries in the hands-free kit from the number of registered entries of the portable phone.
[0018] In step 430 , the microprocessor checks if the entry difference value is zero. If it is zero, in step 440 the microprocessor performs voice recognition. If it is not zero, in step 450 the microprocessor checks whether the entry difference value is larger than zero. If so, in step 450 the microprocessor registers a prerecorded name in the memory of the hands-free kit and increases the number of registered entries of the hands-free kit. But, if the entry difference value is not greater than zero, the microprocessor registers the prerecorded name to the memory of the portable phone and increases the number of registered entries in the portable phone in step 470 .
[0019] Referring to FIG. 2, this operation is performed at the time the portable phone is mounted in the hands-free holder to update the names in the hands-free kit with the names in the portable phone. First, in step 510 , the microprocessor outputs a guiding voice that asks whether a driver wants to register a name to the hands-free kit. This guiding voice is output through a D/A converter and a speaker. In step 520 , the microprocessor checks whether the key ‘*’ is input. If the input is not detected, the microprocessor proceeds to step 530 and checks whether a predetermined time (for example, three seconds) has elapsed. If so, the microprocessor concludes that the driver has no intention of registering and terminates the operation. If it has not elapsed, the microprocessor returns to step 520 to again check whether the key ‘*’ is input. When the key ‘*’ input is detected, step 540 begins the process of having the driver register names that have already been registered in the portable phone, but have never been registered in the hands-free kit. In step 540 , a guiding voice requesting a repetition of the relevant name is output (e.g., “Please repeat after me. [Name]”). Here, the phrase “Please repeat after me” is output using a guiding message recorded in advance in memory, and the name is output by reading a first data packet from a set stored in a voice reproduction data region of the portable phone memory.
[0020] If the driver inputs the name through a microphone in response thereto, the name is transmitted to a voice coder in the form of a PCM (pulse code modulation) signal through an A/D converter. In general, a voice coder is an apparatus for converting analog voice signals into digital signals. The voice coder codes the PCM signal to generate a second data packet. Then, in step 550 , the microprocessor checks whether this second data packet is input from the voice coder.
[0021] In step 560 , the microprocessor outputs a guiding voice requesting a repetition (e.g., “Please repeat again.”). Then the microprocessor checks whether a third data packet from the voice coder is input, i.e., the voice of the driver responding to the second request of repetition. If the input is detected, in step 580 , the microprocessor requests that a voice recognition module compare the two names and determines whether they match, and reports a result. The match is determined when a characteristic data index for each of the two names and a difference value (the difference in characteristic data between the two names) are transmitted from the voice recognition module to the microprocessor. If the microprocessor determines that the difference value is smaller than a predetermined threshold it considers the two names to match. Then, in step 590 , the microprocessor requests that the voice recognition module store the two names in memory. In general, a voice recognition module is an apparatus programmed to convert analog voice signals into digital signals and to extract information from the digital voice signals.
[0022] After registering the two matching names, in step 600 the microprocessor outputs a guiding voice notifying the user that the registration is complete (e.g., “Registered”). But, if the two names did not match in step 580 , in step 610 the microprocessor outputs a guiding voice requesting a retry (e.g., “Retry, since the names do not match.”) and returns to step 540 .
[0023] The operation of the hands-free system according to the embodiment of the present invention described above is as follows. Referring again to FIG. 3, a hands-free system enables the driver to make a phone call freely and eliminate danger. The hands-free system 10 frees the eyes and hands of the driver during phone communication by providing a plurality of functions, such as: wireless connection of the portable phone to the hands-free system, based on the Bluetooth™ protocol that enables voice and character data transmission; voice activation for placing calls; and voice synthesis enabling voice recognition and conversion of displayed information into announced or “spoken” information.
[0024] The hands-free system automatically detects portable phones when the driver gets into the vehicle carrying the portable phone, if the phone is Bluetooth™ equipped. This is called “automatic detection.” If two or more portable phones are detected the system displays the telephone numbers on the LCD display module 14 b and makes the driver select the telephone number of the appropriate portable phone using voice commands. If only one portable phone is detected, it is automatically selected. Then, information from the telephone directory and menu stored in the selected portable phone is automatically transmitted to the hands-free system.
[0025] The driver states “answer the call,” to answer a phone call. In response, the hands-free system mutes the vehicle audio system. The call is terminated when the driver says “end.” At this time the audio system is released from the mute state. When the driver wishes to place a call, and says “phone call”, the hands-free system switches to a mode of making a phone call and mutes the audio system. If the driver verbally states a number, or a name that is in the portable phone telephone directory, then the hands-free system informs the driver of what it recognizes by means of the voice synthesizing module. If the driver verbally confirms a desired telephone number or name and says “make the call”, then the hands-free system connects to the appropriate telephone number and informs the driver of the fact that the portable phone of the appropriate phone number is on standby for reception. When the driver says “end” upon completion of the conversation, the call is terminated and the audio system is released from the mute state.
[0026] When the driver says “character message,” then the hands-free system mutes the audio system and reads by means of the voice synthesis a character message currently stored in the portable phone. In this embodiment, the character message was acquired through the Short Message Service (SMS) that allows short character messages to be communicated to a portable telephone.
[0027] It is also possible for the driver, or for another vehicle occupant, to access the functions described above by using the input key pad on the front panel of the hands-free system, as shown in FIG. 4.
[0028] The present invention as described above makes possible: automatic wireless connection; automatic transmission of the telephone number of the portable phone; and mobile communication, regardless of whether the portable phone is in a pocket or a bag, so long as it is in the vicinity of the system. In the case of the portable phone having the built-in Bluetooth™ module, compatibility is guaranteed, since it has a standardized connection method. In the case of the conventional portable phone, compatibility is guaranteed by using the Bluetooth™ adapter. Thus, the entire operation of the portable phone can be performed using voice commands. The name and telephone number can be chosen by voice command. The character display information can be guided by voice commands. And character messages can be converted into voice messages.
[0029] The present invention is a technology that uses voice recognition, voice synthesis, and wireless communication. In a preferred embodiment of the invention, the wireless communication uses Bluetooth™ technology. Each Bluetooth™ module must get authorization from the Bluetooth™ SIG (Special Interest Group), an international authorization institute. If a Bluetooth™ module is authorized, it is assigned its own ID. Each Bluetooth™ module has an ID that is unique in the world. Compatibility and security are guaranteed for communication between the authorized modules. If the hands-free system user properly uses the functions as described above, 100% compatibility with Bluetooth™ equipped portable phones is possible and the driver does not need to separately register the telephone numbers in the portable phone with the hands-free system.
[0030] Using Bluetooth™, once the portable phone and the hands-free system are connected, information, such as the telephone directory, menu, and battery condition is automatically transmitted to the hands-free system from the portable phone. The hands-free system has a memory for the telephone directory, always downloading the most recent information from the portable phone it is connected to. Therefore, if the telephone directory in the portable phone is updated, the updated telephone directory is automatically sent to the hands-free system and the driver does not have to worry about confusion due to a difference in data between the portable phone and the hands-free system. Thus, without having to mount the portable phone in any holder, information automatically transmitted to the hands-free system from the portable phone, allowing the user to monitor the condition of the portable phone, make phone calls by voice commands (provided the name exists in the telephone directory), and remotely control the menu of the portable phone by voice commands.
[0031] In addition, with the hands-free system for a vehicle according to the embodiment of the present invention, it is possible to control all the functions of an Audio (or Automatic) Response System (“ARS”) telephone using voice commands. That is, if the driver verbally states a number, in the conversation condition, the voice recognition module 12 recognizes the number and instructs the voice synthesizing module 16 to reproduce a key tone corresponding to the recognized number (each number button of a telephone has a tone of a specific frequency corresponding thereto). It is also possible to hear a voice message sent to the ARS phone through the hands-free system.
[0032] The hands-free system for a vehicle according to the preferred embodiments of the present invention receives information from a portable phone via the Bluetooth™ module and delivers the information using voice synthesis or a combination of displayed characters on LCD display module 14 b and voice synthesis. Thus, the driver has all the information that he requires for the operation of the hands-free system.
[0033] The present invention increases driver safety and is convenient, since a portable phone can be operated through the system without being manually connected to the system. The hands-free system can also be adapted to the next generation automobile communication environment in which other vehicle systems will be equipped with Bluetooth™ modules. Furthermore, connection to multiple portable phones is possible, allowing any passenger in a vehicle to use the system, or to hear conversation. In addition, when the portable phone for IMT-2000 is standardized, the driver will be able to retrieve various other kinds of information through the hands-free kit.
[0034] While this invention has been described with reference to the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but covers various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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The method and system of the invention increase the convenience of making a call on a portable phone and improve the safety of making the call while driving a vehicle. The system includes a communication module for wireless voice and character data transmission between the hands-free system and the portable phone and provides for voice command driven use of the portable phone without requiring a physical connection. The method provides for registering the entries on the portable phone into the system and for placing a call on the portable phone using the system.
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BACKGROUND OF THE INVENTION
The present invention concerns a method for producing layers that are generated from mixtures that contain a liquid crystal material and are homogenous and isotropic at suitable temperatures and, after appropriate cooling, have a coherent polymer structure with isolated liquid crystal compartments. These layers are suitable for use in electro-optical displays.
Electro-optical display cells are comprised in general of two panes or plates that are spaced apart from one another by a few μm of which at least one plate is light-transmissive. The plates are pretreated on their inner side in a suitable way, for example, coated with ITO (indium tin oxide), in order to provide electrical conductivity. Between the plates there is a liquid crystal layer. In order to secure the plates so as to be equidistantly spaced apart from one another, spacers are usually employed that, for example, are comprised of balls produced from mineral or organic material or rods or walls produced by UV light. However, the non-uniform distribution, the yielding action when exposed to external pressure, and the unsatisfactory mechanical stability have disadvantageous effects on the display function.
Known in the art are polymer-dispersed liquid crystals (PDLC) that are comprised of micro-heterogeneous liquid crystal polymer composites and are used as electro-optical light switches. Polymer components contained therein are in general incoherent. In order to achieve the desired scattering conditions, the dimensions of the LC regions must be matched accordingly, for example, for visible light must have a diameter of approximately 0.3 to 3 μm. Such polymer-dispersed liquid crystals are disclosed, for example, in WO 87/01822, EP 540353 B1, and WO 2005/072304. Inasmuch as they fulfill further required conditions, they can be switched with the aid of an electric field between a light-scattering and a transparent state. Light scattering, in the context of the present invention, is an effect that should be prevented as much as possible.
In U.S. 2004/0119911 A1 a liquid crystal display with thermal-optical properties is disclosed. The size of the liquid crystal droplets is not indicated therein.
It is an object of the present invention to provide liquid crystal layers for display cells whose intrinsic properties lead to an improved mechanical stability of the display cells. Moreover, it is an object of the present invention to provide liquid crystal layers whose optical properties can be influenced region-selectively without having to fear a later intermixing of the selectively influenced regions with other regions. In a preferred embodiment of the invention, the object of providing display cells that, despite high mechanical stability, are bendable without causing destruction of the region-selective controllability is to be solved furthermore.
SUMMARY OF THE INVENTION
This object is solved according to the invention in that the display cell is filled with an inhomogeneous and anisotropic material, i.e., a liquid crystal polymer composite, that in the cell is present as a layer with different regions that have different properties. A first region of liquid crystal material is divided into individual compartments. A second region of an organic polymer material is coherent in that it encloses the compartments of liquid crystal material. In this connection, the liquid crystal compartments may be comprised entirely, substantially or mainly of a liquid crystal material while the polymers that surround these compartments are entirely, substantially, or mainly comprised of an organic polymer material. In this connection, “substantially” is to be understood such that the proportion of other materials than the material that is to be present substantially is so minimal that the properties of the relevant material are substantially unchanged, i.e., are still predominant and are not affected by the presence of the other material or materials. “Mainly” is to be understood in the context of the present invention such that the material that is “mainly” present is present to more than 50% by weight of the total material when a single further material is present while its proportion, in case that at least two further materials are present, must be greater than that of each individual one of the other materials and preferably surpasses also 50% by weight of the total material.
The compartments of the first region have preferably a lateral expansion between 10 to 100 μm wherein the rule shall be that at least 30%, preferably at least 50%, of the compartments and often an even greater proportion or even all of the compartments should have a diameter of at least 20 μm. The diameter of the compartments perpendicular to the layer are within a similar magnitude, should the layer even allow for this. Since the liquid crystal layers often only have a thickness of approximately 2-10 μm, the compartments of the first region (liquid crystal compartments) in general extend completely through the layer and therefore from one wall to the other wall of the display cell, which is desirable. The coherent polymer material region is in general structured such that the liquid crystal compartments through this region have a spacing of at least 1 pm and in general of approximately 1 to 20 μm relative to one another.
With the structure of the display according to the invention, optical properties of the liquid crystal material can be selectively controlled, for example, in selected liquid crystal compartments, and also the liquid crystal layers can be mechanically stabilized as a whole. The liquid crystal layers according to the invention therefore may be used advantageously in electro-optical displays.
A method for producing display cells that are filled with the afore defined layers comprises providing a mixture that contains a liquid crystal material as well as a suitable polymer material. This mixture is heated past the clearing point of the liquid crystal material so that it becomes homogenous and isotropic. In this state it can be filled into the space between the panes or plates of a display cell. Upon subsequent cooling, the aforementioned mixture will separate into first and second regions.
As an organic polymer material for the present invention, organic polymers are generally suitable that are capable of performing a support function for the display to be produced. In this connection, in accordance with a first embodiment of the invention, organic polymers (A) can be used that enable the manufacture of liquid crystal compartments that are enclosed by rigid walls. Suitable in this connection are in particular organic polymers with glass transition temperatures (T g of at least 60° C., preferably of at least 80° C., and especially preferred of at least 100° C. The higher the glass transition temperature of the employed polymers (A), the higher the obtainable mechanical stability. The polymer material must be capable of forming with liquid crystal materials above their clearing point homogenous, isotropic mixed melts, namely either at least in the presence of solvents or in the absence of a solvent. From the homogenous, isotropic mixed melts, after removal of a possibly employed solvent and after suitable cooling, the described coherent polymer structures are to be generated.
It is a preferred, if not always necessary, feature of the polymers (A) that their glass transition temperatures are more than 20 K above the clearing points of the employed liquid crystal materials, respectively. Particularly beneficial are temperature differences in the range of 25-100 K.
The chemical composition of the aforementioned polymers (A) is in principle not limited as long as the aforementioned conditions are fulfilled. Beneficial are polymers whose molecular volume is not too small. Polyacrylates and polymethacrylates (referred to in the following as a group also as poly(meth) acrylates) are especially suitable in this connection, and among them particularly polyalkyl and polycycloalykl acrylates and methacrylates with at least 2 carbon atoms in the alcohol portion of the ester. Methacrylates with a branched alkyl residue and/or at least one cyclic structure in the alcohol portion, that optionally may be condensed and/or bridged, are beneficial. As cyclic structures substituted or unsubstituted alicyclic structural units such as cyclohexyl are beneficial, as bridged cyclic structures, for example, bicyclodecyl (decahydronaphthyl) or isobomyl. Also, in the alcohol portion of the monomer units several cycloalkyl units may be present. These cyclic structures may form directly the alcohol portion of the ester or may comprise further alkyl(ene) residues, such as t-butyl, as terminal or intermediately positioned groups. An example of such an alcohol portion is 4-cyclohexyl cyclohexyl residue. As condensed cyclic structures, partially or completely hydrogenated naphthyl residues are suitable, for example. Also, aryl or phenyl may be a component of the alcohol portion. Polymethylmethacrylate that is used often for PDLCs is however not suitable: even though it has a satisfactorily high glass transition temperature, it generally does not separate with formation of coherent structures of liquid crystal materials but forms incoherent grainy polymer precipitations. The aforementioned polymers (A) may be used as homopolymers or copolymers, in pure form or in mixed form.
In a second embodiment of the invention the second regions are comprised of polymer material, partially of the aforementioned relatively rigid regions as well as further softer regions. For this purpose, in addition to the polymers (A) further organic polymer materials are used that adjacent to or around groups of compartments with a rigid wall may enable the formation of liquid crystal compartments that are enclosed by soft walls. After their intracellular precipitation adjacent to or around the groups of liquid crystal material compartments with rigid walls of polymer material (A), these organic polymers (B) impart to the layer an improved flexibility, wherein, upon bending of a filled display cell that, for example, has flexible panes, a confluence of liquid crystal material from a larger number of compartments is prevented in case of possible fractures or tears in the rigid regions because the soft regions will be able to yield to the bending action without breaking or tearing (fold hinge effect). The polymers (B) should have glass transition temperatures that are below the glass transition temperatures of the polymers (A) and preferably near or below the clearing point of the liquid crystal mixtures. Beneficial are T g values at or below 85° C. The polymers (B) should moreover be soluble in the liquid crystal material above the clearing point without forming residues, if possible. In general, they are non-crosslinked polymers. Further basic requirements do not exist for the polymers (B) so that a wide range of very different materials may be used, for example, poly(meth)acrylate with alkyl groups that comprise more than 2 carbon atoms, cellulose esters or polyvinyl acetals. Polyethyl methacrylate is a well-suited material; likewise cellulose acetates, butyrates or acetate butyrates. The use of polyethylene is precluded however because of immiscibility of this polymer with the other materials of the invention.
It has been found that the size of the formed liquid crystal compartments as a function of the surrounding polymer material can fluctuate slightly. Liquid crystal compartments that are surrounded by soft walls may be somewhat smaller than those that are surrounded by harder walls. In the second embodiment of the invention, in the regions with the softer polymer it is therefore possible that liquid crystal compartments are present that have a lateral expansion of less than 20 μm, for example, of only approximately 10 μm.
It is advantageous, but not mandatory, that the different polymers (A) and (B) at temperatures below the clearing point of the liquid crystal material are incompatible with one another. However, they should all be soluble without residue in the isotropic liquid crystal melt.
As a liquid crystal material all conventional liquid crystal materials or mixtures thereof may be used, for example, nematic, cholesterol-based or other liquid crystal materials. They are available to a person skilled in the art in a large variety.
For producing the layers, the organic polymer material and the liquid crystal material are mixed with one another. The proportion of the polymer material is in general approximately 5 to 30% by weight, preferably 10 to 20% by weight, relative to the sum of polymer and liquid crystal. Since the mechanical strength of the layer to be formed depends for a predetermined polymer proportion inter alia on the glass transition temperature (T g ) of the polymer (A), the quantity of the polymer material, in case it has a high T g value, can be selected optionally to be within a lower range but in case it has a lower T g value it should be selected to rather have a higher proportion. In the second embodiment of the invention, the proportion of polymer material (B), relative to the sum of the polymers (A) and (B), should be preferably 10 to 40% by weight. Relative to the total mixture of polymer (A), polymer (B), and liquid crystal material it should be preferably approximately 1 to 10% by weight.
The mixture, as needed, may contain a solvent. For producing the layer, the mixture is brought to a temperature that is above the clearing point of the liquid crystal material. When doing so, a homogenous, isotropic mixed melt or solution is formed. Optionally, after removal of the solvent, this mixed melt or solution is enclosed, for example, between two transparent electrically conducting glass panes or polymer films, for which purpose preferably the capillary effect is utilized. Subsequently, the mixed melt is subjected to a controlled cooling process. This causes by means of phase separation the formation of microcellularly structured, polymer-enclosed liquid crystal compartments as described above. By means of the employed cooling regime as well as the composition of the mixed melt, the proportion and the average expansion of the mixed melt can be regulated. A quick cooling action has the effect of forming very fine structures or compartments while a slower cooling action causes larger structures. The only or the last cooling step therefore should not be carried out too fast. It is particularly beneficial to first cause a fast cooling action, to subsequently heat at least for a short period of time to such an extent that the mixed melt becomes homogenous-isotropic, and to subsequently cool so slowly that the desired compartment size is achieved.
As already mentioned above, the liquid crystal compartments of the resulting layer have preferably a lateral expansion that is greater than the thickness of the layer. When the layer, for example, is 2-10 μm, it is therefore desirable that the lateral expansion of the liquid crystal compartments is approximately 10 to 200 μm, preferably 20-100 μm. The thickness of the surrounding polymer walls is preferably 1 to 20 μm.
When cooling, the regions of the polymer material will solidify so that the resulting compartmentalized layer exhibits a high mechanical stability. The regions that are enclosed between the polymer structures that are comprised entirely, substantially, or mainly of the liquid crystal material can be influenced optionally region-selectively, for example, by UV radiation that effects a color change. Since the liquid crystal material cannot or can hardly diffuse through the polymer material into neighboring liquid crystal regions, there is no risk of a later mixing of the influenced regions with non-influenced regions or differently influenced regions.
DESCRIPTION OF PREFERRED EMBODIMENTS
In the following, the invention will be explained in more detail with the aid of examples.
EXAMPLE 1
82.1 g of a liquid crystal mixture that is nematic below a clearing point of 60° C. and that is comprised of 39.0% by weight of 4′-pentyl biphenyl-4-carboxylic acid nitrile, 24.7% by weight of 4′-heptyl biphenyl-4-carboxylic acid nitrile, 13.3% by weight of 4′-octyl biphenyl-4-carboxylic acid nitrile, 9.1 by weight of 1-pentyl-[4,1′;4′,1″]-terphenyl-4″-carboxylic acid nitrile, 8.6% by weight of 4-butyl benzoic acid-4′-cyanophenylester, 1.7% by weight of 4-pentyl benzoic acid-4′-cyanophenylester, 3.4% by weight of 4-heptyl benzoic acid-4′-cyanophenylester, 0,2% by weight of cholesteryl nonanoate, as well as 17.9 mg of poly(cyclohexyl methacrylate), that has a glass transition temperature of 107° C. and an average molecular mass of 65,000, are dissolved in 2 ml of chloroform. A few drops of this solution are freed of solvents by heating to 110° C. in a small glass cup and transformed into a homogenous mixed melt. With the aid of a heated stainless steel tip a drop of this melt is transferred into a fill opening of a glass display cell that is also heated and whose inner surfaces, provided with ITO, have a spacing of approximately 4 μm. After completion of filling the cell is cooled within a few seconds to room temperature. Subsequently, the cell is heated in a furnace with programmable heating/cooling action to 130° C. and then again cooled wherein cooling from 110° C. to 30° C. is realized at a rate of 1 K/min. The obtained composite layer is comprised of isolated liquid crystal compartments of, on average, 40 μm in diameter that are enclosed by polymer walls of approximately 5 μm in thickness. These walls prevent even at external pressure acting on the cell an irreversible impairment of the electro-optical function as well as a destruction of the compartments and thus an intermixing of neighboring liquid crystal regions.
EXAMPLE 2
In accordance with the method described in Example 1 a glass display cell is filled at 120° C. with a homogeneous-isotropic mixture that is comprised of 20% by weight of poly-(1,2,3,4-tetrahydro-1-naphthyl methacrylate) that has a glass transition temperature of 118° C. and an average molecular weight of 25,000 and that is obtained by radical polymerization of 1,2,3,4-tetrahydro-1-naphthyl methacrylate as well as 80% by weight of nematic liquid crystal mixture ZOC-1002 XX (Chisso Co.) with a clearing point of 79° C. After completion of filling the cell is cooled at a rate of 1.5 K/min to room temperature. The obtained composite layer is similar to that obtained in Example 1. It is comprised of liquid crystal compartments with an average width of approximately 40 μm.
EXAMPLE 3
In accordance with Example 2 a glass display cell is produced with the modification that as a polymer poly-(4-cyclohexylcyclohexyl methacrylate) is used that has a glass transition temperature of 127° C. as well as an average molecular weight of 21,000 and that is produced by radical polymerization of 4-cyclohexylcyclohexyl methacrylate. The obtained composite layer is similar to that obtained in Example 2.
EXAMPLE 4
In accordance with Example 2 a glass display cell is produced with the modification that as a polymer poly-(4-tert-butylcyclohexyl methacrylate) is used that has a glass transition temperature of 155° C. as well as an average molecular weight of 33,000 and that is produced by radical polymerization of 4-tert-butylcyclohexyl methacrylate. The composite layer contains closely arranged liquid crystal compartments with an average width of approximately 15 μm and a thickness of polymer walls of approximately 3 μm.
EXAMPLE 5
In accordance with the method described in Example 1, a PET film display cell is filled at 120° C. with a mixture comprised of 80% by weight of the liquid crystal mixture used in Example 1 as well as 20% by weight of poly-(decahydro-2-naphthyl methacrylate) that has a glass transition temperature of 145° C. and an average molecular weight of 25,000 and that is produced by radical polymerization of decahydro-2-naphthyl methacrylate. The inner surfaces of the display cell are provided with ITO and spaced apart by approximately 4 μm. After completion of filling the cell is cooled at a rate of 1.5 K/min to room temperature. The composite layer comprises closely arranged liquid crystal compartments with an average width of approximately 40 μm and a thickness of the polymer walls of approximately 10 μm.
EXAMPLE 6
A homogeneous isotropic mixture, comprised of 79% by weight of the liquid crystal mixture employed in Example 1 as well as 21% by weight of poly-(cyclohexyl methacrylate-co-isobomyl methacrylate) (0.5:0.5) that has a glass transition temperature of 127° C. and an average molecular weight of 55,000 and that is produced by radical copolymerization of cyclohexyl methacrylate and isobomyl methacrylate serves for filling a glass display cell (4 μm spacing of the ITO surfaces) at 116° C. in accordance with the method disclosed in Example 1. Cooling of the filled cell is realized in the range between +60° C. and +40° C. at a rate of 1.2 K/min; above and below this range at a rate of 2 K/min. The composite layer contains closely arranged liquid crystal compartments with an average width of approximately 50 μm and a thickness of the polymer walls of approximately 10 μm.
EXAMPLE 7
A homogenous isotropic mixture comprised of 76.2% by weight of nematic liquid crystal mixture ZOC-1002 XX (Chisso Co.), 4.8% by weight of chiral doping substance 1.4:3.6 dianhydro-D-sorbite-2.5-di(6-n-hexyloxy-2-naphthoic acid ester) (DE 103 51 364 B4) as well as 19% by weight of poly (cyclohexyl methacrylate) serves at 120° C. in accordance with the method disclosed in Example 1 for filling the glass display cell that has a spacing of the ITO surfaces of approximately 10 μm. The composite layer that is obtained by cooling at a rate of 1.5 K/min contains closely arranged compartments, filled with cholesterol-based liquid crystal material. The obtained display is bistable. By applying 50 V and 50 Hz alternating current pulses the display can be switched from the green reflective planar texture to a transparent focal-conical texture and vice versa.
EXAMPLE 8
A homogenous isotropic mixture contains 79.7% by weight of nematic liquid crystal mixture ZOC-1002 XX (Chisso Co.), 17.2% by weight of poly-(decahydro-2-naphthyl methacrylate) as polymer (A) as well as 3.1% by weight of cellulose acetate butyrate (commercial designation CAB 551-0.01, Eastman) as polymer (B), the latter having a glass transition temperature of 85° C. A portion of this mixture serves for filling a glass display cell at 120° C. in accordance with the method disclosed in Example 1. The spacing of the inner sides of the display glasses provided with ITO is 4 μm. Aftercooling of the filled cells to room temperature at a rate of 1.2 K/min, a composite layer is obtained that is comprised of aggregations of compartments of a 1st kind enclosed by polymer A having an average width of 50 μm as well as intermediately positioned chains of smaller compartments of a 2nd kind that are formed by intercellular precipitation and have an average width of 10 μm.
EXAMPLE 9
A homogeneous isotropic mixture is comprised of 79.1% by weight of nematic liquid crystal mixture ZOC-1002 XX (Chisso Co.), 18% by weight poly-(decahydro-1-naphthyl methacrylate) as polymer (A) as well as 2.9% by weight poly-(ethyl methacrylate) as polymer (B). The latter has a glass transition temperature of 65° C. With this mixture, in analogy to Example 8, a glass display cell (spacing of the ITO surfaces 4 μm) is filled at 115° C. The composite layer that is obtained after cooling at a rate of 1.2 k/min is comprised of the arrangement disclosed in Example 8 of compartments of the 1st and 2nd kind and their dimension.
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The invention relates to a display cell, comprising two transparent, equidistant plates, wherein the gap between the plates is filled with a liquid-crystal material-containing layer, characterized in that the liquid-crystal material-containing layer is inhomogeneous and anisotropic, wherein it has a first region made up of compartments, which comprise entirely, substantially or mainly liquid-crystal material, and a second, coherent region which comprises entirely, substantially or mainly an organic polymer material and surrounds the compartments made of liquid-crystal material. In addition, the invention relates to a liquid-crystal material-containing mixture which can be used to produce the layer between the plates, and to a method for producing the display cell.
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I claim the benefit under Title 35, United States Code, § 120 to U.S. Provisional Application No. 60/490,905, filed Jul. 30, 2003, entitled STABILIZED, MELTABLE, HOST AMYLOSE AND AMYLOPECTIN DERIVED MOLECULES FOR COMPLEXING HYDROPHOBIC COMPOUNDS AND THEIR USE IN THE MANUFACTURE OF CHEESE AND OTHER FOOD AND INDUSTRIAL PRODUCTS.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the production of hydrophilic host amylose molecules that manipulate, or form clathrates with, hydrophobic guest molecules, termed herein as “guest/host” chemistry. A product is produced that may be dried and then rehydrated to retain its meltable, thermoreversible host characteristic. This host molecule, which may be termed as a dextrin, dextrin gel, modified amylose, or modified food starch may be also be co-dried with pre-installed guests or co-dried with companion ingredients for combinations of functionalities.
The low flavor amylose/hydrophobic-guest complex compound, or clathrate, of the present invention is useful for a wide variety of applications that encompass emulsification or encapsulation. The complex is also integral to subsequent processes, such as the interruption of hydrophilic/hydrophobic forces in products, such as cheese, to alter the composition of those products. The resulting alterations may then include the introduction of additional fats, water, proteins, or other ingredients for nutritional or cost reduction purposes. The present invention, inter alia, enables the upgrading of over-aged and substandard cheeses and can provide flavor enhancement thereto.
2. Description of Related Art
Industries are constantly struggling with methods of combining hydrophobic substances into hydrophilic environments. In the food industry, emulsions are important in a wide range of products from salad dressings to nutritional formulations in which specialty lipids are incorporated. Traditional emulsifiers tend to function by providing molecules that have both hydrophilic ends and hydrophobic ends. The result of this mechanism is to encourage the formation of agglomerates of like-groups to form tiny droplets of fat, for example, surrounded by hydrophobic ends of emulsifier molecules. These types of emulsifiers, such as lecithin or egg yolks, often impart certain undesirable properties, such as flavor or color. In many cases the amount of emulsifier needed contributes to undesirable secondary effects, such as elevated cholesterol levels or structure inhibiting effects.
Previous technologies for the formation of guest/host complexes or host/guest complexes have, for the most part, involved the use of cyclodextrins, which are produced by the special enzymatic action upon starch by enzymes, such as cyclodextrin-transglycosylase or glucoamylase. This results in a closed doughnut type molecular structure.
The basic building blocks of cyclodextrin are gluco-monomers, which resemble a hexagon. Each hexagon is formed by five carbon atoms, numbered one through five, and one oxygen atom. A sixth carbon atom is also part of each gluco-monomer, but does not participate as a hexagon ring member. The carbon atoms 2, 3, and 6 each hold a hydrogen atom and a hydroxyl group. The hydroxyl groups, which are dipolar and repel anything nonpolar, prefer to attract water. The hydrogen atoms and the carbon atoms form C—H groups. These groups prefer a nonpolar environment and dislike a polar environment, such as water. The six, seven, or eight hexagons, depending on type of cyclodextrin, form a ring enclosure or torus so that all the hydroxyl groups, 18, 21, or 24 in all, are on the outside of the ring band and all of the C—H groups are on the inside. This shields the opposing functions from canceling their conflicting Van Der Waals' forces.
The nonpolar compound resides as a guest molecule inside the torus of the cyclodextrin. Because only 18 to 24 hydroxyl groups can fit on the outside of the ring's mantle, the water solubility is severely depressed when a cyclodextrin clathrates with a nonpolar compound. Therefore, the whole complex is no longer water-soluble.
Channel diameter and volume dimensions are fixed for any given type of cyclodextrin, as is the number of hydrophilic hydroxyl groups on the outside of the mantle. In each case, this number is three times the number of gluco-monomers that form the torus. Attempts to increase the number of hydroxyl groups and the channel volume by trying to achieve the stacked torus configuration have not succeeded and, as a result, in most cases the size of the hydrophobic guest molecule is greater than the cyclodextrin molecule. Thus, once a nonpolar compound has formed a clathrate with a cyclodextrin, the overall water-solubility remains less than is useful for many applications.
Cyclodextrin patents describe in detail the mechanisms and technology for producing donut-shaped host molecules to be used in that branch of host/guest science. Stacks of the torus-like bands of cyclodextrin to form nanotubes with multiples of 18, 21, or 24 hydroxyl groups to increase water solubility would be desirable, but seem unattainable. Cyclodextrins, however, are restricted by their geometry to certain set and specific dimensions and therefore have limitations on the selection of the size of their guests.
U.S. Pat. No. 2,876,160 discloses a process physical phenomenon that involves the preparation of a high solids solution of various film-forming starch materials to physically encapsulate hydrophobic materials.
U.S. Pat. No. 3,557,091 Produced a non-gelling starch derivative having a lowered swelling temperature without substantial depolymerization by soaking with derivatizing agent at a preferred temperature of 40-60° F. in the presence of ferric sulfate and hydrogen peroxide.
U.S. Pat. No. 3,839,320 discloses a process of preparing a slurry of starch in water within the approximate range of about pH 7.5 to 10.5 in a standard etherification reaction which may or may not precede an acetylation process using magnesium oxide or magnesium hydroxide as a buffering agent to control the pH of the subsequent acetylation.
U.S. Pat. No. 3,974,034 discloses malto-dextrins having a D.E. not substantially above about 20, prepared by the enzymatic hydrolysis of oxidized starch. Syrups of the malto-dextrins are said to be capable of remaining haze-free for long periods of time at high solids concentrations. The malto-dextrins are prepared by first liquefying and oxidizing starch at elevated temperatures to provide an oxidized and liquefied starch substantially free of residual starch granules, and in a subsequent step, converting the oxidized and liquefied starch with a bacterial alpha-amylase enzyme preparation to achieve a malto-dextrin product having a D.E. not substantially above about 20.
U.S. Pat. No. 4,048,435 discloses the preparation of highly substituted granular starches by reacting the starch in an aqueous system with a reagent capable of producing an acetal cross-linkage; reacting the resultant acetal cross-linked starch with a mono-functional esterifying or etherifying reagent under aqueous alkaline conditions and removing the acetal cross-linkages by treating under acid conditions. The highly substituted starches are said to be particularly useful in operations, such as papermaking, wherein the cross-linkages can be removed and the starch readily dispersed during a relatively low pH starch cooking process.
U.S. Pat. No. 4,192,783 discloses remoistenable adhesive compositions for use on pre-gummed substrates comprising, in aqueous medium, a low viscosity starch-acrylamide graft copolymer.
U.S. Pat. No. 4,499,116 discloses an imitation cheese product, which is functionally equivalent to a caseinate-based imitation cheese product, that contains selected edible modified starches as replacements for up to 80% by weight of the caseinate present in the cheese product. Suitable starches include pre-gelatinized converted starches having a water fluidity (WF) of about 5-90 and an amylose content of at least about 15% to below 40% and selected derivatives and/or crosslinked products thereof. Suitable converted starches include fluidity starches prepared by acid- or enzyme-conversion or oxidized starches prepared by treatment with up to about 2% active chlorine. The starches may be pre-gelatinized by drum-drying and jet-cooking, or jet-cooking and spray drying.
U.S. Pat. No. 4,501,888 discloses a process for acetylating (esterifying) starches including dispersing the starch in an organic acid; contacting the starch with an organic acid anhydride; and reacting the components in the presence of a quaternary ammonium halide.
U.S. Pat. No. 4,510,166 discloses converted starches, which with water form gels having a neutral taste and perferably a creamy, smooth consistency, are said to be suitable as fat- and/or oil-replacements in various foodstuffs, especially high fat- and/or oil-containing foodstuffs such as ice cream and mayonnaise. The starches (e.g., tapioca, corn, or potato) have a DE of less than 5 and their aqueous dispersions have a hot flow viscosity of at least about 10 sec. at 10-50% solids, and they are capable of forming gels having a strength of at least about 25 g. within 24 hrs. and 4° C. at 10-50% solids. The preferred starches are tapioca dextrins having a DE of about 2 or less and hot flow viscosity and gel strength of about 20-100 sec. and 65-930 g. at 25-35% solids. Acid- and enzyme-converted starches are also said to be suitable.
U.S. Pat. Nos. 4,608,265 and 4,695,475 disclose an imitation cheese product which is functionally equivalent to a caseinate-based imitation cheese product, contains pre-gelatinized modified high amylose starches, preferably converted and/or derivatized, as partial or total replacement for the caseinate present in the cheese. Suitable converted starches include fluidity starches prepared by acid- or enzyme-conversion, oxidized starch prepared by treatment with less than 5% active chlorine, and dextrins having a calcium chloride water fluidity of less than about 50. Suitable derivatives are prepared by treatment with up to 25% propylene oxide, 5% succinic anhydride, and 10% octenylsuccinic anhydride or with a sufficient amount of acetic anhydride or sodium or potassium ortho or tripolyphosphate to provide a maximum of 6% bound acetyl or 0.8% bound phosphate. Mixtures of modified or unmodified high amylose starches with up to 80% by weight of other starches (0-40% amylose) are also suitable. In a preferred embodiment, the cheese is an imitation mozzarella cheese said to be substantially equivalent to the caseinate-based imitation cheese in all properties.
U.S. Pat. No. 4,840,807 discloses branched dextrin and linear oligosaccharides that are produced by degrading starch with alpha-amylase followed by fractionating with a gel-type filtering agent. The branched dextrin is said to be useful in the food fabrication.
U.S. Pat. No. 4,937,091 discloses the replacement in whole, or in part, of caseinates which provide imitation cheeses with desirable texture, melt and oil emulsification characteristics by pregelatinized debranched starches which have been enzymatically prepared by hydrolyzing all, or part, of the alpha-1,6-D-glycosidic bonds of branched starch molecules (amylpectin). The debranched starches may be derivatized, converted or crosslinked, or blended with other selected starches in imitation cheeses.
U.S. Pat. No. 4,971,723 discloses partially debranched starch, prepared by enzymatic hydrolysis of the alpha-1,6-D-glucosidic bonds of the starch, comprising amylopectin, partially debranched amylopectin and up to 80%, by weight, short chain amylose. A method for preparing this starch, employing an endo-alpha-1,6-D-glucanohydrolase is also disclosed. The starch is said to be useful for lending a fat-like, lubricating texture to aqueous dispersions, forming stable opaque clouds, forming thermoreversible gels, high strength gels and water-resistant films, and for thickening and bonding.
U.S. Pat. Nos. 4,977,252 and 5,185,176 disclose the preparation of modified starches said to be useful for emulsifying industrial products, especially foods and beverages containing flavor oils, by enzymatic degradation of the 1,4-alpha-D-glucosidic linkages from the non-reducing ends of a starch molecule, preferably employing beta-amylase, which may be carried out before or after the preparation of a starch derivative containing a hydrophobic group or both hydrophilic and hydrophobic substituent groups. The enzymatic degradation provides a starch emulsifier whose emulsions are said to be characterized by improved shelf stability, which emulsifier may be used as a replacement for gum arabic and in other industrial applications.
U.S. Pat. No. 5,164,215 discloses a batter starch that is esterified to have a degree of substitution between 0.02 to 0.1, and a protein content greater than or equal to 1.0%. The starch is obtained from a starch bearing plant of the duh homozygous genotype. Maize is the preferred source for the starch and the preferred protein source is gluten. The preferred esterification agent is acetic anhydride.
U.S. Pat. No. 5,200,216 discloses that in the manufacture of mozzarella cheese, aging can be dispensed with if the process is controlled to yield a combined moisture and wet milkfat content of at least about 70 weight percent, and the cheese will provide acceptable bake performance under typical cooking conditions used in the pizza industry today. Within about 48 hours after brining, the cheese should either be used or frozen. In a continuous process, the hot stretched cheese from the kneading machine is extruded directly into cold brine. After the cheese has cooled sufficiently, it can be comminuted and frozen by independent quick freezing, preferably in a fluidized bed freezer. Salt preferably is mixed into the cheese during the kneading step.
U.S. Pat. No. 5,244,687 discloses a no-fat cheese analog having the texture, body and eating qualities of cheese is produced by admixing about 15% to about 35% of a coagulated skim milk product having a fat content of less than 2%, about 15% to about 35% dry particulate rennet casein, about 1% to about 3% of an edible emulsifying salt, sufficient quantities of flavoring agents and acidulants to impart desired flavor and pH, and about 30% to about 65% water; the dry rennet casein being hydrated in the water by action of the emulsifying salt at temperatures of about 160° F. to about 200° F. under agitation conditions for a time period sufficient to provide a plastic homogenous body being substantially free of unhydrated rennet casein particles, the edible emulsifying salt being present at about 2% to about 15% by weight of the said particulate rennet casein, the emulsifying salt being selected from the group consisting of alkali metal phosphates, citrate salts and mixtures thereof.
U.S. Pat. No. 5,321,132 discloses the preparation of starch esters having an intermediate DS of about 0.5 to 1.8 in an aqueous one step process by reacting starch with high treatment levels of organic acid anhydride and high concentrations of alkaline reagent.
U.S. Pat. No. 5,378,491 discloses a method for preparing reduced fat foods which employs a fragmented, granular amylose starch having a melting onset temperature (as measured by differential scanning calorimetry) of greater than about 70° C. when measured at 20% starch hydrolysate solids. The fragmented, granular amylose starch hydrolysate is prepared by hydrolyzing a granular amylose starch in a strongly acidic aqueous slurry at a temperature greater than 70° C. or by hydrolysis at a lower temperature followed by heating a slurry, after neutralization, to raise the melting onset temperature. Also disclosed are food formulations in which the fragmented, granular amylose starch hydrolysate is used to replace fat and aqueous dispersions of the fragmented, granular amylose starch hydrolysate which are useful therein.
U.S. Pat. No. 5,380,543 discloses that by adding a minor amount of starch to a natural mozzarella cheese, the baking characteristics of the cheese when used to make a pizza can be altered, making it more suitable for a particular set of baking conditions, e.g., involving time, temperature, type of oven, crust thickness, and the toppings used. For example, the addition of about 0.001 to 0.01 wt. % of a modified high amylose starch allows a pizza with a partially pre-baked crust to be baked at 685° F. in an impingement oven in as little time as 70 seconds, with the cheese being fully melted, evenly browned, and covered with small blisters, as is desired, and the crust being properly baked. Without the addition of the starch, the cheese, although melted, is not brown or blistered by the time the crust is “done.”
U.S. Pat. No. 5,523,111 discloses a process for the formation of clathrate inclusion complexes comprising suspending a suitable starting material such as acetylated starch in water, heating the resulting suspension past the gelation point of the starting material, cooling the resulting hydrocolloid to just above the convolution temperature of the starting material, cooling the resulting hydrogel while adding a lipid such as a triglyceride and homogenizing the resulting product at a temperature below the melting point of the lipid in the case of fats and 45° C. in the case of oils.
U.S. Pat. No. 5,567,464 discloses a process of manufacturing a mozzarella (or mozzarella-like) cheese comprising the steps of a) pasteurizing cow's milk; b) acidifying the milk to convert it to a cheese milk; c) coagulating the cheese milk to obtain a coagulum comprised of curd and whey; d) cutting the coagulum and draining the whey therefrom, thereby leaving a cheese curd; e) heating, kneading, and stretching the cheese curd until it is a homogeneous, fibrous mass of heated, unripened cheese; f) forming the heated cheese into a shape; g) cooling the shaped cheese in cold brine; and h) removing the cooled cheese from the brine. The process is improved by mixing an emulsifier such as a sodium phosphate or citrate into the heated cheese after it has been heated, kneaded, and stretched, but before it has been formed into a shape. It is said that the resultant cheese provides good baking performance over a wider range of conditions than the equivalent cheese without emulsifier, and that it is particularly useful as the stuffing cheese for stuffed crust pizza or as the exposed topping cheese on pizzas.
U.S. Pat. No. 5,629,090 discloses a starch hydrolysate composition that is said to be particularly suited for use as a sequesterer, i.e., it readily interacts noncovalently with other molecules to form stable inclusion complexes which are useful in a variety of applications. The starch molecules in the composition which act as sequesterers are in the form of single helical inclusion complexes with starch molecules having a D.P. of about 10 to 200 and a weight-average D.P. of about 10 to 50 as the host molecule holding one or more guest molecules within their internal cavities. These hydrolysates are prepared by first converting amylopectin molecules from the double helix form to the single helix form and then by cleaving chain segments from the molecules.
U.S. Pat. No. 5,679,396 discloses fat free, reduced fat and low fat cheeses, including natural cheese and processed cheese, and method for making the cheeses. The natural cheeses and processed cheeses contain a pre-gelatinized, high amylose starch based texturizing agent that can partially or totally replace fat and/or fillers which are traditionally incorporated into cheese formulations. The natural cheeses and processed cheeses are said to have the textural and organoleptic mouthfeel properties of full fat, conventional natural cheeses and processed cheeses.
U.S. Pat. No. 5,681,598 discloses a process for producing natural cheese, characterized in that a transglutaminase is included therein for a reaction. The process can provide a large amount of cheese curd compared to conventional methods, making it possible to efficiently use the starting milk. Further, the obtained cheese is said to have an excellent flavor, texture and appearance.
U.S. Pat. No. 5,703,226 discloses a process for the uniform acylation of starch comprising preconditioning the starch with a base for at least six hours, adjusting the pH to a suitable range for acylation, adding the desired acylation agent and isolating the acylated starch. A continuous method for acylating starch is also described.
U.S. Pat. No. 5,711,986 discloses a fat-like carbohydrate, containing 12 to 100%, by weight, short chain amylose, wherein the fat-like carbohydrate is used in foods in an amount effective to function as a replacement for up to 100%, by weight, of one or more fat(s) contained in foods. The short chain amylose may be prepared by the enzymatic debranching of starch, employing an enzyme which specifically degrades the alpha-1,6-D-glucosidic-linkages of the starch molecule. A method of replacing up to 100% of one or more fat(s) contained in foods, wherein the food containing the enzymatically debranched starch exhibits functional and organoleptic qualities equivalent to those of the food containing conventional amounts of fat. Also provided are foods containing the short chain amylose materials in place of fat, cream, oil, oil-in-water and water-in-oil emulsions and other lipids which are conventional components of the foods. These foods include: ice cream, spoonable and pourable salad dressings, margarine, low-fat spreads, low-fat cheeses, baked goods, breaded foods, sauces, whipped toppings, icings, puddings and custards, mayonnaise and coffee whiteners.
U.S. Pat. No. 5,755,890 discloses a method of producing starch-emulsifier compositions by heating a starch in the presence of an emulsifier to form a complex. The product can be further treated to obtain greater than about 20% short chain amylose. Starch-emulsifier compositions (e.g., powders, gels, pastes) produced by this method and food products containing the starch-emulsifier composition are also described.
U.S. Pat. No. 5,807,601 discloses an imitation cheese composition that is made with less than 2% protein and/or less than 1% casein protein and comprises a) about 3% to about 30% starch; b) about 0% to about 30% edible lipid material; c) about 20% to about 60% water; d) about 0.5% to about 25% non-starch carbohydrates; and e) about 0.5% to about 5% hydrocolloid stabilizers; and optionally contains up to about 2% cheese flavor and up to about 2% color.
U.S. Pat. No. 5,866,180 discloses a method for production of an acidified edible gel on milk basis that comprises addition of transglutaminase to milk, followed by a heat treatment. A functionally and/or organoleptically satisfactory edible gel is obtained, which can be used as a yoghurt mousse or cheese.
U.S. Pat. No. 5,882,713 discloses a stable and non-separable composition comprised of starch and a water-immiscible material that can be prepared in the absence of external emulsifying or dispersing agents by thoroughly solubilizing an aqueous dispersion of the starch at elevated temperatures and incorporating the water-immiscible material into the non-retrograded starch under conditions of high turbulence. The resulting dispersions form soft gels that can be converted to pourable fluids by the application of heat. Upon drying, these dispersions yield solid compositions that can be redispersed in water to form smooth, stable dispersions. These compositions are said to be useful as thickening agents, suspending agents, waterproof coating materials, adhesives, fat substitutes, and seed coatings. They are receptive to the addition of a variety of other water-immiscible materials, such as volatile and essential oils, food flavorants, medicinals, waxes, agricultural chemicals, and the like.
U.S. Pat. No. 5,904,949 discloses a fat continuous spread having up to about 65 wt % fat and a dispersed aqueous phase which contains an amylose containing gelling starch characterized by a G′ eq of 400 dyne/cm 2 or greater and a critical strain value (γcr) of 12 or greater at 10° C. provided the starch is prepared at a concentration having an anhydrous starch solid content of 10 wt %.
U.S. Pat. No. 5,925,398 discloses a method of making processed mozzarella cheese that does not require any aging or refrigeration during storage. This is accomplished by dicing cheese curd, adding emulsifier, and thermomechanically treating in an extruder to stretch and cook the curd. Fresh processed mozzarella cheese having functionality similar to the aged mozzarella cheese is achieved by addition of emulsifier to soften casein and inputting sufficient mechanical energy to establish the appropriate fibrous structure. Longer shelf-life and storage without refrigeration is achieved by application of suitable time-temperature combination to inactivate proteolytic enzymes and microorganisms.
U.S. Pat. No. 6,060,107 discloses a multi functional edible spread having both a fat and aqueous phase. The spread contains 65 wt % or less triglyceride fat and 0.5 wt % to 12 wt % emulsifiers. At least a portion of the emulsifiers are incorporated into the aqueous phase and are complexed in a starch based clathrate to diminish the taste and flavor problems associated with emulsifiers.
U.S. Pat. No. 6,086,926 discloses pasta filata cheeses, such as mozzarella, that are made in the conventional way, except that the conventional step of heating and stretching is replaced by treatment with a proteolytic enzyme, thereby providing for significant economies in manufacture. Brine treatment may also be replaced by dry salting in this method.
U.S. Pat. No. 6,093,424 discloses a cheese curd that contains protein products originating from a dairy liquid containing casein and whey protein. In order to obtain the cheese curd, the dairy liquid is acted upon by a transglutaminase and a non-rennet protease, resulting in a substantial proportion of whey protein products being retained in the cheese curd. The invention also discloses a method of making the cheese curd that retains a substantial proportion of whey protein products. Also disclosed are cheese product, such as a soft cheese, a semi-soft cheese, or a hard cheese, that contains protein products originating from a dairy liquid containing casein and whey protein, and a method of making the cheese product.
U.S. Pat. No. 6,113,953 discloses a fat-free or lower-fat pizza cheese said to have excellent melt properties for baking on a pizza without the need for aging and a method of making thereof. The process of manufacturing such fat-free or low-fat mozzarella cheese comprises mixing a food grade acid with liquid milk having a fat content less than 1.5% or a casein to fat weight ratio of greater than 1.5. The acidified milk is then coagulated and processed into pizza cheese. No aging is necessary to obtain excellent melting properties. In a preferred embodiment, after coagulation of the milk and cutting of the curd, a portion of the whey is drained and glucono-δ-lactone is added to gradually further decrease the pH. The remaining whey is then drained and the resulting curd is processed into mozzarella cheese. A method of making a fat-free or low-fat process pizza cheese is also disclosed.
U.S. Pat. No. 6,224,914 discloses a cheese curd containing a substantial proportion of whey protein products and curded proteins originating from a dairy liquid containing casein, as well as a process for making the cheese curd. The process includes the step that a dairy liquid fortified with whey protein is contacted with a transglutaminase to provide a modified dairy liquid containing whey protein products. The modified dairy liquid is then blended with a second dairy liquid and renneted to provide the curd, whereby a high proportion of whey protein products is retained in the curd. The curd can be used to prepare cheese products, including soft, semi-soft, and hard cheeses, where the cheese products contain a substantial proportion of whey protein products and curded proteins originating from dairy liquids.
U.S. Pat. No. 6,228,419 discloses a method of producing high-amylose based starch-emulsifier compositions by heating a high-amylose starch in the presence of an emulsifier to form a complex with unique properties. High-amylose starch-emulsifier compositions (e.g., powders, gels, pastes) produced by this method and food products containing the high-amylose starch-emulsifier composition are also described.
U.S. Pat. No. 6,258,390 discloses a process for making cheese including: a) adding to cheesemilk a transglutaminase, incubating for a suitable period, b) incubating with a rennet so as to cause clotting, and c) separating whey from the coagulate, and d) processing the coagulate into cheese. Cheese products produced by the process are contemplated as is the use of transglutaminase for maintaining proteins in the cheese material during a conventional cheese-making process.
U.S. Pat. No. 6,270,814 discloses a process cheese product made with a cheese and dairy liquid that includes casein, whey protein, and lactose, wherein at least a portion of the casein and/or whey protein in the dairy liquid is crosslinked via γ-carboxyl-ε-amino crosslinks prior to being combined with the cheese, and wherein the lactose in the process cheese product remains dissolved in the aqueous phase upon storage. This product is provided by a process that includes the step of contacting the dairy liquid with a transglutaminase for a time, and under conditions, sufficient to crosslink at least a portion of the casein and/or whey protein to provide crosslinked protein conjugates in the dairy liquid. A process for making the process cheese product is also disclosed. Advantageously, the process permits replacing part of the cheese proteins with the crosslinked proteins of the dairy liquid. Additionally, crystallization of lactose in the process cheese product is inhibited such that lactose levels higher than commonly introduced in cheese products may be employed in the process cheese.
U.S. Pat. No. 6,319,526 discloses a process of manufacturing a mozzarella variety of cheese or a mozzarella-like cheese wherein a milk composition is pasteurized and formed into a coagulum. The coagulum is cut to separate curd from whey and the whey is drained therefrom. The curd is then heated preferably in a liquid-free environment and mechanically worked until the curd forms a fibrous mass. The cheese is then formed into a selected shape. Additionally, generally recognized as safe (GRAS) ingredients are added after the whey is drained but prior to heating the curd. In addition, the curd may be comminuted to a selected size after the whey is drained.
The literature describes numerous starch patents and technologies involving a myriad of methods to chemically and enzymatically modify starch materials to change their characteristics and to degrade their structures or to trap non-starch components. Some of the known art involves treatment of starch at high pH levels, for example, as is known in the various cross-linking technologies. Other art describes various methods for producing starch derivatives.
Further insight regarding the manipulation of hydroxyl groups on glucomonomers may be gained from a study of cellulose chemistry and, while starch components cannot be subjected to the extremes of cellulose processing, certain principles apply. Warwicker “Celluloses and Its Derivatives”, discusses the structure and morphology of cellulose and the postulated factors influencing the engineering of cellulose from a variety of sources. Warwicker states that while cellulose is similar to starch in that they are constructed of glucomonomers and although the beta 1-4 linkages between glucomonomers in cellulose are much more tenacious than the alpha 1-4 and alpha 1-6 linkages in starch nevertheless a study of this field gives some valuable insight into more precise engineering of starch molecules particularly the various amyloses.
The disclosures of the foregoing are incorporated herein by reference in their entirety.
SUMMARY OF THE INVENTION
The present invention relates to a method of combining hydrophobic materials into hydrophilic environments with virtually no flavor contribution and with a very flexible degree of structural engineering.
The method involves the formation of clathrates to combine oils and water. Clathrates are the formation of complexes in which one molecule is encapsulated inside another host molecule. Some definitions require that encapsulation be via a caged structure, that is to say, a structure from which the guest molecule cannot escape. Other definitions include any type of non-ionic control of guest materials. By this definition, clathrate technology is based on guest/host chemistry where one molecule includes or occludes another molecule, similar to molecular encapsulation, but the molecules are not locked away or imprisoned. Guest/host technology encourages the formation of water-soluble helical complexes, or inclusion complexes, of compounds such as fatty acids that are not in themselves water-soluble.
The present invention involves the creation of dynamic host molecules resembling nanotubes that are restricted from retrogradation, thereby permitting permanent reversibility in which the newly meltable host molecule is able to accept guests at any appropriate temperature and any number of times by a process comprising:
1. placing substituents evenly spaced along the amylose and amylette chains to serve two purposes; to prevent the helices from recoiling completely (retrograding), and protecting the 1-4 linkages of the helices from excessive enzymatic cleavage; 2. cooking the starch completely to hydrate the molecule; 3. cooling the cooked starch gel to a suitable temperature for alpha amylase introduction; and 4. inactivating the enzyme to achieve the desired and predictable end product characteristic.
More particularly, the present invention is directed to a method for harvesting amylose host material comprising enzymatically treating starch after the starch has been chemically modified to uniformly insert a steric hindrance substituent.
In a preferred embodiment, the present invention is directed to a method of producing stabilized, meltable, hydrophilic, starch derived amylose and amylopectin host molecules capable of forming guest/host complexes with hydrophobic compounds comprising the steps of:
(A) slurrying starch in water in the presence of a base; (B) cooling the slurry to a temperature below ambient; (C) at least partially esterifying the starch by adding an esterifying agent at a pH above neutral and a temperature below ambient; (D) allowing the pH to drop below neutral; (E) diluting and washing the starch slurry; (F) hydrating the washed starch by heating; (G) dissolving the hydrated starch in water and heating; (H) cooling the starch to a temperature suitable for alpha amylase introduction; (I) adding alpha amylase and holding until a pre-determined desired viscosity is attained; and (J) heating to 92° C. to 105° C. to inactivate the enzyme.
In a further embodiment, the present invention is directed to a method of managing protein/lipid complexes in cheese by incorporating a host molecule into cheese after curd formation but prior to cooking or stretching wherein said host molecule is an amylose host molecule prepared by enzymatically treating starch after the starch has been chemically modified to uniformly insert a steric hindrance substituent.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the effect of pretreatment time and temperature at pH 10 on medium amylose starches.
FIG. 2 is a graph showing the impact of varying the enzyme addition amount and the temperature at which the enzyme is added during a fixed reheating process. The graph represents the relative viscosity or, in the case of a formed, cooled hydrogel, the hardness of the products of this invention at various temperatures. The data points represent individual samples measured after they have been cycled to point of evaluation. The data points are expressed in grams of enzyme per 250-gallon batch of a 20% solids modified starch solution and the temperature at which the enzyme was added in a constant energy reheating reactor.
FIG. 3 is a schematic diagram of the overall cheese manufacturing process of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While naturally formed amylose lipid complexes are well known, they are severely restricted in their ability to control those lipids through storage. First, the amylose molecule in its natural state is generally very prone to retrogradation, which limits the amount of fat which may the complexed and held, whereas the present invention provides stabilized amylose that has fat holding capability in excess of 10 times that of natural amylose. Further, natural amylose produces gels that are generally not reversible whereas the present invention produces thermo reversible or meltable gels. Still further, the present invention enables the engineering of those host amylose type molecules with selectable melt points, viscosity, and re-solidification profiles.
The technology of the present invention allows a practitioner to engineer and define the size and geometry of the host molecules to manage a wide range of hydrophobic guests. This technology has the further advantage that the molecule is produced using substances and variations of traditional processes that are Generally Recognized As Safe (GRAS) in an entirely food grade process.
Accordingly, a stabilized host molecule can be obtained by engineering the configuration of amylose molecules obtained from starch, whereby
a) the finished host molecule has CH groups facing inside to a hydrophobic core of a stabilized, helical, molecular, amylose tube; b) the water-soluble host molecule is water-soluble because hydroxyl groups face the outside on the hydrophilic outer mantel of the tube.
When exposed to a dissolved host molecule, the fatty acid legs of lipids are attracted, as guests, to the hydrophobic or lipophilic core of the molecule. Therefore, this mechanism can be used to create molecular dispersions of lipids and certain other hydrophobic materials in water.
These molecular dispersions, which differ from emulsions, can offer new dimensions in fat management including magnifying the impact of oil based flavors, increasing the exposure of lipids to enzymatic action, stabilizing emulsions, extending mouthfeel of fats, and reducing fat requirements.
A secondary effect of the chemistry is to create an emulsifier produced in situ. The dynamic amylose/lipid complex itself becomes a good emulsification agent and this ability, by itself, offers many applications. In its simplest form, the material acts as a host to one leg of a triglyceride leaving the glycerol and two fatty acid legs exposed. This can be expressed as a stoichiometric ratio in which a specific number of moles of host molecules represent the ability to harbor an equivalent number of moles of potential hydrophobic guests under ideal conditions. As the available core cavities are filled, the newly formed guest/host molecule complexes are characterized as complexes of water-soluble outer mantels with oil soluble triglyceride guest fragments sticking out of one end. In essence the complex takes on the classical definition of an emulsifier. This complexed structure begins to resemble an emulsifier and attractions of other fat molecules begin to give an emulsified structural appearance as fat globules build on the complexed triglyceride. This provides a secondary emulsifying capacity as the complex begins to act more as a traditional emulsifier.
The host molecule has an additional attribute. The amylose chain is an excellent film former and as foods containing a guest/host molecule are chewed, the complex is temporarily held on the palate as a film containing hydrophobic flavor components. As saliva enzymes degrade the film, the flavor components are sequentially released enhancing and prolonging flavor perception.
Additionally, the remaining available hydroxyl groups of outer mantel of the guest/host complex act as a sponges carrying bound, secondary, and tertiary water into the food system. This water, which has varying degrees of availability, provides an ability for selective hydration of native components, such as proteins, thus allowing an additional dimension of engineering for the overall product.
Amylose tends to form an alpha helix with seven gluco-monomers per turn and then the number of hydrophilic groups is three times the degree of polymerizations. However, with non-modified amylose, the benefit of this large product is unavailable because the energy barrier is larger to hydrate the hydrogen bridge bonds, which locks up the large molecule, and the tendency to return to this state is equally strong. Amylose, as such, will take advantage of the two possibilities to undergo hexagonally closest (HCP) or face-centered cubic packing (FCCP).
Typically, modification of amylose and amylopectin tends to be concentrated in the amorphous regions of the C type legume starches, while the molecules in the crystalline regions receive less esterification. As a result, unmodified amylose from the center of the granule can exert an undue influence on the over-modified surface molecules so that when the unmodified amylose retrogrades in its natural fashion it overpowers the modified material effectively negating the visible effects of the system. It is important to begin with substantially purified starch because starch-containing-substrates, such as pea flour, have too many conflicting components, such as non-starch polysaccharides and proteins, that prevent the production of the predictable modification of the amylose and amylopectin fractions. Such predictability is essential for subsequent engineering of chain length.
In modified amylose, the energy barrier to hydrate the remaining skeleton is lowered, as is the tendency to retrograde and undergo closest packing, either HCP or FCCP. In addition, there is control over the dissociation constants of such a complex via the degree of polymerization, which is chosen by hydrolysis. Thus, many combinations are possible, giving good control over the magnitude of dispersion, viscosity, and dissociation constants.
In polar environments, hydrophobic fatty materials would prefer to harbor themselves in the hydrophobic core of the helix, but proximity is a key factor since ionic attraction is not a factor in the attraction of the guests. The guests must stumble across these oil-friendly zones and so time, temperature, physical mixing, and shear play a role in the degree of population of available host zones. Also, the degree of polymerization of the host influences the availability of host cavities. Longer chains of modified amylose close in on themselves more completely and only the kinks in the chains are visible or available for hosting. Amylose with a high degree of polymerization has a greater tendency to form rigid gels on cooling and this restricts the temperatures at which complexing can take place. Uniform hydrolysis of the chains can inhibit this gelling tendency and make the helical cavities more available to hydrophobic guests over a longer period of time and at a lower temperature.
Acid hydrolysis is a very crude method of shortening the amylose chains. It is very temperature dependant and somewhat uncontrollable resulting in mixtures of varying chain lengths. Low pH environments also result in the dismantling or removal of the substituent acetyl groups thus removing the amylose stabilizing components. Without a predictable substituent construction the resulting gels will release gust material in a haphazard fashion. The use of a suitable enzyme, when combined with specific temperature thresholds to cleave bonds selectively, preserves these substituents, thereby resulting in a product of much more predictable uniformity and effectiveness. The host molecule can thus be engineered in this fashion to yield a material that can act as a host to hydrophobic materials at a much wider range of temperatures and concentrations and can be dried while retaining its hosting/emulsification capabilities.
The foundation of the guest/host technology of the present invention is the uniform chemical and enzymatic modification of amylose and amylopectin derived from starch. The raw material may be any starch such as, but not limited to, pea, corn, potato, rice, wheat, tapioca, or any starch having an amylose content or having a content of amylopectin containing amylose-like ends. Higher degrees of polymerization of the amylose fraction offer an additional flexibility of functionality of subsequent products. Legume starches, particularly pea, mung bean, adzuki bean, and lentil starches are more desirable because they have a C type crystallinity and the A-chains of the amylopectin molecules can be liberated or harvested with a higher yield to serve as short chain amylose type hosts.
Individual starch molecules within the starch granule are found both as amylose, slightly-branched chains comprised mostly of α-1,4-linkages between the anhydroglucose units, and amylopectin, highly-branched chains consisting of both α-1,4- and α-1,6-linkages. See Whistler, R., et al. (eds.), Starch: Chemistry and Technology, 2 d ed ., Academic Press, Inc., 1984, pp. 154-155 and 260.
The amylopectin molecule contains three types of chains: C-chains, B-chains, and A-chains. Manners, D., “ Recent Developments in Our Understanding of Amylopectin Structure,” Carbohydrate Polymers, Vol. 11, 1989, pp. 87-112. The amylopectin molecule has only one reducing group and it is located on the root C-chain. Numerous B-chains are attached to the C-chain structure and are bound to two or more chains. In typical starches, A -chains contain about 12 to 16 anhydroglucose units. These A-chains are also distinctive in that they are attached in individual clusters to the B-Chains and, reminiscent of end branches on a willow tree, are a main source of amylose-type molecule fragments. That is to say, when these A-chains are separated from their B-chain roots, they are comprised only of α-1,4 linkages. The characteristic 1,6 linkages of amylopectin remain with the B-chain and C -chain components of the original structure.
Some native starch is in the form of a double helix. Some of the amylose ends of the A-chain amylose attached to the amylopectin structure are more likely in this parallel or winding chain structure, while the amylose molecules themselves are more likely single helixes. Galliard, T., Starch: Properties and Potential , John Wiley & Sons, 1987, pp. 69-75.
It has been reported that pea starches, like other members of the Legumiosae family, have A-chain lengths that are longer than those of dent corn, for example. Rather than 12-16 anhydroglucose units per branch, pea starches have been shown to have 20-24 anhydroglucose units per A-chain. Pea starch and other members of the Legumiosae family also show a different type of crystallinity from cereal or root derived starches. Under x-ray radiation cereal starches are characterized by the A pattern of crystallinity while root starches the B type. Pea starches exhibit a third C type crystallinity, which is a form of a combination of the first two, typical in part, of both A and B.
Furthermore, the starch granules of some varieties, such as legume starches, are formed in alternating crystalline and amorphous regions or layers, so it is necessary to pretreat the starch with an agent to prepare the granule for penetration by the acetylating agent.
The appropriate modification should yield molecules within a starch granule that is uniformly modified rather than surface modified. Esterification with any of the esterification agents known to the art is suitable. Starch esters of this type include, but are not limited to, starch acetate, starch propionate, starch butyrate, starch hexanoate using acetic anhydride, propionic anhydride, butyrate anhydride, hexanoate anhydride, and the like. Esterification with acetic anhydride is preferred. The modification may be conducted on soaked granules or on pre-gelatinized hydrolyzed gels. The advantage of the granular modification is the ease of removing sodium acetate byproducts. The advantage of pre-gelled material is that the molecule can be sized for specific application and the resulting modification is more predictable and uniform. Because the typical usage of this material in a food is low, the byproducts normally do not conflict with the intended food application.
The acetylation modification stabilizes the amylose molecule in a helical configuration. The amylose in unmodified starch retrogrades after it has been heated and then cooled. At high temperatures, the molecule stretches out and, as it cools, becomes a tight coil. In between these two points, the amylose molecule is a helix. The target esterification modification stabilizes the amylose molecule at this point by placing a substituent every seventh gluco-monomer; there being seven gluco-monomers per turn. These derivatized gluco-monomers prevent the amylose from shrinking and recoiling after cooking. The resulting helix is not rigid; it can flex and bend. The helix creates a super dispersion by scintillating molecules of fat. The rate is determined by the configuration and molecular shape of the molecule and the ambient temperature.
When this helix comes in contact with a fat globule, some of the individual fat molecules are attracted to the lipophilic interior of the helix. The interior of the helix is lipophilic because it has no polar groups facing inward, the only functional groups that are present are C—H, just as in a fat molecule. The outside of the helix is entirely hydrophilic because it contains all of the groups with dipolar moments and therefore the host is water-soluble.
Products made according to the present invention also possess thermoplastic characteristics, becoming liquid when heated and resolidifying when cooled. At room temperature, the coils of the helix are well organized and contain a guest. The yield of guests per helical volume depends upon the degree of polymerization. The fat molecules are scintillated many times per second. Logically, as the temperature increases, the guests become more active and visible, but are constantly interchanged. In addition, as the temperature increases, the molecule takes advantage of its Degrees of Freedom of Motion to absorb the energy. Eventually the vibrations due to the absorbed energy become so large that the helix attempts to unravel. Once again, this point is dependant upon degree of substitution and Degree of Polymerization with longer chains of amylose being more cumbersome and less predictable than the shorter, more manageable, hydrolyzed chains.
As long as the temperature is not pushed to the point where major molecular alterations occur, such as chemical degradation or dehydration, the chemical make-up of the molecule remains the same. Therefore, when the temperature decreases, the molecule remembers the thermodynamically-favored state and will form a helix again, thereby resolidifying and, if the guest materials are evenly distributed, the complexes will reform.
The subsequent acylation must be performed at as low a temperature as possible so as to minimize the participation of the solvating water in the acetylating reaction to achieve the highest degree of efficiency. However, pre-treating the starch at such low temperatures requires extended pretreatment times, which, in turn require excessive tankage for commercial process holding capacity, thus making low temperature soaking or pretreatment impractical.
The time requirement can be shortened so as to fit commercial circumstances by preparing a heated solution of the catalyst or soaking agent in water and mixing the purified dry starch raw material into this warm solution directly. By this method, it is possible to reduce pretreatment times from 30 hours at 2° C. and 10 hours at 20° C. down to 1 hour at 53° C. High amylose starches require higher/longer pre-soaking temperatures/times relative to their gelation points.
The pretreated solution is then cooled to prepare for penetration by the acylating agent at low temperature. The purpose of conducting the acylating reaction at low temperature is to minimize the participation of the solvating water in the penetrated solution and give the starch granules with their penetrated sodium ions as much opportunity as possible to convert acetic anhydride to acetyl groups.
The acetyl groups are also important to render the starch granule more open to hydration and subsequent enzymatic hydrolysis. The acetyl substituents tend to protect neighboring regions of the anhydroglucose chain from enzyme attack, thereby ensuring that the enzyme will not overly digest the chains. If they were overly hydrolyzed, the amylose chainlets would become too short to form complete helixes and thus lose their hosting ability.
It is important to keep the 1,6 linkages intact to a great extent. The enzyme is unable to cleave closer that 2 glucomonomers from the 1,6 linkage. This protects the amylose-like A-chains from over-hydrolysis by eliminating those zones from attack. The acetyl substituents placed along the chains then give further protection from over-hydrolysis. While it is possible to digest the amylose chains to very short fragments, this buffering protection permits extra degrees of processing freedom when the final desired product characteristics are engineered.
The present invention is dependent upon complete hydration of the starch granules after the insertion of the acetyl groups to convert crystalline regions into the more accessible amorphous regions, thus opening up the amylose molecules for enzymatic attack. It is known in the art to rely upon a shortage of water to retain the granular structure of the starch in the end product. According to the present invention, however, molecules are completely hydrated in a water soluble gel. The host molecules of the method of the present invention are uncomplexed as they have no guests remaining from the process. The hosts remain substantially unretrograded in spite of the absence of a guest molecule and this is achieved by the acetyl groups sterically hindering the super recoiling of the molecules.
Researchers in this art have found that amylopectin gels are mildly gelling in that they form soft gels over time. Addition of amylose caused a significant formation of firm gels over a short period of time. So, if the addition of amylose to maltodextrin solutions led to remarkable acceleration of aggregation process and maltodextrins can be slow gelling without the addition of amylose, then several things can be assumed:
1. when the gels or the present invention are fast gelling, it must be because of longer chain amylose; 2. this is exactly what happens when the starting temperature for the initial addition for the enzyme treatment is increased; and then 3. the amylase attacks preferentially more amylopectin groups than amylose chains at the higher starting temperatures or at least the amylose chain is not attacked as aggressively.
This is possibly because the A-chain segments of the amylopectin groups are more unraveled and more vulnerable at the higher temperatures. In other words, at higher temperatures amylopectin A-chains participate more in the enzymatic conversion and, as temperatures increase toward the terminal temperature of the enzyme and the exposure time decreases proportionately, more amylopectin A-chains are hydrolyzed than amylose. Therefore, at an 80° C. enzyme addition temperature, there is less time to hydrolyze amylose and so the resulting finished gel product is much faster gelling upon cooling. That is not to say that the amylose chains would not eventually become degraded given enough time; just that the amylettes are more vulnerable and this feature allows for that.
Analytical treatment of completed clathrates systems with a combination of endo α-amylases, such as Termamyl, and with pullulanase results in the destruction of the host molecule, the amylose, and amylettes and a release of the guest molecules, which in the case of lipids, float to the surface leaving a flocculent precipitated residue in a clear solution of short glucose chains. This residue does not react with iodine and does not complex with fats and is probably a residue of the C and B chain fragments, perhaps limited by the ester groups inhibiting the pullulanase as indicated by Biliaderis.
The process for making the host molecule involves the low-temperature modification of starch granules that have previously been impregnated or permeated with catalyst ions, such as sodium from sodium hydroxide. While the starch may be pre-soaked in a sodium hydroxide solution at low temperature to facilitate the low temperature modification, it is more commercially acceptable to effect this soaking at elevated temperatures to reduce the time requirement. Soaking temperatures on the order of about 4° C. require soaking times of up to 30 hours, while soaking temperatures of about 53° C. require 1 hour to prepare the starch granule for modification. Soaking temperature may range from a point just below the point of birefringence of the starch to 0° C. The modification should be conducted as low as possible to minimize the participation of the water in the reaction with the esterifying agent.
Granular pea starch that has had substantially all of the non-starch constituents removed is soaked in a sodium hydroxide solution to allow sodium ions to migrate uniformly throughout the granule (pH 10 at 35° C. for 4 hours). The slurry is cooled to 14° C. Acetic anhydride is slowly added while a 9% sodium hydroxide solution is used to maintain the pH of the reaction at pH 8.5 and a temperature of 14° C. Although previous references have stated a preferred pH range of 6 to 8, it has been found in accordance with the present invention that this does not produce the desired degree of uniformity. Surprisingly, dried gels made by the present method of modifying at a fixed pH of 8.5 at 14° C. may be rehydrated to re-form a solution in water and this solution may be cooked to boiling without degradation, and then may be chilled to 4° C. to form a gel which exhibits thermoreversible properties. This characteristic is an important indicator of the ability of a gel to later dissolve and participate in the chemistry of various interactions in food systems. To emphasize the distinction, dried gels made with starch modified by the prior art of maintaining a modification pH range between pH 6 and 8 form discrete, white particles upon rehydration. These re-hydrated particles do not exhibit an ability to be solubilized or melted.
When enough acetyl groups have been formed to produce a DS of 0.08 to 0.15, as calculated between the consumption of sodium hydroxide against acetic anhydride addition, the difference representing acetyl groups, the reaction is stopped and the solution neutralized. In addition to the formation of acetyl groups, sodium acetate is produced as a byproduct. The consumption of sodium hydroxide represents the production of sodium acetate. That portion of the acetic anhydride not involved in the production of sodium acetate contributes the desired acetyl groups.
The acetic anhydride will slowly react with water and this reaction rate increases with an increasing temperature of the water. Therefore, the reaction should be carried out at as low a temperature as possible. A reaction temperature between 0° C. and 15° C. is desirable. It has been found that the ideal pH for the acetylation process is temperature dependant. Lower temperatures allow higher target pH settings for conducting the modification, while higher temperatures benefit from a lower pH. See Kruger et al., Production of Starch Acetates . Starch: Chemistry and Technology 2d ed.”, R. Whistler et al., (eds.) Acedemic Press, Inc., 1984. The optimum acetylation pH is temperature dependent: at 38° C. the optimum pH is about 7; at temperatures below 20° C., the optimum pH may be above 8.4
The modified granular starch may be washed to remove reaction byproducts and dried. However, if the material is to be hydrolyzed in the subsequent step, drying is unnecessary. Sodium acetate serves as a continuing catalyst to improve the efficiency of the acylation reaction and it is useful to recycle some of the wash water in the washing step back to the initial hydration stage to slurry the original starch raw material.
The modified starch slurry is cooked to 75° C. to 105° C. or higher. The solids may be between 1% and 40%. Different applications will require different solids contents depending on the desired concentration of available host helixes and the desired moisture content of the finished application. It is important to hydrate the starch molecule properly and thoroughly during this cooking stage to expose all available amylose chains and to unfold amylopectin branches and clusters.
The cooked gel is temperature adjusted within the temperature limits of the appropriate enzyme and enzyme hydrolysis follows. The enzyme of choice is an endo amylase, such as a bacterial amylase from Bacillus amyloliquefaciens with the systematic name of 1,4-alpha-D-glucan glucano-hydrolase that hydrolyzes 1,4-alpha-glucosidic linkages. The example brand name is Ban produced by Novozymes AS. While this enzyme has the ability to attack the 1,4 linkages within the amylopectin branches, this enzyme offers the additional advantage of being unable to attack the actual 1,6 linkages attaching the amylopectin fraction to the amylose, thereby offering the amylopectin bond to complement the acetyl groups attached through the modification process as barriers to complete hydrolysis. This results in the ability to hydrolyze the material aggressively while still retaining significant hosting potential in the finished product.
While the 1,6 linkage attaching the amylopectin clusters to the amylose chains are unable to be cleaved by the alpha amylase enzyme, the internal 1,4 linkages of the actual amylose-like branches of the amylopectin are vulnerable to cleaving by the enzyme and these liberated helical amylopectin fragments offer additional hosting capability for shorter chain guest molecules. The remaining intact amylopectin groups or side chain stubs attached by 1,6 linkages continue to provide a type of colloidal protection against retrogradation.
The enzyme attacks the 1,4 linkages at different sites depending on temperature. Exposure to the enzyme starting at lower temperatures yields thinner solutions with shorter chain hosts, while exposure at higher temperatures yields longer chain amylose molecules with the amylopectin branches being preferentially hydrolyzed.
This enzyme reaction is moderated by temperature or pH or a combination of both to achieve the desired end functionality. Increasing the temperature or storing the material at a disabling pH ends the reaction and the material may be used directly to produce a wide variety of products, including cheeses and the like.
Finished materials containing the mixtures of stabilized amylose and stabilized amylopectin prepared via this method will result in fluid, hot solutions with high solids contents that will resist gelation or will form meltable gels at selectable rates and degrees and be able to encapsulate/emulsify upward of 10 times their weight in lipid material.
If a shorter version of host material is desirable for special applications, the starch molecule may first be aggressively hydrolyzed to cleave a greater number of 1,4 alpha-glucosidic linkages to produce a thin, non-gelling solution. The amylase enzyme is then inactivated.
For some applications and after the production of the amylose material and inactivation of the enzyme, it may be desirable to provide a pre-installed guest molecule to enhance the mechanism of the host gel in its final product application. Suitable guests may include any hydrophobic material that is compatible with the material to be treated. Butter oil or short chain fatty acids for flavor enhancement are but two of the myriad of possibilities. Pre-installed guests are especially desirable when the dextrin gel is being incorporated into the target mass at low starting temperatures. The existence of a starter guest molecule multiplies the ability of the gel to infiltrate the molecular structure of the mass and acts as a buffer to retard the aggressive nature of the pure dextrin gel. While it is true that guests are not attracted by ionic forces to the hydrophobic core of the host molecule, the aggressive mixing techniques necessary to infiltrate tough, cool lipid bearing masses may create a prematurely high introduction ratio. This may create a counterproductive excessive division of globules of fat in the target mass. Pre-existing guests seem to increase the mixing tolerance for difficult substrates such as cheese. The pre-installed guest can also be employed to form a sort of scaffold or lattice effect to provide a more rigid structure in which subsequent short chain guests may be stabilized. Saturated mono- and di-glycerides for example can provide this re-bar type structure.
The hosting capacity of the molecule has a sort of stoichiometric definition. Theoretically, amylose molecules of more than 6 or 7 glucomonomers may act as hosts to many hydrophobic materials, but most amylose material is much larger and in practice there is always some kinking involved in these longer chains of amylose. This, then, limits the volumetric exposure of the host, as longer, straight segments may not present themselves as vacant cavities. Medium length chains, such as those of the amylettes derived from the amylopectin fractions of, for example, peas, with a cleaved glucomonomer chain length of perhaps 15 to 24, offer a high degree of vacancy per mole. Nevertheless, a solution of these molecules can be described as having a certain capacity to host a relative number of guest molecules. This stoichiometric ratio may be shear dependant as the success of guests in finding vacant hosts depends on the intimacy of their introduction. When complexes of guests and hosts reach the stoichiometric balance, as adjusted by the shear factor applied to that particular mixture, they transition from a molecular dispersion to a more traditional emulsion with the guest/host complexes acting then as emulsifiers. In this super-phase, the additional guests are not clathrated or complexed; rather, they are emulsified by the guest/host complex itself, but outside the host and in an oil-in-water environment. This accounts for the unusually high oil management capacities of this system because it is a combination of first dispersion and then emulsification.
It should be noted, however, that for applications that rely upon the guest being occluded or hidden, for example, in pharmaceutical applications to protect sensitive components from premature degradation, it is important not to exceed this stoichiometric factor as guests that exceed the stoichiometric definition may be exposed.
It is interesting to note that when a clear guest, such as melted paraffin or a siloxane product, is introduced into a clear or slightly opaque solution of host material, the resulting clathrate is always white. In fact, this can be used as an indicator of the formation of the clathrate. Colorless oils will usually form pure white complexes with the host of the present invenition. This optical effect can be observed with tri, di and monoglycerides, fatty acids, and a variety of other hydrophobic materials.
Complexes formed with this mechanism exhibit unusual specific gravity. While the host macromolecule has a density greater than water, it is the combined characteristic of the complex, including the guest, that determines the final density. Typically, complexes of lipid guests in medium-chain hosts will rise to the top of a centrifuge tube during centrifugation, while virgin amylose, should there be any, and amylopectin dross, the remnants of the amylette harvesting process, drop to the bottom of the tube. The fate of the final complex therefore may be predetermined, in a way, by selecting the desired degree of hydrolysis of the amylose fractions to match the molecular weight of the intended guest.
This observation has led to the discovery of a convenient method of separating potential hosting materials from non-hosting amylopectin fragments by introducing a low density hydrophobic guest, such as hexane, to the slurry, centrifuging the resulting lighter guest/host complex from the denser amylopectin dregs, and evaporating and distilling off the volatile hexane guest, leaving virgin, stabilized, nanotubes of pre-engineered amyloses in solution.
The liquid host material may be spray dried, freeze dried, or co-dried with companion materials to produce a powder with unusual fat management capabilities.
Solutions prepared by the method of the present invention, even if they have been reconstituted from their dried state, will form complexes with guest molecules at cold temperatures under the proper conditions. There is no longer any need to rely on co-cooking or temperature related convolution of the host around the guest.
The advantages and the important features of the present invention will be more apparent from the following examples.
EXAMPLES
Example 1
1. Prepare a 35% solids solution by slurrying purified pea starch in warm water to which has been added sufficient sodium hydroxide to produce a slurry with a pH of 10 and maintain by stirring and temperature control for 3 hours at 48° C.
2. Agitate well during this step. Cool the reaction to maintain 10° C. Add acetic anhydride at a constant rate while maintaining the pH of the slurry at pH 8.5 with added 9% sodium hydroxide solution. Add an amount of acetic anhydride that, when corrected for sodium hydroxide consumption, provides for a starch with a Degree of Substitution of 0.10. Maintain the temperature below 15° C. Dilute and wash the starch.
3. Make a 20% solids solution, pH 5.8, with water and a suitable acidulant, such as HCl. Heat to 95° C. to 105° C. and hold for 2-5 minutes.
4. Cool to 73° C. (the selected beginning of the temperature range for the following enzyme).
5. Treat with a suitable amount (0.00067%) of Ban enzyme and hold until the desired viscosity is attained. Heat to 92° C. to 105° C. to inactivate the enzyme. The heating time is typically 15 minutes to reach the target temperature. Combinations of enzyme dosage and time to reach the terminal point of the enzyme may be inversely varied to achieve the target finished product. Cooked slurry will start out as a very viscous mass and eventually thin to a thin fluid viscosity. The factors for selection here are that the gel is thermoplastic and will behave as a cheese when heated. The shorter the hydrolysis time, the longer the amylose, the more the film forming, and the longer the melt characteristics, the shallower the melt/temperature slope. The longer the hydrolysis, the shorter the amylose, the less film forming, and the thinner the melt characteristics, the steeper the melt/temperature slope.
6. The product may then be packaged as a hydrated gel or dried to a powder for future re-hydration.
7. If a pre-installed guest is desirable, then, prior to drying, add the starter guest lipid component. This increases the efficiency of the host molecule. Homogenization is not necessary, as the gel will hold the guest fat with even mild agitation; however, homogenization will result in a more aggressive mixture. In the case of preparing an ingredient for cheese manufacturing, butterfat is added and may be added at a level of 1% to 40% of the total mass. 10% is often a useful level. Butter flavors may also be used alone or in combination with butter. The short chain fatty acids involved in butter flavors are ideal guest molecules. The guest may be combined immediately or may be added at some future time. The gel will remain fluid for a period of time after melting and a fluid guest may be added at any temperature while they are fluid. The guest may also be added as a solid to the solid gel at cool temperatures, if desired, by providing enough energy to combine the two fractions thoroughly. With time, the guest molecules will migrate to the available host cavities to form molecular dispersions.
Example 2
1. Three thousand pounds of isolated pea starch are added to 630 gallons of water that has been prepared with 4.5 pounds of caustic soda beads and preheated to 45° C.
2. The slurry is allowed to soak at 45° C. for 2 hours and then cooled to 10° C.
3. Acetic anhydride (220 pounds) is added over the course of two hours concomitant with 1100 pounds of 9% caustic soda solution so as to maintain the pH of the slurry at approximately 8.5.
4. When the required reactants have been added, the flow of caustic soda solution is stopped and the acetic anhydride is allowed to continue until the pH reaches 6.0.
5. The reacted starch slurry is washed using a liquid hydrocyclone array to extract a substantial portion of the dissolved reaction byproducts.
6. The washed reacted starch slurry is diluted with clean water to 22% solids.
7. The diluted slurry (220 gallons) is cooked in a steam jacketed, scraped surface kettle to 92° C.
8. The cooked solution is cooled to 72° C.
9. Three grams of Ban enzyme is diluted in 400 grams of distilled water and then added to the cooked solution with the mixer operating at medium high speed.
10. The enzyme-treated, pre-cooked solution is re-cooked to an end point of 92° C.
11. The re-cooked, thinned solution is dried in a spray drier.
12. This produces a reconstituted 20% solution that, when heated to boiling in a microwave, produces a hot gel with medium thick viscosity and forms a firm gel after storage at 4° C. for 4 hours.
Example 3
1. Isolated pea starch (770 pounds) is added to 165 gallons of water at 10° C. that has been prepared with 300 grams of caustic soda beads.
2. The slurry is allowed to soak at between 15 and 20° C. for 10 hours.
3. Seventy-two pounds of acetic anhydride is added over the course of 2 hours concomitant with 450 pounds of a 9% caustic soda solution so as to maintain the pH of the slurry at approximately 8.3.
4. When the required reactants have been added, the flow of caustic soda solution is stopped and the acetic anhydride is allowed to continue until the pH reaches 5.7.
5. The reacted starch slurry is diluted with 400 gallons of water and allowed to settle. After six hours of settling, the supernatant is siphoned off to remove dissolved reaction by-products.
6. The washed reacted starch slurry is diluted with clean water to 22% solids.
7. The diluted slurry (220 gallons) is cooked in a steam jacketed, scraped-surface kettle to 92° C.
8 The cooked solution is cooled to 72° C.
9 Ten grams of Ban enzyme is diluted in 400 grams of distilled water and then added to the cooked solution.
10 The enzyme-treated, pre-cooked solution is re-cooked to an end point of 92° C.
11 The re-cooked, thinned solution is dried in a spray drier.
12 This produces a reconstituted 20% solution which when heated to 95° C. produces a hot gel with low, water-like viscosity and forms a medium firm gel after storage at 4° C. for 24 hours.
The slow gelling characteristics of Example 3, with an enzyme addition temperature of 72° C., indicates the presence of shorter amylose chains, but the increased fat-holding ability indicates that starting the enzyme treatment at a lower temperature, therefore giving the reaction more time, yields a shortening or division of liberated A-chains. The fact that these liberated A-chains still have an iodine blue reaction, indicating chain length of over 6 or 7 glucomonomers and they still hold fat, even after prolonged enzyme exposure, confirms that the endo-enzyme degradation is limited by the ester groups.
Example 4
1. Isolated pea starch (770 pounds) is added to 165 gallons of water at 4° C. that has been prepared with 300 grams of caustic soda beads.
2. The slurry is allowed to soak at between 4 and 8° C. for 24 hours.
3. Seventy-two pounds of acetic anhydride is added over the course of two hours concomitant with 450 pounds of a 9% caustic soda solution so as to maintain the pH of the slurry at approximately 8.3.
4. When the required reactants have been added, the flow of caustic soda solution is stopped and the acetic anhydride is allowed to continue until the pH reaches 5.7.
5. The reacted starch slurry is diluted with 400 gallons of water and allowed to settle. After six hours of settling, the supernatant is siphoned off to remove dissolved reaction by-products.
6. The washed reacted starch slurry is diluted with clean water to 22% solids.
7. The diluted slurry (220 gallons) is cooked in a steam jacketed, scraped surface kettle to 92° C.
8. The cooked solution is cooled to 78° C.
9. Four grams of Ban enzyme is diluted in 400 grams of distilled water and then added to the cooked solution.
10. The enzyme-treated, pre-cooked solution is re-cooked to an end point of 92° C.
11. The re-cooked, thinned solution is packaged as a warm, viscous gel at 50° C. in plastic liners in 40 pound corrugated boxes and then placed in a cooler for chilling.
12. This produces a cold, hard gelatin-like gel that, when warmed in a microwave oven at 100% power to the boiling point, produces a hot gel with a thick viscous characteristic and which re-forms a hard gel after storage at 4° C. for 1 hour. This gel re-melts again in repeated microwave treatments and repeated chill heating cycles.
Example 5
1. Isolated pea starch (770 pounds) is added to 165 gallons of water at 4° C. that has been prepared with 300 grams of caustic soda beads.
2. The slurry is allowed to soak at between 4 and 8° C. for 24 hours.
3. Seventy-two pounds of acetic anhydride is added over the course of two hours concomitant with 450 pounds of a 9% caustic soda solution so as to maintain the pH of the slurry at approximately 8.3.
4. When the required reactants have been added the flow of caustic soda solution is stopped and the acetic anhydride is allowed to continue until the pH reaches 5.7.
5. The reacted starch slurry is diluted with 400 gallons of water and allowed to settle. After six hours of settling the supernatant is siphoned off to remove dissolved reaction by-products.
6. The washed reacted starch slurry is diluted with clean water to 22% solids.
7. The diluted slurry (220 gallons) is cooked in a steam jacketed, scraped surface kettle to 92° C.
8. The cooked solution is cooled to 72° C.
9. Four grams of Ban enzyme is diluted in 400 grams of distilled water and then added to the cooked solution.
10. The enzyme-treated, pre-cooked solution is re-cooked to an end point of 92° C.
11. Butterfat (120 pounds) is added to the hot solution at normal mixing speed. The butter melts into the solution and forms a clathrate without any additional shear or agitation and no free fat appears on the surface.
12. The re-cooked, thinned, butter-clathrated solution is packaged as a warm, somewhat viscous gel at 40° C. in plastic liners in 40 pound corrugated boxes and then placed in a cooler for chilling.
13. This produces a cold, firm butter-like gel that, when warned in a microwave oven at 100% power to the boiling point, produces a hot gel with a slightly viscous characteristic without any evidence of free fat and that re-forms a firm buttery gel after storage at 4° C. for 12 hours. This gel re-melts again in repeated microwave treatments and repeated chill/heating cycles.
Example 6
Formation of a Complex with Soybean Oil
Thirty grams of the low viscosity powdered emulsifying gel prepared in Example 3 is dispersed in 500 mL water at 10° C. in a 1 liter beaker. The powder is dissolved into solution with the use of a Braun electric hand mixer, a very low shear device.
Three hundred grams of soybean oil are added to the beaker without mixing. The soybean oil floats on top of the solution.
The Braun hand mixer is submerged to the bottom of the beaker and turned on. The mixer is angled so that the vortex draws the top oil fraction down into the mixer.
When the entire oil layer has been incorporated, it is evident that no free oil is visible. Additional mixing develops a more complete molecular dispersion and emulsion. After one minute of mixing, a 25 mL portion of the dispersion is mixed into cold tap water and a homogeneous milky solution is created with no evidence of free oil.
This example shows the unusually high oil holding capacity and the low shear necessary to form a molecular dispersion of this invention.
Application of this Technology to Cheese Manufacturing
Attempts to use amylose or starch to manage fats have previously taken the path of
(a) binding chemical residues onto certain sites on the starch molecule to bind onto fats, or (b) creating one-time amylose/lipid complexes in which the lipid is co-cooked with the gelatinizing starch and wrapping the lipid in the unraveling amylose where after the amylose retrogrades to form a permanent irreversible, non-meltable complex.
The preparation of irreversible amylose or starch lipid complexes prepared by co-cooking as described above and then mixing that ingredient into the milk phase of the cheese making process (at the very beginning of the process) is known in the art. The present invention, on the other hand, involves proteins that are the result of the coagulation proteins after the cutting of the curd.
Other known art describes methods to add fillers, such as starch, to cheeses, but the guest/host approach is not used, and it appears that the traditional calcium binding mechanism of phosphate salts and citrates is relied upon to tame the proteins and enable the mixing of starch into cheese. The known art does not use the starch in gel form and as a result does not enable, nor does it discuss, the significant cost reduction benefit of the present invention.
The calcium-binding approach to processed cheese is the time-honored approach to cheese protein management. It is so entrenched and widely used that the unique products produced by reducing the stretchy effect of protein calcium bonds actually have their own standards of identity and their own end-food-product applications. The technology of the present invention permits the processing of cheese while retaining the natural character of the proteins, thereby allowing for the production of processed mozzarella with all of the characteristics of natural traditional mozzarella. The pasty, gummy texture of normal processed cheese is avoided.
The technology of the present invention also opens up the hitherto impenetrable virgin cheese mass to permit the addition of other functional ingredients. These ingredients can include calcium chloride, transglutaminase, and other enzyme systems.
Calcium is normally the nemesis of cheese processors. With the present system, it is even desirable to add calcium to the cheese mass so as to extend the strength of the proteins as much as possible and thereby permit the most aggressive dilution for economic purposes. The protein is the single most expensive component of the mozzarella cheese product and the ability of this technology to reduce the content of protein while maintaining or indeed increasing its overall effect is very attractive economically. Adding calcium to encourage additional calcium protein bonds is contrary to the art of traditional cheese processing, but can be employed within the scope of the present invention.
Similarly, hitherto-unavailable approaches may be taken to the use of enzymes, such as transglutaminase, which may be introduced to the cheese mass inside of the dextrin gel as an additional functional ingredient. This enzyme has a significant effect on cross linking the proteins in a cheese mass and therefore affects the economics favorably, as well. Known means for using this enzyme have been restricted to adding it to the milk at the beginning of the cheese making process or by pre-treating whey proteins with it before adding them to the milk at the beginning of the cheese making process. Adding it at the curd cooking stretching stage or to the finished young cheese is not known to have been disclosed or suggested in the art.
This chemistry plays an important dual role in mozzarella cheese. Fresh mozzarella has a protein matrix composed of a high proportion of hydrophobic, or more importantly, lipophilic groups. Over time, proteolytic enzymes fragment these proteins, thereby changing the nature of the protein matrix and having the effect of rendering the cheese more meltable. The changes in the proteins have to do with a gradual hydration and a reduction in the relative influence of the lipophilic groups or an increase in the effectiveness of the calcium-containing hydrophilic ends.
One of the keys to manipulating the mozzarella characteristic has to do with modifying the distribution of the fat.
The processed cheese industry uses melting salts or emulsifying salts including phosphates or citrates to sequester the calcium ions, which on one hand reduce the solubility of the proteins and on the other hand form the power base for the strength of the protein interactions. Once these calcium ions are diverted from their protein-complexing role the proteins are more vulnerable to hydration using energy in the form of high temperatures. Unfortunately, proteins that have been chemically and thermally altered with this processing system are unable to be restored to their previous character and cannot be used for traditional mozzarella applications, for instance, those that require the calcium ions to participate in providing the typical mozzarella stretch.
The technology of the present invention is capable of reassigning the role of traditional emulsifiers, such as the native proteins in cheeses, from one of primary emulsifiers and secondary structure builders to one of primary structure builders and secondary emulsifiers. The subject host molecule takes over the primary role of emulsification and, by dividing the fat globules, makes the protein more intimately exposed to the various bound waters of the host molecule. This controlled accelerated hydration permits the immediate formation of additional protein-protein linkages, thereby reducing the amount of protein needed to obtain stretch and strength and at the same time stabilizing the fat to minimize separation. The combination of all of these effects reduces the ingredient cost of cheese by as much as 15% and returns a greater than usual margin for the ingredient molecule.
The fat-complexing function of the helical lipophilic core of this stabilized amylose divides the pools of fat that serve as focal points for the lipophilic ends of the proteins. The traditional cheese making process does not involve a great deal of shear and, as a result, the fat globules in normal cheese tend to be rather large instead of the aggressive emulsions that one might find in mayonnaise for example. The modified amylose has the ability to intrude upon that fat/protein matrix and effectively divide the fat pool into smaller and smaller bodies. This has the secondary effect of dividing the protein molecules or strands into more numerous, more finely distributed groupings. These finer groupings are more vulnerable or accessible to water hydration. While the opposite ends of the proteins are hydrophilic, the localization of the lipophilic forces around fat globules normally prevents the migration of water into proximities near enough to achieve hydration. This is where the amylose molecule, with its outer mantel of bound water on its hydroxyl groups and the associated secondary and tertiary water, plays a key role because, effectively, the amylose acts like a water soaked sponge working its way into the interstitial zones and helping to hydrate the proteins as they become available through the action of the amylose molecule on the redistribution of fat.
Therefore, as the molecule reduces the size of the fat droplets and increases the number of lipid zones, it also provides a source of bound, partially bound, and loosely bound water to satisfy the requirements of the newly divided hydrophilic parts of the proteins. All of this happens without destroying the important calcium/protein interactions. It is thus reasonable to expect that original functionality can be retained. It is also reasonable to expect that the material balance can change, since a new component and additional water are incorporated with this technology. Further, since the molecule increases the system's ability to deal with or hold fat, more fat can be added.
Accordingly, what results is a new tool for manipulating final characteristics. Additional calcium or similar ions can be added at the appropriate stage, cream extracted from the cheese whey can be added back to the cheese to improve yields, enhance flavor, and fine tune melting properties. Butterfat, alone or complexed in the molecule, can be added to achieve finished baked characteristics. Additional enzymes, such as transglutaminase, can be used to finish the process to affect final product characteristics. The net effect is to produce a marketable cheese earlier, have more control over the final characteristics, and improve the economics through addition of less expensive components.
This is achieved through the introduction of the appropriate amount of the molecule material either as a gel or as a dried powder into the cheese and then heating the cheese to temperatures through the melting point of the fat component. The appropriate amount depends on the age of the cheese. New cheese curd may require the introduction of the dextrin gel in stages as the fat content is slowly divided allowing time for hydration of newly exposed zones. Older cheeses may have the entire targeted amount of the ingredient introduced at one point at the first blending and formation of paste. For new cheeses, the gel ingredient may be introduced in stages with the first stage introduced in such a way as to form a paste or intimate mixture of the ingredient into the cool cheese curd after which the product is warmed to begin melting. Too much of the ingredient at this stage can result in an over-emulsified product having a soupy texture. Conversely, too little of the dextrin gel ingredient will result in a bucky cheese with free liquid. Once the initial melt has been achieved, resulting in a smooth homogeneous mass, more gel ingredient in combinations of whey cream, ingredient, and, perhaps, butter may be added gradually with continuing heating and stretching. The cheese may be worked to develop the proteins up to a temperature of approximately 150° F. to 170° F. The degree of work and the final pH of the cheese affect the hardness and shreddalbility of the chilled product.
Alternatively, the dextrin gel ingredient may be manufactured so as to have a high pH. This helps to raise the pH of the cheese mass and make the proteins more vulnerable to intervention. After a homogeneous heated mass has been produced, the pH may be reduced by the use of various food acids to a desirable level. In this way, by increasing the initial pH to 6.3 to 7.5 with sodium hydroxide/dextrin gel for the initial mixing and heating stage and then reducing the pH to 5.2 to 5.6, a superior cheese product may be made from even the youngest brined cheese.
Different cheese culture systems produce cheeses with different characteristics at various stages of aging and as a result the ingredient system must be tailored specifically for the target cheese. This tailoring process also applies to the production of different grades of finished product to suit a variety of customer needs.
Samples of “tempered” or modified cheese prepared in accordance with the present invention have been made with various cheeses and have been reported to be “superior” in all aspects. These aspects include, but are not limited to, hot stretch, color, bite, texture flavor, melt, rate of hardening on re-cooling, shreddalbility, hot flow, and browning. Variations of formulae and processing variables may be used with the technology of the present invention to predetermine any and all of the foregoing characteristics.
A paste or intimate mixture should be made of the cheese and the dextrin ingredient. A steam jacketed mixer, or a direct steam-injected cooker with a system of screw augers, or a sequential combination of these devices should be used to melt the cheese/gel mass and work the cheese into a cohesive, stretchable mass.
As alluded to above, the age of the mozzarella is a very important factor to use in determining the proper dosage and sequence of dosing the gel into the mozzarella. Aged cheeses already have their butterfat globules divided to a certain extent by the natural action of the remaining cultures in the cheese and by the normal migration of water and the hydration of proteins. For these aged cheeses no special precautions must be taken and all of the desired target dextrin gel may be blended into the mozzarella at the beginning of the process. Indeed, if the cheese is old enough, for example 21 days, the cheese may be melted and the dextrin gel added after or as the mass reaches target temperature.
Younger cheeses may also be used as starting material. Cheese curd may be taken before the traditional cooking or stretching stages and used as starting material. In all cases, an evaluation of the condition of the proteins must be made to ascertain the proper dosage and sequence of dosage. Young curd that has not yet been cooked and is fresh may be dosed aggressively as the proteins have not yet established a strong hydrophobic position. Cheeses that have been cooked and stretched must be dosed more cautiously. Failure to form a complete paste prior to introduction of the heat or incorporation of too much or too little of the dextrin gel can result in either an over-emulsified or under-absorbed condition.
The “over-emulsified” condition takes on the appearance of a cheese soup in which no protein structure is observed and the cheese mass acquires a very thin consistency. This results from an overly aggressive division of the lipid pools or globules. Under the right conditions, addition of an amount of finished cheese to this pool can result in a reversal of the over emulsion. The age or stage of process and the type of culture system used in the making of the original curd will dictate the necessary dosage and sequence. Generally, it is desirable to conduct a series of test batches to determine the type of dosage that will be required to deal with a particular circumstance. This optimal profile will remain valid for subsequent batches and may be used for scale-up purposes.
The “under-absorption” condition results when the proteins are allowed to interact too aggressively without sufficient water to buffer the interaction. As opposed to over-emulsification, this under-absorbed condition takes on the appearance of well-defined thin threads of overdeveloped proteins. The protein masses continue to aggregate giving the appearance first of cellulite-type islets within the cheese, later developing into hard balls of concentrated protein. During this phase, free whey liquids are expelled. This condition results from an insufficient amount of dextrin being added at the primary or pasting stage, resulting in an insufficient division of butterfat globules. This condition is reminiscent of normal attempts to melt mozzarella at a very young age. If addressed early enough, the condition can be reversed with the addition of the corrected amount of dextrin gel.
Mozzarella that is cooked, brined, and between one and four days old is the most sensitive to dosage with the dextrin gel. The sensitivity of the four-day-old cheese is probably related, in part, to its salt content. Example formulas used to make these test cheeses resulted in as much as a 30% dilution of the cheese with dextrin gel and it is reasonable to assume that the gradual dilution of the salt during “finishing” modifies the functionality of the proteins and might result in apparent sensitivity to the changing characteristic of the brined cheese.
The purpose of this dextrin gel ingredient in the cheese is to provide an inexpensive (high water) meltable ingredient that will act as a processing aid to handle the fat content. The fat content issue has multiple dimensions:
(1) This technology can be used for extending full fat cheese by allowing for added low cost replacement or filler fat in which case the fat complexing ability of the dextrin gel tames the fat component and eliminates oiling out. (2) The dextrin gel converts the small existing fat content in low fat or fat-free cheeses into the complexed form, in which case the flavor profile of the fat is enhanced by virtue of the molecular dispersion that the dextrin encourages, and the individual flavor components are highlighted, creating a more rewarding fat reduced cheese product. (3) The dextrin enables the introduction of lower cost ingredients to reduce cost.
In all cases, the amylose component forms a film on the palate when the cheese is eaten. That film contains complexed fats and thereby enhancing the flavor perception of the system in both full fat and fat-reduced cheeses. When eaten alone or as part of an entree, such as pizza, the enzymes in the saliva slowly hydrolyze the amylose whereupon the flavorful fats are released, whereby the flavors of the cheeses made with this product are longer lasting and more satisfying.
The foregoing aspect of the present invention can be achieved by first chopping a suitable mixture of cheeses into shreds or pieces and adding any discretionary ingredients, such as maltodextrin, salt, caseinates, and the like to the chopped cheese mixture. Melting salts, such as disodium phosphate or sodium citrate, may be added, but are normally not needed since the melting characteristics can be substantially controlled by the engineering of the subject dextrin product.
Other chemicals may be added, such as acidulants to influence the remelting and shreddability characteristics of the cheese. Ironically, calcium ions, e.g., calcium chloride or other calcium source, may be added to increase the strength of the cheese proteins. This is contrary to existing cheese processing teaching, where calcium must be removed from active participation to allow the proteins to be melted. Also, enzyme systems, including transglutaminase and whey/glucose oxidase/catalase systems, may be added to strengthen the proteins.
A portion of the full fat cheese used in this process may be pre-treated with a dextrin gel which disperses the fat more uniformly making the fat more available to a lipase enzyme treatment, which further contributes flavor to reduced fat cheeses. In this case, the pre-treated cheese may be heated to inactivate the lipase enzyme prior to being incorporated into the main process.
Other enzyme systems may also be added at this point. Enzymes, such as lactase to reduce the lactose content of the cheese, are useful to control the browning characteristics of the finished cheese product. Glucose oxidase may be added to convert the resulting glucose to gluconic acid. Catalase enzymes can convert the resulting hydrogen peroxides to oxygen and strengthen the protein matrix by converting free sulfhydryl groups to disulfide linkages. Transglutaminase may be added to cross-link proteins, thereby further strengthening the protein matrix.
Secondly, the hydrogel host product of this invention is mixed in with the chopped cheese mixture at ambient temperature. The sequence and amounts of the addition of the dextrin depends on the age of the cheese as earlier discussed. The dextrin may be stored in its original hydrated form for a significant period of time at refrigerated temperatures as a gel. It will remelt on heating. Alternatively, the dextrin may be spray dried and mixed in with the cheese mass followed by the addition of water.
Next, the cheese mass is heated to 60° C.-70° C. and mechanically mixed to fully incorporate the ingredients and to work the native and added proteins, if any, to develop strength.
An example of a cheese manufacturing formula using this invention is as follows:
1. Mozzarella cheese, Low Moisture part skim,
3,000
g
75.2%
2 days old.
2. Salt
24
g
0.6%
3. Hydrated host gel
220
g
5.5%
Form paste
Mix/Heat to about 130° F. (about 54° C.)
4. Hydrated host gel 2 (melted)
180
g
4.5%
Mix/Heat 130-140° F. (54-60° C.)
5. Whey Cream (33.15% fat)
150
g
3.8%
Mix/Heat 130-150° F. (54-66° C.)
6. Hydrated host gel 3 (melted)
90
g
2.2%
Mix/Heat 130-150° F.
7. Butter Fat
120
g
3.0%
8. (Optional) Transglutaminase enzyme mixed
1
g
0.025%
with butter
Mix/Heat 130-150° F.
9. Water
200
g
5.0%
10. Mix/Heat 130-170° F. (54-77° C.) knead
to develop protein elasticity & strength
This procedure was used with cheese of different ages. The pasted cheese mass melted well without the characteristic formation of rubbery casein masses and free whey. Mixing was done in a Hobart mixer with a steam-jacketed bowl. If mixing is inefficient or cannot incorporate the dextrin gel efficiently into the cheeses mass, a localized under-absorbed condition may result. That situation may be recovered with the addition of additional dextrin gel at the proper time. The batch may taken to a higher temperature 165-167° F. (74-75° C.). The finished cheese product does not appear to suffer from the higher temperature and subsequent baking tests showed that the chilled, shredded sample of this cheese had superior baking characteristics. This higher temperature is commercially important, as the product with more heat treatment has less enzymatic activity remaining and therefore less storage related quality issues.
It is desirable to use this technology to “finish” the cheese as close to the time of original manufacturing as possible because the proteins in fresh cheese are the strongest and offer the most opportunity for dilution for optimum economics.
Alternatively, this technology involves taking finished cheese loaves of suitable age and retro processing that cheese to upgrade the functionality and economics. That remains a good use of this technology; however, the current technology is also capable of taking cheese directly from the curd stage or the cooker and finishing it prior to shredding.
This technology is capable of successfully finishing cheese curds taken prior to the cooker. This represents a significant process advantage because of reduced processing costs, higher capacity, and lower inventory loads. However, the fresh curd normally has higher whey content, which is normally leeched out during the brining stage. Bypassing this stage increases the whey content for this “curd intercept” approach. Traditional cheese processes attempt to balance off the aggressiveness of curd cutting with the need to preserve yield. This results in certain acceptable whey content in the cut curd. Some of this whey is then normally washed out of the cheese mass during the cooking stage. This is followed by a subsequent migration of additional whey out of the cheese during brining.
The process of the present invention allows whey cream and fines to be readily recombined into the mixing/cooking/kneading stages. This then enables the cheese curd to be more aggressively harvested and the original curd can be processed more aggressively, expelling more whey in a more aggressive cutting stage and then proceeding directly to the present process, thereby bypassing the traditional cooking stage.
The appropriate level of salt can be added upstream at the mixing/pasting stage, thereby replacing the less controllable brining stage. Varying saltiness is a major issue with the traditional mozzarella cheese making process. Since salt is added as needed to the cheese mass before or during cooking the method or the present invention eliminates this unpredictable brining stage.
Cooling can be achieved in a chilling tunnel after which shredding can take place in line. This process should result in a lower capital cost, higher capacity, lower operating costs, fewer process and quality variations, reduced ingredient cost of production, lower inventory loads, more control over final functional characteristics, and more efficient use of by-products.
It is very important to note that this technology may be used to extend cheese by as much as 40% and, at the same time, produce a mozzarella that actually has higher quality with more desirable attributes, in every respect, than traditional mozzarella.
The following is a discussion of the basic manufacturing considerations including the addition and mixing zones as well as indications of the types of control systems to automate the addition of the various ingredients.
The Preparation Stages
The starting cheese material (temperature less than about 120° F., i.e., about 49° C., or below melting)
Curd or Cooked cheese pre brining or Brined cheese.
The Pasting
Ricing or other size reduction Pre-Mixing—e.g. ribbon blender, mixing screw
Dextrin gel 1 addition Salt Enzymes
Pasting—Plate mill, etc. or alternatively the ribbon blender may be set at discharge mode with the discharge gates closed to force the cheese mass to mix more vigorously. Screw pump/conveyor linked to mixer.
The Mixing
The mixer is a multi zone, steam/cool water jacketed closed mixer with intermittent paddles to provide strain testing zones utilizing strain gauges to measure the elastic nature of the cheese mass throughout the mixing/heating/addition stages. Conductivity, pH, temperature, and specific ion measurement can be taken at various points to characterize the changing nature of the cheese as it flows through the process to control the correct levels of addition of each of the ingredients and to determine the exact characteristic of the final cheese product. The measurements are fed to a programmable logic controller to automate the addition of ingredients and application of temperature to match particular product specifications.
1. The first stage heating mixing
The measurement The addition of Dextrin gel 2 in stages
2. The second stage—conditioning and cream addition
The measurement The addition of Cream and Dextrin gel 3 as necessary
3. The third stage—Butter fat addition, addition enzymes
The measurement The addition of Butter and enzymes.
4. The fourth stage—Additional water
The measurement Addition of the finishing water Measurement to confirm finishing characteristics.
5. Extrusion into packages for cooling or to ribbon chiller,
Alternative Manufacturing Method 2 Using Dry Emulsifying Dextrin Powder and Cooking in a Cheese Processor:
Mozzarella Cheese Curds
1500
lbs
Emulsifying Dextrin Powder
64
lbs
Anhydrous Butter
80
lbs
Salt
2
lbs
Non fat dry milk
44
lbs
Water (added at cooker, batch equivalent)
200
lbs
Total
1,890
lbs
Grind cheese and pneumatically convey to double screw blender.
Add dextrin powder.
Add non-fat dry milk for flavor augmentation.
Add salt.
Add anhydrous butter
Mix to a paste by mixing while in discharge mode with the exit gates closed until a smooth paste is formed.
Add a portion of the cheese paste to the twin screw, steam injected, cheese cooker
Add Water proportionate to the cooking batch
Inject steam until cheese mass reaches a minimum of 132 deg F. ideally 150 to 160 degrees F., with the mixing screw speed at 100 RPM.
Continue to operate screw to stretch the cheese for 2 to 3 minutes.
Dump into holding tank and pump into molds.
The following is a description of a few of the emulsifying dextrin gels that may be produced and a brief discussion of their characteristics and methods of use.
Medium Chain. This product is the primary gel to be used at the first stage of the process as the initial dose in the cheese according to the sample starting formula. It may be used as the only gel in the formula at all stages or in combination with secondary doses of the any or both of the following gels. It will melt easily and has the highest fat management ability.
Short Chain. This product has a low melt point and may be used at the second or third stages of the process to increase spread and reduce the melt temperature of the finished mozzarella. This probably won't be used at a rate higher than 2 to 4 percent of the finished cheese weight.
Long Chain. This product is exceptionally strong and is used to manage unusually high free-water situations in the second or third stages. It may also be used at a low percentage in the original grind in combination with the primary gel, 450e. Generally 700eL will strengthen the cheese, giving it a longer, chewier texture, and increase the melt point to decrease melt and flow. 700eL has a high melt temperature and should be pre-melted to 95° C. with agitation. It may be diluted with some of the additional formula water for easier handling.
The following formulations describing methods of the use of the guest/host complex structure described herein are merely examples of many possible recipes. Those skilled in the art will realize that subtle variations in ratios can make one product more desirable for some applications than others. The formulas stated here are not necessarily the only ratios available, nor are they necessarily the best, but rather they are presented as starting points that demonstrate the utility of the underlying invention.
Formulations Using the Technology of the Present Invention:
Cream Cheese Analogue
Partially Hydrogenated Corn Oil
22.00
lbs
Emulsifying dextrin gel 20% solids
20.00
lbs
Liquid Premix
Water
16.14
Non fat dry milk
1.29
Bravo 500 Whey Protein Concentrate
1.61
Calcium Caseinate
1.41
Maltrin 100 Maltodextrin
3.38
ButterBuds Manchego Cheese Flavor
0.20
Salt
0.45
Lactic Acid 88%
0.35
Firminich nat. Flavor 73161202SD
0.01
Firminich art. Flavor 598259S16
0.01
Total
66.85
lbs
Premix liquid premix ingredients.
Melt emulsifying dextrin gel in steam jacketed kettle.
Agitate with propeller type mixer, add corn oil to melted dextrin gel.
Add liquid premix to dextrin/oil mixture.
Add lactic acid and adjust to pH 4.65 as needed.
Add additional flavors.
Homogenize at 75° C. with a two stage homogenizer at 500/2500 lbs.
Package and chill.
Blue Cheese analogue
Fleischmann's Corn Oil Mixture
200
g
Emulsifying dextrin hydrogel 20% solids
300
g
Cargill Phyto Sterol Ester
10
g
Butter
110
g
Vit A Palmitate
0.6
g
Nonfat Dry Milk Powder-Non Instant
20
g
Whey Protein Concentrate
25
g
Calcium Caseinate-Dispersible EX
22
g
Milk Protein Concentrate
40
g
Butter Buds Blue Cheese Flavor
65
g
Maltrin M100 Maltodextrin GP
40
g
Water
250
g
Lactic Acid 80%
7.2
g
Salt
7
g
TOTALS:
1097
g
Add powder to water, let hydrate 2 hours.
Melt ButterGel.
Melt Butter and oil mixture.
Blend together with Braun hand blender while warm.
Blend powder slurry into ButterGel mixture.
Add acid to pH 4.7.
Cook in microwave to 180° F. (82° C.) (stir often).
Cool while stirring occasionally.
Curry Powder Paste
Curry Powder
20
g
Butter
10
g
Coconut Oil
40
g
ButterGel 450e 10/02
100
g
Fibrim 2000 Soy Fiber PT
10
g
Hydrol. Vegetable Protein
7
g
Fermented Soy Sauce Powder
1
g
Black Pepper
1
g
Dehydrated Garlic
0.5
g
White Cake Flour-Enriched-Sifted
10
g
Chicken Broth Base
2
g
Water
20
g
TOTALS:
221.5
g
Half-Fat Butter Spread
Emulsifying dextrin hydrogel 20% solids
60
g
Butter
114
g
Water
50
g
Salt
1
g
TOTALS:
225
g
Paraffin Complex
Emulsifying Dextrin Powder
15
g
Water
85
g
Paraffin
20
g
TOTALS:
120
g
Preheat paraffin till melted.
Dissolve dextrin powder in water and heat in microwave to 90° C.
Float melted paraffin on top of hot dextrin solution.
Submerge electric hand mixer in container of dextrin solution and begin mixing to draw paraffin down into dextrin solution. The resulting clathrate of paraffin is water disperable and forms a white milky solution which disperses completely in any quantity of excess water.
Mashed Potato Cream
Emulsifying Dextrin Powder
45
g
Water
546
g
Nonfat Dry Milk Powder-Non Instant
54
g
Butter
100
g
Mono + Diglycerides - Soybean Oil
15
g
Sodium Stearoyl Lactylate-
6
g
NaturalButter Flavor
6
g
Peeled Potato-Cooked
4250
g
Skim Milk
0.1
g
Salt
22
g
TOTALS:
5044
g
Proper use is at 15% of cooked potato weight.
Used at 20% of cooked potatoes, salt to taste (approx 0.5% of potato weight) added additional skim milk 6.5% of cooked potato weight.
Whipped Cream
Nonfat Milk Solids
131.7
g
Butter Oil-anhydrous
322
g
White Granulated Sugar
131.7
g
Water
834.1
g
Emulsifying Dextrin Powder
14.63
g
Water
58.54
g
Mono + Diglycerides - Palm Oil
7.317
g
TOTALS:
1500
g
Blue Cheese Mild cultured,
Fleischmann's Corn Oil Mixture
300
g
Emulsifying dextrin hydrogel 20% solids
300
g
Nonfat Dry Milk Powder-Non Instant
10
g
Water
200
g
Nonfat Dry Milk Powder-Non Instant
20
g
Whey Protein Concentrate
25
g
Calcium Caseinate-Dispersible
18
g
Milk Protein Concentrate
10
g
Butter Buds Dried Cream Extract
4
g
Butter Buds Blue Cheese
24
g
Maltrin M100 Maltodextrin GP
65
g
Butter
50
g
Salt
4
g
TOTALS:
1030
g
ButteryGel Lite, enzyme
Emulsifying dextrin hydrogel 20% solids
250
g
Butter
217
g
Enzyme Preparation
0.03
g
TOTALS:
467
g
Enzyme preparation: 3 drops Palatase
Add at 50.3° C.
10 minutes reaction time while agitating intermittently with a Braun hand mixer.
Heat to boiling in a microwave oven set at full power.
Cover with plastic and cool at room temperature.
ICING, Cream Cheese Low Fat
Cream Cheese Lite Oct. 15, 2002 v.2
5
lb
Emulsifying dextrin hydrogel 20% solids
1
lb
White Powdered Sugar-Sifted
5
lb
Nonfat Milk Solids
0.25
lb
Salt
0.24
oz-wt
Water
0.1
lb
Pure Vanilla Extract
1
oz-wt
TOTALS:
5184
g
Cheddar Cheese analogue
Fleischmann's Margarine-Stick
350
g
Emulsifying dextrin hydrogel 20% solids
300
g
Cargill Phyto Sterol Ester
20
g
Vegetable Shortening (Crisco/Fluffo)
0.01
g
Nonfat Dry Milk Powder-Non Instant
0.01
g
Water
250
g
Nonfat Dry Milk Powder-Non Instant
30
g
Whey Protein Concentrate
25
g
Calcium Caseinate-Dispersible
18
g
Milk Protein Concentrate
40
g
Butter Buds Cheddar EX Cheese
17
g
Butter Buds Manchego Cheese
4
g
Butter Buds Parmesan Cheese
3
g
Butter Buds Romano Cheese
2
g
Maltrin M100 Maltodextrin GP
80
g
Lactic Acid 80%
6.5
g
Salt
6
g
TOTALS:
1152
g
Add powder to water, let hydrate 2 hours.
Melt Emulsifying dextrin hydrogel 20% solids.
Melt Butter and shortening.
Blend together with Braun hand blender while warm.
Blend powder slurry into ButterGel mixture.
Add acid to pH 4.7.
Cook in microwave to 180° F. (stir often)
Cool while stirring occasionally. Less stirring results in harder cheese.
Boston Creme Filling, Low Fat TruSweet 42 High Fructose Corn Syrup 1.5 lb 43/62 DE CSU Corn Syrup 3.234 lb Emulsifying dextrin hydrogel 20% solids 1.25 lb Butter 100 g Water 1 lb Two Fold Vanilla Extract 4.256 g Salt 20.57 g Nonfat Milk Solids 107.8 g TOTALS: 3401 g Butter-oil Clathrate Emulsifying dextrin hydrogel 20% solids 120 g Water 150 g Butter Oil Anhydrous 180 g Potassium Sorbate 0.8084 g TOTALS: 450.8 g Low Fat Ice Cream with Whey Cream Emulsifying dextrin hydrogel 20% solids 75 g Water 250 g Cream-Medium (25%) Fat 300 g White Granulated Sugar 85.51 g Maltrin M200 Corn Syrup Solids GP 57.56 g Ice Cream Stabilizer 3.289 g Nonfat Milk Solids 95.38 g White Granulated Sugar 85.51 g Maltrin M200 Corn Syrup Solids GP 57.56 g Ice Cream Stabilizer 3.289 g Nonfat Milk Solids 95.38 g Water 522 g TOTALS: 1630 g Perstearic Acid Emulsifying dextrin hydrogel powder 355.5 g Water 1421 g Stearic Acid 284.4 g Hydrogen Peroxide 35% 97.2 g TOTALS: 2158 g
The dextrin is arbitrarily set at 125% of the stearic acid weight to make the powder more soluble. One mole of stearic acid (284.4 g) to one mole of H 2 O 2 (34.0 adjusted to 35% solution=97.2 g).
Co-Dried ButterGel/Low DE MD Emulsifying dextrin hydrogel 20% solids 500 g 83.33% Maltrin M040 Maltodextrin 100 g 16.67% TOTALS: 600 g 100% Lactylate Hydrate Emulsifying dextrin hydrogel 20% solids 45.9 g Water 16.7 g Sodium Stearoyl Lactylate-Emulsifier 18.7 g Mono + Diglycerides - Palm Oil 18.7 g TOTALS: 100 g Butter Cheese Emulsifying dextrin powder 5.88 g Water 24.3 g Phosphoric Acid MNS 0.4 g Baking Soda/Sodium Bicarbonate 0.26 g Butter 9.15 g Butter 8 g Salt 0.8 g Disodium Phosphate Dihydrate-DSPD MNS 0.4 g Sodium Hexametaphosphate (Graham's Salt) 0.4 g Dry Curd Cottage Cheese 100 g TOTALS: 149.6 g Mashed Potato Cream Emulsifying Dextrin 45 g Water 546 g Nonfat Dry Milk Powder-Non Instant 54 g Butter 100 g Mono + Diglycerides - Soybean Oil 15 g Sodium Stearoyl Lactylate-Emulsifier AI 6 g Hi Concentrate NC-NaturalButter FlavorCU 6 g Skim Milk-No Added Vit A 350 g Peeled Potato-Cooked 4250 g Skim Milk-No Added Vit A 0.1 g Salt 22 g TOTALS: 5394 g Butter, ½ Fat Emulsifying dextrin hydrogel 20% solids 234 g Citric Acid Anhydrous 0.125 g Lactic Acid 80% 0.4 g Butter Oil-anhydrous 156 g Tenox TBHQ Antioxidant EK 0.1 g Salt 1.4 g Butter Buds 32X-Flavor Concentrate CU 0.6 g Butter Buds 32X-Flavor Concentrate CU 0.6 g Water 13 g Sweet Buttermilk-Dried 6 g Potassium Sorbate 0.4 g TOTALS: 412.6 g Cream Cheese Lite Cream Cheese 600 g Emulsifying dextrin hydrogel 20% solids 600 g Guar Gum AQ 1 g Butter 0.1 g Whey Protein Concentrate 80 g Water 120 g Lactic Acid 80% 0.4 g Salt 7 g TOTALS: 1408 g Cream Cheese, ⅓ Less Fat Cream Cheese 500 g Emulsifying dextrin hydrogel 20% solids 250 g Water 40 g Whey Protein Concentrate 25 g Lactic Acid 80% 0.15 g Salt 2.5 g TOTALS: 817.6 g
Melt Emulsifying dextrin hydrogel 20% solids. Add whey to water (Grande Bravo/500) Heat cheese to 70° C., microwave 4 or 5 times at 30 sec, stir between times, pour complex into cheese, while blending, pH 4.9, use 4 drops of 88% lactic acid to bring to 4.8. A homogenizer could be used, possibly at a cooler temprature, for firmer texture.
Cream Cheese, Pumpable Cream Cheese 400 g Butter Oil-anhydrous 100 g Emulsifying dextrin hydrogel 20% solids 250 g Water 150 g Potassium Sorbate 0.2 g Salt 7 g Hi Concentrate-Natural Butter Flavor CU 0.1 g Lactic Acid 80% 0.2 g TOTALS: 907.5 g
Cook dextrin, reserve ⅓, hydrolyze ⅔, denature enzyme with heat (3× to boiling), recombine, add at 85° C. to room temperature cream cheese, blend at low speed, adjust the pH to 5 with malic acid & lactic acid.
To make cheesecake, blend ⅓ Improver with ⅔ cream cheese at room temperature. Universal Old Fashioned Butter 4-6 drops. Lactic Acid 10 drops. Salt 8 grams. Hydrolyze with Ban 5 minutes+2 minutes after some stirring dropwise (5 drops in 10 grams H 2 O). Made with good dextrin
Cream Filling Butter Gel
White Powdered Sugar-Sifted
1242
g
Nonfat Milk Solids
104.4
g
Salt
9
g
Two Fold Vanilla Extract VD
9
g
TruSweet 55 High Fructose Corn Syrup
756
g
Emulsifying dextrin hydrogel 20% solids
790
g
Vegetable Shortening (Crisco/Fluffo)
846
g
Mono + Diglycerides - Palm Oil
1
g
TOTALS:
3757
g
Mix first 4 ingredients.
Pre-blend water and corn syrup and add.
Add shortening, mix ½ minute slow, 4½ minutes medium
Add water slowly, ½ minute.
The Enzymes
Transglutaminase, supplied by Ajinomoto, is an enzyme with the ability to cross-link proteins through the formation of covalent bonds. The two amino acids that it uses to cross-link are glutamine and lysine. These two amino acids are normally found in the casein structure of cheese curd and therefore the effect is synergistic. In other words, the use of the transglutaminase enzyme strengthens the cheese by magnifying or increasing the intermolecular linkages in the existing proteins. This results in a magnification of stretchiness.
Novozym 771 is a liquid preparation of glucose oxidase (EC 1.1.3.4) containing catalase (EC 1.11.1.6). It catalyzes the oxidation of glucose to gluconic acid (a GRAS organic acid with a neutral taste) and removes oxygen simultaneously according to the reaction scheme:
Glucose+O 2 +H 2 O--→glucose oxidase-→gluconic acid+H 2 O 2 H 2 O 2 →catalase→½O 2 +H 2 O
The overall reaction is:
Glucose+½O 2 →glucose oxidase/catalase→gluconic acid
Novozym 771 is produced by a selected strain of Aspergillus niger microorganism containing an amount of catalase activity. The enzyme blend causes the oxidation of free sulfhydryl groups, whereby disulfide linkages are formed resulting in stronger, more elastic cheeses.
It has now been found that this mechanism may be used in cheese systems. The proteins that are normally remaining in cheese curds are relatively low in sulfhydryl groups, these groups having been washed out with the soluble whey portion of the process. By adding variable amounts of these whey products back into the cheese mass, either dried and reconstituted with water, or in their original wet form, or concentrated provides a sulfhydryl content to provide an additional functional component to the cheese matrix. Additionally, a lactase enzyme may be added to convert some of the indigenous lactose into additional glucose, which then can fuel the glucose oxidase activity. The action of the catalase enzyme on the byproduct hydrogen peroxide then serves to oxidize the sulfhydryl groups to form disulfide linkages.
These disulfide linkages are in addition to the normally existing linkages that bind caseins. They act as an additional scaffolding of structure that stabilizes the protein mass. This additional structure inhibits the flex of the protein structure and thereby inhibits the flow and stretch characteristics of cheeses at higher temperatures. This is useful for the manufacture of cheeses where decreased flow properties of hot cheese are desirable.
Palatase is a fungal lipase produced by fermentation of a strain of Rhizomucor miehei and is used to hydrolyze fatty acids and produce enhanced flavors in cheeses. Normally the enzyme takes a longer period of time to act on the relatively large globules of fat present in young cheese. The internal portions of the fat globules are hidden and not available to the action of the enzymes. It is only after aging, as the naturally occurring proteases shorten the chain lengths of the proteins, that the lipase enzymes can attack the fat component more aggressively and produce the characteristic flavored cheeses. The technology of the present invention divides the fat globules earlier and makes the fat more susceptible to enzymatic attack sooner and to a much more significant degree. In this way, the flavors can be developed much more quickly and economically. The enzymes are then denatured during the cooking process.
Lactozyme is a beta galactosidase (lactase) produced from the yeast Kluyveromyces fragilis , which converts lactose to glucose and galactose. These sugars do not brown as much as lactose upon heating and therefore the enzyme can be used to reduce the excess browning that may occur with the higher lactose content associated with higher whey concentration.
Ban 480L is an alpha-amylase produced from Bacillus amyloliquefaciens 1,4-alpha-D-glucan glucano-hydrolase. It is an endo amylase attacking the 1-4 bonds along the starch chain internally in a random fashion, but is unable to cleave 1-6 bonds that attach amylopectin branches to the amylose molecule. Thus, the amylopectin branches provide natural built-in barriers to complete hydrolysis and therefore help to maintain a useful minimum size of dextrin end product. (The acetyl groups also have a similar effect). This is contrasted to beta amylases, which are exo-amylases that cleave off maltose units in a step-wise fashion from the ends of starch chains and destroy the hosting capability of the amylose.
Pullulanase enzymes, such as Promozyme from Novo, cleave alpha 1-6 bonds in amylopectin and may be used to de-branch the amylose enzyme to remove the 1-6 linkages and allow the alpha amylase more complete access to the amylose molecule.
In view of the many changes and modifications that can be made without departing from principles underlying the invention, reference should be made to the appended claims for an understanding of the scope of the protection to be afforded the invention.
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Disclosed herein is a method for harvesting amylose host material comprising enzymatically treating starch after the starch has been chemically modified to uniformly insert a steric hindrance substituent.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates generally to the field of electronic record keeping. More specifically, the present invention is related to gathering and storing input data and automatically generating journal entries according to a rules-based mechanism.
[0003] 2. Discussion of Prior Art
[0004] Many people desire to keep some sort of formal account of their personal or professional doings. Unfortunately, life is often so busy that most either do not wish to take the time to record events that happen in their life or simply do not remember to do so until after a good recollection of those events has already passed. Therefore, individuals find it difficult to maintain the level of journaling they desire for their personal and professional lives. Even those who do keep a diary or journal on a regular basis often wish that their record was more complete.
[0005] In addition, corporate entities must often spend valuable resources trying to record and maintain histories of all of their business events. The rise of pervasive computing and wireless electronic communication has increased the amount of information available electronically to those people making extensive use of these technologies. While such information seems to be potentially harmful if used inappropriately, it may also be used to significantly benefit a person who utilizes these resources wisely.
[0006] Information about a person, such as location, time, proximity of associates, and events, has always been the crux of information recorded in a journal or diary. Current event archiving systems are error prone and often of inconsistent format. With all of this information now potentially available to a single computer system, the journal entry process can be extended to become more automated.
[0007] The prior art has failed to provide for a fully automated rules-based journal mechanism.
SUMMARY OF THE INVENTION
[0008] A system for journal entry generation continuously receives information from a person or group of people and compares that information through a rules-based mechanism. If the mechanism determines that an entry should be generated, it passes the data obtained by the system along with the appropriate template to a journal entry generator. The generator then uses the information to populate the template as appropriate to create the journal entry. The entry is placed in the person's electronic journal, and, if desired, some form of notification can be sent to the person of the entry's creation.
[0009] In an alternative embodiment, memory cues can be set up in advance to assist a user in entering or acknowledgment of entries to a journal at a predefined later time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 illustrates a general overview of generating a journal entry.
[0011] [0011]FIG. 2 illustrates a general system used for data input and filtering.
[0012] [0012]FIG. 3 illustrates a journal entry process.
[0013] [0013]FIG. 4 illustrates a general overview of the process of the creation of reminders.
[0014] [0014]FIG. 5 illustrates a second embodiment of the system's automatic journal entry generator.
[0015] [0015]FIG. 6 illustrates a sample journal template.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] While this invention is illustrated and described in a preferred embodiment, the device may be produced in many different configurations, forms and materials. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will envision many other possible variations within the scope of the present invention.
[0017] A thorough and trusted system for journal entry could aid corporations, governments, and, most of all, individuals and families. Corporations and governments are able to review past business meetings, both formal and informal, and provide a mechanism for recording histories that reduce overhead costs of a manual system. Individuals are able to preserve information as memories about themselves for access years later and pass these memories on to their future generations. Of course, the real advantage of this system is that the effort of starting and maintaining a system of thorough record keeping is automated, thereby reducing costs, and more significantly, improving reliability and thoroughness. Important occasions are far more likely to be recorded and thus far less likely to be permanently forgotten.
[0018] Implementation of a system that monitors information about a person or resource and generates journal entries for that person or resource at the appropriate times will alleviate the problems mentioned previously. The appropriate times for entry generation can be defined for each individual through a rules-based mechanism. The individual defines rules that, when met, automatically generate a journal entry according to a template defined in the computer system.
[0019] The general process of generating a journal entry is shown in FIG. 1. Information is continuously gathered about a person or resource 100 that will be stored and compared through a rules mechanism 102 . Should the conditions of the designated rules be met 104 , a journal entry is generated 106 . For instance, a user might tell a system that whenever a group of their friends are gathered together in one place, and if it is the birthday of one of the people gathered, a journal entry should then be generated about the user's attendance to the birthday party for the friend. The entry includes the names of those present, where they were, and what they did, as well as any additional information the user entered into an electronic calendar kept on the system.
[0020] This journal system is general enough to work for any entity for which pervasive information is known. A Global Positioning System (GPS) device attached to a suitcase (with sensors hooked up to the suitcase) records and shares information about its surroundings. Rules and templates are defined for creating journal entries for the suitcase. Hereafter, the entity, be it a person, animal, object, etc., will be referred to as a ‘person’, without loss of generality.
[0021] [0021]FIG. 2 shows an illustration of parts of the journal system 200 used for data input and automatic journal entry. Computing system 202 continuously gathers and stores external information 201 . Information does not need to be obtained from personal devices only; any external device may communicate information to the system. Therefore, this is a continuous process so as long as the devices are transmitting information.
[0022] Information internal to the system is then gathered 204 from the system data 206 and combined with the information obtained externally to the system 201 . System data 206 includes, for example, calendar entries, past journal entries, associates of resources with locations, etc. The information is gathered by, for example, electronic personal/corporate calendars, previous journal entries, coordinates from a GPS device, activity on a personal computer or hand-held device, communication through a cell phone or pager, and other similar devices. Once gathered, the combined information is passed 208 to the rules mechanism 210 .
[0023] Using the information 208 gathered by the computing system 202 , the rules mechanism 210 evaluates whether or not the factors merit a journal entry. If so, the rules mechanism gathers the appropriate template 212 for such an entry. Both the data and template are then passed 214 to A an entry generator 216 . The generator 216 then creates an entry through a transformation process, which applies the information given by the rules mechanism 210 to the template 212 , and produces a journal entry that is sent and inserted 218 into the person's journal 220 .
[0024] [0024]FIG. 3 further illustrates the flow of the journal entry process for the system in FIG. 2. External information or data 201 is sent to the computing system 202 and stored 300 . After all information is received, the internal information of the system is gathered and stored 302 to be evaluated for possible journal entry. All data is to be evaluated according to a rules-based mechanism 304 . Once rules are applied and a decision for journal entry is made, a proper template is selected and populated with the data to create an entry 306 by entry generator 214 . This entry is then inserted and stored into a person's journal 308 .
[0025] In a second embodiment, the invention is extended to include creation of reminders for journal entries that alert a user of previously recorded information. This embodiment allows for creation of triggered memory cues for delayed journal entries. FIG. 4 shows the general overview of the process of the creation of reminders. The system continuously gathers information about a person or resource 400 , the system waits for prompts from a user 402 to create a memory cue 404 , waits for information recorded that associates the user at the given time and place 406 , and then activates a reminder to alert the user of the entry 408 . The user then acknowledges the completed journal entry or manually adds additional information, which is then stored in their journal records.
[0026] [0026]FIG. 5 illustrates 500 the system 200 of FIG. 2 with new elements 506 and 507 . As with the system of FIG. 2, computing system 503 continuously receives and stores external information 501 . The system additionally stores internal data 502 about individuals, places, and resources associated with possible future journal entries (i.e., calendar entries, old journal entries 508 , locator information (e.g., GPS 510 ), etc.). Such information is obtained by electronic sources, such as personal calendars located within the system (or transferred thereto from remote sources). System 503 then receives a request for a delayed journal entry memory cue by a user 504 . Information internal to the system is gathered 511 from the internal system data 502 and combined with the information obtained externally to the system 501 . Once gathered, the combined information is passed 505 to data filter 506 . Data filter 506 separates data relevant to requester 504 . The filtered data is sent to the journal memory cue generator 507 . The memory cue generator will create a time-based cue for completion of the template entry, either automatically or manually by the user. Once a cue is created, it is populated with known internal system data 502 and waits until this memory cue is activated at a later time, for instance, when the cued event for a journal entry actually takes place or soon thereafter, the journal entry is completed and placed 509 in a person's journal 508 .
[0027] [0027]FIG. 6 illustrates a sample rules template 600 for the preferred embodiment described above. Shown in the template is a method using the XML standard for document formatting, but other formatting methods can also be used for defining a rules mechanism for journal entry.
CONCLUSION
[0028] A system and method has been shown in the above embodiments for the effective implementation of rules-based automatic generation of journal entries. While various preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention, as defined in the appended claims. For example, the present invention should not be limited by software/program, computing environment, specific computing hardware and specific journal entry types, rules, filtering techniques, sources of input data or template requirements.
[0029] The above enhancements for icons and its described functional elements are implemented in various computing environments. For example, the present invention may be implemented on a conventional IBM PC or equivalent, multi-nodal system (e.g., LAN) or networking system (e.g., Internet, WWW, wireless web). All programming, templates, and data related thereto are stored in computer memory, static or dynamic, and may be retrieved by the user in any of: conventional computer storage, display (i.e., CRT) and/or hardcopy (i.e., printed) formats. The programming of the present invention may be implemented by one of skill in the art of database programming.
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A system for record keeping that utilizes the advances in computer technology and alleviates problems such time constraints by monitoring information about a person or resource and automatically generating journal entries for that person or resource at the appropriate times. The appropriate times for entry generation can be defined for each individual through a rules-based mechanism. When an individual's rules are met, a journal entry is automatically generated according to a template defined in the computer system. The entry is placed in the individual's electronic journal, and, if desired, the individual can be notified of the generated entry or delay entry of said journal entry until receiving a notification at a later designated time.
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This application is a continuation-in-part of application Ser. No. 08/747,092, filed Nov. 7, 1996, now pending.
FIELD OF THE INVENTION
This invention relates to methods and apparatus for organizing and processing information, and more particularly, to computer-based graphical user interface-driven methods and apparatus for associative organization and processing of interrelated pieces of information, hereinafter referred to as "thoughts."
BACKGROUND
The general-purpose digital computer is one of the most powerful and remarkable information processing tools ever invented. Indeed, the advent of the digital computer, and the proliferation of a global digital information network known as the Internet, has thrust the world headlong into what is now recognized by many analysts as an "information era" and an "information economy," in which the ability to access and process information in an effective manner is one of the most important forms of economic power.
The potential impact of the digital computer and the Internet on information distribution and processing is undeniably revolutionary. Yet, conventional software environments are generally organized around metaphors and principles from earlier eras. Text-based operating systems like Microsoft ® DOS essentially treat the computer as a giant filing cabinet containing documents and applications. A strictly hierarchical file directory provides a rigid, tree-like structure for this digital file cabinet. Individual documents are the "leaves" of this tree hierarchy. The directory structure generally does not include or express relationships between leaves, and users generally access documents and applications individually, using the directory structure. Even the now ubiquitous graphical "desktop" computing environment, popularized for personal computers by the Apple Macintosh® and Microsoft Windows® operating systems, also simulates a traditional office environment. Individual documents and applications, represented by graphical icons, are displayed on the user's screen, to be accessed one-at-a-time. Once again, a strictly hierarchical, tree-like directory structure is imposed to organize the contents of the desktop.
Although the desktop and file cabinet metaphors have been commercially successful, the limitations and drawbacks of these traditional metaphors become clear when one considers the strikingly different way in which the world's other powerful information processing machine--the human brain--organizes information. Instead of being confined and limited to strictly hierarchical file directory structures, the human brain is thought to interconnect numerous pieces of information through flexible, non-hierarchical, associative networks. As those of skill and experience in the art are aware, it is often clumsy for users of traditional, prior art operating system interfaces to process multiple pieces of information if these pieces are contextually related in some way, but are stored in separate files and/or are associated with different application programs. Too often, the prior art of organizing information lead users to "misplace" information amongst hierarchical categories which often lose their relevance soon after the user creates them. Intended to assist users, traditional hierarchical structures and "desktop" metaphors compel users to organize their thought processes around their computer software, instead of the reverse. The inadequacy of "real-world," hierarchical metaphors for information management was recognized prior to the advent of the computer, but until now has not been successfully remedied.
The recent deluge of digital information bombarding everyday computer users from the Internet only heightens the need for a unified, simple information management method which works in concert with natural thought processes. Additionally, users' ready enthusiasm for the World Wide Web graphical "hypertext" component of the Internet demonstrates the appeal of associative, nonlinear data structures, in contrast to the limiting structure of computerized desktop metaphors. And yet, prior art web browsers and operating systems awkwardly compel users to navigate the associative, non-dimensional structure of the World Wide Web using linear, or at best hierarchical user interfaces.
What is desired is an effective methodology for organizing and processing pieces of interrelated information (or "thoughts") using a digital computer. The methodology should support flexible, associative networks (or "matrices") of digital thoughts, and not be limited to strict, tree hierarchies as are conventional, prior art technologies. A related goal is to create an intuitive and accessible scheme for graphically representing networks of thoughts, providing users with access to diverse types of information in a manner that maximizes access speed but minimizes navigational confusion. Finally, that methodology should be optimized to enable users to seamlessly manage, navigate, and share such matrices consisting of files and content stored both locally on digital information devices, as well as remotely via digital telecommunications networks such as local area networks, wide area networks, and public networks such as the Internet.
SUMMARY OF THE INVENTION
The present invention enables users to organize information on a digital computer in a flexible, associative manner, akin to the way in which information is organized by the human mind. Accordingly, the present invention utilizes highly flexible, associative matrices to organize and represent digitally-stored thoughts. A matrix specifies a plurality of thoughts, as well as network relationships among the thoughts. Because the matrix structure is flexible, each thought may be connected to a plurality of related thoughts. A graphical representation of a portion of the matrix is displayed, including a plurality of user-selectable indicia (such as an icon) corresponding to the thoughts, and in some embodiments, a plurality of connecting lines corresponding to the relationships among the thoughts. Each of the thoughts may be associated with at least one thought document, which itself is associated with a software application program. Users are able to select a current thought conveniently by interacting with the graphical representation, and the current thought is processed by automatically invoking the application program associated with the current thought document in a transparent manner. Upon the selection of a new current thought, the graphical representation of the displayed portion of the matrix (the "plex") is revised to reflect the new current thought, all thoughts having predetermined relations to that current thought, and the relations therebetween. Users can modify the matrix by interactively redrawing the connecting lines between thoughts, and relationships within the matrix are then redefined accordingly. Further aspects of the invention include techniques permitting automated generation of thought matrices, delayed thought loading to facilitate navigation through a plex without undue delay due to bandwidth constraints, and matrix division and linking to allow optimal data structure flexibility. Finally, the present invention is interoperable with digital communications networks including the Internet, and offers an intuitive methodology for the navigation and management of essentially immeasurable information resources that transcends the limitations inherent in traditional hierarchical-based approaches.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the basic architecture of a computer system for use in implementing one embodiment of the present invention.
FIG. 2 illustrates one embodiment of the data architecture for thoughts, in accordance with the present invention.
FIG. 3 illustrates a graphical user interface screen display, in accordance with an aspect of the present invention.
FIG. 4 illustrates the graphical user interface of FIG. 3, reflecting the selection of a new current thought by a user.
FIG. 5 is a flow diagram showing the process for creating and relating thoughts in an embodiment of the present invention.
FIG. 6 is a flow diagram showing the process for severing relationships between thoughts in an embodiment of the present invention.
FIG. 7 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 8 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 9 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 10 discloses an algorithm which may be implemented in an embodiment of the present invention.
FIG. 11 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 12 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 13 illustrates a graphical user interface screen display, in accordance with another aspect of the present invention.
FIG. 14 illustrates one embodiment of a dialog window for editing thought fields.
FIG. 15 illustrates one embodiment of a calendar window in conjunction with a hypothetical plex.
FIG. 16 illustrates the data architecture of one embodiment of the ".brn" (modified headcase) file of the present invention.
FIG. 17 sets forth algorithms for implementing forgetting and remembering operations that are used with one embodiment of the present invention.
FIG. 18 depicts five interrelated screen displays of one embodiment of the present invention.
FIG. 19 illustrates a hypothetical screen display of an information storage arrangement having non-differentiated links.
FIG. 20 illustrates the screen display that would result upon the selection of an element from the hypothetical screen display of FIG. 19.
FIG. 21 illustrates an alternative graphical user interface screen display, in accordance with one embodiment of the present invention.
FIG. 22 illustrates a flow chart describing one method for implementing the delayed loading feature of one embodiment of the present invention.
FIG. 23 illustrates a method for drawing a plex having distant thoughts.
FIG. 24 illustrates an alternative algorithm for searching thoughts that may be implemented in an embodiment of the present invention.
FIG. 25 illustrates a graphical user interface screen.
NOTATION AND NOMENCLATURE
The detailed descriptions which follow are presented largely in terms of display images, algorithms, and symbolic representations of operations of data bits within a computer memory. These algorithmic descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art.
An algorithm is here, and generally, conceived to be a self consistent sequence of steps leading to a desired result. These steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It proves convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, images, terms, numbers, or the like. It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.
In the present case, the operations are machine operations performed in conjunction with a human operator. Useful machines for performing the operations of the present invention include general purpose digital computers or other similar devices. In all cases, there should be borne in mind the distinction between the method operations of operating a computer and the method of computation itself. The present invention relates to method steps for operating a computer and processing electrical or other physical signals to generate other desired physical signals.
The present invention also relates to apparatus for performing these operations. This apparatus may be specially constructed for the required purposes, or it may comprise a general purpose computer selectively activated or reconfigured by a computer program stored in the computer. The algorithms, methods and apparatus presented herein are not inherently related to any particular computer. In particular, various general purpose machines may be used with programs in accordance with the teachings herein, or it may prove more convenient to construct more specialized apparatus to perform the required method steps. The required structure for a variety of these machines will appear from the description given below.
One aspect of the present invention relates to the organization, storage, and retrieval of information with highly-flexible associative data structures, and it is therefore convenient to explain the disclosed processes by analogy to processes commonly associated with human cognition. For example, as explained above, items of information that are processed in accordance with the present invention are referred to by the label "thoughts," and designations such as "forgetting" are used metaphorically to refer to functions or relations relating to the associative data structure of the present invention. These analogies are employed merely to facilitate explanation of the present disclosure. Based on everyday assumptions regarding the way humans think, the distinctions between the presently disclosed computer-implemented invention and actual human cognitive operations must not be overlooked. The interrelations among these thoughts are sometimes similarly defined by reference to genealogically-derived terms such as "parent" and "child" thoughts. In the spirit of the present invention, the assignment of these terms is based largely on human intuition, as they reflect relations between thoughts that may easily be grasped by users not proficient with the use of non-traditional information storage schemes. The terms are merely labels that serve to enhance the clarity of the disclosure. They should not be construed as restricting the flexibility of the described information storage structure. Finally, the term "the Brain" is used in the following disclosure as a label to refer to the methods or apparatus of the present invention. "The Brain" is a trademark of the assignee of this patent application.
DETAILED DESCRIPTION OF THE INVENTION
General System Architecture
FIG. 1 depicts the general architecture of a digital computer system 90 for practicing the present invention. Processor 100 is a standard digital computer microprocessor, such as a CPU of the Intel x86 series. Processor 100 runs system software 120 (such as Microsoft Windows®, Mac OS® or another graphical operating system for personal computers), which is stored on storage unit 110, e.g., a standard internal fixed disk drive. "Brain" software 130, also stored on storage unit 110, includes computer program code for performing the tasks and steps described below, including the digital representation of matrices, the display of graphical representations of such matrices, and the processing of such matrices in accordance with the principles of the present invention. Display output, including the visual graphical user interface ("GUI") discussed below, is transmitted from processor 100 to an output device such as a video monitor 140 for display to users. Users utilize input devices such as standard personal computer keyboard 150, cursor control device 160 (e.g., a mouse or trackball), touch-screen sensors on the monitor display, virtual reality gloves, voice input, or similar techniques to enter the GUI input commands discussed below, which are then transmitted to processor 100. Software for implementing the Brain may be stored in a variety of locations and in a variety of mediums, including without limitation, RAM, data storage 111, a network server, a fixed or portable hard disk drive, an optical disk, or a floppy disk.
Internal Implementation of a Thought
In one embodiment of the present invention as illustrated in FIG. 2, a plurality of interrelated thoughts collectively make up a "thought." Each such thought (i.e., a piece of information, such as a collection of spreadsheet data) is represented internally as comprising various elements, including properties and relationships. Properties can include, as in the example of thought 200: number 205, name 210, key words 215, document 220, usage statistics 225, priority 230, flags 235, category 240. Relationships can include currently linked thoughts 245 and past linked thoughts 250. Except for document 220, all of the data for all thoughts is stored in a set of files 255 (which we designate "the headcase" in one embodiment), which is invisible to the user and is transparently loaded to RAM and saved to data storage 111 as the user works.
Number 205. Each thought has a unique number which, in some embodiments of the present invention, is invisible to the user but is used internally, by other thoughts or lists, to reference the thought. References to each thought thus occupy only a small amount of internal storage, and changes to a thought's user-specified name do not affect internal references.
Name 210. The "name" of a thought is intended to be a brief, textual description of that thought, written by the user. One purpose of a name is to enable users to identify the associated thought in a convenient manner.
Key Words 215. The "key words" of a thought are a list of descriptive terms inputted by the user, which list may be interactively searched using the search methods described in more detail below (see "Searching").
Document 220. Each thought includes an associated "document," which stores all of the specific content for that thought, such as word processing data or spreadsheet data. Each such document is stored internally in its own file in data storage 111 or separately stored in mass storage devices accessible by the computer system.
In some embodiments of the invention, the document name is based on the associated thought's number. In other embodiments, the document name may be based on the name of the associated thought. More particularly, the document name can be the same as the thought name, unless a preexisting file with the identical name already exists. If such a file already exists, the method of the present invention can name the location by appending a number to the name. For some embodiments of the Brain used with operating systems that use filename extensions, the extension for the location may be determined by the thought type in accordance with common practices in the art, for example, ".tht" for thought editor documents, and ".htm" for web pages.
When the name of a thought is changed, the location of the document it references is not changed. This allows the user to use the location to share the file with users who are not using the method of the present invention and therefore must access these files through traditional operating system methods. Of course, a user may edit the location of a document by the same methods used to edit all other thought properties. If the user makes the location point to a nonexistent or unsupported file, the Brain will be unable to edit the document. The referenced file may be either locally or remotely located.
Referenced files may also be used as sources for Microsoft Windows® drag and drop operations known in the art and extensively documented in Windows® Software Development Kits. These operations are capable of exchanging file locations between programs for the purpose of making references, embedding, copying, and pasting. By implementing these operations into the Brain, a user can use the Brain as a drop source. A file stored in the Brain may thereby easily be copied to a Windows Explorer® folder or any other application supporting file drag and drop.
As discussed below, the user need not consciously manage these files. Instead, accessing a thought automatically provides the user with a seamless, transparent way of accessing the document contents, calendar information, notes and other information associated with thought, along with the appropriate application program(s) or utility(ies) for processing those contents.
Usage Statistics 225. "Usage statistics" may be generated and stored for each thought as the user works on that thought, as discussed in greater detail below in the "Additional Features" section.
Priority 230. A priority number set by the user indicates the relative importance of a particular thought. The priority is normally manually set by the user, but can be calculated based upon the usage statistics and the relationships at the user's request. The priority can then be used to filter thoughts when searching or creating thought lists.
Flags 235. Flags provide a mechanism for designating the state of each thought. In one embodiment of the invention, each flag can be in one of three states: on, off, or default. When a flag is in default, the thought value is determined by the category of thought (see Category, below). Flags can be user-defined, or may be automatically provided by the system. One example of a system flag is one that states whether a thought is part of long term memory.
Category 240. A thought's "category" is a number which designates a thought to be of a specific category. Thought categories are defined and named by the user. Each category specifies that thoughts of that category will have certain attributes or "fields," as well as certain default flag values (see the discussion of "flags" above). An example of a category might be "Person," in which case an example field might be "City of Residence." The use of fields to perform indexed searching is discussed in further detail below, in the "Processing Thoughts" section. Category definitions may be stored separately, as templates.
Relationships Between Thoughts 245. In one embodiment of the invention, at least three types of relationships are possible among thoughts: child, parent, and jump. Each thought includes a separate list for each type of relationship. The utility of enabling at least three types of links among thoughts is discussed more fully below. Each such relationship list stores a list of the other thoughts (identified by number) that are related to the instant thought by the instant type of relationship. The relationship lists are used to generate and navigate graphical representations of the matrix, as described in detail below, and are otherwise invisible to the user.
Past Relationships 250. In some embodiments of the invention, there is another set of at least three lists: for child, parent, and jump relationships, respectively, which archive information about those relationships which have been severed or "forgotten" but which may be reattached or remembered upon request by the user. Essentially, this provides a long term memory facility that allows users to recall previous relationships when desired, without cluttering the current display with non-current data, as discussed below.
Graphically Representing and Navigating a Matrix
The present invention simultaneously enhances navigational efficiency through its strategic graphical arrangement of display icons representing thoughts. The placement of the thoughts reflects second-level relations that may not be as easily communicated by techniques employing arbitrary thought placement. FIG. 3 illustrates a typical, graphical representation ("plex 300") of a matrix of related thoughts which will be displayed on the monitor 140, in accordance with one embodiment of the present invention. FIG. 21 illustrates an example of an on-screen display of an alternative embodiment of the present invention, in which the plex is displayed in the upper-right-hand section of the screen, the thought document is on the left-hand portion of the screen, and properties, list manager, and notes windows are on the lower right section of the screen.
Thought Types and Interrelation. In the example of FIG. 3, central thought 310 labelled "Natrificial" is displayed in the center of the plex, preferably surrounded by a circle, a dashed rectangle, and a rotating or blinking graphic that visually draws attention to the central thought. Thoughts that are directly related to the central thought 310 are represented in the plex 300 by display icons connected by lines to the central thought. In one embodiment of the present invention, multiple categories or types of thought relationships can be specified, in the interests of providing users maximum organizational flexibility and clarity. Specifically, the present invention allows a plurality of parent thoughts, a plurality of child thoughts, a plurality of sibling thoughts, and a plurality of jump thoughts.
Sibling thoughts (such as the thought "ParaGen" 322), are child thoughts of any and all parent thoughts (such as the thought "Software" 312) of the current central thought ("Natrificial" 310). For example, in the embodiment illustrated in FIG. 3, above the central thought 310 are related parent thoughts. In this plex there is only one, "Software" 312. Below the central thought are child thoughts. In this plex there are three: "Projects" 314, "Resources" 316, and "Information" 318. To the left of the central thought are jump thoughts; in this plex there is only one: "Nomenclature" 320. Finally, to the right of the central thought are sibling thoughts which share a parent with the central thought. In this plex there is only one--"ParaGen" 322. The underlying significance and semantics of these or other categories of thought relationships is entirely unique to the individual practitioner and user. In one embodiment, parent thoughts are displayed in three columns extending upward from the central thought, jump thoughts are displayed in a single column extending upward from the central thought and to the left of the parents, and children are displayed in four columns beneath the central thought and extending downward.
The display of sibling thoughts is not required for navigation through a plex. For this reason, some embodiments of the present invention allow the user to elect in the preferences not to display siblings. Such an election may conserve display space, but will do so at the cost of displaying fewer available thoughts.
One embodiment of the invention is configurable in the display preference settings to display other more distantly related thoughts (collectively "distant thoughts"), including grandparents, grandchildren, and partner thoughts. Grandparent thoughts are the parents of the parents, and may be displayed above the parents in two columns extending upward. Grandchildren are the children of the children, and are displayed below the children in four columns extending downward. Partners are the parents of the children, and may be displayed to the left of the active thought and below the jumps. If there are many partners or many jumps, the jumps may be shifted to accommodate the partners. Graphical representations of distant thoughts may be smaller than those for thoughts more directly related to the central thought, and may not contain gates from which relationships may be originated; these distant thoughts can be highlighted as the selection cursor passes over them. One method for graphically representing a plex having distant thoughts is outlined in FIG. 23. As this figure illustrates, this process includes generating a list of thoughts to be drawn and their respective screen locations, drawing connecting lines between these thoughts, and then drawing the thoughts themselves. FIG. 25 is an illustrative screen display having distant thoughts 2500A-N, as described above.
Parent, child and jump thoughts are all equally related insofar as each is directly linked to that central thought. The jump thought is unique in that no thought related to a jump thought is displayed within the plex, unless that thought is itself a parent, child, or sibling of the central thought. Sibling thoughts are secondary relations, connected to the central thought only indirectly through parent thoughts and children thoughts. The distinctions amongst the types of thought relationships can be symbolized within a single plex by displaying lines connecting the thoughts. Those distinctions achieve added significance in the plexes resulting from a user navigating the matrix, activating a different thought as the new central thought. Preserving the distinctions amongst types of thought relationships permits a data management structure which at once lends itself to easy, logical navigation-like hierarchial structures and yet enjoys the dimensionless and unlimited flexibility of a totally associative structure.
The differing relations among thoughts are reflected in the following general rules, which define the collection of thoughts graphically represented in a plex as well as the nature of this representation in some embodiments of the present invention.
Depending upon the defined interrelations between the old central thought and the newly selected central thought, the other thoughts in the old plex may be included or excluded from the new plex. The old central thought, however, will always remain in the new plex. Parent thoughts are related to all of their child thoughts, and child thoughts are related to one another. Therefore, when a child thought is selected, all the other children will remain in the plex as siblings. Likewise, when a parent is selected, the other children of the parent (i.e., some or all of the siblings of the current central thought) will remain in the plex. Furthermore, sibling thoughts are related to each other and their parents, so that when a sibling is selected, all of its siblings (some or all of the siblings of the original central thought) will remain in the plex as siblings.
Jump thought relationships link the jump thought with only the central thought and no other thoughts; therefore, when a jump thought is selected, typically only it and the current central thought will remain in the plex. Non-contextual links such as those inserted into hypertext are effectively the same as jump links, as they do not help to define relationships beyond those that are directly linked. The availability of such non-contextual links within, for example, hypertext documents, expands the breadth and enhances the flexibility of the presently disclosed invention and therefore increases its capacity to provide an optimally intuitive and adjustable structure for organizing information.
Graphical Representation of Matrix. In one embodiment of the invention, each thought in a plex has three circles near it. These circles are thought "gates" (e.g., gates 330, 340, and 350 in FIG. 3), and are used to show and create the relationships between thoughts. The location of each gate tells what kind of relationship it represents. Thus, gate 330 above thought 310 is for relationships to parent thoughts; gate 350 below thought 310 is for relationships to child thoughts; and gate 340 on the side of thought 310 is for relationships to jump thoughts. Note that each thought in the display of FIG. 3 is connected to central thought 310 by the appropriate gate. Each gate circle being used (i.e., a gate through which a thought is connected) may be filled (e.g., gate 330); if no thought is connected through a gate, that gate's circle is empty (e.g., gate 340). In addition, gates may be color-coded according to the currently displayed thoughts. For example, in one embodiment, if a gate is red (e.g., gate 350), this indicates that all the thoughts to which it connects are currently displayed. If a gate is green (e.g., gate 365), this indicates that there are other thoughts to which it is connected and which are not displayed within the plex at this time.
Display of the plex may be configured based upon the current thought. More specifically, the display positions of thoughts are determined by the way they are related and the number of thoughts that are related in that way. Thus, in one embodiment, the central thought (e.g., 310) is always drawn in the center. Above the central thought are the parent thoughts (e.g., 312), which are drawn in up to two columns extending upward. Below the central thought are the child thoughts (e.g., 314, 316, 318), which are drawn in up to four columns extending downward. The jump thoughts appear to the left in a single column which extends up and down until it hits the child thoughts, at which point it begins to extend only upward. Sibling thoughts appear to the right of the central thought in a single column which extends up and down until it hits the child thoughts, at which point it begins to extend only upward. In practice, the actual drawing sequence on screen may be performed as follows. First the background is cleared. The scaling circle and the lines that connect the thoughts are then drawn. Next, the lines are drawn between the locations of the gates representing the appropriate relationships. Finally, the actual thought names and the gates are drawn.
Occasionally a central thought will be linked to so many thoughts that it will be impossible to simultaneously display all thoughts in a plex. In one embodiment of the present invention, the Brain will display arrows above and/or below thoughts with particular relations to thoughts that could not be accommodated on the display. By clicking on or dragging these arrows, the user may scroll through the entire list of thoughts. When second-level thoughts are displayed, only those which are linked to the thoughts displayed will be displayed.
Matrix Navigation. Navigation and movement through the matrix is accomplished by selecting the thought to be moved to, using control device 160 or keyboard 150. In one embodiment, navigation is accomplished by selecting a thought indicium with a cursor control device such as a mouse. When a thought in the plex is selected to become the new central thought, the plex is rearranged according to the links associated with the newly selected central thought. In some embodiments, this process may be graphically reflected with animation showing the movement of the thoughts. For example, FIG. 4 shows the plex of FIG. 3, but rearranged after a user has interactively selected Software 312 as the new central thought, in place of Natrificial 310. Window 360 is used to display and edit the document for the current thought, as discussed below in the section entitled "Processing Thoughts."
One method of navigation using a keyboard utilizes the arrow keys in connection with other keys. In one particular embodiment, thoughts may be activated using a combination of the [Alt] key and the arrow keys. Upon the depression of the [Alt] key, a cursor is initially displayed over the central thought. Subsequent depression of the [Up] key may move the cursor to the closest parent, [Down] to the closest child, and so on. Within a group of thoughts, the arrow keys can be used to move the cursor among the group. The [Left] key may be assigned to return to the central thought from the siblings, and the [Right] may be assigned to return to the central thought from the jumps. The [Down] key will only return to the central thought from the parents if the cursor is over the bottom parent thought. The [Up] key will only return to the central thought from the children if the cursor is over the top child thought. If the display includes scrollbars, the [Up] and [Down] keys may be used to scroll. A selected thought may then be activated by the release of the [Alt] key, or in another embodiment, the [Alt] key may be pressed once to begin a thought selection routine and a second time to activate a selected thought.
Navigation Example. FIG. 18 illustrates five related screen displays of one embodiment of the Brain. These connected displays demonstrate the practical significance of the novel interrelations among the different types of thought relationships of the present invention. Specifically, using differentiated types of thought relationships enhances the relevancy of the plex, by displaying only the most interrelated thoughts. The center screen 1800 illustrates a hypothetical plex, and each of the four screens bordering this hypothetical plex 1810, 1820, 1830, and 1840 illustrates the plex that would be displayed upon the user's selection of a particular one of the thoughts from the original hypothetical plex to be the central thought. As FIG. 18 shows, the original plex 1800 comprises a central thought ("Central") in the center of the plex, surrounded by and connected to a multiplicity of jump, parent, sibling, and child thoughts. For simplicity, this example presumes that, contrary to thoughts in a typical plex, none of the thoughts in the original plex are connected to any thought outside the original plex, and that each thought is connected to that central thought by only one type of thought relationship. Also for simplicity's sake, FIG. 18 assumes that sibling thoughts are the only indirect thought relationships displayed, and that the illustrated embodiment will not display distant thoughts.
The screen 1810 above the original plex illustrates the plex that would result if the user selected the "Parent 1" thought from the original plex. As FIG. 18 illustrates, the Parent 1 thought in the original plex was connected only to the central thought and to the thoughts labeled Sibling 1 and Sibling 2. Upon the selection of "Parent 1" from the original plex, the Parent 1 thought moves to the center of the plex display, and the thoughts linked thereto move accordingly into position around the Parent 1 thought. The names assigned to the thoughts in each of the five screens are based on the position of the thoughts in the original (center) plex, and were not changed so that one could follow the movement of each thought from the original plex to each of the peripheral plexes. Therefore, Sibling 1 and Sibling 2, which were siblings of the original central thought and therefore were displayed on the right-hand side of the plex, move into position under Parent 1 in the top plex because Sibling 1 and Sibling 2 are children of Parent 1 (the new central thought). As explained above, children thoughts are displayed at the bottom of the plex. The original central thought, labeled "Central," is also a child of Parent 1 and therefore is also displayed below Parent 1. Jump 1 and Jump 2 were related only to the central thought within the original plex, are not directly related to Parent 1, and are therefore not displayed within the new plex. Child 1, Child 2 and Child 3 are now grandchildren and are not displayed. Neither is Parent 2 which is now a partner, nor Siblings 3 and 4 which are related to Parent 1 only through three thought relationship links ("links").
The plex 1840 to the right of the original plex 1800 is the plex that would result upon the selection of Sibling 1 as the new central thought. Specifically, as shown in the original (center) plex, Sibling 1 is directly connected only to Parent 1. Therefore, the new plex shows Sibling 1 as the new central thought, with Parent 1 (Sibling 1's parent) connected above. Furthermore, because Sibling 1, Sibling 2 and Central share Parent 1 as a common parent, they are siblings of one another. Sibling 2 and Central are displayed as sibling thoughts to the right of Sibling 1 in the new plex. Again, Jump 1 and Jump 2 were related only to the central thought within the original plex, are not directly related to Sibling 1, and are therefore not displayed within the new plex. Child 1, Child 2 and Child 3, Parent 2, Sibling 3, and Sibling 4 are not displayed because each is at least three links removed.
The plex 1830 below the original plex 1800 is the plex that would result upon the selection of Child 1 as the new central thought. Specifically, as shown in the original (center) plex, Child 1 is directly connected only to the original central thought. Therefore, the new plex includes Child 1 as the new central thought and includes the original central thought as a parent thought displayed above Child 1 (because Child 1 is a child of Central, Central is a parent of Child 1). Furthermore, as the original plex shows, Child 1, Child 2, and Child 3 share Central as a common parent and therefore are all siblings. Thus, Child 2 and Child 3 are displayed as siblings of Child 1 on the right-hand side of the plex. Again, Jump 1 and Jump 2 were related only to the central thought within the original plex, are not related to Child 1, and are therefore not displayed within the new plex. Parents 1 and 2 would now be grandparents and are not displayed. Neither are Siblings 1, 2, 3 and 4 which are at least three links removed from Child 1.
The plex 1820 to the left of the original plex 1800 is the plex that would result upon the selection of Jump 1 as the new central thought. Specifically, as shown in the original (center) plex, Jump 1 is directly connected only to the original central thought, and is not directly related to any other thoughts in the original plex. Therefore, the resulting plex includes only Jump 1 as the new central thought and Central as a jump thought.
Advantages of Associative Interrelations. As this example graphically illustrates, the relatedness of particular thoughts is reflected in the manner in which those thoughts are displayed as the user navigates the matrix. By choosing one type of link over another, the user has the power to affect the content of the plexes that are displayed upon the selection of any thought from the current plex as the new central thought. The method of the present invention utilizes intuitively-derived thought interrelations and graphical representations to optimize the benefits human users will obtain from the Brain. Harnessing this power offers the user informational displays that are as or more relevant than hierarchical displays, yet free of the artificial spatial limitations inherent in hierarchies and "real world" metaphors.
These advantages become particularly clear when the interface and storage structure of the present invention are contrasted against a system having nondifferentiated links. A hypothetical screen display of such a system is shown in FIG. 19. This display is one possible representation of a central thought related to eight other thoughts. However, no information about the nature of this interrelation may be gleaned by the graphical representation of FIG. 19. The inherent limitations of systems capable of only a single type of association are strikingly apparent when one considers the plex that would result upon the selection of one of the thoughts depicted in FIG. 19. As FIG. 20 illustrates, the plex resulting from the selection of a thought from the hypothetical plex of FIG. 19 would contain only two individual thoughts connected by a single nondifferentiated link. The present invention overcomes these deficiencies and allows an optimally flexible, intuitive, and therefore efficient means for organizing information.
Defining a Matrix
Creating New Thoughts. New thoughts may be created by interactively clicking and dragging, using mouse/control device 160, from any of the gates around an existing thought. FIG. 5 provides a flow diagram showing the basic steps of this process. At step 500, the user selects by clicking on a gate of an existing thought (a "source thought"), to which the new thought is to be related. At step 510, the user drags control device 160 away from the source thought; during this step, a "rubber-band" line may be displayed coming out of the source thought gate and tracking the cursor controlled by mouse/control device 160. At step 520, the mouse/control device's 160 button is released. At that point, if the cursor controlled by mouse/control device 160 is located over an existing thought (a "target thought"), as indicated at decision point 530, then the system assumes the user desires to create a new relationship between the source thought and the target thought, as will be described shortly below. In order to create a new thought, the user simply releases mouse/control device 160 with the cursor at an unoccupied location on the screen. In that case, as shown at step 540, a new thought is created and added to headcase 290. In one embodiment, a dialog box 710 (see FIG. 7) appears and asks for the new thought's name and/or other properties; a unique new thought number is created to refer to this thought; all of the new thought's data fields are initialized to default values; and the thought's number is added to a global list of all thoughts. At this time a user may specify a plurality of thoughts to be linked in the same manner. The Brain can automatically link preexisting thoughts specified at this time.
Next, at step 550, a relationship is created between the source thought and the new thought, based in some embodiments upon the type of gate of the source thought that was selected at step 500. In particular, the new thought's number is added to the appropriate relationship list (245) of the source thought, and the source thought's number is added to the appropriate relationship list (245) of the new thought. Finally, at step 560, the updated plex is redrawn, reflecting the newly created thought and its relationship to the source thought.
Relating Existing Thoughts. Existing thoughts may be related using the same method as is used to create new thoughts. Referring again to FIG. 5, steps 500 through 520 are the same. However, at decision point 530, control device is determined to have been released with the cursor located over an existing thought (the "target thought"). In that case, at step 535, the relationship list 245 (FIG. 2) of the source thought and target thought are checked to ensure that the thoughts are not already directly related. If such a relationship does exist, it may be deleted at step 545 by removing the source and target thoughts' numbers from each other's current relationship lists, to avoid any ambiguities. Next, at step 550, the source and target thoughts' numbers are added to each other's appropriate relationship list (245), as determined by the source thought's gate type originally selected at step 500. The redefined matrix is redrawn at step 560. If such a relationship does not exist, then step 545 is inapplicable and step 550 is processed immediately after step 535 is executed.
Reordering Relations. Related thoughts are drawn in the plex according to the order they are listed in the relationships list of the central thought. By dragging the thoughts in the display, the user can specify in what order they should be listed and as a result, where they will appear. In reference to FIG. 3, FIG. 8 provides an example of the display 800, in one embodiment, which would result if a user were to interactively reverse the order of thoughts 316 and 318, causing the icons representing those thoughts 316 and 318 to switch horizontal positions as demonstrated by the positions of those thoughts 316 and 318 in FIG. 8 or if a digital computer were to reorder those thoughts based upon an alphanumeric sequence, usage statistics, or other logical criteria.
Severing Relations Between Existing Thoughts. It is possible to sever the relationship between two existing thoughts, such as central thought 310 ("Natrificial") and child thought 314 ("Projects"), using a process similar to the process used to define a new relationship between existing thoughts. As the flow diagram in FIG. 6 outlines, at step 600, the user requests that a particular relationship be severed by clicking on the lines which connect two thoughts such as the line connecting thoughts 310 and 314 in FIG. 3. Next, at decision point 610, a check is made to see if the requested severing would involve the special case of "forgetting," as will be explained shortly. If no "forgetting" will occur, then at step 660 the numbers of the two thoughts are removed from each other's relationship lists and the line between thoughts 310 and 314 in the graphical display shown in FIG. 3 may be removed.
The special case of "forgetting" an existing relationship will now be explained. Consider the example plex shown in FIG. 3. If the relation between thought 314 ("Projects") and central thought 310 ("Natrificial") is severed, then there will be no path at all connecting thought 314 with central thought 310, and thus no way to access thought 314 from the current thought. Thought 314 will be isolated. In that sense, thought 314 will be "forgotten" if the severing is performed. Therefore, in the process depicted by FIG. 6, decision point 610 detects such cases (see below, "Determining if thoughts will be isolated"). In such cases, the number of the "forgotten" thought (i.e., thought 314) is deleted from the current relationship list 245 (FIG. 2) of central thought 310 at step 620, and is added to the corresponding past relationship list 250 of central thought 310. Recall that the past relation lists 250 are included as part of each thought's data structure, as illustrated in FIG. 2. Next, the forgotten thought's own fields are revised to reflect its status as a "forgotten" thought: namely, at step 630, thought 314's current relationship lists 245 are merged into its past relations lists 250 (i.e., copied from 245 to 250 and then erased from 245), and at step 640 its "long term memory" flag is set to "on." At step 650, forgotten thought 314 may be added to a global long term memory thought list. At step 670, the plex is redrawn, reflecting the absence of forgotten thought 314. It is possible to forget more than one thought at once, in which case all of the forgotten thoughts will be modified as described for thought 314.
By reference to particular usage statistics, the forgetting operation may be automated. More precisely, the present invention may automatically forget a thought that has not been accessed within some user-definable period of time, as reflected by the usage statistics associated with that thought.
Determining If Thoughts Will Be Isolated. A thought will be isolated when it is not possible to return to the central thought via any link other than that link which is being severed. Similarly, any thoughts ("Rodin" 950 and "Liquid Noise" 960 in FIG. 9) related to the severed thought ("Projects" 314) will be forgotten so long as their only link to the central thought existed via the severed thought ("Projects" 314). One method of determining whether it is possible to return to the central thought from a thought whose link has been severed is illustrated by the recursive algorithm disclosed in FIG. 10.
An alternative method that may provide enhanced performance is disclosed in FIG. 24. This method relies on a programming object termed a ThoughtList, which utilizes a map of bits representing thought numbers. Each bit in the map corresponds to a thought, with a (1) indicating a thought on the list and a (0) indicating a thought not on the list. In accordance with this methodology, one can store the existence or nonexistence of over a million thoughts using merely 128 kilobytes of storage. The storage required for this technique is determined by the highest possible thought number divided by eight. All memory or storage used for this list is zeroed out, and is subsequently modified (to 1's) at locations corresponding to thoughts. Specifically, when a thought is added to the list, the bit number X of byte number Y is set, where X is the remainder of the thought number divided by eight, and Y is the thought number divided by eight. This method may also be used for storing normal thought lists.
Parentless Thoughts. An alternative embodiment of the Brain maintains a list of parentless thoughts (thoughts without parents) that is updated whenever changes are made. When a thought is created, linked, or unlinked, the affected thoughts are checked for parents. If these thoughts have parents, they are removed from the list; otherwise, they are added to the list. If necessary, the list of parentless thoughts may easily be regenerated by checking all thoughts for parents. Because this list is maintained, it is not necessary to ensure that all thoughts are connected. Thoughts may therefore be unlinked without verifying the existence of alternative return routes to the original thought.
Forgetting and Remembering Without Searching. When thoughts are unlinked without searching, it becomes necessary to have an alternative interface for forgetting. Among the possible methods for accomplishing this result are dragging the thought to a forget icon or selecting a command. The thought will then be forgotten along with all of its childward descendants that do not have other partners and are not the active thought. To decide which thought to forget, the Brain makes a list that includes the thought to be forgotten and all thoughts childward of it. The Brain does not add the active thought to this list. To remember the thoughts, the user can drag a thought to a remember icon or select a command. The thought and all its forgotten childward descendants will thereby be remembered. More detailed algorithms for implementing these forgetting and remembering operations are set forth in FIG. 17.
Accessing Long Term Memory. To access thoughts that are stored in long term memory, in some embodiments the user can interactively activate the display of long term memory relationships (for example, by means of a menu selection or function key). The display will then be refreshed, and thoughts related by long term memory relationships will become visible and are connected (as shown in FIG. 11) to the central thought with a line, such as line 1110, of a different sort than that used for normal relationships. A long term relationship can then be recreated as a current relationship by using the "Relating Existing Thoughts" technique described above. In that case, the appropriate thought numbers (see FIG. 2) are copied from past relationship lists 250 to the appropriate, current relationship lists 245. The appropriate thought numbers are then moved in the global long term and short term memory lists, and the display is once again redrawn.
In an alternative embodiment of the present invention, each thought's headcase does not include a list of past relationships. Rather, each thought's headcase merely contains a flag identifying it as a forgotten thought or a present thought. When a user interactively turns on a display of long term memory within this alternative embodiment, forgotten thoughts and their relationships to present thoughts are added to the display, and severed relationships between present thoughts will not reappear. This alternative embodiment may offer certain advantages, including without limitation (i) presenting the user with a simpler, more readily comprehensible set of information regarding past relationships within the matrix; and (ii) reducing the complexity of the matrix's data structure and hence the computing resources used to operate the matrix.
These same principles used for implementing long and short term memories are equally applicable for creating many other classes or levels of memory. A plurality of memory levels may be created and thereafter any or all of the relationships stored at each level or in each class may be selectively chosen for viewing. For example, a user may elect to display only the top level, all levels, up to a specified level, or particularly designated levels having no immediate connection.
Permanently Deleting a Thought. It is also possible to permanently remove a thought from the matrix. This is accomplished by clicking on a line (such as line 1110) which connects a thought which is already in long term memory. When severing a relationship in this manner results in a thought or thoughts becoming isolated, this thought or thoughts are removed from the global thought list and from the past relationships list 250 of the central thought. Although a portion of the thought data relating to a deleted thought will be erased, in one embodiment of the invention, the space occupied by the thought in the flat file database will be retained so that the Brain does not have to remove all references to it. The Brain may be unable to remove all such references because they may occur on other lists or in other matrices which the Brain cannot control. Furthermore, comprehensive elimination of references may be computationally prohibitive, and leaving the thought's space in the flat file database requires relatively little storage space.
Dividing a Matrix. When a user selects a link that will result in the isolation of particular thoughts, the user may optionally forget the thoughts, permanently forget the thoughts, or split the matrix into two parts. Splitting the matrix into two parts will create a new thought that has the same name as the first thought to be isolated, but the document associated with this newly created thought will be a new matrix that is named after this first thought to be isolated. This new matrix will consist of all the thoughts which will be isolated in addition to the thought located at the position of the last link to be selected. That thought will reference the original matrix, and will be named after the original matrix.
Creating New Thought Flags and Types. To define a new thought flag, the user interactively selects a thought and then enters a flag name and its default state. To define a new thought type, the user enters the name of the new type, its default flag states, and any fields that the type has. The new types and flags can thereafter be referenced by the user when creating new thoughts or changing thought properties. The type of a thought dictates which application program is used to edit the information associated with that thought. Application programs may be directly associated with a thought in the same way that the document window 360 in which a thought may be edited is associated with active thought 330. One embodiment of the invention assigns a preferred thought type to thoughts, but the user can override this thought type assignment by selecting another thought type either at the time of creation or by changing the default thought type in the preferences. Acceptable thought types include any computer application capable of communicating with the Brain employing the methods disclosed herein. In some embodiments, the correct thought type for a document is determined by the file extension that the location specifies.
Thought Pins. Thought pins are used to get instant access to commonly used thoughts. In the upper left corner of FIG. 3 are two thought pins 370 and 375, labelled "Rodin" and "Liquid Noise." Thought pins can be moved by the user to any location or deleted. To create a new thought pin, the user simply moves the cursor (using mouse/control device 160), and clicks on or otherwise highlights the existing thought for which a thought pin is to be created, and then selects a "Create Pin" command or the like from an ensuing pop-up command menu (such as menu 1210). Alternatively, pins may be created by dragging thoughts to predefined zones within the display. Selecting an existing thought pin (e.g., using mouse/control device 160 to position the cursor over the pin, then clicking the control devices's button) makes the pin-represented thought into the new central thought of the current plex. For example, selecting thought pin 370 ("Rodin") in FIG. 3 would result in the plex transforming into the plex displayed in FIG. 13, with thought 370 ("Rodin") as the central thought. Note that thought pins may be represented internally by the number(s) of the thought(s) they reference and an explicit, user-specified display location.
Brain Messaging System. An embodiment of the present invention utilizes a brain messaging system ("BMS") to enhance interoperability between the Brain and the applications used to create, edit, and display documents; this messaging system plays a central role in matrix creation, as discussed below. Applications that comply with the BMS are referred to as "Brain-enabled" applications. Some embodiments of the present invention only interoperate with Brain-enabled applications. Other embodiments take advantage of the program-to-program interface features of operating systems such as Windows® by Microsoft to enable any application to be launched and operated within documents associated with thoughts, without need for a specialized BMS. Whether or to what extent a BMS is necessary to enable Brain-application interoperability depends partly upon the capabilities of the underlying operating system. A Windows® embodiment of the present invention, for example, allows the user to specify a list of Windows® applications which will create, read and write to files corresponding to thoughts of a certain "type."
For instance, a spreadsheet application such as Microsoft Excel® would enable the creation of Excel-type thoughts which, when activated by the user, launch Excel, and load the Excel document associated with the specified thought. Further, in one embodiment of the present invention, the display icons corresponding to thoughts are specialized according to thought type. For example, a thought of the Excel type would be symbolized by a display icon graphically depicting the thought as such an Excel type. A BMS may not be required under Windows® to enable the limited interoperability described in this paragraph. Methods of processing thoughts are described in greater detail below.
Even in Windows®, however, the incorporation of a BMS enables improved interoperability between the Brain and Brain-enabled application programs. Brain-enabled applications permit users to link thought directly to objects within Brain-enabled application documents by dragging to the document windows. With applications that incorporate hyperlinks, the BMS allows the user to drag thoughts directly to those hyperlinks and associate with the objects that they reference. The BMS can be configured to work in concert with messaging systems native to the operating system. For example, Microsoft Windows® uses Dynamic Date Embedding ("DDE").
Using the program-to-program messaging capabilities of known operating systems, the BMS permits the Brain to provide specific instructions to Brain-enabled applications. For instance, the BMS may include the following core messages from the Brain to the application. The Brain may request the identity of the document over which the mouse pointer presently resides; the application would respond with the current document name and file location using the name and address symbol of the native operating system, or the hyperlink's name and file location. The Brain may signal the activation of a particular thought, and the Brain will provide the number, name, and location of this thought; if a thought is being created, the Brain will also provide the template parameter(s) corresponding to this new thought; in response, the application will save the current document and load or create the new document if the new document is of the same type, and if creating the new document, will use the template parameter to open the default document. The Brain may request that the application move its window to the top; in response, the application will make its window visible over any other applications. Finally, the Brain may request that the application move its window in a requested manner, save, rename, or relocate its document; in response, the application will do so, as instructed by the Brain.
The BMS may also include by way of example the following core messages from applications to the Brain. An application may ask the Brain to identify the active thought; the Brain will respond with the active thought's number, name, and location using Brain-specific symbols. An application may ask the Brain to activate a thought with a specified number, name, and location, and the Brain will do so. An application may ask what thought corresponds to a particular number, name, and location; the Brain responds with the thought's number, name, and location, or will return "false" if the specified thought does not exist. An application may ask the Brain to create or link a specified thought, related by designated child/parent links to another designated thought; if requested, the Brain performs the specified operation. Finally, an application may tell the Brain that the application is Brain-enabled, and will provide the information needed to start the application, the application's document types, and their respective descriptions; if so, the Brain stores this information and adds that application's document types to the list of permissible thought types.
Automatic Thought Recognition. The Brain can activate thoughts based on commands sent from other application programs as well, including without limitation, the editor or calendar applications. For instance, the editor may contain a word that is also a thought name. Using the BMS, the editor can identify the specific word or words as being a thought and automatically highlight them on the display. Alternatively, the Brain could be queried when the user selects one of these words. When a word is successfully identified as being a thought and is selected by the user, the application may then send a message to the Brain requesting the activation of the specific thought. A similar process may be used to recognize and activate thoughts through any Brain-enabled application.
Creating Thought Plexes. As described earlier, thought plexes are the graphical displays of a group of related thoughts, consisting of a central thought and any parent, child, jump, and sibling thoughts. There is always at least one thought plex. In one embodiment of the present invention, additional thought plexes can be created by using the control device 160 to position the cursor over any thought other than the central thought, and dragging the selected thought to the desired location of the new plex. Each time a user creates a plex, that plex is added to the screen display along with the other plexes previously presented on the screen display (see FIG. 9).
The figures demonstrate an example of the manner in which a new plex may be created. First, in FIG. 3, a user interactively selects the thought 314 ("Projects") to be a new central thought by using control device 160 to position the cursor over that thought, then selects the thought by clicking and holding a button on the cursor control device. The user then employs control device 160 to move the cursor to the desired location of the new plex and releases the button. FIG. 9 demonstrates the screen display which results. Plex 920 has been added to the screen display, with the thought 914 ("Projects") as the central thought of new Plex 920. The Plex is the on-screen interface to the matrix in which data is stored.
Automated Matrix Creation. Matrices may be created either on command or, in one embodiment of the present invention, they may be created on the fly. When created on command, matrices are static and will not change unless a user explicitly commands that a change be made. When created on the fly in response to user inputs and navigation, by contrast, a matrix will change as the information represented by that matrix changes.
Automated matrix creation has many potential applications, including the automatic creation of a matrix representing a standard hierarchy such as those commonly used in directory structures. In this application, the Brain begins at the root of the hierarchy and creates a child thought for every file and folder, and then goes into each folder and repeats the process. This recursive process effectively generates a plex representing a directory structure, and as discussed above, can be performed on the fly or as the user navigates amongst thoughts. The Brain begins by displaying the current thought within the hierarchy. Each item within the presently displayed thought is displayed as a child, and children that contain other items are displayed with a highlighted child gate to indicate the same to the user. The level of the hierarchy that contains the current item is displayed as a parent, and the other items within the level containing the current item are displayed as siblings.
The automated conversion of a standard hierarchy to a Brain matrix allows users to subsequently modify the resulting matrix in a nonlinear nonhierarchical manner, thereby creating a nonlinear nonhierarchical information structure with a minimum of effort. Furthermore, the ability to view and activate siblings may be valuable irrespective of whether nonhierarchical relationships are established within the matrix.
The present invention additionally may automatically generate matrices reflecting self-referencing hierarchies, such as those used to organize the World Wide Web ("WWW"). When an item in a self-referencing hierarchy is encountered and has already been added to the matrix, the present invention links to the existing thought rather than creating a new thought. This technique may result in "wrap around" structures and multiple-parent structures that actually exist in a self-referencing hierarchy and can now be displayed with the advent of the present invention.
Similarly, the present invention permits a matrix to be automatically generated from a hypertext document. This document becomes the central thought, and the linked items within the document become children thoughts. Those linked children may subsequently be explored in a similar manner. In cases where hypertext uses somewhat predictable link names, the present invention may link thoughts in a more context-sensitive manner. For instance, files located on a remote computer or Internet URL may be displayed as jump thoughts, and files which are disposed in a hierarchical directory location above the current directory may be displayed as parent thoughts. This method for automated generation of matrices may be restricted so that it does not create overly cumbersome plexes. For example, it may be designed so that it does not create thoughts relating to files located on remote machines.
A matrix may also be created on the fly to reflect a user's navigation within a collection of hypertext content such as the Internet's World Wide Web. In this embodiment, each hyperlinked document selected by the user is linked as a child to the document from which it was selected, and the hyperlinked document becomes the active thought. Once such a structure has been created, the "back" command may be used to activate the parent thought, thereby moving the user to the previous page. Similarly, the child thought is activated if the user selects the "Forward" command. The added benefit to using this matrix arises in cases where the user selects a different hyperlink rather than the "Forward" command; in such cases, the new hyperlink is added as a child thought. Also, if a user navigates to a page which has already been visited, there will already be a thought representing that page which will be linked to as a child. In this fashion, users may generate a matrix that is exceptionally useful for tracking browsing history relative to traditional methods.
Furthermore, matrices representing the results of a database search may also be generated. Such searches are typically performed in response to words input by the user, and the results are usually displayed in an ordered list arranged by some measure of frequency or relevance. One embodiment of the present invention parses such lists to identify other common words or themes from among the results. In accordance with the result of this parsing step, a matrix is created with the query as the central thought and with the other common words or themes as child thoughts. Results that do not share common words or themes are displayed as children. When a child thought is activated, if the child has a common word or theme, the results sharing that commonality are broken down again. If the child is a result, then results that are contained within that result are displayed as children, and items related to that result are displayed as jumps.
Moving Thought Pins and Plexes. In one embodiment of the invention, thought pins can be repositioned by dragging them with the mouse or other control device. Thought plexes can be repositioned by dragging their central thought with the mouse or other control device. Thought pins and plexes can be deleted by dragging them off of the display. Eliminating a plex from the display does not result in any thoughts being forgotten. Forgetting involves a different user-interactive process discussed above (see "Severing Relations Between Existing Thoughts").
Resizing a Thought Plex. In one embodiment, a thought plex can be sized by dragging the circle which surrounds the central thought. Making the circle bigger makes the entire plex bigger and vice-versa.
Changing a Thought Pin. In one embodiment of the present invention, a thought pin can be made to reference a different thought simply by dragging the desired thought onto the pin.
The Brain Freeze. In response to a user's request or in response to a regularly scheduled system request for backup, a "Brain Freeze," in one embodiment, saves the state of all parts of a matrix at a given point in time, copying all the information to a read-only format for later use.
Processing Thoughts
Naming Thought Files. By default, a thought does not have a matrix or operating system file location specified when it is created. If the user selects an active thought without a specified location, a Windows® embodiment of the Brain opens a dialog that allows the user to select the type of file to create. After the user selects a file type, that Brain uses standard operating system methods to create a file of the selected type and thereafter names the file by appending the file type to the name of the thought. The file associated with that thought is placed in a Brain specified folder ( -- brn folder) (discussed below) and is opened immediately. The file name and the thought name are independent, and the renaming of a thought does not compel the renaming or relocating of its file within the network or operating system. Therefore, if the file is shared, other programs and users not operating the Brain will still be able to locate it.
Opening a Thought. A thought's headcase file may specify an item (a thought document) within a traditional file system that is associated with the thought. This thought document may reside in the storage system of a local computer, or may be retrieved through a network, including without limitation a LAN or the Internet. When a thought is activated, the Brain may request that the operating system open the thought document associated with the selected thought. When a thought document is saved, it will typically be stored by most application programs to the file location from which it was loaded. This location is, of course, the location that the thought references. Accordingly, a user may both open and close files from the Brain without navigating a traditional operating system's file reference means, and irrespective of the storage location of that file.
A user may optionally limit automatic thought document loading to those documents having specified file types or residing in certain locations. File extensions typically may be used to distinguish among file type. For example, file location, usually placed before the filename and separated from the filename by a backslash, allows a Windows® embodiment of the invention to discern the location of each file; periods and forward slashes allow a UNIX or Internet embodiment the same utility.
Editing Thought Documents. Each thought's document contents are displayed in document window 360, as illustrated in FIG. 3. When the current thought is changed, the last thought's document is saved (unless otherwise directed by the user) if necessary and then the new current thought's document is loaded automatically. The user never has to issue "save" or "open" commands to access thought documents, nor does the user need to explicitly identify or invoke an editor or other application program to process the thoughts. These operations are performed automatically by the Brain, seamlessly and transparently. When a thought is activated by the user, the Brain saves the previously active thought, if it has changed, then loads the newly active thought. Well-known computer programming object technologies, including without limitation Microsoft's Object Linking and Embedding ("OLE"), allow the document to make references to data which is created and edited by other programs. Using standard operating systems calls, the present invention can display and allow the user to edit these objects with the appropriate computer programs. In addition, the document may also store references to the location of other documents on the storage systems available to the computer, allowing the user to open them with the appropriate computer programs using a more traditional operating system method.
Linking to Remote Files. Using the BMS or another method of interprocess communication, the Brain can request an application to identify the file it presently has open. The availability of this technique allows the Brain to create thoughts representing files that are open in other application programs. In one embodiment, the user may do so by simply dragging a link from a thought and releasing the selection button on the cursor control device when the pointer is situated over the desired application window. Upon the performance of these steps, the Brain queries the application for the identity of the file it has loaded, and the Brain creates a thought and sets the name and location of this thought in accordance with the application's response to the Brain's query. The thought (in this case, the active document in the application window) is thereby linked to the gate from which the user dragged the cursor. For instance, if the document is a Hypertext Markup Language ("html") World Wide Web site stored remotely on the Internet being viewed using a web browser application such as Navigator® by Netscape, the Brain will name a new thought based upon the document's Internet URL (Uniform Resource Locator) or the contents of an html "title" tag. When, in later use, a user reactivates this thought, practicing methods described above, the Brain will launch the user's preferred web browser application, and request that the web browser download the html file from the remote URL.
Delayed Loading. In some instances, the loading of the contents of a thought may require the expenditure of considerable computing resources, and it may be desirable to allow the user to navigate through a series of thoughts without loading the content of every thought through which a user passes along the path to reaching a particular destination thought. This functionality is implemented in accordance with the flow chart illustrated in FIG. 22, and allows the passage of a duration of time noticeable to the user before loading the contents of a selected thought. More particularly, upon the selection of a thought by the user at step 2110, the plex is redrawn in step 2112 using the animation techniques discussed herein, and a loading delay procedure initiates. One embodiment of the present invention uses an expanding circle to appraise the user of the status of the loading delay. At step 2114, this expanding circle begins as a small circle oriented within or about the area representing the central thought, and the circle expands with the passage of time. At step 2116, the circle is enlarged and is redrawn. Next, at step 2118, the method queries whether another thought has been selected. If so, the routine returns to its beginning, step 2110, and the loading delay process is initiated with respect to the newly selected thought. If another thought has not yet been selected, in step 2120 the routine queries whether the circumference of the circle has grown to reach the periphery of the Brain window in which the present plex is graphically displayed. If so, the routine generates and sends a message to load the contents of the selected thought in step 2122. If not, the routine returns to step 2116 where the circle is enlarged and redrawn, and the routine continues. With this method, thoughts are not loaded during a predetermined period of time after their selection, and are not loaded if another thought is selected during this time. This delayed loading may be used to allocate optimally the computing power available to a user.
Some prior Internet browsing means require every World Wide Web site to incorporate user navigation methods within hypertext documents. Those methods inefficiently force users to download irrelevant information, merely for the purpose of navigating through it. One strikingly powerful application of the present invention's delayed loading technique allows expedited navigation through Internet pages or files without waiting for the content of intermediate pages or files to load.
Changing Thought Properties. Thought properties such as name, flags, priority, and category can be changed using a thought properties dialog box, such as dialog box 710, which is accessed by the user employing mouse/control device 160 and/or keyboard 150 to select a particular thought and then the thought properties dialog box. In some embodiments, the properties dialog box remains visible at all times, and changes to reflect the properties of the current central thought.
Editing Thought Fields. Thought fields can be edited in a dialog box or window such as 1410 in FIG. 14. In one embodiment, the field names are displayed to the left and their contents to the right. Thought fields are automatically loaded and saved, in the same fashion as are the contents of thought documents, invisibly to the user every time a thought field is modified. All thoughts of a certain category possess the same available thought fields, which fields are defined by the user in establishing and modifying thought categories (see above, "Category").
In one embodiment, every thought category 240 possesses at least two fields. Those default fields are the "Name" field and the "Key Words" field. The contents of these default fields are identical to the contents of the properties called "Name" and "Key Words" respectively.
Rewinding and Replaying Previous Operations. An event list is created automatically by the Brain, as the user works. The event list is a recording of each action the user takes. It stores how to undo each action and how to repeat each action. At the user's request, the Brain can then use this information to "rewind" and "replay" the actions of the user.
Thought Lists. Internally, within a computer, the Brain stores thought lists as a list of thought numbers. To the user, the Brain displays as a list of thought names. One embodiment of the present invention keeps a list of all short term memory thoughts and long term memory thoughts. In addition, a list of thoughts is created for each defined thought type. Lists of thoughts can also be manually created (see below, "Trains of Thought" and "Searching"). The user can activate a thought in a list (make it central in the current plex) by clicking on it. Thought lists can also be used to perform group operations on thoughts such as printing, changing properties, or even saving (to save only a selected portion of the matrix). One embodiment used to maintain thought lists, using bitmap lists, is discussed in the "Determining If Thoughts Will Be Isolated" section above.
The Past Thought List. One special example of a thought list is the past thought list. FIG. 3 illustrates how a past thought list 380 can be created automatically as the user works. Each time the user changes the current thought, the number of the new central thought and the time it was activated are added; when the user stops working, a null and the time are added. In this manner, the Brain tracks the user's work with reference to the timeframe in which it was performed, and this information is recorded for later reference. In the one embodiment, it is possible to display the past thought list as a list (such as past thought list 380) of thoughts which scrolls along the bottom of the display as the user activates thoughts. For example, each time a user activates a separate thought, the previously activated thought is placed at the right-hand end of past thought list 380 pushing the older thoughts to the left of the screen. The oldest thought that cannot fit on screen is eliminated from view from the left-hand end of past thought list 380. This list may be scrolled to reveal thoughts that have disappeared.
Trains of Thought. Another special example of a thought list is the "train of thought," which lists a series of thoughts in a particular sequence as desired by the user. A train of thought can be created by simply navigating through the desired thoughts in the same order as the user wants them to appear in the train of thought. This will automatically cause the desired sequence of thoughts to become part of the past thought list, as noted above. As shown in FIG. 11, the user then interactively selects the desired section of the past thought list using mouse/control device 160. In the case of FIG. 11, the user has selected "Projects" and "Natrificial" the two most recent thoughts--for inclusion in a train of thought. The user then interactively selects the Create Train command 1120 by using a pull down menu, function key or similar means. In response, the selected sequence of thoughts is copied to a new thought list and the user is asked to name it, thus creating a new "train of thought" thought list.
Trains of thought can be used for accomplishing tasks that involve a number of pre-existing parts. For example, an attorney might use a train of thought to assemble a number of pre-existing sections of text (stored in separate thought documents) into a new contract, or an engineer or computer programmer can use trains of thought to assemble a new computer program out of a pre-existing library of subroutines.
In one embodiment of the invention, a selected train of thought may be identified in a plex so that it is easier for a user to follow. Specifically, the active thought in a train may be identified, and the next and previous thoughts on the train may be highlighted in the plex. If the active thought is not in the train, then any thoughts in the train are highlighted. Optionally, arrows may also be drawn between thoughts in the plex to reflect the order of the train of thought.
Searching. Thought lists can be filtered or "searched" according to thought category, priority, name, flags, fields, or any other subject stored within a thought's headcase file or document. This allows the matrix to be used as a searchable database. For example, one thought type might be the type "Person," which might include the attribute "City." Each thought of the Person type would then be assigned a specific "City" value by the user. Users could then request a search of the matrix for all thoughts involving persons they know who live in a certain city, by requesting a display of all thoughts on the "Person" type list, filtered as to those whose "City" attribute equals the desired value.
Similarly, the Brain enables users to create project plans, daily agendas, or to-do lists or other task-oriented thought lists and create relevant thought lists. First, the user assigns priority levels (e.g., "urgent," "important," "unimportant") or flags (e.g., "completed" or "incomplete") to thoughts as they work (see "Changing Thought Properties" above). The present invention enables users later to create a to-do list, for example, by searching for thoughts associated with a flag set in the "incomplete" position and a priority level of "urgent." The matrix search engine operates in a method similar to those widely used in commercially available database programs.
Layers. A set (or sets) of layers may be applied to every document in the Brain. Subsequently, these layers may be selectively activated and deactivated. Layers that are "on" are displayed and available for editing, while layers that are "off" are hidden. Examples of layers can be found in many applications well known in the art such as Autocad® by Autodesk and Photoshop® by Adobe.
Usage statistics. Usage statistics suitable for keeping track of billable time, productivity, work habits or efficiency may be generated and stored for each thought as the user works on that thought, according to the system clock. These statistics include time of creation, time of last modification, time of last access by user and the time (if applicable) at which the thought was "forgotten." Each thought also stores the total number of seconds the user has so far spent processing it, the number of "events" (keyboard and mouse clicks) that occurred, and the thought's modification history (e.g., a list of all dates when that thought was modified and how long each such modification took).
In some embodiments, the system supports interactive commands for requesting the display of these usage statistics. For example, in one embodiment, a user can request to view usage statistics falling within a given time period. The Brain preferences can be set so that the display reflects different aspects of the usage statistics. FIG. 3 demonstrates how one embodiment of the present invention can display usage information automatically. By default, some embodiments show a "C" next to each thought which was recently created (380); an "A" next to each thought which was recently accessed (380, 385); an "L" next to the last active thought (390, 395); and an "M" next to each thought which was recently modified (not illustrated). Alternatively, usage statistics may be reflected by differences in the color of thoughts, or by the addition of markers. For example, thoughts that have not been accessed for a relatively extended period of time might be displayed in a color such as gray that is less likely to attract the attention of the user.
Undoing and Redoing. Undoing and redoing of operations may be supported by an internally stored event list which keeps track of how data is affected and what is necessary to undo the effects of each event. When something is undone the undo event is recorded to the redo list to enable redoing.
Calendar Scheduling. By storing thought numbers in events, appointments, schedule data, or other time-based items, it is possible to associate time-based events with thoughts. A calendar can then be used by the user to keep track of events and link related thoughts to the events. For example, in one embodiment, rather than displaying thoughts graphically in plexes, thoughts can be displayed on a calendar as demonstrated in FIG. 15. For example, the calendar event 1510 ("9:00 am meeting with Liquid Noise project team") may be associated with "Liquid Noise" thought 960. Some embodiments of the present invention permit a user to create that association by using the mouse/control device 160 to draw a line connecting the calendar event 1510 and the desired thought 960. When a user interactively selects calendar event 1510, thought 960 becomes the new central thought (as illustrated).
In addition, thoughts may be associated through calendar events with computer program operations. For example, if calendar event 1510 were associated with an alarm program, then at 9:00 am, the alarm would sound, and the present invention could also be configured to display a reminder message, or activate "Liquid Noise" thought 960 as the new central thought.
Preferences. Particular preferences relating to the operation of the presently disclosed technique may be selected by the user. The user may designate, for example, the set of colors to be used in the graphical representation of the interface and content organized thereby, the speed of the animation, the loading delay, the levels of thoughts to be displayed (e.g., which of the distant thoughts), and the wallpaper. Also saved to this table is information about the positioning of the various windows comprising the user interface and the information organized thereby.
Furthermore, all necessary information about the location of the present computer is stored with the preferences. Storage of this location information allows the user to move a matrix to another computer while preserving one's ability to access the files referenced by that matrix, provided that the files resident on the remote computer remain accessible from the computer to which that matrix is transferred.
Network-Related Features
Some embodiments of the Brain include features that enhance operability of the Brain in connection with both local and remote networks, including the Internet, as discussed below.
Remote Access to a Brain. Some embodiments of the present invention allow the use of a matrix with a second computer, although the matrix was originally created on a first computer. To the extent the files on this first computer may be locally accessed, for example through a local network, the present invention will simply access these local files. However, if the files on the first computer are not locally accessible, the Brain can copy such files from the first computer to the local computer; so that this change is incorporated into the operation of the present invention, the Brain will additionally change the location of the computer with the file (to the second computer) so that the file may be locally accessed.
Sharing Thought Documents. With most current operating systems, document sharing is based on the location of a file within a hierarchical file system. The Brain locates thought documents according to the desired sharing properties. When the user sets the sharing properties of a thought, the document is moved to a folder that possesses the requisite sharing properties. When thoughts are created, they are assigned the same sharing properties as the thoughts from which they are created. The user may optionally change the sharing properties of several thoughts by using the List manager to create a list of thoughts and subsequently assigning the desired sharing characteristics to the thoughts on this list.
Version Control. By associating a thought with a special document type that stores the names of multiple documents, a thought may be made to contain a plurality of documents. The initial steps for creating a thought that contains more than one version of a document are the same as those normally used for creating a thought. When the user wishes to create a second version, however, the create version command is interactively selected, and the user can name the new version and select its type. The user may alternatively select the default type for the new version, which is that of the old version. With this process, the location property is changed to a new file which lists the versions of the document and contains a name and location for each version. In the thought's data within the headcase, the current version number is set to the current version. The names and locations of different versions of a thought can be changed using the thought properties dialog box. A version control is displayed in proximity to an active thought having multiple versions. The user may select this control to display a list of all versions of that active thought, and may thereafter select a desired version from this list.
Selection Feedback. One embodiment of the present invention facilitates the user's navigation through the matrix by monitoring the position of the user's cursor or pointer and highlighting the elements on the display that the user could select given the present position of the user's pointing device. In other words, this feedback system indicates the elements that would be activated upon the depression of a selection button resident on the user's pointing device, in view of the present position of the pointing device. For example, a gate, link, thought, or any other display element could change color to indicate that the element would be selected if the user depressed a mouse button.
Matrices Referencing Other Thought Matrices. A thought type can be a matrix, so it is possible for one matrix to reference another matrix. For example, in one embodiment of the present invention, when an active thought is itself a matrix, a second instance of the Brain is started and it loads the appropriate matrix. This matrix is then displayed in a separate window. The ability of a user to create several matrices makes the present invention adaptable to a wide range of information storage needs, and accordingly diminishes the requisite complexity of individual matrices in cases suitable for multi-matrix storage schemes. In most of these cases, this added flexibility would likewise reduce overall system complexity. Furthermore, such an arrangement advantageously facilitates sharing of matrix data, as for example, a computer network administrator can more readily assign access privileges to single or multiple discrete matrices.
Linking Matrices. One embodiment of the present invention allows the user to link matrices together. In particular, when two matrices are displayed in separate windows, the user may copy a second matrix into a first matrix simply by dragging (with the cursor control device) from the first matrix to the second. The matrix that is dragged, the first matrix, is thereby linked to the active thought of the matrix to which it is dragged, the second matrix. The two matrices and all of their linked thoughts are thereby incorporated into the first matrix. Each of these thoughts from the second matrix that are copied into the first matrix must be renumbered during the copying process so that they do not conflict with previously-existing thoughts associated with the first thought matrix.
Matrix Sharing. A token system is used in one embodiment of the invention to allow multiple users to simultaneously modify a single matrix. In accordance with this system, when a user requests a modification, all other users are not permitted to make modifications until the matrix is updated to reflect the first user's modification. In a multi-user environment, the past thought list and other usage data may be stored once for each user, and optionally may be unified to produce data for all of the users.
Semi-Hierarchical Arrangement. In some instances, a user may prefer to arrange portions of their information in a traditional hierarchical manner. This may occur, for example, if the data is particularly susceptible to storage in a highly-structured manner and if the user has some preexisting familiarity with a hierarchical information storage structure. One embodiment of the present invention therefore allows users to store information in a purely hierarchical structure, and to access this data through traditional operating system methods. This traditional storage structure, however, may be integrated with the storage structure of the present invention to allow Brain-based storage of other data. For example, a company may wish to store information organized by the management divisions within the company. The company could create a set of folders for each division and then a second level of folders for each employee within a division; then, matrices may be placed within each employee folder, for example, corresponding to each individual employee.
Server Model for Sending Plexes. When a large matrix is created and subsequently must be accessed over a communications channel having a relatively narrow bandwidth, it is possible to send only data that is relevant to a user's location within that matrix. This is accomplished with client/server computer network architecture. In one embodiment, the client Brain identifies for the server the presently active thought. The server Brain then sends the numbers of all thoughts within the present plex, as well as the numbers of all thoughts that would become part of the plex upon the selection of any thought within the present plex. In other words, the server will send the number of the active thought, its children, parents, jumps, and siblings, as well as the children, parents, jumps, and siblings of those thoughts. This list of numbers is used by the client to determine which thoughts are already in the client's cache. Those thoughts that are already in the client's cache should be removed from the list, and then the list is returned to the server. At this point, the server sends the data corresponding to all thoughts remaining on the list. The above-described cycle is repeated upon the selection of a new central thought.
In another embodiment of the invention, an alternative procedure may be used to implement client-server communication. Specifically, on a client's first interaction with a server, the client sends an initialization message to the server that includes its location on the network. The server creates a blank list that may be of the same type as the ThoughtList used to identify isolated thoughts, and uses this list to identify the thoughts already sent to the client. Then, for each thought activated by the client's user, the client identifies the presently active thought to the server. In response, the server generates a list of thoughts having a predetermined relation (e.g., within a set number of generations) to the active thought, removes from the list any thoughts already present on the client, sends to the client the data corresponding to all thoughts remaining on the list, and adds these sent thoughts to its list of thoughts present on the client.
In accordance with these methods, the present invention minimizes the extent to which data is unnecessarily downloaded, and assures that data relating to the next-selected plex will be immediately accessible. The above-described methods enhance performance by minimizing the delay inherent in a client-server system constrained by a narrow bandwidth telecommunications facility.
Integration With Hypertext. One can incorporate matrices into hypertext by embedding so that the Brain is launched and displays the file when the hypertext page is loaded by a browser program. Alternatively, the file could be loaded and displayed in response to the selection of its link by the user. Furthermore, it is possible to define a matrix using text that is transferred to the Brain in a format such as: [Thought Number, Thought Name, Thought Location, Parents, 0, Children, 0, Jumps, 0]. Such a format could be embedded and created using a typical hypertext editor, and the Brain would simply convert this format into the normal file format and display it. Hypertext languages could also be modified to be more similar to the matrix structure simply by identifying links as either parent, child, or jump links. Such a modification would allow the present invention to base matrix creation directly upon a reading of the hyperlinks, without the need for an intermediate format conversion step.
Spider Site. Using the methods disclosed above, the present invention has the capacity to automatically generate a matrix corresponding to a map of a web site. A server can be employed to create and store such matrix-maps, and to send cached versions of the matrix-maps upon request. The sites to be mapped by this server may be identified through a list provided to the server, or the server could use web crawler techniques presently known to those of ordinary skill in the art to identify sites to be mapped.
Alternative Matrix File
In an alternative embodiment of the present invention, the characteristics of the above-described matrix and Headcase files may be modified to permit improved functionality for certain applications. The data architecture of this modified file, hereafter referred to as the ".brn" file, is illustrated in FIG. 16. As can be seen, the .brn file contains additional elements and a different organizational structure than the headcase file illustrated in FIG. 2. While multiple file structures are clearly permissible, the selection and implementation of a single standardized structure may be particularly advantageous; the use of a universal file format allows data to be transferrable across different operating platforms. For example, a Brain created in a Microsoft Windows® operating environment could be read by a UNIX-based Brain. With this background, the principal differences between the .brn file and a generic matrix file are addressed below.
The .brn file stores all information describing the interrelation among thoughts. The file may be named by the user, and is assigned the extension ".brn." The Brain also creates a folder that is assigned a name similar to the .brn file, except that the folder is given the extension " -- brn." A preponderance of the .brn file is composed of a flat file database. This structure allows thoughts to be located based on their numbers. As FIG. 16 illustrates, a thought's location in the .brn file is equal to the size of the header information, added to the size of the preference information, added to one less than the number of the thought multiplied by the size of a thought ("thought size" in the header information).
The -- brn folder. All information specific to a Brain that is not contained in the .brn file is stored in the -- brn folder. This folder may contain an index file for locating thoughts within the thought data, using either thought name or location. It may also contain a variable field length database for storing information relating to thoughts having unpredictable sizes, notes, and perhaps even files and versions of files. These notes may be created by a simple word processor capable of including OLE objects and thus pictures, spreadsheets, and other data. In one embodiment, notes relate to individual thoughts and are automatically loaded and saved as the associated thought is activated and deactivated. The -- brn folder may also contain the past thought list, as well as the list of parentless thoughts.
Internal and External Files. Internal files, such as files located in the -- brn folder, are deleted when their thoughts are permanently forgotten. Internal files are convenient because they are aggregated at a single location and are easily copied or backed-up along with the remainder to the -- brn folder. External files are those not in the -- brn folder, such as those in another folder, or stored remotely on a computer network including, for example, the Internet. As distinguished from internal files, these external files are not deleted when their thoughts are permanently forgotten because they could have some other use.
The user can request that an external file be converted to an internal file by selecting a "To Internal" command and specifying a location. In response, the Brain will then move the files to the specified location and will change the location of the thought file. The user can similarly use a "To External" command to convert an internal file into an external file stored at a specified location. The Brain implements this change by moving the file to the specified location and changing the location of the thought file. If the Brain attempts to create or move a file into the -- brn folder, but the file name is already in use, the Brain will add a number to the end of the file name and will continue to increment that number until the conflict is resolved.
Other Variations
Detailed illustrations of an improved scheme of organizing information by an associative thought process in accordance with the present invention have been provided above for the edification of those of ordinary skill in the art, and not as a limitation on the scope of the invention. Numerous variations and modifications within the spirit of the present invention will of course occur to those of ordinary skill in the art in view of the embodiments that have now been disclosed. For example, while in the described embodiment, the present invention is implemented for a GUI for desktop computers or local area or wide area computer networks (e.g., the Internet), the present invention may also be effectively implemented for any information appliance which can take advantage of the novel associative thought scheme of the present invention. The scope of the inventions should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
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A method and apparatus for organizing and processing pieces of interrelated information (or "thoughts") is used with a digital computer. The invention employs a graphical user interface to facilitate user interaction with highly flexible, associative "matrices" that enable users conveniently to organize digitally-stored thoughts and their network of interrelationships. Each of the thoughts may be affiliated with one or more application programs, such as a word processing or spreadsheet utility, or an Internet browser. Users are able conveniently to select a current thought along with any applications or content associated with that thought by interacting with the graphical representation. That representation is automatically reoriented about the selected thought, and is revised to reflect only those thoughts having predetermined relations to that current thought. Users can easily modify the matrix by interactively redefining relations between thoughts. Further aspects of the invention include techniques permitting automated generation of thought matrices, delayed loading to facilitate navigation amongst thoughts without undue delay due to bandwidth constraints, and matrix division and linking to allow optimal data structure flexibility. Finally, the present invention is interoperable with computer networks including the Internet, and offers an intuitive scalable methodology for the navigation and management of essentially immeasurable information resources and knowledge bases that transcends the limitations inherent in traditional hierarchical approaches.
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BACKGROUND OF THE INVENTION
The movement and handling of freight, for example in the form of containers, often involves the use of a conveyor track on which the freight article is movably supported. The conveyor track may include caster roller units each comprising at least one support roller which is mounted on a roller carrier rotatably about its axis of symmetry. The roller carrier is mounted on a base rotatably about an axis which is arranged eccentrically and perpendicularly with respect to the axis of rotation of the support roller.
Caster roller units of that kind, as can be found for example in U.S. Pat. specification No. 3,435,938, are used whenever an article is to be moved over a normally horizontal floor surface on which it is supported, and in that situation is to be provided with a `weak` guiding action in its respective direction of movement. In that connection the term `weak` guiding action means that the article to be moved is subjected to a stronger guiding action than is the case for example when it rests on ball-type support array, but on the other hand the guiding action is not so rigid that the direction of movement of the article cannot be altered at any time. When such an alteration in the direction of movement has occurred, then the same `weak` guiding action is to take effect in the new direction of movement, as in the preceding direction of movement.
Such a caster roller unit generally comprises two support rollers which are mounted on a roller carrier in juxtaposed relationship in such a way that their axes of symmetry about which they are rotatable independently of each other are in alignment with each other. The unit may be mounted either on a surface over which the article to be moved is actually moved, as in the case of a conveyor track as mentioned above, but equally it may be mounted on the actual article to be moved. The first-mentioned configuration is used in a particularly important situation of use, namely in relation to freight loading equipment for aircraft, in which freight containers must each be turned through 90° in the region of a load compartment door, during loading and unloading operations.
If, in such a loading operation, a container runs with its flat underside on a caster roller unit, then, if the axes of rotation of its two directly juxtaposed support rollers are not oriented normal to the direction of movement of the container, the caster roller unit will rotate about its vertical axis until the above-described orientation is reached. When that happens, the two support rollers rotate in opposite directions of rotation and roll against the bottom of the container which is disposed thereon, whereby a very small amount of friction is produced After the unit has been turned into the correct orientation, the two support rollers rotate in the same direction, in the direction of movement of the container, and afford same a `weak` guiding action in that direction of movement as they support the container with a linear contact. It will be appreciated that guiding action is not so rigid that the direction of movement of the container could not be altered. If that happens, the caster roller unit rotates about its vertical axis until the axes of rotation of the support rollers are again normal to the new direction of movement of the container.
In the caster roller unit which can be found in U.S. Pat. specification No. 3,435,938, in order to achieve the above-described functions, the roller carrier which is approximately in the form of a downwardly tapering right circular truncated cone is fixed to a base member by means of a vertically arranged bolt which extends along the axis of symmetry of the truncated cone, and a nut which is screwed on to said bolt, in such a way that the roller carrier is rotatable about the fixing bolt, with an annular ball bearing assembly serving as a support means in relation to the base member. Laterally of the fixing bolt the roller carrier has two openings in which the two carrier wheels or rollers are respectively arranged rotatably about a horizontal axis in such a way that their peripheral surfaces project beyond the upward surface of the roller carrier in order to support the article to be moved. In that arrangement the two support rollers are mounted by means of a single shaft which extends through the assembly and which is arranged eccentrically with respect to the vertical bolt and which is fixedly mounted on the roller carrier and on which each of the two support rollers is freely rotatably mounted by means of ball bearing assemblies.
The disadvantages of that known caster roller unit are that it involves a high level of production expenditure and is of comparatively great weight. In particular the roller carrier is of such a complicated form that the production thereof requires a multiplicity of machining steps involving boring, turning and milling operations. In addition assembly of the individual components is not an entirely simple procedure as screwing operations have to be carried out and it is only after the support rollers have been fitted into the openings in the roller carrier that the mounting shaft for the support rollers can be passed through the mounting bores thereof in the roller carrier, and through the support rollers, and secured to the roller carrier.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a caster roller unit which is of a simple design configuration while being reliable in operation.
Another object of the present invention is to provide a caster roller unit which is constructed from components which are simple to produce or are commercially available in a finished condition, and which can be easily assembled and installed at the point of use.
Still another object of the invention is a caster roller unit which is low in weight to make it suitable for use in an aircraft freight context.
In accordance with the principles and teachings of this invention the foregoing and other objects are attained by a caster roller unit of the configuration defined in accordance with the present invention.
The construction according to the invention enables a central component of the caster roller unit, namely the roller carrier, to be produced in the form of a simple deep-drawn member. The or each support roller is then mounted in the deep-drawn member by the respectively associated bearing shell member being filled with bearing needles disposed in juxtaposed relationship, the support roller being positioned on the bearing needles and retained thereon by the roller holder which is pushed thereover from above and which is fixedly connected to the roller carrier. As the roller holder only serves to prevent the support roller and the bearing needles from falling out of the bearing shell member, it can be in the form of a simple injection-molded plastic member. The roller carrier is supported on the base member in the usual way by means of a ball bearing assembly. That therefore provides a caster roller unit which includes commercially available components, namely bearing needles, bearing balls and the support roller, and other parts which are simple to produce, namely the roller carrier and the roller holder, so it can be produced and assembled in an extremely simple fashion.
The parts of the caster roller unit according to the invention can be low in weight, so that it is well suited to use in freight loading units for aircraft.
In order to provide that the support roller which is supported on the bearing needles can rotate about the axis of symmetry thereof with a particularly low level of friction, a preferred feature provides that arranged at the side of the roller carrier which is in opposite relationship to the support roller is a rotational shell carrier which includes a part-cylindrical rotational shell which extends around the bearing shell member and the radius of the cylindrical configuration of which is such that a part-cylindrical annular space is formed between the inside of the rotational shell carrier and the outside of the bearing shell member, the internal width of the part-cylindrical annular space being somewhat greater than the outside diameter of the bearing needles and also being filled with bearing needles and communicating with the interior of the bearing shell member by way of openings which are provided in the two edge regions of the part-cylindrical wall of the bearing shell member and parallel to the longitudinal axis thereof and are of such a dimension that, upon a rotary movement of the associated support roller, the bearing needles can transfer through one of the two openings from the interior of the bearing shell member into the part-cylindrical annular space and through the other of the two openings from the part-cylindrical annular space into the interior of the bearing shell member.
In a caster roller unit which includes two support rollers, the roller carrier is of a particularly simple configuration by virtue of the features that the two support rollers are arranged in a common bearing shell member in such a way that between the oppositely disposed ends thereof there is a spacing which ensures that they can rotate independently.
A particularly good supporting action for the support rollers in the respective bearing shell member is afforded by the bearing needles being of the same axial length as the respectively associated support roller.
So that the roller holder can be connected to the roller carrier in as simple a fashion as possible and in a releasable manner, there are preferably provided first locking elements, by means of which the roller holder is adapted to be secured to the roller carrier by a simple retaining engagement or detent action. Preferably the rotational shell carrier may also be fixedly connected to the roller carrier by a simple retaining engagement or detent action, by means of said first locking elements.
A particularly preferred embodiment is characterised in that there is provided a housing base member which is open in a cup-like configuration and which is of substantially circular-cylindrical cross-section and which is stationary in operation of the caster roller unit and which, in the end region of the wall of its cylindrical configuration, has a mounting shoulder which extends substantially perpendicularly to the wall of the cylindrical configuration and which extends over the entire periphery thereof and on which the roller carrier is supported by way of bearing balls for rotational movement about the axis of the caster roller unit, and that a housing cover member substantially in the form of a circular ring is secured to the housing base member in such a way that it engages over the mounting shoulder from the outside and in so doing rotatably fixes the roller carrier to the housing base member.
By virtue of those features, in a development of the invention, the base member can also be produced in the form of a simple deep-drawn member of metal while the housing cover member can again be made from plastic material as it only serves to prevent the roller carrier and the bearing balls from falling out of the housing base member.
Preferably the roller carrier is supported on the bearing balls by way of the rotational shell carrier which is then also in the form of a deep-drawn metal member as it transmits the load forces acting by way of the rollers and the bearing needles on the roller carrier, to the housing base member.
In order to make the fixing of the housing cover member to the housing base member as simple as possible, the unit preferably has second locking elements, by means of which the housing cover member, in the form of a circular ring, is adapted to be secured to the housing base member by a simple retaining engagement or detent action. In accordance with a particularly preferred embodiment the second locking elements may be used at the same time to secure the caster roller unit to a base structure, for example a conveyor track panel member, by a simple retaining engagement or detent action.
Further objects, features and advantages of the invention will become apparent hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a caster roller unit according to the invention,
FIG. 2 is a view of the caster roller unit of FIG. 1 in vertical section taken along line II--II in FIG. 1,
FIG. 3 is a view of the caster roller unit in vertical section taken along line III--III in FIG. 1, and
FIG. 4 is a perspective view of a portion of a conveyor track panel member with an opening into which a caster roller unit according to the invention can be inserted.
DESCRIPTION OF PREFERRED EMBODIMENTS
As can be seen from FIGS. 1 through 3, a caster roller unit 1 according to the invention includes a housing base member 3 which is substantially of a circular-cylindrical configuration and which is open upwardly in a cup-like form; the bottom wall 4 of the housing base member 3, which extends horizontally in the usual position of operation has a circular opening 6 which is arranged concentrically with respect to the vertical axis of symmetry 5 of the housing base member 3. The vertically upwardly extending cylindrical wall 8 of the housing base member 3, in the upper region thereof, has a horizontal bearing shoulder 9 which extends over the entire periphery thereof and which is adjoined in an upward direction by a short, vertically extending cylindrical wall portion 10 which at its upper end goes into a horizontal support flange 12 of the housing base member 3, the support flange 12 being in the form of a circular ring and extending over the entire periphery of the housing base member 3.
Arranged on the top side of the bearing shoulder 9 are bearing balls 14 which are distributed over the entire periphery of the housing base member 3 and on which a rotary unit 16 is supported in such a way that it can rotate freely about the axis of symmetry 5 of the caster roller unit 1. The rotary unit 16 includes a rotational shell carrier, 18, a roller carrier 19 and a roller holder 20 which are described in greater detail hereinafter.
The rotary unit 16 is held in its position on the bearing balls 14 by a housing cover member 22 which is substantially in the form of a circular ring and which lies flat on the support flange 12 of the housing base member and is fixedly connected thereto by way of two locking elements 24 which are described in greater detail hereinafter. The housing cover member 22 is of approximately the same outside diameter as the horizontal support flange 12 of the housing base
The roller carrier 19 which forms the central component of the rotary unit 16 comprises a circular disc 26 which in the assembled condition is arranged horizontally and which has a rectangular opening 27 extending therethrough, the opening 27 being so positioned that it is disposed symmetrically with respect to a diameter of the circular disc 26 but eccentrically with respect to the center point of the circular disc 26, which is formed by the point at which the axis of symmetry 5 passes therethrough. Beneath the opening 27 is a bearing shell member 28 which is in the form of an upwardly open segment of a circular cylinder, with its axis extending horizontally. The bearing shell member 28 is integrally connected by way of the end walls 29, 30 of the segment of the circular cylinder, to the circular disc 26 of the roller carrier 19, as can be seen in particular from FIG. 3. In comparison therewith the bearing shell member 28 which is of a part-circular cylindrical configuration is not connected to the circular disc 26, in the region of the edges 31 and 32 of the bearing shell member 28, which are parallel to the axis of the assembly. On the contrary provided in that region are two openings 33 and 34 which extend over the entire axial length of the bearing shell member 28 and the significance of which will be described in greater detail hereinafter.
Inserted into the mounting space formed by the bearing shell member 28 are two circular-cylindrical support rollers 35 which are supported on the bearing shell member 28 by way of bearing needles 37. The diameter of the support rollers 35 is of such a magnitude, in relation to the depth of the bearing shell member 28, that the peripheral surfaces of the support rollers 35 project beyond the upward flat surface of the housing cover member 22, to such an extent that articles which are supported thereon can move freely over that surface.
The axial length of the two support rollers 35 is approximately half the axial length of the bearing shell member 28 so that the support rollers 35 can rotate freely and independently of each other about their mutually aligned, horizontally extending axes of symmetry 38. Between the mutually directly oppositely disposed end faces of the support rollers 35 and between the outwardly disposed end faces thereof and the end walls 29, 30 of the bearing shell member 28 are respective intermediate spaces which are of sufficient size but which are not shown in the drawings.
The bearing needles 37 are of approximately the same axial length as the respectively associated support roller 35. Therefore, disposed in the bearing shell member are two groups of bearing needles 37, which groups are arranged one behind the other in the axial direction and each of which extends in a part-circular configuration around the associated support roller 35.
From above, the bearing shell member is closed by a roller holder 20 which is fixedly connected thereto by way of locking elements 40. As can be seen in particular from FIG. 1, the roller holder 20 is also in the form of a circular disc in which there is provided a rectangular opening 42 corresponding to the rectangular opening 27 in the circular disc 26. The support rollers 35 can project upwardly through the rectangular opening 42. The upward surface of the roller holder 20 is coplanar with the upper surface of the housing cover member 22. It is above the axes of symmetry 38 of the two support rollers 35 and the rectangular opening 42 disposed therein is of such a dimension that, with its edges which are parallel to the axis, it extends immediately to the peripheral surfaces of the support rollers 35. The side walls of the rectangular opening 42, which extend downwardly from said edges which are parallel to the axis, are of a part-circular cylindrical form so that they also are disposed in opposite relationship to and at a small spacing from the outward peripheral surfaces of the support rollers 35. Since, as already mentioned, the axes of symmetry 38 of the support rollers 35 are lower than the upward surface of the roller holder 20, the support rollers 35 are held in the bearing shell member 28 by the roller holder 20 in that way.
In the region of the openings 33, 34 of the roller carrier 19, which are parallel to the axis of the assembly, the roller holder 20 is provided at its underside with two projections 39 which extend over the entire length of the openings 33, 34 and which project downwardly into those openings and the lower surfaces of which are of such a configuration that, with the edges 31, 32 of the bearing shell member 28, which are disposed in opposite relationship to said surfaces of the projections 39, the projections 39 form passage portions 43 which lead out of the interior of the bearing shell member 28 and which open downwardly and through which the bearing needles 37 can issue from the space inside the bearing shell member 28 and can pass into said space.
The third component of the rotary unit 16 is formed by the rotational shell carrier 18 which essentially also comprises a circular disc 44 with an eccentrically disposed, rectangular opening 45 and a rotational shell portion 46 which extends under the opening 45. The rectangular opening 45 and the shell portion 46 are so arranged that, in the assembled condition, they are disposed beneath and aligned with the rectangular opening 27 and the bearing shell member 28 respectively. The dimensions of the shell portion 46 are so selected that enclosed between the inside part-cylindrical surface thereof and the part-cylindrical outside surface of the bearing shell member 28 is a part-cylindrical annular space 48 into which the passage portions 43 open and the internal width of which is somewhat greater than the outside diameter of the bearing needles 37. The part-cylindrical annular space 48 which is arranged concentrically with respect to the part-cylindrical configuration enclosed by the bearing shell member 28, and thus also concentrically with respect to the axes of symmetry or rotation 38 of the support rollers 35, makes it possible for bearing needles 37 which for example in the case of a rotary movement of the support rollers 35 about their axes of symmetry 38 in the clockwise direction in FIG. 2, issue from the interior of the bearing shell member 28 through the passage portion 43 which is on the left-hand side in FIG. 2, to be passed around the outside of the bearing shell member 28 and go back into the interior of the bearing shell member 28 again through the passage portion 43 which is on the right-hand side in FIG. 2.
The groups of bearing needles associated with each support roller 35 are therefore arranged in a circulatory or rotational system in such a way that, upon a rotary movement of the associated support roller 35, they do not have to rotate on the spot, at the location where they are disposed, but can roll against and move along the bearing shell member 28. That results in a considerable reduction in the level of bearing friction which must be overcome upon a rotary movement of the support rollers 35.
The axial length of the shell portion 46 is so selected that the end walls 50 and 51 thereof bear with their inside surfaces directly against the outside surfaces of the end walls 29 and 30 of the bearing shell member 28 (see FIG. 3). Unlike the bearing shell member 28, the shell portion 46, in the region of its edges 52 and 53 which are parallel to the axis of the assembly, merges into the circular disc portion 44, without any interruption therebetween. At the shoulders which are formed at those locations, the roller holder 20 bears against the shoulders from above with its downwardly projecting projections 39 in such a way that the passage portions 43 are open only towards the interior of the bearing shell member 28 and the part-cylindrical annular space 48, but are otherwise closed.
The circular disc 44 of the shell carrier 18 is of a diameter which is larger than the diameter of the circular disc 26 and the roller holder 20 and approximately corresponds to the diameter of the housing base portion 3 between its cylindrical wall portions 10. At its outer edge the circular disc 44 has an upwardly and outwardly bulging edge bead portion 54 which at its underside provides a channel or groove which is of part-circular cross-section and which extends over the entire periphery of the circular disc and which lies on the bearing balls 14 and embraces same in a cage-like configuration, in combination with the bearing shoulder 9 of the housing base member 3.
At its underside the housing cover member 22 has an annular groove 57 which is adapted in regard to its shape to the edge bead portion 54 and which engages over same in the assembled condition, whereby, in the assembled condition, in which, as mentioned above, the housing cover member 22 is fixedly connected to the housing base member 3, the shell carrier 18 is secured to the housing base member 3 in such a way that it can rotate only about the vertical axis of symmetry 5, but otherwise cannot move with respect to the housing base member 3. As the locking elements 40, by means of which the roller holder 20 is fixedly connected to the roller carrier 19, serve at the same time also for securing those two components as just mentioned above to the shell carrier 18, the entire rotary unit 16 and therewith the support rollers 35 held by the roller holder 20 is rotatably secured to the housing base member 3.
As can be seen in particular from FIG. 3, the retaining connecting elements 40 comprise projections or lugs 58 which project downwardly from the underside of the roller holder 20 and which are each provided at their lower end with an enlarged head having an inclined surface 59 which extends inclinedly outwardly in an upward direction, and a retaining shoulder which adjoins the surface 59 in an upward direction. In the assembled condition the lugs 58 extend through mutually aligned openings 61 and 62 in the circular discs 26 and 44 respectively of the roller carrier 19 and the shell carrier 18 respectively, the internal width thereof being such that the enlarged head of each lug 58 can be pushed therethrough. In that assembly operation, each of the lugs 58 is bent somewhat laterally by virtue of the inclined surface 59 sliding against the upper edge of the opening 61. From that laterally bent position, the lugs 58 spring back into their precisely vertically downwardly directed position shown in FIG. 3, as soon as the enlarged head has passed entirely through the associated lower opening 62. In that situation the retaining shoulder engages behind the lower edge of the associated opening 62, whereby the roller holder 20 is fixedly locked in position.
Therefore the assembly of a caster roller unit according to the invention is effected in such a way that two groups of bearing needles 37 are firstly fitted into the shell portion 46 of the shell carrier 18 in the manner shown in FIG. 3. Thereupon, a roller carrier 19 is fitted on to the shell carrier 18 and the interior of the bearing shell member 28 is also filled with two groups of bearing needles 37 on to which the support rollers 35 are then placed. The roller carrier 20 is then pushed from above over the support rollers 35 and secured to the shell carrier 18 by means of the locking elements 40, whereby at the same time a firm connection between those two elements and the roller carrier 19 is also made. The rotary unit 16 which is formed in that way can then be fitted downwardly into the housing base member, after bearing balls 14 have previously been arranged on the bearing shoulder 9 thereof, with the bearing balls lying closely against each other over the entire periphery of the bearing shoulder. The housing cover member 22 is then fitted into position from above and secured to the housing base member 3 by means of the locking elements 24.
As is described in greater detail hereinafter with reference to FIG. 4, a caster roller unit 1 which is formed in that way can then be fitted for example into an opening 64 in a conveyor track panel member 65, with the locking elements 24 performing a dual function insofar as, after that insertion operation, they connect not only the housing cover member 22 and the housing base member 3 but also the entire unit 1 to the conveyor track panel member 65. As can be seen from FIGS. 1 and 2, each of the locking elements 24 includes an upwardly open U-shaped spring portion 68, the inner vertical leg 69 of which is integrally connected to the housing cover member 22. The outer vertical leg 70 which extends upwardly at a small spacing from the inner leg 69, in the vicinity of its upper free end, carries a radially outwardly projecting locking shoulder 71. The spacing of the outer leg 70 from the inner leg 69 is so selected that, when a pressure is applied to the free end of the resiliently deflectable outer leg 70, the outer leg 70 can move towards the center of the housing cover member 22 to such an extent that the locking shoulder 71 can above inwardly towards the middle of the housing cover member 22 which is in the form of a circular ring, at least by a distance corresponding to the radial width of the locking shoulder 71.
In the assembled condition of the caster roller unit 1, the U-shaped spring portions 68 of the locking elements 24 engage downwardly through rectangular apertures 73 in the support flange 12 of the housing base member 3, and in particular the locking shoulder 71 engages under a limb portion 74 of the respective aperture 73 whereby, as already mentioned above, the caster roller unit 1 consisting of the rotary unit 16, the housing base member 3 and the housing cover member 22 is held together.
However the locking shoulders 71 are of such a radial width that they project outwardly beneath the respective limb portion 74 and can engage under the peripheral edge 75 of the associated opening 64 in the conveyor track panel member 65. In that condition the caster roller unit 1 is held in a downward direction by base segments 76 (see FIG. 4) which project into the opening 64 while it is supported against the underside of the peripheral edge 75 of the opening 64 in the conveyor track panel member 65, and as a result cannot move out upwardly, by the outer ends of the locking shoulders 71.
To remove the caster roller unit 1 from the conveyor track panel member 65, a force which is directed towards the center of the caster roller unit 1 is applied to the free ends of the locking elements 24 by means of a suitable tool until the outer vertical legs 70 are sprung inwardly towards that center to such an extent that the respective locking shoulder 71 comes out from under the peripheral edge 75 of the conveyor track panel member 65. In that condition the caster roller unit 1 can then be removed from the opening 64 in an upward direction without the way in which the caster roller unit 1 is securely held together being adversely affected as a result, since the locking shoulders 71 still engage under the limb portions 74 of the housing base member 3.
If the caster roller unit is to be taken apart, the free ends of the outer vertical legs 70 are bent still further resiliently towards the center of the caster roller unit 1 until the outer ends of the locking shoulders 71 come out from under the limb portions 74 so that the housing cover member 22 can be removed from the housing base member 3 in an upward direction. In a corresponding manner, the downwardly projecting lugs 58 of the locking elements 40 can then also be bent inwardly in order to permit the rotary unit 16 to be dismantled.
The load carried by the support rollers 35 is transmitted from same by way of the bearing needles 37 to the bearing shell member 28 of the roller carrier 19 and from same to the circular disc 44 of the shell carrier 18 which in turn is supported by way of the bearing balls 14 on the bearing shoulder 9 of the housing base member 3. From the bearing shoulders 9, the load to be carried is transferred over a very short distance by way of the support flange 12 which in the assembled condition lies on the base segments 76 of the opening 64. The bearing needles 37 in the part-cylindrical annular space 48 do not have any load to carry and can therefore above with minimum friction from one passage portion 43 to the other.
The load-bearing members, that is to say the housing base member 3, the shell carrier 18 and the roller carrier 19, are preferably made from metal in the form of deep-drawn components. In contrast the roller holder 20 and the housing cover member 22 can be made from resilient plastic material. The opening 6 in the bottom wall 4 of the housing base member 3 contributes to reducing the weight of the unit. That therefore provides a caster roller unit which is of very low weight, which is made from a small number of components which are simple and inexpensive to be produced, and which can be very easily assembled.
It will be appreciated that the foregoing description of preferred embodiments has been set forth only by way of example and illustration of the principles of the invention and various other modifications and alterations may be made therein without thereby departing from the spirit and scope thereof.
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A caster roller unit for a freight conveyor track includes first and second support rollers to support the freight articles from below. The rollers are mounted on a roller carrier rotatably independently of each other about horizontally extending, mutually aligned axes. The roller carrier is supported on a stationary housing base member by a ball bearing assembly rotatably about a vertical axis which is eccentric with respect to the axis of the rollers. The roller carrier, for each of the support rollers, has an upwardly open bearing shell member in the form of a cylinder portion accommodating a plurality of bearing needles on which the respective support roller is rotatably disposed and the longitudinal axes of which are oriented parallel to the horizontally extending axis of rotation of the respective support roller. A housing cover member fixedly connected to the roller carrier embraces the support rollers from above to retain the support rollers and the bearing needles in the bearing shell member, with the support rollers projecting upwardly beyond the upper outward surface of the housing cover member.
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GOVERNMENT INTEREST
The invention herein described may be manufactured, used and licensed by or for the U.S. Government for governmental purposes without payment to me of any royalty thereon.
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation in part of U.S. patent application Ser. No. 07/578,033, filed 9-4-90 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In one aspect of this invention it relates to tools useful for applying a rotating force to nuts, bolts and the like. In further aspect this invention relates to tool extensions useful for addition to normal driving devices where the location of the object to be driven is located in a hard to reach position.
2. Prior Art
Socket and square drive type wrenches are frequently used for tightening bolts. In particular torque wrenches are used for tightening fasteners such as bolts to a specified tension in order to provide uniform holding power. Frequently the bolt to be tightened is located in a position where the socket or other drive means cannot be brought into close proximity to the bolt. Under these circumstances it is necessary to use an extension to place the socket or other tightening means on the bolt to be tightened. Such extensions are normally straight shafts having a square drive end at one end and a attachment end adapted to fit and engage the drive means. In addition, universal type joints can be attached to a drive means to allow a certain amount or angular misalignment between the drive of the socket, and the fastener.
For the majority of operations the straight shaft extension combined with universal or other type joints provides an adequate means for extending the reach of the drive handles. However, there are situations where the fastener to be tightened is offset in such a manner that the standard joints and extensions will not allow access to the fastener.
SUMMARY OF THE INVENTION
The present invention provides an extension suitable for use with a socket or other driving means and useful for tightening a fastener at a position offset from the location in which the handle can be conveniently located for the motion necessary to provide a driving force. The problems of the prior art are solved by the wrench extension of the present invention which has a frame member with an adjustable center portion variable in length which can be locked at the desired length. First and second mounting members are located one on each end of the frame member with each mounting member being adapted to hold a driving means. In one mounting member an input drive means is rotatably positioned, the input drive means being adapted to receive an externally applied force such as might be applied by a socket, drive handle or other driving device. A first sprocket is mounted on the input drive and rotated when a rotating force is applied to the input drive means. A second sprocket is rotatably mounted on an output drive in the other mounting member the output drive means being adapted to engage the fastener to be rotated. An adjustable endless chain adapted to engage the sprockets is disposed about the two sprockets so that a force applied to the input drive will cause rotation of the first socket and through the chain a corresponding rotation of the second socket rotating the output drive means and the fastener.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a top view of one embodiment of this invention;
FIG. 2 is a sectional view of the construction or FIG. 1 taken along the line 2--2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawing wherein like numerals designate like parts and initially to FIG. 1, the invention will be described with specific reference to the square socket drive found on standard socket wrenches and extension bars. The extension of this invention would be useful with drive means other than the normal square drive socket wrenches, i.e. pneumatic tools, torque wrenches and the like. The improved wrench extension of this invention has a frame member 10 with an adjustable center portion 12 adapted to be varied in length and locked at the desired length. The variable center portion 12 has a first mounting member 14, attached to one end and a second mounting member 16 attached to the other end. Both mounting members have an input means and an output means mounted therein as will described later.
The center portion 12 comprises a threaded rod 24 and cylindrical extension 29, which are threadably engaged. The threaded rod 24 and cylindrical extension 29 can be rotated relative to each other to adjust the length of the center portion. To begin adjusting the center portion 12 clamp 20 is loosened by untightening bolt 22 allowing collar 25 to open and a threaded flange 18 is rotated away from the clamp. With threaded flange 18 moved toward the second mounting means 16, threaded rod 24 can be rotated to move second mounting member 16 longitudinally closer to or further away from the first mounting member 14. The collar 25 has a key portion 26 extending radially inwards which engages a corresponding slot 28 in the threaded rod 24. The key 26 helps keep the rod and cylindrical extension 29 axially aligned during adjustment. When the desired length is achieved the collar 25 is moved into engagement with the end of cylindrical extension 29 and the bolt 22 tightened so that clamp 20 is securely fastened. The threaded flange 18 is then tightened to jam against the end of the clamp 20 to hold the entire center assembly 12 in a rigid, fixed configuration.
The chain 42 connecting the drive means can then be engaged with the sprocket. As shown the chain 42 is of the flat standard roller chain variety with a plurality of links 44 flexibly joined with a plurality of arms 45 using pins 49. Such chains can have one or more links removed to adjust the length of the chain. Such chains are made in a wide variety of sizes from very small up to the size used in motorcycles. The size of the chain would be determined by the duty cycle and expected force to be transmitted by the chain. Other adjustable, flexible chains ameanable for use with gear drives could also be used. Because there is flexibility in the chain 42 there is flexibility in the connection between the first and second drive means the axis of the first and second mounting members 14, 16 can be disposed at an angle to allow a driving force and an input force to operate at an angle to each other.
The first mounting member 14 has an input drive means designated generally 30 with a body 31 rotatably mounted on and extending through the first mounting member. As shown the body 31 has two separate and distinct square drive cavities 32, 34. The larger drive cavity 32 could be sized for a 1/2 inch socket and the smaller drive cavity could be sized to correspond to the standard 1/4 inch socket. As shown, the input drive means 14 is held in position by means of two retaining rings 36 which engage the body 31 and are located at each end of the mounting means 30. In use, the desired driving force would be inserted into the complimentary drive cavity of the body portion 31 of input drive means 14 and the body portion rotated.
The input body 31 has a square surface 37 adapted to engage a corresponding cutout in a sprocket 38. The sprocket 38 shown has a plurality of teeth 40 which are adapted to engage the links of the flat standard roller chain 42 which comprises a plurality of links 44 flexibly joined by a plurality of arms 45 in a manner well known in the art.
The output drive means of the present invention 46 has a body portion 47 rotatably mounted in the second mounting member 16 and held in place by retaining rings 36 in a matter similar to the input drive means 30. The output drive means body 47 as shown has a square chamber 48 formed longitudinally therethrough with a slideable driving head 50 located and retained within the chamber 48. The slideable driving head 50 can be moved longitudinally through the chamber 48 to provide a driving force on either side of the output drive means. As shown the driving head 50 is located so that a socket or other fastener engaging means would be attached on the side of the driving head 50 opposite the sprocket 38.
In operation the fastener engaging means such as a socket, screw driver or "TORX" type fastener engaging means having a square drive portion would be placed on extended part of the driving head 50 and the adjustable center portion 12 extended to the desired length. A driving means such as a socket wrench, square drive extension or pneumatic device would be placed in engagement with the input means and rotation commenced causing a rotating action on the fastener. Because of the flexible nature of the chain engaging the sockets there can be an angle between the axis of the input means and the output means. The maximum angle between the two axis will depend on the flexibility of the chain and the distance between the sprockets. It could be as much as 90 degrees but in general it will need to be only a few degrees.
The sprockets are shown as being equally sized providing a one-to-one mechanical ratio with respect to the input and output drive means. If desired, the size of the sprockets can be varied in order to provide increased or decreased torque with respect to the input or can be used to vary the speed of rotation between the input and output means.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described for obvious modifications will occur to a person skilled in the art, without departing from the spirit and scope of the appended claims.
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An improved extension for use with tools is disclosed. The extension has a pair of gears located on a frame. The gears have a chain drive therebetween to allow the force applied to one gear to be applied to the other gear. The structure allows a drive member such as a socket to be offset from the drive handle.
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RELATED APPLICATIONS
This application claims priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/758,442, filed Jan. 30, 2013 the contents of which are herein incorporated by reference.
FIELD
The present disclosure is related generally to compositions for prevention of ice build-up on a surface.
BACKGROUND INFORMATION
Icing in a cold environment causes many problems, including glazing rotors and blades of wind turbines, breaking power lines, and stalling airfoil of aircrafts. Most of these problems are due to build-up of ice on surfaces. Such ice build-up may be removed by heating, by applying chemicals that reduce the melting point of ice, by applying a mechanical force (such as shock or vibration), or by occluding air to break the bonding between ice and the substrate surface. However, all of these methods have limitations and disadvantages. An alternative method to prevent ice build-up is to protect the surface with a coating that has an ultra-low ice adhesion strength (i.e., ice barely adheres to the coating), so that ice formed on such a coating can be released by the weight of ice alone when the substrate surface is slightly inclined from horizontal or by a very small shear force applied to the ice (e.g., by spinning of the blade of a wind turbine or by flowing of air over the surface).
Many approaches have been explored to make coatings for prevention of ice build-up, for example, by using coatings with a low surface free energy (such as silicone resins, fluorinated polymers, polyethylene, hydrophobic polyurethanes, epoxies, etc.), and by tuning the surface texture and roughness of the coating to reduce the contact area between ice and the substrate and/or to induce cracking of ice. In general, coatings made by following these approaches are able to significantly reduce the ice adhesion strength to substrates, sometimes by an order of magnitude or more, and consequently, ice may be released considerably easier from these coatings than from uncoated conventional substrates such glass, metals, and concrete. However, the ice adhesion strength on these coatings, even though significantly smaller than on uncoated substrates, is still too strong to satisfy the need of many industrial applications, and spontaneous ice release is still impossible in most circumstances. In quantitative terms, the shear stress that is required to release ice from these substrates (at about −20° C.) is in the order of 10-100 kPa, compared to the order of 100-1000 kPa for ice adhesion to uncoated metal and glass; however, the shear stress for ice release needs to be smaller than 10 kPa for spontaneous ice release in many applications. In some circumstances, ice adhesion strength is characterized by a cohesive strength in terms of adhesion energy per contact area, in which case it is generally believed that adhesion strength in the order of 0.1 J/m 2 is required for spontaneous ice release. Heretofore, no viable technology has been able to produce coatings with such low ice adhesion strength.
Most recently, superhydrophobic surfaces have been used to prevent ice formation and to reduce ice adhesion on substrates. These surfaces show remarkable water repellency, characterized by a water contact angle of higher than 150°, which has been explained by the interplay between the surface chemical composition and the surface texture with a two-tier roughness in micrometer and nanometer scales, respectively, for each tier. Although some promising experimental results have been demonstrated which indicate that superhydrophobic surfaces may prevent ice formation and reduce ice adhesion strength in certain circumstances, it has been found that the superhydrophobicity of these surfaces is completely removed and ice adheres strongly to the substrates when condensation occurs before or with icing.
Thus, there remains a considerable need for ice release compositions for use as or in coatings, paints and the like for a wide range of surfaces and applications that provide ice adhesion strengths smaller than 10 kPa for spontaneous or easy ice release.
SUMMARY OF THE DISCLOSURE
In a preferred aspect, the present disclosure is directed to compositions for prevention of ice buildup comprising a silicone oil or fluorosilicone fluid combined with a cross-linked silicone resins. The silicone resin forms a cross-linked polymer matrix, and the silicone oil or fluorosilicone fluid is embedded within the cross-linked polymer matrix of the silicone resin. When the viscosity of the silicone oil or fluorosilicone fluid is within a defined range and the silicone oil or fluorosilicone fluid and the silicone resin are mixed at a weight ratio within a defined range, the cross-linked polymer matrix of the silicone resin serves as a storage place for the silicone oil or fluorosilicone fluid, and the silicone oil or fluorosilicone fluid is released (or leached) gradually out of the cross-linked polymer matrix over time, thereby constantly forming a thin layer of oil on the surface of the coatings. This thin layer of silicone oil serves as a lubricant between ice and the substrate. Therefore, the adhesion strength between ice and the substrate is extremely low, and ice may slip off the coating by the weight of the ice alone when the substrate surface is slightly inclined from horizontal or by applying a very small force to the ice (e.g. by spinning the blade of a wind turbine or by flowing air over the substrate surface). With correct combination of the cross-linked silicone resin and the silicone oil or fluorosilicone fluid, this oil release (or leaching) mechanism can last many years, and the ice release coatings made through this approach can remain effective in preventing ice from building up on a substrate over many years in a natural environment.
In another preferred aspect, the composition of the present disclosure comprises a silicone oil or fluorosilicone fluid infused in a cross-linked silicone resin matrix. Preferably, the weight ratio of the silicone oil or fluorosilicone fluid to silicone resin is 1-20:1, more preferably 1-10:1 and still more preferably 2-8:1.
In a further preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid may comprise a linear polymeric siloxane.
In another preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid preferably has a viscosity ranging from about 2 cP to about 300,000 cP, more preferably from about 10 cP to about 10,000 cP and still more preferably from about 50 cP to about 500 cP.
In a further preferred aspect, the composition of the present disclosure comprises, by weight, 75% polydimethylsiloxane (PDMS) and 25% silicone resin matrix. Preferably, the PDMS may have a dynamic viscosity of 200 cP and the silicone resin matrix comprises a three dimensional polymer matrix comprising a trifunctional siloxane crosslinked with one or more other trifunctional siloxanes or difunctional siloxanes.
In a further preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid may comprise a copolymer of siloxane or a linear copolymer of siloxane.
In another preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid may comprise a branched silicone.
In a further preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid may comprise a cyclic siloxane.
In yet a further preferred aspect of the composition of the present disclosure, the silicone oil or fluorosilicone fluid may comprise a linear or branched polymeric siloxane functionalized with one or more of the following groups: alkyl, fluoroalkyl, aryl, benzyl, halo, hydride, hydroxyl, -alkyl-OH, -alkyl-SH, halo, -aryl-halogen, -alkyl-COOH, -alkyl(COOH)-alkyl-COO-alkyl, alkenyl, vinyl, -alkyl-acryloyl, -alkylamino, -alkyl-NH-alkyl-NH2, -alkyl-OOC—NH-alkyl-NCO, -alkyl-O-oxiranyl, monofluoromethyl, difluoromethyl, trifluoromethyl, or alkeneoxide co-polymer.
In a further preferred aspect, the composition of the present disclosure comprises a silicone oil or fluorosilicone fluid infused in a cross-linked silicone resin matrix and may additionally comprise one or more of a group consisting of a paint, a liquid coating, a solid coating, silicone oil or fluorosilicone fluid encapsulated in vesicles, an alcohol, an ester, an ether, a ketone, an ether-alcohol, an aromatic hydrocarbon, an aliphatic hydrocarbon, a halogenated hydrocarbon, and a volatile silicone.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present disclosure to be easily understood and readily practiced, the disclosure will now be described, for the purposes of illustration and not limitation, in conjunction with the following figures, wherein:
FIG. 1 is a schematic of the artificial freezing rain chamber used in the Examples to evaluate the ice release coatings;
FIG. 2 is an optical image of 2 coated aluminum panels coated with a preferred ice release coating of the present disclosure and of 2 uncoated aluminum panels, all after being exposed to simulated freezing rain for 30 min. It was observed that the uncoated panels were covered by a thick layer of ice, while the coated panels had little ice on the surface—only ice islands at the bottom edge of the coated panels were observed which appeared to be in the process of slipping off the surface.
FIG. 3 is a schematic setup for measuring ice adhesion strength of preferred ice release coatings of the present disclosure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about”, even if the term does not expressly appear. Also, any numerical range recited herein is intended to include all sub-ranges subsumed therein.
The present disclosure is directed to ice release coatings whose preferred composition comprises silicone oil or fluorosilicone fluid and a cross-linked silicone resin. Other components may be added to the coating formula, for example, to aid the application of the coating to various substrates, to improve the ultra-violet (UV) resistance, and to change the appearance of the coating. These components include solvents, flow additives, UV blockers, pigments and particles, and organic dyes. They are known to those skilled in the art, and can be added to the coating formula either individually or in combination with each other as long as they do not change the function of the silicone oil or fluorosilicone fluid and the silicone resin used in the ice release coating. The following describes the molecular structure and the properties of the two key components used in the ice release coating: (i) silicone oil or fluorosilicone fluid and (ii) silicone resin.
Silicone Oil or Fluorosilicone Fluid
In a preferred embodiment of the present disclosure, the kinematic viscosity of the silicone oil or fluorosilicone fluid used in the ice release coating ranges from 2 to 300,000 centistokes (cSt, or 106 m 2 /s), preferably from 10 to 50,000 cSt, and more preferably from 300 to 10,000 cSt. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
The silicone oil used in the ice release coating preferably may be a linear polymeric siloxane of the following general structure I, where R is an organo group such as C 1 -C 5 alkyl (e.g. methyl, ethyl, vinyl) and C 6 aryl (e.g. phenyl), and n ranges from 1 to 50,000, preferably from 50 to 1,000. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP. Such silicone oils are commercially available from companies such as Dow Corning, Wacker-Chemie, and Union Carbide. Particularly, when R in Structure I is a methyl group, the molecule is known as polydimethylsiloxane (PDMS). PDMS with various molecular weight and various viscosity is commercially available from companies such as Dow Corning, Wacker-Chemie, and Union Carbide.
The silicone oil used in the ice release coating preferably may also be a linear polymeric siloxane with functionalized end groups as shown in the following general structure II, where R 1 and R 2 can be the same or different, chosen from C 1 -C 5 alkyl, phenyl, benzyl, halide, hydride, fluoroalkyl [—CF 3 ], [—CHF 2 ], [—(CH 2 F], hydroxyl [—(CH 2 ) 3 H], mercapto [—(CH 2 ) 3 SH], halo [—C 6 H 4 Cl], carboxyl such as [—(CH 2 ) 3 —CH(COOH)—CH 2 —COO-alkyl], alkenyl such as [—CH═CH 2 ] and [—(CH 2 ) 3 —OOC—CH═CH 2 ], amino such as [—(CH 2 ) 3 —NH—CH 2 CH 2 NH 2 ], isocyano such as [—(CH 2 ) 3 —OOC—NH—(CH 2 ) 4 —N═C═O], epoxy such as [—(CH 2 ) 3 —O—H 2 CH(O)CH 2 ], or alkene oxide copolymer such as [—(CH 2 ) 3 —(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )O) y H], and n ranges from 1 to 50,000, preferably from 50 to 1,000. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP. Silicone oils with some of these structures are commercially available from companies such as Dow Corning, Wacker-Chemie, and Union Carbide.
More generally, the silicone oil used in the ice release coating preferably may also be a linear polymeric siloxane with the following general structure III (which is a more general structure of Structures I and II), where R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 can be chosen from C 1 -C 5 alkyl, phenyl, benzyl, halide, hydride, fluoroalkyl [—CF 3 ], [—CHF 2 ], [—(CH 2 F], hydroxyl [—(CH 2 ) 3 H], mercapto [—(CH 2 ) 3 SH], halo [—CH 4 Cl], carboxyl such as [—(CH 2 ) 3 —CH(COOH)—CH 2 —COO-alkyl], alkenyl such as [—CH═CH 2 ] and [—(CH 2 ) 3 —OOC—CH═CH 2 ], amino such as [—(CH 2 ) 3 —NH—CH 2 CH 2 —NH 2 ], isocyano such as [—(CH 2 ) 3 —OOC—NH—(CH 2 ) 4 —N═C═O], epoxy such as [—(CH 2 ) 3 —O—CH 2 CH(O)CH 2 ], or alkene oxide copolymer such as [—(CH 2 ) 3 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )O) y H], and n (in Structure III) ranges from 1 to 50,000, preferably from 50 to 1,000. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
The silicone oil used in the ice release coating preferably may also be a copolymer of siloxane with the following general structure IV, where R can be chosen from C 1 -C 5 alkyl, phenyl, benzyl, halide, hydride, fluoroalkyl [—CF 3 ], [—CHF 2 ], [—(CH 2 F], hydroxyl [—(CH 2 ) 3 H], mercapto [—(CH 2 ) 3 SH], halo [—CH 4 C], carboxyl such as [—(CH 2 )—CH(COOH)—CH 2 —COO-alkyl], alkenyl such as [—CH═CH 2 ] and [—CH 2 ) 3 —OOC—CH═CH 2 ], amino such as [—(CH 2 ) 3 —NH—CH 2 CH 2 —NH 2 ], isocyano such as [—(CH 2 )—OOC—NH—(CH 2 ) 4 —N═C═O], epoxy such as [—(CH 2 ) 3 —CH 2 CH(O)CH 2 ], or alkene oxide copolymer such as [—(CH 2 )—(CH 2 CH 2 O) x —(CH 2 CH(CH)O) y H], and m (in Structure IV) ranges from 1 to 1000, preferably from 2 to 100, and more preferably from 2 to 30, and n (in Structure IV) ranges from 1 to 5,000, preferably from 20 to 1,000. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP. Such silicone oils are commercially available from companies such as Dow Corning, Wacker-Chemie, and Union Carbide.
The silicone oil used in the ice release coating preferably may also be a linear copolymer of siloxane with the following general structure V (which is a more general structure of Structure IV), where R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 5 , R 9 , and R 10 can be chosen from C 1 -C 5 alkyl, phenyl, benzyl, halide, hydride, fluoroalkyl [—CF 3 ], [—CHF 2 ], [—(CH 2 F], hydroxyl [—(CH 2 ) 3 H], mercapto [—(CH 2 ) 3 SH], halo [—C 6 H 4 Cl], carboxyl such as [—(CH 2 ) 3 —CH(COOH)—CH 2 —COO-alkyl], alkenyl such as [—CH═CH 2 ] and [—(CH 2 ) 3 —OOC—CH═CH 2 ], amino such as [—(CH 2 ) 3 —NH—CH 2 CH 2 —NH 2 ], isocyano such as [—(CH 2 ) 3 —OOC—NH—(CH 2 ) 4 —N═C═O], epoxy such as [—(CH 2 ) 3 —O—CH 2 CH(O)CH 2 ], or alkene oxide copolymer such as [—(CH 2 ) 3 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH)O) y H], and m and n (in Structure V) range from 1 to 5,000, preferably from 2 to 1,000. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
The silicone oil used in the ice release coating preferably may also be a branched silicone of the following general structure VI, where m, n, and p (in Structure VI) range from 1 to 5,000, preferably 5 to 1000, and more preferably 10 to 100. The dynamic viscosity of the silicone oil ranges from 5 to 30,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
The silicone oil used in the ice release coating preferably may also be a branched silicone of the following general structure VII (as a more general structure of Structure VI), where R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 5 , R 9 , R 10 , R 11 , R 12 , R 13 , R 14 , R 15 , and R 16 can be chosen from C 1 -C 5 alkyl, phenyl, benzyl, halide, hydride, fluoroalkyl [—CF 3 ], [—CHF 2 ], [—(CH 2 F], hydroxyl [—(CH 2 ) 3 H], mercapto [—(CH 2 ) 3 SH], halo [—C 6 H 4 Cl], carboxyl such as [—(CH 2 ) 3 —CH(COOH)—CH 2 —COO-alkyl], alkenyl such as [—CH—CH 2 ] and [—(CH 2 )—OOC—CH═CH 2 ], amino such as [—(CH 2 ) 3 —NH—CH 2 CH 2 —NH 2 ], isocyano such as [—(CH 2 ) 3 —OOC—NH—(CH 2 ) 4 —N═C═O], epoxy such as [—(CH 2 ) 3 —O—CH 2 CH(O)CH 2 ], or alkene oxide copolymer such as [—(CH 2 ) 3 —O—CH 2 CH 2 O) x —(CH 2 CH(CH 3 )O) y H], and m, n, and p (in Structure VI) range from 1 to 5,000, preferably 5 to 1000, and more preferably 10 to 100. The dynamic viscosity of the silicone oil ranges from 2 to 300,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
The silicone oil used in the ice release coating preferably may also be a cyclic siloxane of the following general structure VIII, where n ranges from 3 to 8, preferably from 3 to 5. The dynamic viscosity of the silicone oil ranges from 2 to 50 centiPoise (cP, or 10 −3 Pa·s), preferably from 2 to 20 cP, and more preferably from 2 to 10 cP. Such cyclic silicone oils are commercially available from companies such as Dow Corning, Wacker-Chemie, and Union Carbide.
[(CH 3 ) 2 SiO] n Structure VIII
The silicone oil used in the ice release coating preferably may be replaced or mixed with fluorosilicone fluids. The fluorosilicone fluids may have a molecular structure similar to those shown in Structures I, II, III, IV, V, VI, VII, and VIII but with any, some, or all of the hydrogen (H) atoms in those structures replaced by fluorine (F) atoms. One example is shown in the following structure.
The silicone oils defined by structures I-VIII above preferably may be used in the coating composition either individually or in combination with each other. When the silicone oils are used in combination, the kinematic viscosity of the mixed silicone oil used in the ice release coating ranges from 2 to 30,000 centistokes (cSt, or 10 −6 m 2 /s), preferably from 10 to 50,000 cSt, and more preferably from 300 to 10,000 cSt. The dynamic viscosity of the mixed silicone oil ranges from 2 to 30,000 centiPoise (cP, or 10 −3 Pa·s), preferably from 10 to 50,000 cP, and more preferably from 300 to 10,000 cP.
Silicone Resin
The silicone resin in the ice release coating preferably is a three dimensional polymer matrix, typically formed by crosslinking a trifunctional siloxane with other trifunctional siloxanes or difunctional siloxanes, and is typically described by structure IX shown below. Such silicone resins are commercially available from companies such as Dow Corning, Wacker-Chemie, Air Products, and Union Carbide. Such silicone resins are also contained in most silicone-based coatings, and these silicone-based coatings preferably may be used as the source of silicone resin in the ice release coating of the present disclosure. These silicone-based coatings are typically formulated as either 1-component or 2-component coatings. The silicone resin may be cross-linked during the curing process. These silicone-based coatings are commercially available from companies such as PPG Industries, Sherwin-Williams, Valspar, and Minwax.
Combination of Silicone Oil with Silicone Resin
According to preferred embodiments of the present disclosure, an effective ice release coating that can function long term comprises silicone oil disposed or stored within the cross-linked silicone resin matrix, where the silicone oil will be released gradually to the surface of the silicone resin over time.
A preferred embodiment of an ice release coating according to the present disclosure has a weight ratio of the silicone oil to silicone resin that is greater than 1. In other words, the weight percentage of the silicone oil in the coating ranges from 50 to 99, and the weight percentage of the silicone resin ranges from 1 to 50. Various percentages of silicone oil and silicone resin in between may be used. The optimum weight ratio of the silicone oil to the silicone resin is determined by the nature and the composition of the oil and the resin. An effective range of performance is typically obtained with the weight ratio of the silicone oil to the silicone being from 1 to 20, preferably 1 to 10, and more preferably 2 to 8.
Optionally, the mixture of silicone oil and silicone resin preferably may be further diluted by suitable solvents, such as alcohols, esters, ethers, ketones, ether-alcohols, aromatic hydrocarbons, aliphatic hydrocarbons, halogenated hydrocarbons, and volatile silicones.
Optionally, other components preferably may be added to the coating formula, for example, to aid the application of the coating to various substrates, to improve the ultra-violet (UV) resistance, and to change the appearance of the coating. These components include solvents, flow additives, UV blockers, pigments and particles, and organic dyes. They are known to those skilled in the art, and can be added to the coating formula either individually or in combination with each other as long as they do not change the function of the silicone oil and the silicone resin used in the ice release coating.
In preferred cases according to the present disclosure where commercial silicone-based coatings, in either one-component or two-component formulations, are used as the source for silicone resin and/or silicone oil, the weight ratio of the silicone oil to the silicone resin needs to be calculated based on the weight of the oil and the resin in the mixture (excluding solvents, additives, and other compositions in the coating). Additional silicone resin and/or silicone oil may be added to the commercial silicone based coating to adjust the final weight ratio of silicone oil to silicone resin according to the present disclosure.
In cases that the silicone-based coating is formulated in an aqueous phase, the silicone oil preferably may be added to the silicone-based coating in an emulsion form. The silicone oil preferably may also be encapsulated in vesicles and mixed with the silicone resin.
The mixture of silicone resin and silicone oil formulated according to the present disclosure may be added to other coating formulas such as commercial paints to make ice release coatings which function according to the present disclosure.
The formulated mixture of silicone oil, silicone resin, and other optional components preferably may be applied to a substrate (including metals, metal oxides, glass, ceramics, wood, plastics, concretes, and substrates that have been pre-coated with varied types of coatings) by a variety of techniques such as spraying, brushing, roller, dip coating, spin coating, wire coating, and the alike.
Examples
The following examples are intended to illustrate the present disclosure and should not be construed as limiting the present disclosure in any way.
Example I
An ice release coatings was made by the following procedure. 100 parts by weight of hydroxy-terminated polydimethylsiloxane (viscosity: ˜750 cP, Sigma-Aldrich), 200 parts by weight of fluorosilicone oil with a viscosity of ˜300 cP at 25° C. (Mw: ˜120,000, Sigma-Aldrich), 10 parts by weight of methyltris(2-methoxyethoxy)silane (Sigma-Aldrich), and 0.1 parts by weight of Dabco® T-12 catalyst (Air Products & Chemicals) were mixed together at room temperature and degassed. The coating was applied to aluminum panels by a spray gun or by brush.
Example II
The aluminum panels coated in Example I were placed in an artificial freezing rain chamber ( FIG. 1 ) with uncoated aluminum panels. Both the coated and uncoated panels were exposed to a fine vertical water spray equivalent to freezing drizzle. The temperature of the chamber was kept at −20° C. Water was introduced into the nozzle at about 2° C., which was about 1.8 m above the aluminum panel. The panel was tilted at about 20° to the horizontal for ice to slip off by gravity. FIG. 2 shows an optical image of 2 coated and 2 uncoated aluminum panels after being exposed to simulated freezing rain for 30 min. It was observed that the uncoated panels were covered by a thick layer of ice, while the coated panels had little ice on the surface-only ice islands at the bottom edge of the coated panels were observed which appeared to be in the process of slipping off the surface.
The amount of ice accumulated on the coated and uncoated panels was determined from the difference in weight before and after icing. Ice accumulation reduction factor (IARF) was measured, which is defined by the following equation:
Ice Accumulation Reduction Factor (IARF)=(Mean ice mass on bare aluminum)/(Mean ice mass on the coated aluminum)
IARF was measured to be greater than 40 for the coating made in this example.
Example III
An ice release coatings was made by the same procedure as in Example I, except that the fluorosilicone oil with a viscosity of ˜300 cP at 25° C. was replaced with a fluorosilicone oil with a viscosity of ˜8,000 cP at 25° C.
Example IV
This example measures the ice adhesion strength to the ice release coating made in Example III by using a setup schematically shown in FIG. 3 . Briefly, an aluminum panel coated with the ice release coating was placed onto a cold plate. A water droplet was placed on the coating. A nylon wire with a tie on its end and a tray on another end was carefully inserted into the water droplet. The whole setup was placed into a cold chamber at −20° C. and the cold plate was also cooled to −20° C. The water droplet froze with the wire embedded inside the ice. Then both the sample and the cold plate were rotated 90 degree to the horizontal, and weights were gradually added to the tray until ice started to slip off the surface. The ice adhesion strength was then calculated based on the weight needed to move the ice and the contact area between ice and the substrate. This method was used to measure the ice adhesion strength of the ice release coating made in Example III, which was compared to the ice adhesion strength of 3 commercially available coatings: DuPont™ Teflon coating, Wearlon Super F-1 Icephobic coating, and Dow Corning Sylgard 184 Silicone. The results are shown below in Table I. When the coating made in Example III was used in this test, ice was observed to slip off spontaneous (due to the weight of ice) without adding any weight. Therefore, the ice adhesion strength was determined to be less than 2 kPa based on the weight of the ice alone.
TABLE I
Comparison of ice adhesion strength between 3 commercially
available coatings and the coating made in Example III.
Stress needed to detach ice
Coatings
(kPa)
DuPont ™ Teflon Coating
~90.5
Wearlon Super F-1 Icephobic
~50
Coating
Dow Corning Sylgard 184
~140
Silicone
Ice Release Coating Made in
<2
Example III
Example V
This example examines the ice release performance of the coating made in Example III under repeated release cycles. The coatings were tested by repeated icing-and-release cycles. In each cycle, ice was formed on the coating and released while the ice adhesion strength was measured as described in Example IV. The ice adhesion strength remained less than 2 kPa and ice spontaneous slipped off the coating after up to 50 cycles.
Example VI
An ice release coatings was made by mixing 75 w.t. % of a silicone oil (with a molecular structure defined by Structure I where R is a methyl group and a dynamic viscosity of 500 cP) with 25 w.t. % of a silicone resin (with a molecular structure defined by Structure IX). The coating was applied to aluminum panels by a spray gun.
Example VII
This example examines the ice release performance of the coating made in Example VI by using a centrifuge adhesion test (CAT). The test consists of a two-step procedure where the extremity of bare and coated small beams are iced in a cold room and then rotated in a centrifuge to evaluate ice adhesion. In the first step, the extremity of bare and coated small beams (32 mm wide, 340 mm length, and 6 mm thick aluminum bar) was iced in a freezing drizzle in a climatic chamber at −8.0±0.2° C. and about 72% relative humidity. Ice was formed on a surface of about 1100 mm 2 area with a thickness of around 8 mm. The water droplets of the freezing drizzle have a median volumetric diameter of 110 m. To measure the ice adhesion strength of coatings, the coating was applied on an area covering at least 3200 mm 2 at one extremity of the beam. Prior to the second step following icing, the iced beams were left in a climatic chamber at −10.0±0.2° C. for one hour. In the second step, the iced beams were spun at an accelerating speed of ˜300 rpm/s 2 . The detachment of ice was monitored by piezoelectric cells on the centrifuge cover, and the rotation speed at the ice detachment was recorded. The apparent ice adhesion strength was measured as the bulk shear stress (τ) needed to detach ice from the beam, which was calculated using the beam speed of rotation (ω) at the ice detachment, the mass of ice (m), the beam radius (r) and the ice detachment area (A) according to τ=(mrω 2 )/A. For each substrate, 3 tests were conducted and the average of the three results was reported. The average ice adhesion strength for the ice release composition of Example VI was measured to be 9.2±1.3 kPa.
Example VIII
This example examines the effect of the silicone oil's viscosity on the ice release performance of the coating. As a comparison to the coating made in Example VI, another two coatings were made by the same method as described in Example VI with the only exception that the viscosities of the silicone oils used in these two coatings were different from that (500 cP) of the silicone oil used in Example VI. The dynamic viscosities of the two silicone oils used in these two coatings were 0.6 cP and 60,000 cP, respectively. Ice adhered to both coatings with adhesion strength of greater than 50 kPa.
While the present disclosure 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 of the embodiments. Thus, it is intended that the present disclosure cover any such modifications and/or variations provided they come within the scope of the appended claims and their equivalents.
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A composition comprising a silicone oil or fluorosilicone fluid infused in a cross-linked silicone resin matrix. The silicone oil or fluorosilicone fluid may comprise a linear or branched polymeric siloxane that may be functionalized with one or more of: alkyl, fluoroalkyl, aryl, benzyl, halo, hydride, hydroxyl, -alkyl-OH, -alkyl-SH, halo, -aryl-halogen, -alkyl-COOH, -alkyl(COOH)-alkyl-COO-alkyl, alkenyl, vinyl, -alkyl-acryloyl, -alkylamino, -alkyl-NH-alkyl-NH2, -alkyl-OOC-NH-alkyl-NCO, -alkyl-O-oxiranyl, monofluoromethyl, difluoromethyl, trifluoromethyl, or alkeneoxide co-polymer.
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FIELD OF THE INVENTION
This application relates to the bladder shaping of green tire carcasses prior to vulcanization, and more particularly to large tire shaping of carcasses.
BACKGROUND OF THE INVENTION
Tire uniformity is important for all tires, especially large off the road tires. One type of tire nonuniformity can occur in the tire carcass. For the green tire carcass, it is important that the carcass ply wire spacing be evenly distributed. It is further important that the liner gage be evenly distributed as well. Failure to meet specific uniformity criteria often results in the scrapping of tire carcasses, which can be expensive and wasteful. One cause of carcass nonuniformity may be attributable to the bladder shaping process. For very large radial tires, there tends to be a shape mismatch between the collapsed bladder and the green tire carcass. For example, prior to inflating the bladder, the collapsed outer diameter or circumference of the bladder used in the tire shaping process may exceed the inner diameter or circumference of the green tire. In addition, as the bladder is inflated, the bladder has an outer diameter much larger than the carcass inner diameter.
FIG. 1 illustrates a simplified schematic of a green carcass 30 with a folded bladder 40 inside. Certain edges 42 of the folded bladder are in contact with the inner surface 32 of the green tire carcass. The bladder edges have a tendency to grip the tire carcass, so that as the bladder is inflated, it results in the over stretching of the casing between the contact points and a localized thinning of the liner gauge. Once the overstretching occurs, the tire carcass must be scrapped. Thus an improved method and apparatus for shaping a large green tire carcass is desired, without any of the afore-mentioned disadvantages.
SUMMARY OF THE INVENTION
The invention provides in a first aspect a method of shaping a green tire carcass comprising the steps of: positioning a green tire carcass about an internal bladder, mounting a first bead of the green tire onto a first ring, and a second bead onto an air shaping ring, injecting pressurized fluid through said air shaping ring, into the cavity formed between the carcass and the bladder to inflate the carcass, and then inflating the bladder to further shape the carcass. Preferably the fluid between the carcass and the bladder is removed prior to inflating the bladder.
The invention provides in a second aspect an apparatus for shaping a green tire carcass comprising: a bladder mounted to a first and second support, a retractable support shaft mounted inside the bladder, and upper and lower bead ring for mounting the beads of the tire carcass thereon, wherein one of said bead rings has a channel in fluid communication with a pressurized source of fluid, wherein said channel has an outlet located between said bladder and said carcass for injecting pressurized fluid between the carcass and the bladder.
DEFINITIONS
“Aspect Ratio” means the ratio of a tire's section height to its section width.
“Axial” and “axially” mean the lines or directions that are parallel to the axis of rotation of the tire.
Bead” or “Bead Core” means generally that part of the tire comprising an annular tensile member, the radially inner beads are associated with holding the tire to the rim being wrapped by ply cords and shaped, with or without other reinforcement elements such as flippers, chippers, apexes or fillers, toe guards and chafers.
“Bias Ply Tire” means that the reinforcing cords in the carcass ply extend diagonally across the tire from bead-to-bead at about 25-65° angle with respect to the equatorial plane of the tire, the ply cords running at opposite angles in alternate layers
“Carcass” means a laminate of tire ply material and other tire components cut to length suitable for splicing, or already spliced, into a cylindrical or toroidal shape. Additional components may be added to the carcass prior to its being vulcanized to create the molded tire.
“Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction; it can also refer to the direction of the sets of adjacent circular curves whose radii define the axial curvature of the tread as viewed in cross section.
“Cord” means one of the reinforcement strands, including fibers, which are used to reinforce the plies.
“Ply” means a cord-reinforced layer of elastomer-coated, radially deployed or otherwise parallel cords.
“Radial” and “radially” mean directions radially toward or away from the axis of rotation of the tire.
“Radial Ply Structure” means the one or more carcass plies of which at least one ply has reinforcing cords oriented at an angle of between 65° and 90° with respect to the equatorial plane of the tire.
“Radial Ply Tire” means a belted or circumferentially-restricted pneumatic tire in which the ply cords which extend from bead to bead are laid at cord angles between 65° and 90° with respect to the equatorial plane of the tire.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 illustrates a simplified schematic of a cross sectional view of the uninflated green carcass with a folded bladder inside.
FIG. 2 is a simplified schematic of cross-sectional view of a deflated bladder shown inside a green tire carcass of a tire shaping device;
FIG. 3 is a perspective view of a large tire shaping bladder shown under internal vacuum in solid lines, and in the relaxed state in phantom;
FIG. 4 is a perspective view of an air shaping ring;
FIG. 5 is a cross-sectional view of the air shaping ring in the direction 5 - 5 of FIG. 4 ;
FIGS. 6-10 illustrate the various stages of the carcass shaping process;
FIG. 9 is a top view of the air shaping ring;
FIGS. 10A , 10 B, 10 C are cross sectional views taken in the directions indicated on FIG. 9 ;
FIGS. 11A , 11 B, 11 C are cross sectional views taken in the directions indicated on FIGS. 10A , 10 B and 10 C, respectively.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 illustrates a cross-sectional view of a green tire shaping mechanism, shown generally at 10 . The tire shaping mechanism 10 is mounted upon a support frame 12 . Connected to the support frame 12 is a lower end of a bottom annular mold ring 14 . The mold ring 14 is removably mounted to the support frame 12 . The mold ring 14 has an interior hole 15 for receiving an inner support shaft 16 . The support shaft 16 has a first end 17 received in the upper part of the tire shaping mechanism 18 . The support shaft has a second end 20 received in a cylindrically shaped chamber 22 of the support frame 12 , to allow the support shaft to retract into the chamber 22 during tire shaping.
The bottom mold ring 14 is connected to a lower annular bead ring 26 for receiving and securing a first bead ring 32 of a green tire carcass 30 . A bladder retention ring 34 is secured to the lower annular bead ring 26 . The bladder retention ring 34 has an annular groove 36 for securing the bottom end 42 of a bladder 40 to the retention ring. The bladder 40 , as shown in this embodiment, is a very large, cylindrically shaped bladder in the at rest position, typically with multiple folds as shown in FIG. 3 . The bladder folds may be numerous, with the bladder outside circumference greater than the tire inside circumference (position shown in phantom). The bladder has a second end 44 which is received in a groove of an upper bladder retention ring 50 . Connected to the upper bladder retention ring is an annular fluid shaping mold ring 60 . The shaping ring 60 has an inner bore 62 for receiving the shaft 16 . A pressure retaining cap 18 is received onto shaft end 17 .
As shown in FIG. 5 , the fluid shaping ring 60 has an internal annular manifold 64 for channeling pressurized supply fluid, typically air, from a pressurized fluid supply 68 to the inner portion of the shaping ring 60 . Supply fluid is channeled through the shaping ring manifold 64 to one or more interior channels 66 , typically 5 or more, which extend from the manifold on the upper surface of the ring to the lower radial surface or toe end 70 of the ring 60 . Pressurized fluid is directed from manifold through the channel 66 and out the orifices 71 located on the lower toe end 70 of the ring 60 and then through annular channel 73 . The pressurized fluid is then directed from the annular channel into the space between the bladder 40 (shown in phantom in FIG. 5 ) and the tire carcass 30 (shown in phantom) to help shape the tire carcass, as described in more detail, below.
The fluid shaping ring 60 may additionally comprise optional vent holes 75 spaced along the outer circumference of the shaping ring 60 located on lower radial toe end surface 70 . The fluid shaping ring may further comprise one or more optional jumper channels 77 typically about 0.5-1.0 inch wide, located on the lower toe end 70 . The jumper channels 77 interconnect annular channel 73 located on the inner surface of the toe end of the shaping ring. The optional jumper channel and vents function to provide additional pathways for the pressurized fluid to follow should one of the orifices 71 be blocked by the bladder during filling.
The fluid shaping ring may further comprise optional labyrinth grooves 90 located on the radially inner surface of the fluid shaping ring 60 which mates with the upper bladder retention ring 50 . The labyrinth grooves provide a controlled venting of the pressurized medium during bladder shaping without the need for valves or other mechanical means.
The steps for shaping the carcass can now be described. First the green tire carcass to be shaped is mounted upon the tire shaping device 10 . Then, an internal vacuum is drawn on the bladder to reduce the bladder outer diameter, as shown in FIG. 3 (in solid lines). Next, the green tire carcass is positioned over the bladder so that a first end of the bead is mounted on the lower bead ring 26 . The air shaping ring 60 is positioned over the tire shaping device so that the outer circumferential edge of the shaping ring is in contact with the tire bead. The pressure retaining cap is next installed over the support shaft. The tire carcass is now ready for shaping.
As shown in FIGS. 2 and 6 , the shaping bladder is inflated and pressurized to an internal pressure of about 0.5 to 1 psig. Just holding the tire carcass in place, the bladder is still with many longitudinal folds, as the circumference of the curing bladder at rest has a larger diameter than the inside of the green tire carcass. Shaping fluid as indicated by the flow arrows in FIG. 2 , is introduced between the bladder and the tire carcass. Pressurized fluid, typically air at about 4 to about 5 psig at about 100-300 scfm, typically about 200 scfm, is fed to inflate the tire casing in the range of about 4 to about 5 psig. See FIG. 7 . During this step, the bladder initially collapses due to the higher external pressure (Pressure*volume=constant), and then the pressure balances resulting in the bladder expanding slightly.
As shown in FIG. 7 , the tire shaping device draws the green casing down in height when the support shaft 16 is retracted within the chamber 22 . The bladder and supply fluid pressure is maintained constant, at about 4-5 psig. As the casing is drawn down in height, the carcass inner circumference increases to a value greater than the interference diameter of the bladder. The casing is now free from the bladder so when the bladder is inflated, the tire carcass will not adhere or pull on the inner liner and body ply causing cord spacing anomalies and thin liner gauge.
Next the shaping fluid may be turned off. The shaping fluid vents out the labyrinth grooves 90 , which act like air brakes to slowly vent the supply fluid from the chamber. As the pressure medium is pumped out, the bladder slowly increases in volume.
The bladder is then inflated to suitable pressure, typically about 6 psig. The bladder inflates and assumes the shape it would have at 1.5-2 psig. The shaping air has been completely evacuated, and the curing bladder expands due to the pressure differential. The casing is then further shaped by the bladder as shown in FIG. 8 .
The benefit to this process is that the tire cords and liner gauge are more uniform. Further, there is an increase in bladder life as there is less wear and tear on the bladder due to the bladder sticking and slipping issues described above.
Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.
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An apparatus for shaping a green tire carcass is provided having a bladder mounted to a first and second support, a retractable support shaft mounted inside the bladder, and upper and lower bead ring for mounting the beads of the tire carcass thereon, wherein one of said bead rings has a channel in fluid communication with a pressurized source of fluid, wherein said channel has an outlet located between said bladder and said carcass for injecting pressurized fluid between the carcass and the bladder.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to earth-working equipment and particularly to a detachably mounted ripper tool for a conventional excavator type bucket.
2. History of the Prior Art
When utilizing conventional backhoe type equipment, it is not uncommon that the excavation operations are complicated by poor soil conditions. Often the ground to be worked is frozen, rocky, or simply extremely well packed or dense. In such instances, some means must be provided to break up the hardened earthen material before a backhoe bucket or scoop can be used to excavate the same.
Heretofore, numerous cutting and ripping attachments have been designed either for use with or attachment to backhoe or other excavator buckets so as to enable such equipment to be used when poor soil conditions are encountered. Some of these attachments may be mounted directly on the bucket or scoop to break, cut, or rip through hardened material. The advantage of such a direct mounting is that the excavation operation may, for the most part, be carried out simultaneously with the ground breaking operation.
In order to concentrate the penetrating or earth breaking force of the bucket and ripper combination, many prior art devices utilize a single or primary ripper tooth as the earth breaking implement. Normally the ripper tooth is of a greater dimension than the earth working teeth which are carried or mounted on the bucket, being of a sufficient length to permit the ripper to extend beyond the cutting or digging edge of the bucket, and frequently greater in cross-sectional width or depth dimensions to provide increased structural strength.
Due to the localization of stresses on the ripper tooth as it penetrates through the hardened ground, it is not only necessary that the ripper be strong, but it is also important that its connection to the bucket be secure. However, because it is not always necessary to use the ripper attachment, the mounting should be simplistic enough to permit the equipment operator to quickly and easily attach or remove the assembly to or from the bucket respectively.
To simplify the mounting, several prior art devices utilize a single pivoted connector by which the ripper is attached to one portion of the bucket while a hooked, cupped, or friction type fit is used to support another portion of the ripper shank. In this manner, the ripper is quickly attached to the bucket using a single bolt or pin. However, such mountings have not provided for a complete or uniform distribution of the stresses across the bucket structure. Rather, the bulk of the stresses will frequently be imparted to a weaker structural member than the ripper tooth itself, as for instance, to the mounting pin or bolt or perhaps a portion of the edge of the bucket or bucket tooth.
Another problem often encountered when using ripper attachments has been that, in excavating trenches or ditches, the dirt walls are left rough and uneven. Such edging problems, although to a lesser degree, are frequently encountered when using the bucket alone. Therefore, side cutters, such as those disclosed in U.S. Pat. No. 3,748,762 to Tarrant, may be required on some types of buckets during normal trenching operations. However, in order to correct such a problem when using ripper attachments, some means must be provided along both sides of the bucket to obtain a relatively even cut without greatly reducing the earth penetrating force being concentrated at a relatively localized area of ground by the earth breaking ripper tooth.
Some examples of the prior art include U.S. Pat. Nos. 2,783,558 to Morgan; 2,838,856 to Buisse; 3,039,210 to Slaughter; 3,097,439 to Calkin; and 3,724,899 to Clark.
SUMMARY OF THE INVENTION
The present invention is embodied in a ripper tool for an excavator type bucket or scoop which includes a mounting frame having a yoke portion which is frictionally engaged about the entire cutting edge of the bucket and a ripper mounting portion which extends from the yoke portion to the upper surface of the bucket and is releasably connected thereto. A side cutter tooth is mounted adjacent each side and along the lower edge of the mounting yoke and an enlarged ripper tooth is releasably mounted on the ripper mounting portion of the assembly.
It is the object of this invention to provide a ripper tool having at least one tooth which may be selectively mounted on a conventional excavator bucket for use in penetrating frozen, rocky, and other hardened earthen material in such a manner that the stresses imparted to the tooth during earth penetrating operations are more uniformly distributed across the bucket and to the bucket supporting members.
It is a further object of this invention to provide a detachably mounted ripper tool which may be quickly and securely attached to a conventional excavator bucket with a single pinned connection.
It is another object of this invention to provide a ripper tool for a backhoe or other such excavator bucket in which side cutting teeth are provided to permit even or clean trenching operations without decreasing the penetrating effectiveness of the ripper tool.
It is another object of this invention to provide a ripper tool for an excavator bucket in which side cutter teeth are provided to protect portions of the main frame of the ripper tool from possible damage which might otherwise occur due to stresses developed and/or abrasive materials encountered as the sides of the bucket and tool pass in contact with the side walls of the trench during operations.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation of the invention mounted on a conventional excavator bucket.
FIG. 2 is a front view thereof.
FIG. 3 is a perspective view of the mounting frame portion of the invention.
FIG. 4 is an enlarged fragmentary section taken along the line 4--4 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With continued reference to the drawing, a ripper mounting tool 10 is provided which is selectively secured to a conventional excavator or backhoe type bucket or scoop 11. The bucket 11 usually includes generally parallel opposing side walls 12 and 13 which are disposed on opposite sides of an arcuate back wall or bucket pan 14. The pan 14 forms the upper and lower edges 15 and 16 respectively of the bucket 11. Disposed along the lower edge of the bucket are a plurality of earth-working teeth 17 which loosen the soil being scooped into the bucket.
The bucket is operatively supported on a backhoe, tractor, or other such earth-working vehicle (not shown) via a boom 18 and a fluid cylinder 19. Relative movement between the bucket and the support and control members is accomplished by pivotal connections 20 and 21 with pairs of upstanding lugs 22 and 23 which extend outwardly along the upper surface of the bucket.
One of the primary concerns in the development of the ripper mounting tool 10 was to provide a device which may be selectively attached to and removed from the bucket and effectively distributes forces or stresses, encountered during earthworking operations, across the bucket 11 and to the supporting boom 18. With particular reference to FIG. 3, the tool 10 includes a generally T-shaped mounting frame 25 which has a yoke type first mounting portion 26 which is disposed generally perpendicular to a second mounting portion or ripper support arm 27.
The yoke or first mounting portion is generally rectangular in configuration having a forwardly and downwardly inclined upper wall 28, a bottom wall 29, and side walls 30 which define an open channel that is tapered inwardly from the back edge to the front edge 31 and 32 of the yoke, respectively. As will be apparent from the drawings, the tapered design of the yoke is such as to be complementary to and slidably receive the earth-working teeth 17 of the bucket. The fit between the yoke and the teeth may be somewhat loose to permit alignment of the second mounting portion of the mounting frame as will be discussed below. Further, to insure maximum contact of the tool 10 with the bucket 11, the yoke is preferably of sufficient dimension to extend around or encompass the plurality of earth-working teeth 17.
The second mounting portion or support arm 27 is welded or otherwise secured to the upper wall 28 of the yoke 26 and extends therefrom, across the opening or mouth of the bucket 11 to a pair of inner mounting brackets or lugs 33 which are fixed within the bucket. The inner mounting lugs 33 are disposed generally opposite the boom mounting lugs 22 along the upper portion and adjacent the upper edge 15 of the bucket. In order to reinforce the connection between the support arm 27 and the yoke 26, a pair of reinforcing webs 42 are connected between the side members 34 and 35 of the mounting arm and the upper surface 28 of the yoke.
The support arm 27 includes a pair of generally parallel side members 34 and 35 which are connected and reinforced by several spacers 36, and upper and lower generally parallel ripper tooth guide members 37 and 38. Two sets of opposed pin receiving holes 39 and 40 are provided through the side members. Further, the lowermost surfaces 41 of the support arm side members 34 and 35 are flush with the upper surface 28 of the yoke.
As is readily apparent, the mounting frame 25 is quickly and easily attached to the bucket 11 by inserting the yoke over and around the bucket teeth 17, as shown in FIGS. 1 and 2. The support arm 27 is subsequently secured to the inner mounting lugs 33 by inserting a pin, bolt or other such connector or retainer 43 through the holes 39 of the mounting arm and the lugs 33. Therefore, the cooperation between the pinned and yoked or frictional engagements of the mounting frame permit the bucket to be secured using the single pin 43.
Either before or after the mounting frame has been secured to the bucket, an enlarged ripper tooth 50 is inserted into the channel created by the ripper tooth guide members 37 and 38 and the mounting arm side members 34 and 35. A connector pin 51 is then inserted through the holes 40 in the mounting arm side members and through an aligned hole 52 in the upper portion of the ripper tooth shank.
As shown in the drawing, the ripper tooth is greater in dimension than the shovel or bucket teeth 17 and extends substantially below the same. The exact size of the ripper tooth will, of course, depend on the particular purpose for which the tool is to be used and therefore may vary considerably. Further, the tooth is provided with a replaceable shoe member 53 which is connected by a pin 54 to the toe of the ripper shank.
As previously pointed out, it is usually preferred to obtain a clean side wall cut when using a backhoe or similar excavator equipment. In order to adapt the ripper mounting tool 10 so that a clean side wall cut can be made, concurrently with the ripping operation, a pair of downwardly disposed side cutter teeth 55 are welded or otherwise secured to the bottom wall 29 of the yoke 26 adjacent the yoke side walls 30. The placement of the side cutter teeth is such that they are generally coextensive with the side walls 12 and 13 of the bucket and the side walls 30 of the yoke type mounting portion 26. Further, they are generally larger than the bucket teeth 17 and are shown as being smaller than the ripper tooth. Their size, however, may be varied depending upon their anticipated usage.
The side cutter teeth also provide a secondary function in that they aid in preventing damage to the yoke mounting portion 26 of the ripper tool. Specifically, as the tool is used, substantial stress is developed between the side walls 30 of the yoke mounting portion and the side walls of the trench being excavated. Such stress together with rocks and other earthen or abrasive material which are continuously encountered as the tool is used, may cause structural damage to the yoke portion of the tool, particularly along the area of the yoke side walls 30. As the side cutter teeth will initially cut through the earthen material in advance of the side walls of the yoke mounting portion of the ripper tool, the amount of stress and material resistance applied relative thereto will be significantly decreased.
Whatever size of side cutter teeth is used, they are placed or positioned so as to be behind the penetration portion of the ripper tooth shoe 53. Further, as can be seen in FIGS. 1 and 4, the plane defined by the bottom of each of the side cutter teeth is substantially even with a plane defined by the same portion of the ripper tooth. Therefore, during ripping operations, the ground will always be first or initially penetrated by the ripper tooth regardless of the foward angle of the bucket approach to the working surface. The side cutter teeth will not impact the ground until the ripper initially penetrates and loosens the hardened material. As the point or shoe of the ripper is the only portion of the tool making initial contact with the working surface, a maximum penetrating force is concentrated to a localized area, thus enhancing effective ground penetration.
To permit the side cutting teeth to be maintained in good working condition, replaceable shoes 56 are attached by pins 57 to the toe portion of the cutter teeth shanks.
During earth-working operations, should poor ground conditions be encountered, the ripper mounting assembly may be quickly attached to the excavator bucket or scoop. The equipment operator simply secures the mounting frame to the bucket by sliding the yoke portion of the frame around the bucket teeth. The fit between the yoke and the teeth will permit some play in the engagement so that the holes in the mounting arm side members may be aligned with the inner mounting brackets. Subsequently, a locking pin is inserted through the aligned holes and the mounting frame is then secured to the bucket. After the mounting frame has been attached, a ripper tooth is inserted and secured in position between the ripper tooth guide members.
The equipment is now ready for use in breaking through and excavating dense, rocky and frozen earth, or other such materials. As the ripper tooth is brought into engagement with a working surface, because the yoke portion of the mounting frame is engaged about the bucket teeth, the stresses transmitted through the ripper tooth are distributed across the outer digging or cutting edge of the bucket. Further, because the inner mounting lugs 33 are generally opposite the boom support connection, forces established along the support arm are transmitted directly through the tool's pinned connection with the bucket to the bucket support boom. Thus, the stresses developed during the excavation operation will be evenly distributed and transmitted through the bucket to the load bearing structure of the bucket support.
As the ripper penetrates through the material being worked, the bucket follows within the arcuate movement of the ripper tooth and scoops out the loosened material. Simultaneously, the side cutters insure that the walls of the excavated area are left clean and uniform while the possibility of damage to the yoke mounting portion of the ripper tool is decreased.
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A ripper tool apparatus detachably mounted on a conventional excavator bucket so as to distribute the stresses developed as the implement is used. The apparatus includes a central ripper tooth to break hardened or dense earthen material and a pair of side wall cutter teeth to clean the excavated trench walls.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to steam generating devices. In particular, the present invention relates to steam generating devices for use with associated irons.
BACKGROUND OF THE INVENTION
[0002] Typically, steam irons that are used in residential households, clothing stores, and/or clothing factories can be categorized into three types. The first type includes irons having a small water container and which cannot produce vertically continuous steam. The second type includes irons suitable for use in households and which has an embedded water container. This second type of iron can only be used for a limited period of time, after which time the water container must be filled. The water container cannot be filled while the iron is in operation. This limited operation time is not convenient and steam cannot be supplied immediately and thus, is inefficient.
[0003] The third type of irons include those suitable for use in clothing factories. This third type of iron includes two parts: a steam generating device and an iron or spray gun for ironing clothes. The steam generating device is typically a boiler which is used to generate a continuous supply of steam that is directed to the iron or spray gun via a tube for ironing clothes. However, these types of irons are only suitable for use in large-scale clothing factories since they are prohibitively costly and inconvenient for use in residential households due to their large size and heavy components.
[0004] Conventionally, a steam generating device and iron that is low in cost and suitable for use in large and medium-sized households and small-sized clothing stores or clothing factories does not exist.
SUMMARY OF THE INVENTION
[0005] Briefly stated, a steam generating device of the present invention in a preferred form comprises a control circuit for monitoring temperature, controlling water filling, and generating steam. The steam generating device has a sealed container which is constructed of a high temperature resistant material. An electric heating tube is mounted within the container and a temperature sensor is mounted on the outer surface of the container. The electric heating tube and the temperature sensor are each connected to the control circuit. On the top of the container there is installed a four-way electromagnetic valve on the wall of which there is installed a water intake tube connected to a water supply. The four-way electromagnetic valve is connected to the control circuit.
[0006] The ends of the electric heating tube may be directly welded to the inner wall of the container and extend outside of the container.
[0007] The electromagnetic valve includes a steam intake. The steam intake is connected to three steam outlets. Spring elements and a rubber plug capable of withstanding pressure are mounted to each of two steam outlets of the three steam outlets. The spring elements and rubber plugs form a pressure release valve on one steam outlet and an overflow valve on the other steam outlet.
[0008] A middle portion of the electric heating tube may be attached by welding to the inner wall of the container. The temperature sensor may be mounted on the outer surface of the container at a point corresponding to the position of the welding on the other side of the wall.
[0009] The steam iron system in the present invention may comprise a steam generating device, a control circuit and an iron connected to the steam generating device. The steam generating device includes a sealed container which is constructed of a high temperature resistant material. An electric heating tube is mounted within the container and a temperature sensor is mounted on the outer surface of the container. The electric heating tube and the temperature sensor are each connected to the control circuit. On the top of the container there is installed a four-way electromagnetic valve on the wall of which there is installed a water intake tube connected to a water supply. The four-way electromagnetic valve is connected to the control circuit.
[0010] The iron may be a steam iron which includes a base plate, an upper housing, and a steam regulating device between the upper housing and the base plate. Both an ordinary steam outlet and a strengthened steam outlet are located on the base plate. Both the ordinary steam outlet and the strengthened steam outlet are connected to the steam regulating device. The steam regulating device is connected to one of the three steam outlets of the four-way valve.
[0011] The steam regulating device is provided with a steam intake connected to the four-way valve. The steam regulating device also includes an ordinary steam outlet and a strengthened steam outlet which are respectively connected to the ordinary steam outlet and the strengthened steam outlet mounted on the base plate. The steam intake of the steam regulating device is connected to both of the ordinary steam outlet and the strengthened steam outlet. Located between the ordinary steam outlet, the strengthened steam outlet, and the steam intake is a pushdown regulating rod. The pushdown regulating rod includes a spring element for the restoration of the pushdown regulating rod after being pushed down.
[0012] An object of the present invention is to provide a steam generating device that is simple in structure, low in cost, and capable of providing steam continuously and fully.
[0013] Another object of the present invention is to overcome the defect of discontinuous steam production as commonly found in conventional irons.
[0014] A further objective of the present invention is to provide a steam iron when used with a steam generating device which allows clothes to be ironed continuously with the iron needing substantially no time for an operating condition to be reached. Thus, the iron can be operated efficiently such that it substantially replicates the capacity of a boiler with respect to steam generation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a schematic view showing a steam iron consistent with the present invention that is discharging ordinary steam;
[0016] FIG. 2 is a schematic view showing a steam iron consistent with the present invention that is discharging strengthened steam;
[0017] FIG. 3 is a schematic view showing a steam iron consistent with the present invention that is directing steam to a water container;
[0018] FIG. 4 is a side view of a four-way electromagnetic valve consistent with the present invention;
[0019] FIG. 5 is a schematic diagram of the four-way electromagnetic valve of the present invention;
[0020] FIG. 6 is a schematic diagram of a steam generating device showing the structure of a welding point of an electric heating tube and an inner wall of a container consistent with the present invention;
[0021] FIG. 6A is an enlarged view of FIG. 6 showing the structure of the welding point of the electric heating tube and the inner wall of the container;
[0022] FIG. 7 is a side perspective view of a steam regulating device consistent with the present invention;
[0023] FIG. 8 is a schematic diagram of the steam regulating device consistent with the present invention;
[0024] FIG. 9 is an elevated perspective view from the rear quarter of a steam regulating device in association with a base plate consistent with the present invention;
[0025] FIG. 10 is a view from below of a base plate consistent with the present invention;
[0026] FIG. 11 is a schematic diagram of the control circuit consistent with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The detailed description of the preferred embodiment of the present invention shall be described hereinafter with reference to the drawings wherein like numerals represent like parts throughout the views.
[0028] In one embodiment of the invention, as shown in FIGS. 1 to 3 , the steam iron system in the present invention includes a steam generating device 9 and a steam iron 14 . The steam generating device 9 and the steam iron 14 are connected by a tube 15 attached to a four-way electromagnetic valve 12 . The steam generating device 9 is connected to a cold water container 1 via a second tube 16 . The second tube 16 may be connected to a pump 4 such that the pump is intermediate the ends of the second tube 16 . A float valve 2 is installed inside the cold water container 1 . Located underneath the float valve 2 is a magnetic switch 3 . It should be noted that in one embodiment of the invention, the cold water container 1 can be replaced by a water pipe and the float valve 2 and the magnetic switch can be replaced by other control devices to regulate water flow.
[0029] As shown in FIGS. 1-3 and 6 , the steam generating device 9 includes a sealed container 90 which is constructed of high temperature resistant material. An electric heating tube 8 is mounted within the container 90 . The connection end 80 of the electric heating tube 8 extends outside of the container 90 and may be welded to the wall of the container 90 . The middle portion of the electric heating tube 8 may also be welded to the wall of the container 90 . As shown in FIGS. 6 and 6 A, a temperature sensor 7 may be mounted at the location on the outer surface which corresponds to the location adjacent to where the heating tube 8 is welded on the outer surface of the container 90 . The temperature sensor 7 and the electric heating tube 8 are connected to the control circuit of a printed circuit board (PCB) 5 via, for example, wires. The operation of the control circuit is responsive to signals from the temperature sensor 7 .
[0030] In one embodiment of the present invention, the temperature within the device is monitored with a temperature sensor 7 mounted on the outer surface of the device. The temperature sensor 7 generates signals and transmits the signals to the PCB 5 which controls both the operation of the heating tube 8 and the pump 4 inside the steam generating device. When the temperature in the inner part of the steam generating device rises to a preset value, the pump 4 starts to pump water. When the temperature drops below a preset value, due to such things as cold water being added to the device, the pump 4 stops pumping. This regulation of circulation allows the temperature of the steam generating device to be kept within a desired range, for example, at a range where steam is generated continuously. When the water level in the water container reaches a preset low level, a magnetic switch 3 is activated and an indicator is triggered. For example, the control power supply in the PCB 5 may flash an indicator. At the same time, the control circuit of the steam generating device may stop energizing the heating element 8 .
[0031] As shown in FIG. 6 , on the side wall of the container 90 there is a water intake 10 which is connected to the second tube 16 . Water can be added to the container 90 under the control of the control circuit which controls the pump 4 . On top of the container 90 there is a steam outlet 91 to which a four-way electromagnetic valve 12 is associated.
[0032] In one embodiment of the present invention, as shown in FIGS. 1 and 2 , the steam iron 14 includes a base plate 140 , an upper housing and a steam regulating device 13 between the upper housing and the base plate 140 . On the base plate 140 there is an ordinary steam outlet 143 and a strengthened steam outlet 144 (shown in FIG. 10 ). As shown in FIGS. 8 and 9 , the steam regulating device 13 has a steam intake 130 which is connected to the tube 15 , an ordinary steam outlet 131 , and a strengthened steam outlet 132 . The ordinary steam outlet 131 and the strengthened steam outlet 132 are respectively connected to the ordinary steam outlet 143 and the strengthened steam outlet 144 on the base plate 140 (shown in FIG. 10 ). As shown in FIGS. 7 and 9 , the steam intake 130 of the steam regulating device 13 is connected to both the ordinary steam outlet 131 and the strengthened steam outlet 132 .
[0033] In one embodiment of the present invention, A regulating device may be associated with the ordinary steam outlet 131 , the strengthened steam outlet 132 , and the steam intake 130 . The regulating device, as shown in FIG. 8 , may include a pushdown regulating rod 133 and a spring element 134 for the positional restoration of the regulating rod 133 to its normal position. When the regulating rod 133 is at its normal position, the steam intake 130 is connected to both the ordinary steam outlet 131 and the strengthened steam outlet 132 . When the regulating rod 133 is pushed down, the steam intake 130 is connected only to the strengthened steam outlet 132 .
[0034] As shown in FIGS. 4 and 5 , the four-way electromagnetic valve 12 may include a steam intake 120 and three steam outlets 121 , 122 and 123 . The steam intake 120 , in one embodiment of the invention, is connected to the steam outlet 121 . As shown in FIG. 5 , positioned inside the steam outlet 121 is a silicon rubber plug 124 and spring element 125 . Under normal operating conditions, the silicon rubber plug 124 does not seal the steam outlet 121 . Under certain pressure conditions, the silicon rubber plug 124 seals the steam outlet 121 and together they form an overflow valve (shown in FIG. 3 ). Inside the steam outlet 122 there is also a silicon rubber plug 126 and a spring element (not shown) that form a release valve. Under normal conditions, the silicon rubber plug 126 seals the steam outlet 122 and is opened when the pressure of steam reaches a certain value. The opening and closing between the steam outlet 123 and the steam intake 120 is controlled by an electromagnetic valve.
[0035] In one embodiment of the present invention, the normal operation of a steam iron is shown in FIG. 1 . When the cold water container 1 is filled with water, the float valve 2 activates the magnetic switch 3 . The PCB 5 then controls the device. For example, the water pump 4 , controlled by PCB 5 , begins to pump water through the second tube 16 into the container 90 . The PCB 5 then operates to cause the electric heating tube 8 in the container 90 to be energized.
[0036] In one embodiment of the invention, the operation of the pump 4 is controlled by the PCB 5 with a change of resistance. The operation of the pump 4 may allow for a continuous circulation wherein the pressure in the container 90 is less than, for example, 0.2 bar. Steam generated in the container 90 by heating tube 8 is discharged through the outlet 91 and into the steam intake 120 of the four-way electromagnetic valve 12 . The steam is then discharged through the steam outlet 121 .
[0037] In one embodiment of the present invention, air in the container 90 is discharged to ensure, when the iron is in a cold condition, that outer air pressure and air pressure inside the container are balanced in order to prevent air pressure caused by change of the steam generating device from a cold state to a hot state due to the cold water being pumped into the steam generating device by the water pump during a preheating of the device. When the preheating time reaches, for example, 2 minutes and 30 seconds (a time value preset in the PCB 5 ) the steam is discharged out the iron 14 . It should be understood that the other time values can be preset in the PCT and that the pressure in the container 90 may be, for example, more than or less than 0.2 bar.
[0038] The silicon rubber plug 124 , in one embodiment of the invention, seals the steam outlet 121 with the aid of the spring element, the steam outlet 123 is opened and steam is discharged from the container 90 and conveyed to the steam intake 130 of the steam regulating device 13 of the steam iron 14 through the tube 15 , then the steam is conveyed to the steam outlet of the base plate 140 of the iron through strengthened steam outlet 132 and ordinary steam outlet 131 , as shown in FIG. 1 . In this configuration, ordinary steam and strengthened steam is generated. When the regulating rod 133 of the steam regulating device 13 is at a normal up position, the steam comes out from the strengthened steam outlet 132 and the ordinary steam outlet 131 . When the regulating rod 133 is pushed down, the ordinary steam outlet 131 is sealed and, as shown in FIG. 2 , the steam comes out from only the strengthened steam outlet 132 .
[0039] As shown in FIG. 3 , when the pressure in the container 90 reaches, for example, about 5 bars, the steam outlet 122 in the four-way valve 12 on the top of the container 90 is opened and high-pressure steam is released and is directed to, for example, the cold water container 1 through a water pipe connected to the steam outlet 122 .
[0040] In one embodiment of the present invention, the operation of the steam iron of the present invention is divided into two stages, stage 1 and stage 2 .
[0041] Stage 1 is the period of time before the steam comes out of the device when, for example, as shown in FIG. 11 , the voltage of the 10th leg of an integrated (IC) module 1 , for example a Type-LM324 integrated module, is about 15 V, the voltage of the 5 th leg of the integrated module IC shall be induced to about 12.25 V. When the temperature of the container 90 rises, for example, to about 143°, there is a decrease of the resistance of the temperature sensor 7 , and the voltage of the 6 th leg of the integrated module IC 1 is induced to be more than 12.25 V of the 5th foot of the integrated module IC 1 . The 7 th leg of the integrated module IC 1 is then reversed to a low level and the electric tube 8 in the container 90 is no longer energized. When the temperature of the container 90 falls, for example, to about 131° from about 143°, the resistance of the temperature sensor 7 rises as there is a decrease of the temperature. The voltage of the 6 th leg of the integrated module IC 1 is then induced to be less than 12.25 V of the 5 th foot of the integrated module IC. The 7 th foot of the integrated module IC is then reversed to a high level and the electric tube 8 in the container 90 is energized. In such a circulation, the pressure in the container 90 is kept between about 1.8 to about 3.2 bars.
[0042] In one embodiment of the present invention, the PCB 5 is provided with another integrated circuit, for example a Type-4001 integrated circuit, which functions as the protection of the preheating delay. In one embodiment of the present invention, the temperature rise of the container 90 can be sustained for about 2 minutes and 30 seconds from the cold state, and since only the temperature of the container 90 must be increased from the cold state and sustained, the four-way electromagnetic 12 is activated. For example, when the pressure of the steam in the container 90 exceeds 5 bars, the release valve of the four-way electromagnetic 12 starts to operate to release the high-pressure steam in the container 90 .
[0043] Stage 2 , in one embodiment of the invention, is the stage of steam discharge after, for example, a preheating of 2 minutes and 30 seconds, when steam is discharged from the device. For example, when the voltage of the 10 th leg of the integrated (IC) module 1 is, for example, about 20 V, the voltage of the 5 th leg of the IC module 1 is induced to about 15.20 V. When the temperature of the container 90 is increased to about 160° by the electric heating tube 8 , the water pump 4 begins to pump water. At a point when the temperature of the container 90 is decreased to about 145°, the water pump 4 stops pumping under the control of the IC module 1 . However, since the water pumped into the container 90 is cold, the temperature of the container 90 may be decreased further to about 134°. At this lower temperature, the temperature is increased with the heating tube 8 under control of the IC module 1 . During the whole process of steam discharge, the electric heating tube 8 stops heating for 3 to 4 seconds only when the temperature is at the highest set temperature, for example, about 160°. When the temperature is lower than, for example, about 160°, the heating tube 8 starts to heat immediately to ensure that there is steam in the container 90 during the whole process.
[0044] In one embodiment of the present invention, the steam generating device in the present invention can generate continuously steam in a certain range of temperature and also, the steam generating device can be used together with steam irons and spray guns. During the whole process of ironing, water can be filled in and steam can be generated continuously.
[0045] Moreover, the installation of the release valve and the overflow valve in the four-way electromagnetic valve may ensure the safety in operation.
[0046] While certain embodiments of the foregoing invention have been set forth for the purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one of skill in the relevant art without departing from the spirit and scope of the present invention.
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The present invention discloses a steam generating device comprising a control circuit for monitoring the temperature and controlling water filling and heating and steam discharging, and a sealed container which is highly temperature resistant. An electric heating tube is mounted in the container and a temperature sensor is mounted on the outer surface of the container. The electric heating tube and the temperature sensor are connected respectively to the control circuit. On the top of the container there is installed a four-way electromagnetic valve, and on the wall of the four-way electromagnetic valve there is installed a water intake tube connected to a water supply. A steam iron using the steam generating device is also disclosed in the present invention, wherein the steam iron can be used together with the steam generating device and has the virtue of continuous water filling steam generation.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to earlier filed U.S. provisional application Ser. No. 60/759,606 filed on Jan. 17, 2006, the entire contents of which is incorporated herein by its reference. The electrical energy harvesting power sources disclosed herein are described in detail in U.S. patent application Ser. Nos. 10/235,997 and 11/116,093, each of which are incorporated herein by their reference.
GOVERNMENTAL RIGHTS
This invention was made with Government support under Contract No. DAAE30-03-C1077, awarded by the U.S. Army. The Government may have certain rights in this invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to power supplies, and more particularly, to power supplies for projectiles, which generate power due to an acceleration of the projectile.
2. Prior Art
Fuzing of munitions is necessary to initiate a firing of the munition. Currently, there is no reliable and simple mechanism for differentiating an accidental drop of a munition from a firing acceleration, to prevent an accidental drop from initiating a fuzing of the munition. Similarly, there is a need to reliably validate firing and start of the flight of a munition. For rounds with booster rockets, this capability can provide the means to validate firing, firing duration and termination. Munitions further require the capability to detect target impact, to differentiate between hard and soft targets and to provide a time-out signal for unexploded rounds. Lastly, in order to recover unexploded rounds (munitions) it would be desirable for the munition to have the capability to notify a recovery crew.
SUMMARY OF THE INVENTION
The power sources/generators/supplies disclosed in U.S. patent application Ser. Nos. 10/235,997 and 11/116,093 are based on the use of piezoelectric elements. Such power sources are designed to harvest electrical energy from the firing acceleration as well as from the aerodynamics induced motions and vibration of the projectile during the entire flight. The energy harvesting power sources can withstand firing accelerations of over 100,000 Gs and can be designed to address the power requirements of various fuzes, communications gear, sensory devices and the like in munitions.
The electrical energy harvesting power sources are based on a novel approach, which stores mechanical energy from the short pulse firing accelerations, and generates power over significantly longer periods of time by vibrating elements, thereby increasing the amount of harvested energy by orders of magnitude over conventional methods of directly harvesting energy from the firing shock. With such power sources, electrical power is also generated during the entire flight utilizing the commonly present vibration disturbances of various kinds of sources, including the aerodynamics disturbances or spinning. Such power sources may also be used in a hybrid mode with other types of power sources such as chemical reserve batteries to satisfy any level of power requirements in munitions.
While the piezoelectric power generators are generally suitable for many applications, they are particularly well suited for low to medium power requirements, particularly when safety and very long shelf life are critical factors.
The electrical energy harvesting power sources for munitions are based on a novel use of stacked piezoelectric elements. Piezoelectric elements have long been used in accelerometers to measure acceleration and in force gages for measuring dynamic forces, particularly when they are impulsive (impact) type. In their stacked configuration, the piezoelectric elements have also been widely used as micro-actuators for high-speed and ultra-accuracy positioning applications with low voltage input requirement and for high-frequency vibration suppression. The piezoelectric elements have also been used as ultrasound sources and for the generation and suppression of acoustic signals and noise.
In the present application, the electrical energy harvesting power sources are used for powering fuzing electronics as acceleration and motion sensors, acoustic sensors, micro-actuation devices, etc., that could be used to enhance fusing safety and performance. As such, the developed electrical energy harvesting power sources, in addition to being capable of replacing or at least supplementing chemical batteries, have significant added benefits in rendering fuzing safer and enhancing its operational performance. Fir example, the piezoelectric-based electrical energy harvesting power sources can provide the following safety and performance enhancing capabilities:
1. Capability to detect accidental drops and differentiate them from the firing acceleration. 2. Capability to validate firing and start of the flight. For rounds with booster rockets, this capability will provide the means to validate firing, firing duration and termination. 3. Capability to detect target impact. 4. Capability to differentiate between hard and soft targets. 5. Capability to provide time-out signal for unexploded rounds. 6. In an unexploded round, the capability to detect acoustic and vibration wake-up signals generated by a recovery crew and respond to the same via an RF or acoustic signal or the like.
Accordingly, a system is provided for use with a munition for detecting a target impact of the munition. The system comprising: a power supply having a piezoelectric material for generating power from an axial vibration induced by the munition; and a processor operatively connected to the power supply for monitoring an output from the power supply and determining if the munition has axially impacted a target based on the output.
The processor can determine one or more of a time of axial impact, an axial impact acceleration level, peak axial impact acceleration and a total axial impact impulse based on the output of the power supply.
The processor can determine a degree of hardness of the target in the axial direction based on the output of the power supply.
The power supply can be adapted to further generate power due to at least a lateral component of the vibration and the processor operatively connected to the power supply for monitoring an output from the power supply and determining if the munition has laterally impacted a target based on the output.
The system can further comprise a lateral power supply having a piezoelectric material for generating power from a lateral vibration induced by the munition and the processor operatively connected to the lateral power supply for monitoring an output from the lateral power supply and determining if the munition has laterally impacted a target based on the output. The processor can determine a degree of hardness of the target in the lateral direction based on the output of the lateral power supply.
Also provided is a method for detecting a target impact of the munition. The method comprising: providing the munition with a power supply having a piezoelectric material for generating power from an axial vibration induced by the munition; monitoring an output from the power supply; and determining if the munition has axially impacted a target based on the output.
The method can further comprise determining one or more of a time of axial impact, an axial impact acceleration level, peak axial impact acceleration and a total axial impact impulse based on the output of the power supply.
The method can further comprise determining a degree of hardness of the target in the axial direction based on the output of the power supply.
The method can further comprise providing a lateral power supply having a piezoelectric material for generating power from a lateral vibration induced by the munition; monitoring an output from the lateral power supply and determining if the munition has laterally impacted a target based on the output. The method can further comprise determining a degree of hardness of the target in the lateral direction based on the output of the lateral power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the apparatus and methods of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 illustrates a schematic cross section of an exemplary power generator for fuzing of a munition.
FIG. 2 illustrates a schematic view of a system of harvesting electric charges generated by the power generator of FIG. 1 .
FIG. 3 illustrates a longitudinal acceleration (firing force, which is equal to the longitudinal acceleration times the mass of the round) versus time plot for a fired munition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the methods and apparatus disclosed herein, the spring end of a mass-spring unit is attached to a housing (support) unit via one or more piezoelectric elements, which are positioned between the spring end of the mass-spring and the housing unit. A housing is intended to mean a support structure, which partially or fully encloses the mass-spring and piezoelectric elements. On the other hand, a support unit may be positioned interior to the mass-spring and/or the piezoelectric elements or be a frame structure that is positioned interior and/or exterior to the mass-spring and/or piezoelectric elements. The assembly is provided with the means to preload the piezoelectric element in compression such that during the operation of the power generation unit, tensile stressing of the piezoelectric element is substantially avoided. The entire assembly is in turn attached to the base structure (e.g., gun-fired munitions). When used in applications that subject the power generation unit to relatively high acceleration/deceleration levels, the spring of the mass-spring unit is allowed to elongate and/or compress only within a specified limit. Once the applied acceleration/deceleration has substantially ended, the mass-spring unit begins to vibrate, thereby applying a cyclic force to the piezoelectric element, which in turn is used to generate electrical energy. The housing structure or the base structure or both may be used to provide the limitation in the maximum elongation and/or compression of the spring of the mass-spring unit (i.e., the amplitude of vibration). Each housing unit may be used to house more than one mass-spring unit, each via at least one piezoelectric element.
In the following schematic the firing acceleration is considered to be upwards as indicated by arrow 113 .
In FIG. 1 , power generation unit 100 includes a spring 105 , a mass 110 , an outer shell 108 , a piezoelectric (stacked and washer type) generator 101 , one socket head cap screw 104 and a stack of Belleville washers 103 (each of the washers 103 in the stack is shown schematically as a single line). Piezoelectric materials are well known in the art. Furthermore, any configuration of one or more of such materials can be used in the power generator 100 . Other fasteners, which may be fixed or removable, may be used and other means for applying a compressive or tensile load on the piezoelectric generator 101 may be used, such as a compression spring. The piezoelectric generator 101 is sandwiched between the outer shell 108 and an end 102 of the spring, and is held in compression by the Belleville washer stack 103 (i.e., preloaded in compression) and the socket head cap screw 104 . The mass 109 is attached (e.g., screwed, bonded using adhesives, press fitted, etc.) to another end 106 of the spring 105 . The piezoelectric element 101 is preferably supported by a relatively flat and rigid surface to achieve a relatively uniform distribution of force over the surface of the element. This might be aided by providing a very thin layer of hard epoxy or other similar type of adhesives on both contacting surfaces of the piezoelectric element. The housing 108 may be attached to the base 107 by the provided flange 111 using well known methods, or any other alternative method commonly used in the art such as screws or by threading the outer housing and screwing it to a tapped base hole, etc. The mass 109 is provided with an access hole 110 for tightening the screw 104 during assembly. Between the free end 106 of the spring and the base 107 (or if the mass 109 projects outside the end 106 of the spring, then between the mass 109 and the base 107 ) a gap 112 is provided to limit the maximum expansion of the spring 105 . Alternatively, the gap 112 may be provided by the housing 108 itself. The gap 112 also limits the maximum amplitude of vibration of the mass-spring unit.
During firing of a projectile (the base structure 107 ) containing such power generation unit 100 , the firing acceleration is considered to be in the direction 113 . The firing acceleration acts on the mass 109 (and the mass of the spring 105 ), generating a force in a direction opposite to the direction of the acceleration that tends to elongate the spring 105 until the end 106 of the spring (or the mass 109 if it is protruding from the end 106 of the spring) closes the gap 112 . For a given power generator 100 , the amount of gap 112 defines the maximum spring extension, thereby the maximum (tensile) force applied to the piezoelectric element 101 . As a result, the piezoelectric element is protected from being damaged by tensile loading. The gap 112 also defines the maximum level of firing acceleration that is going to be utilized by the power generation unit 100 .
When the firing acceleration has ended, i.e., after the projectile has exited the gun barrel, the mechanical (potential) energy stored in the elongated spring is available for conversion into electrical energy. This can be accomplished by harvesting the varying voltage generated by the piezoelectric element 101 as the mass-spring element vibrates. The spring rate and the maximum allowed deflection determine the amount of mechanical energy that is stored in the spring 105 . The effective mass and spring rate of the mass-spring unit determine the frequency (natural frequency) with which the mass-spring element vibrates. By increasing (decreasing) the mass or by decreasing (increasing) the spring rate of the mass-spring unit, the frequency of vibration is decreased (increased). In general, by increasing the frequency of vibration, the mechanical energy stored in the spring 105 can be harvested at a faster rate. Thus, by selecting appropriate spring 105 , mass 109 and gap 112 , the amount of electrical energy that can be generated and the rate of electrical energy generation can be matched with the requirements of a projectile.
In FIG. 1 , the spring 105 is shown to be a helical spring. The preferred helical spring, however, has three or more equally spaced helical strands to minimize the sideways bending and twisting of the spring during vibration. In general, any other type of spring may be used as long as they provide for vibration in the direction of providing cyclic tensile-compressive loading of the piezoelectric element.
The power generation unit 100 of FIG. 1 is described herein by way of example only and not to limit the scope or spirit of the present invention. Other embodiments described in U.S. patent application Ser. Nos. 10/235,997 and 11/116,093 can also be used in the applications described below as well as any other type of power generation unit which harvests electrical energy from a vibrating mass due to the acceleration of a projectile/munition as well as from the aerodynamics induced motions and vibration of the projectile during the entire flight.
The schematic of FIG. 2 shows a typical system of harvesting electric charges generated by the piezoelectric element of the energy harvesting power generation unit 100 as the mass-spring element of the power source begins to vibrate upon exiting the gun barrel. Electronic conditioning circuitry 202 , well known in the art, would, for example, convert the oscillatory (AC) voltages generated by the piezoelectric element to a DC voltage and then regulate it and provide it for direct use or for storage in a storage device 204 such as a capacitor or a rechargeable battery as shown in the schematic of FIG. 2 . The piezoelectric output is connected by wires 203 to the electronic converter/regulator/charger 202 , the output of which is connected to the storage device (a capacitor or rechargeable battery) 204 by wires 205 , or is used to directly run a load 206 via wires 207 . A processor 208 is also provided for processing information from the output of the power generation unit 100 . Although the processor 208 is shown connected by way of wiring 209 to the electronic conditioning circuitry 202 , it can be connected to or integral with any of the shown components such that it is operative to process the output or output information from the power generation unit 100 .
Accidental Drop Detection and Differentiation From Firing
During the firing, the force exerted by the spring element of the power generation unit 100 generates a charge and thereby a voltage across the piezoelectric element that is proportional to the acceleration level being experienced. The generated voltage is proportional to the applied acceleration since the applied acceleration works on the mass of the spring-mass element of the energy harvesting power source (in fact the mass of the piezoelectric element itself as well), thereby generating a force proportional to the applied acceleration level.
In certain situations and particularly in the presence of noise and at relatively low acceleration levels, the mass-spring system of the power generation unit 100 begins to vibrate and generates an oscillatory (AC) voltage with a DC bias, which is still proportional to the level of acceleration that is applied to the munitions. Hereinafter, when vibratory motion is present, the piezoelectric voltage output is intended to indicate the level of the aforementioned DC bias.
The level of voltage produced by the piezoelectric element is therefore proportional to the level of acceleration that is experienced by the munitions in the longitudinal (firing) direction. This information is obviously available as a function of time. A typical such longitudinal acceleration (firing force, which is equal to the longitudinal acceleration times the mass of the round) versus time plot may look as shown in FIG. 3 . From this plot, the processor 208 may calculate information such as the peak acceleration (impulsive force) level and the acceleration (firing force) duration, Δt, can be measured. The processor 208 can be dedicated for such calculations or used for controlling other functions of the munition. The plot information can also be used to calculate the average acceleration (firing force) level and the total applied impulse (the area under the force versus time curve of FIG. 3 or the product of the average firing force times the time duration). The amount of impulse that the round is subjected to in its longitudinal (firing) direction is thereby known. In practice, the processor may be used onboard the munitions (or the generally present fuzing processor could be used) to make the above time and voltage (acceleration or firing force) measurements and perform the indicated calculations and provide the safety and fuzing decision making capabilities that are indicated in the remainder of this disclosure.
However, a round is subjected to such input impulses in its longitudinal direction during its firing as well as during accidental dropping. The level of input impulse due to accidental dropping of the round is, however, orders of magnitude smaller than that of firing.
For example, consider a situation in which a round is dropped on a very rigid concrete slab, generating around 15,000 G of acceleration in the longitudinal direction (here, it is assumed that the round is dropped perfectly on its base, resulting in the highest possible longitudinal impact acceleration). Assuming that the elastic deformation that occurs during the impact is in the order of 0.1 mm, a conservative estimate of the impact duration with a constant acceleration of 15,000 Gs becomes about 0.04 msec. Now, even if we assume a similar acceleration profile in the gun barrel, but spread it over a time duration of 8 msec (close to what is experienced in many large caliber guns), then the impulse experienced during the firing is (8/0.04) or 200 times larger than that experienced during a drop over a hard surface. This is obviously a conservative estimate and the actual ratio can be expected to be much higher since in most situations, the round is not expected to land perfectly on its base and on a very hard surface and that the firing acceleration is expected to be significantly larger than those experienced in an accidental drop.
The above example clearly shows that by measuring the impact impulse, accidental drops can be readily differentiated from the firing acceleration by the processor 208 . This characteristic of the present piezoelectric based power generation units 100 can be readily used to construct a safety feature to prevent arming of the fuzing during accidental drops and/or to take some other preventive measures. This safety feature can be readily implemented in the electrical energy collection and regulation electronics of the power source or in the fuzing electronics (e.g., the processor 208 can have an input into the electrical energy collection and regulation electronics 202 of the power source or in the fuzing electronics to prevent fuzing when the calculated impact pulse is below a predetermined threshold value indicative of a firing).
Firing Validation and Booster Firing and Duration Time and Total Impulse
As was described in the previous section on accidental drop detection and differentiation from firing, the firing impulse as well as its acceleration profile and time duration can be readily measured and/or calculated from the output of the piezoelectric elements of the power generation units 100 by the processor 208 . Similarly, the completion of the firing acceleration cycle and the start of the free flight are readily indicated by the piezoelectric element. In the presence of firing boosters, their time of activation; the duration of booster operation, and the total exerted impulse on the round can also be determined by the processor 208 from the output of the power generation unit 100 .
As a result, the piezoelectric based power generation units provide the means to validate firing; determine the beginning of the free flight; and when applicable, validate booster firing and its duration.
Target Impact Detection
During the flight, the munition/projectile is decelerated by aerodynamic drag. Projectiles are commonly designed to produce minimal drag. As a result, the deceleration in the axial direction is fairly low. In addition, there may also be components of vibratory motions present in the axial direction. Axially oriented piezoelectric based power generation units 100 can also be very insensitive to lateral accelerations, which are also usually fairly small except for high spinning rate projectiles.
When impact occurs (assuming that the impact force is at least partially directed in the axial direction), the piezoelectric elements of the power generation units 100 experience the resulting input impact, including the time of impact, the impact acceleration level, peak impact acceleration (force) and the total impact impulse. As a result, the exact moment of impact can be detected and/or calculated by the processor 208 from the output of the power generation unit 100 .
In addition, when desired, lateral impact time, level and total impulse may be similarly detected by employing at least one such piezoelectric based power generation unit 100 in the lateral directions, noting that at least two piezoelectric power sources directed in two different directions in the lateral plane are required to provide full lateral impact information. Alternatively, a single power generation unit 100 can be provided which is aligned offset from an axial direction so as to have a vibration component in the axial direction and a vibration component in the lateral direction. Such laterally directed power sources are generally preferable for harvesting lateral vibration and movements, such as those generated by small yawing and pitching motions of the round.
Hard and Soft Target Detection
When the munition impacts the target, ground or another object, the munition's deceleration profile can be measured from the piezoelectric element output voltage during the impact period and peak deceleration level, impact duration, impact force and total impulse can then be calculated as previously described using the processor 208 . This information can then be used to determine if a relatively hard or soft target has been hit, noting that the softer the impacted target, the longer would be the duration of impact, peak impact deceleration (force). The opposite will be true for harder impacted targets. This information is very important since it can be used by the fuzing system to make a decision as to the most effective settings.
It is worth noting at this point that the hard or soft target detection and decision making, in fact all the aforementioned detection and decision making processes, are expected to be made nearly instantly by the power source electrical energy collection and regulation electronics or the fuzing electronics by employing, for example, threshold detecting switches to set appropriate flags.
Time-Out Signal for Unexploded Rounds
Once a munition has landed and is not detonated, whether due to faulty fuzing or other components or properly made decision against detonation, the piezoelectric based power generation unit 100 will stop generating electrical energy once its initial vibratory motion at the time of impact has died out. The electrical power harvesting electronics and/or the fuzing electronics can utilize this event, if followed by target impact, to initiate detonation time-out circuitry. For example, the power source and/or fuzing electronics can be equipped with a time-out circuit that would disable the detonation circuitry and/or components to make it impossible for the round to be internally detonated. The time-out period can be programmed, for example, while loading fuzing information before firing, and/or may be provided by built-in leakage rate from capacitors assigned for this purpose.
Wake-Up Signal Detection and Detection Beacon Provision
Consider the situation in which a round has landed without detonation and its detonation window has timed-out. Then at some point in time, a recovery crew may want to attempt to safely recover the unexploded rounds. The present piezoelectric based power generation unit 100 can readily be used to transmit an RF or other similar beacon signals for the recovery crew to use to locate the projectile. This may, for example, be readily accomplished through the generation of acoustic signals that are produced by the dropping or hammering of weights on the ground or by detonating small charges in the suspect areas. The acoustic waves will then cause the piezoelectric elements of the power source to generate a small amount of power to initiate wake-up and transmission of the RF or similar beacon signal.
When appropriate, the acoustic signal being transmitted by the recovery crew could be coded. In addition, this feature of the power generation unit 100 provides the means for the implementation of a variety of tactical detonation scenarios. As an example, multiple rounds could be fired into an area without triggering detonation, awaiting a detonation signal from a later round, which is transmitted by a coded acoustic signal during its own detonation.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
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A method for detecting a target impact of the munition. The method including: providing the munition with a power supply having a piezoelectric material for generating power from an axial vibration induced by the munition; monitoring an output from the power supply; and determining if the munition has axially impacted a target based on the output.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a color television system which maintains high definition together with significantly reduced crosstalk between frequency interleaved luminance and chrominance components of a received video signal, and particularly to such a system wherein at both the transmitter and receiver comb filtering is employed to a variable extent corresponding to the variation in vertical correlation of luminance and chrominance on successive scanning lines of the video picture, thereby minimizing crosstalk without loss of high frequency components of the luminance and chrominance signals which provide fine detail in the video picture.
2. Description of the Related Art
Existing standards for broadcast television were originally developed for monochrome transmission. However, in order to maintain compatibility with present and contemplated higher definition color television, as required by national regulatory authorities, the frequency band of the chrominance component of the composite color video signal overlaps the upper portion of the frequency band of the luminance component. This is achieved by frequency interleaving, which is possible if the luminance signal substantially only includes frequencies which are clustered at even harmonics of half the line scanning frequency, so that the frequency components of the chrominance signal can be placed there-between by transmitting the chrominance signal in the form of amplitude modulation of a subcarrier wave at an odd multiple of half the line scanning frequency. In the NTSC system, relative to the frequency of the carrier of the complete video signal the color subcarrier is at about 3.5 MHz, the luminance (Y) signal extends to 4.2 MHz, the sidebands of the Q component of the modulated chrominance signal extend 0.5 MHz to each side of the subcarrier, and the sidebands of the I component of the modulated chrominance signal extend from 1.5 MHz below to 0.6 MHz above the subcarrier. The subcarrier wave itself is suppressed in the transmitted video signal.
Formation of the transmitted video signal from the original RGB signals from a video camera is referred to encoding, and recovery of the RGB signals from the received video signal at the receiver is referred to as decoding. The decoding operation includes separating the modulated chrominance signal from the luminance signal, which has most commonly been effected by bandpass filters. However, that inevitably loses luminance detail since it is comprised in the upper portion of the luminance band which is overlapped by the chrominance band and so will be separated with the chrominance signal. This also results in crosstalk between the luminance and chrominance signals, producing effects in the received video picture known as "cross-color" and "cross-luminance", or more popularly as "rainbow" and "dot" patterns, respectively.
It is therefore preferable to effect decoding of the video signal by comb filtering, employing line, field or frame delays for that purpose. Such filtering presumes, as a result of interleaving of the luminance and chrominance signal frequency components, that the phase of the luminance signal will remain substantially the same on successive scanning lines during successive fields of the video picture, whereas the phase of frequency components of the chrominance signal will alternate on successive scanning lines of successive fields, requiring four fields (1/15 seconds) to repeat. However, such vertical phase relationships between the luminance and chrominance signals are only true in regions of the video picture having a high degree of vertical correlation, i.e. no substantial changes in the vertical direction from line to line. If there are vertically stepped or diagonal shapes in the picture, the frequency components of the luminance and chrominance signals will not be respectively clustered only at even and odd harmonics of half the line scanning frequency, and will overlap to an extent dependent on such departure from vertical correlation in the picture. In such cases, comb filtering would result in loss of high frequency components of the luminance and chrominance signals, with consequent loss of detail in the picture.
Various methods have been proposed to provide comb filtering of the interleaved luminance and chrominance signals while minimizing loss of detail. For example, U.S. Pat. No. 4,688,080, issued Aug. 18, 1987, describes an adaptive chrominance separation circuit wherein a comb filtered chrominance signal is provided for portions of the video picture having high vertical correlation, a lowpass filter otherwise being employed to separate the luminance and chrominance signals. Since luminance detail is above the passband of such a filter, in order to preserve such detail the aforesaid patent teaches to make the decision to either bypass or not bypass the comb filter depend not only on the presence of vertical chrominance detail but also on the presence of luminance detail. However, such adaptation is only an approximation based on certain discrete levels of the changes in the chrominance and luminance signals on successive scanning lines. Such patent also teaches to switch between a combed and a bandpass filtered chrominance signal, and to provide an average of the two during switching from one to the other. However, there is no adaptation of the relative proportions of said signals in accordance with the degree of vertical correlation in the video picture.
Applicant's own published article "Adaptive Filter Techniques for Separation of Luminance and Chrominance in PAL TV Signals", I.E.E.E. Trans. on Consumer Electronics, Vol. CE-32, No. 3, August 1986, describes an adaptive filter for separation of luminance and chrominance which effects a continuously variable transition between line comb filtering and frame comb filtering depending on the degree of vertical change in the picture from frame to frame or from line to line caused, for example, by movement in the picture. Movement adaptive "fading" between frame and line comb filtering is thereby achieved to provide luminance-chrominance separation to an extent consistent with preservation of high frequency detail.
The article "Some Thoughts on Using Comb Filters in the Broadcast Television Transmitter and at the Receiver" by R. Turner, I.E.E.E. Trans. on Consumer Electronics, Vol. CE-23, No. 3, August 1977, describes comb filtering at the receiver as well as at the transmitter so as to exclude frequency components in the transmitted video signal which are not clustered at either even and odd harmonics of half the line frequency. That renders the comb filtering at the receiver more effective in regions of the picture having low vertical correlation, such as diagonals, but excessive exclusion of other frequency components of the video signal will cause noticeable degradation of vertical resolution in the picture. Best results are achieved if the transmitter encoder and receiver decoder employ the same type of comb filtering, such as by line or by frame. However, crosstalk will still occur because with comb filters having a reasonable number of line and frame delay elements there will be some overlap of the luminance and chrominance passband slopes of the filter. Such overlap will also result in loss of vertical resolution.
SUMMARY OF THE INVENTION
The present invention provides a color television system wherein adaptive line comb pre-filtering is employed at the transmitter for the luminance and chrominance signals, and adaptive line comb post-filtering is employed at the receiver to recover and separate such signals from the received composite video signal. The filter adaptation is such that chrominance and luminance separation is effected entirely by comb-filtering for portions of the video picture in which there is a high degree of vertical correlation of luminance and chrominance of corresponding pixels on successive scanning lines, exceeding a predetermined level, and is effected entirely by bandpass filtering when there is essentially no vertical correlation. Between those extremes, where there are intermediate degrees of vertical correlation, a continuously variable proportioning or "fading" is provided between line comb filtering and bandpass filtering for both the luminance and chrominance signals. The fading proportion is established by an adaptive control signal (ACS) derived from a vertical detection signal (VDS) corresponding to the degree of change in the luminance and chrominance signals for corresponding pixels on successive scanning lines. Since the same type of fading and the same luminance and chrominance passbands are employed for pre-filtering at the transmitter and post-filtering at the receiver, coordination between the transmitter and receiver is achieved without any necessity for transmission of a common control signal for that purpose. The pre-filtering significantly reduces crosstalk between luminance and chrominance in the transmitted signal, so that the subsequent post-filtering at the receiver results in far more effective reduction in crosstalk than has heretofore been possible without significantly reducing picture resolution.
A color television system in accordance with the invention comprises a transmitter which includes an encoder for combining the luminance (Y) and chrominance (C) signals to form the transmitted video signal, and a receiver which includes a decoder for deriving the Y and C signals from the received video signal. The encoder comprises at least one adaptive filter to which one of the Y and C signals is supplied as an input, and the decoder comprises at least one adaptive filter to which the received video signal is supplied as an input. Each of such adaptive filters comprises a multi-line delay for receiving the input signal to the filter and deriving therefrom respective line signals corresponding to respective ones of a plurality of successive scanning lines of the video picture. A line comb filter derives from such line signals a comb filtered signal which only includes those frequency components of the line signals having a particular phase relationship on the successive scanning lines, such as alternating in phase or remaining of the same phase. In the case of high vertical correlation of the line signals, phase alternation is characteristic of the C signal component and constant phase is characteristic of the Y signal component. The filter also comprises a fading circuit for receiving the comb-filtered signal and one of the line signals and combining them in variable relative proportions to derive a corrected signal, such variable proportioning ranging from a corrected signal consisting of only the comb-filtered signal and a corrected signal consisting of only said one line signal. A detector circuit derives from the line signals a vertical difference signal (VDS) of a magnitude corresponding to the degree of vertical correlation of the line signals, and a processor circuit derives from the VDS signal an adaptive control signal (ACS) which controls the fading circuit to set the relative line signal in accordance with the magnitude of the ACS signal. Via a bandpass filter such one line signal is then combined with the corrected signal from the fading circuit to derive an output signal which is equivalent to such one line signal comb-filtered to an extent consistent with the degree of vertical correlation of pixels on the scanning lines to which the successive line signals correspond.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete description of the invention and various embodiments thereof is presented below with reference to the accompanying drawings, in which:
FIG. 1 is an overview of a color television system in accordance with the invention;
FIG. 2a is a block diagram of a complementary form of the encoder in FIG. 1, and FIG. 2b is a block diagram of a non-complementary form of such encoder;
FIG. 3 is a block diagram of a non-complementary form of the decoder in FIG. 1;
FIGS. 4a, 4b, and 4c are block diagrams of an adaptive filter in accordance with the invention, the differences in such figures being dependent on whether the adaptive filter is employed in the complementary encoder of FIG. 2a, or as the Y or C filter of the non-complementary encoder of FIG. 2b, or as the Y or C filter of the non-complementary decoder of FIG. 3;
FIGS. 5a and 5b are alternative embodiments of the line comb filter in FIGS. 4a-c, and FIG. 5c shows the frequency transfer characteristic of such comb filter;
FIG. 6 is a block diagram of the VDS processor circuit in FIGS. 4a-c;
FIG. 7 is a graph of the frequency characteristic of the VDS detector circuit in FIGS. 4a-c;
FIG. 8 shows the non-linear transfer function of the VDS processor circuit in FIG. 6;
FIG. 9 is a block diagram of the fading circuit in FIGS. 4a-c;
FIG. 10a is a graph of the frequency characteristic of the VDS signal produced by the detector circuit in FIGS. 4a-c, and FIGS. 10b and 10c illustrate various different non-linear frequency characteristics of the ACS signal produced by the VDS processor in FIGS. 4a-c; and
FIGS. 11 and 12a-12e are graphs of various frequency characteristics of an adaptive filter in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an overview of a color television system in accordance with the invention. A conventional video signal source 1 supplies luminance (Y1) and chrominance (C1) signals representing a picture to be transmitted, as derived by an RGB matrixing circuit from, for example, a video camera, photographic film scanner, or video tape or disc reading apparatus. The Cl signal includes the conventional I and Q (or R-Y and B-Y) color-difference signals modulated on a sub-carrier. The Y1 and C1 signals are supplied to encoder 2, a circuit which filters and combines them to form a composite output video signal N1 in accordance with NTSC specifications. The signal N1 is modulated on an RF carrier wave by an RF circuit 3 which then transmits it over a radio or cable transmission path. Additional signal components such as synchronizing pulses and a modulated audio carrier are also conventionally included in the transmitted signal. At the receiver, the received signal is demodulated by an RF circuit 4 to recover the video signal N2 and also the additional signal components. Inasmuch as such additional signal components are not involved in the present invention, and transmission and recovery thereof are well-known in the art, further description in that regard is unnecessary. The received video signal N2 is applied to a decoder circuit 5 which post-filters it to separate and recover the luminance (Y2) and chrominance (C2) components thereof, which can then be supplied to an RGB de-matrixing and video display device 6, such as a CRT, to reproduce the transmitted picture. Preferably, the encoder 2 and decoder 5 are provided with A/D and D/A converters at the inputs and outputs thereof, respectively, so that the signals to be pre-filtered and post-filtered are in digital form and such converters can employ digital signal processing circuits.
FIG. 2a is a block diagram of a complementary form of the encoder 2 in FIG. 1, requiring only one adaptive filter 8. The chrominance signal C1 is subtracted from the luminance signal Y1 by a subtractor 7, resulting in a signal S 0 =Y1-C1, which is supplied to an adaptive filter 8 in accordance with the invention as described in detail hereinafter. The filter 8 produces an output signal S 50 which is a filtered C1 signal from which frequency components included in the Y1 signal have been eliminated. The Y1 signal is delayed by an adjustable delay element 9, for example a FIFO memory, which equalizes the phase delay of signal S 50 , and the latter signal is subtracted from Y1 by a subtractor 10. This removes from Y1 frequency components which are included in C1, resulting in the signal N1 comprising Y1 and C1 and in which crosstalk between those components has been eliminated or substantially reduced. The encoder in FIG. 2a is termed "complementary" because filtering of the Y1 signal is achieved by subtracting therefrom those frequency components which are of the C1 signal, so that all spectral energy is conserved.
FIG. 2b is a block diagram of a non-complementary encoder and FIG. 3 is a block diagram of a non-complementary decoder. In FIG. 2b the Y1 and C1 signals are applied to respective adaptive filters 14 and 15, which serve to filter from each those frequency components which are included in the other of such signals. As described in more detail hereinafter, a signal S 54 from Y filter 14 is supplied to C filter 15 and a signal S 55 from C filter 15 is supplied to Y filter 14. The filtered Y signal S 52 at the output of filter 14 and the filtered C signal S 53 at the output of filter 15 are then combined by an adder 12 to obtain the output video signal N1. The decoder in FIG. 3 is similar to the non-complementary encoder in FIG. 2b, but the input is the received video signal N2. It is applied to each of an adaptive Y filter 16 and an adaptive C filter 17, which respectively produce the filtered Y2 and C2 signals. For a decoder, there is no need to interchange signals such as S 54 and S 55 as in the encoder filter in FIG. 2b. The decoder could alternatively employ complementary filtering, as in the complementary encoder in FIG. 2a. However, it is preferable to employ non-complementary filters in a decoder because of the greater flexibility that is then possible in design of the filters. From the description herein of the complementary encoder it will be apparent how to design the filters of a complementary decoder.
FIGS. 4a-c are block diagrams of the adaptive filters for the encoders and decoder shown in FIGS. 2a, 2b and 3 and also for a complementary decoder, as follows:
FIG. 4a:
the Y filter 14 of the non-complementary encoder in FIG. 2b, in which case the input signal S 0 is the signal Y1 in FIG. 2b and the output signal is the signal S 52 in FIG. 2b; or the Y filter 16 of the non-complementary decoder in FIG. 3, in which case the input signal S 0 is the signal (Y2+C2 in FIG. 3 and the output signal is the signal S 14 in FIG. 3.
FIG. 4b:
the of the non-complementary encoder in FIG. 2b or the C filter 17 of the non-complementary decoder in FIG. 3. In the case of filters 8 and 17 the signals S 54 and S 55 are not present. The filter input signal S 0 and output signal S 13 would be the corresponding input and output signals in such related figures.
FIG. 4c:
the adaptive filter for a complementary decoder corresponding to the non-complementary decoded in FIG. 3, the filter input signal S 0 being a received video signal N2 as in FIG. 3 and the filter output signals S 14 and S 13 respectively being signals Y2 and C2 as in FIG. 3.
The filters in FIGS. 4a-c are similar in structure and operation, corresponding elements being similarly identified. The common functions of such filters will be described with reference to FIG. 4a. Therein the input signal S 0 (Y1 of the non-complementary encoder in FIG. 2b, or N2 in the case of the non-complementary decoder in FIG. 3), is applied to a multiline delay circuit 18 comprising two line stores each of which provides a storage period T L of one scanning line. Consequently, the output signals S 1 , S 2 , S 3 of multiline delay circuit 18 will be the line signals corresponding to input signals S 0 for three successive scanning lines of the video picture. If there is no vertical change in such signals for corresponding pixels on such lines, the C signal will alternate in phase and therefore in sign for such lines. The three line signals S 1 , S 2 and S 3 are supplied to respective inputs of a line comb filter 19. The signals S 1 and S 3 for the first and third lines are also supplied to respective inputs of a vertical difference signal (VDS) detector circuit 20. The line signal S 2 for the second line is also applied to each of a pair of pixel delay elements 21a, 21b, and the output S 6 of comb filter 19 is applied to a pixel delay element 21c. Such pixel delay elements equalize the phase delays of the signals in the various branches of the circuit in FIG. 4a.
Two alternative implementations of line comb filter 19 are shown in FIGS. 5a and 5b. In FIG. 5a the line signals S 1 , S 2 and S 3 are respectively applied to multiplier or barrel shift (a shift of bit position) units 22a, 22b, and 22c wherein they are respectively multiplied by constant factors in the proportions - 1/4+1/2 and - 1/4, and the products are summed by adder 23 to produce output signal S 6 . If the filter input signal S 0 is Y1-C1, the line signals S 1 , S 2 , S 3 will therefore be Y1-C1, Y1+C1, Y1-C1. The described summation will therefore eliminate Y1, resulting in an output signal S 6 which is just C1. In the alternative embodiment in FIG. 5b, the inputs S 1 and S 3 are summed by adder 24, and such sum and input S 2 are respectively applied to multiplier or barrel shift units 25a, 25b wherein they are multiplied by constant factors in the proportions - 1/4 and 1/2, and the resulting products are summed by adder 26 to produce output signal S.sub. 6. If the signals on the filter inputs are as described above for the filter in FIG. 5a, output signal S 6 will again be C.
In the case where the filter in FIG. 4a serves as the Y filter of the non-complementary encoder in FIG. 2b the filter input signal S 0 will be just the signal Y1 in FIG. 2b, which includes frequency components belonging to signal C1. In that case the above-described operation of the line comb filter 19 will result in an output signal S 6 which is Y 1 filtered of frequency components thereof belonging to C1.
In FIG. 4b, in the case where the filter therein is the C filter of the non-complementary encoder in FIG. 2b, the filter input signal S 0 will be the signal C1 in FIG. 2b and which includes frequency components belonging to signal Y1. In that case the above-described operation of line comb filter 19 will result in an output signal S 6 which comprises just the frequency which belong to C1. Consequently, subtraction of signal S 6 from Y 1 will derive Y 1 filtered of such frequency components. This operation is described in more detail hereinafter.
A more complete understanding of the operation of the line comb filter in each of FIGS. 5a and 5b can be had from FIG. 5c, showing the frequency transfer characteristic H CCF of such filter relative to a normalized frequency of cycles per picture height. With an interlaced scanning line raster of 525 line, there will be 262.5 cycles during each vertical field of the picture,referred to herein as cycles per picture height (c/ph). If there is no vertical change in the picture from line-to-line during a vertical field, the luminance signal Y will consist of sidebands clustered at 0 and 262.5 c/ph and the chrominance signal C will consist of sidebands clustered at 131.25 c/ph. Consequently, the frequency transfer characteristic in FIG. 5c will effectively comb the frequency components of the Y signal from the composite video signal, resulting in a C signal free of crosstalk from the Y signal. However, on horizontal or diagonal colored edges, which create color transitions in the vertical or diagonal direction, the Y and C signal sidebands shift as shown in FIG. 5 c and so the frequency transfer characteristic results in considerable overlap of frequency components of the Y and C signals. Consequently, the line comb filter should not be applied for pictures having very low vertical correlation.
Vertical correlation adaptive utilization of the comb filtered signal is provided by first deriving a vertical difference signal (VDS) corresponding to vertical changes in the video picture during each vertical field. That function is performed by the VDS detector 20 in FIG. 4a, wherein the signals S 1 and S 3 are subtracted by a subtractor 20a and the resulting difference is halved by a multiplier 20b. Since the signals S 1 and S 3 are two lines apart, the output signal S 7 from detector 20 will correspond to the average change in the picture in the vertical direction between those lines. The frequency characteristic H vds of VDS detector 20 is shown in FIG. 7. It is zero at the frequencies at which the Y and C signal components are located when there is no vertical change in the picture, and gradually increases up to a maximum at the intermediate frequency to which those signal components are shifted when there is a maximum vertical change in picture content. Thus, frequency components f y which represent vertical changes in the picture migrate into the passbands of the frequency characteristic of detector 20 and result in the VDS signal denoted S 7 in FIG. 4a which is utilized to control the relative proportioning of the comb filtered component of the output of the adaptive filter.
Before the VDS signal can be used to control the degree of adaptive filtering it must be processed further, as was pointed out in Applicant's above-cited article published in 1986. For example, periodic changes in vertical detail in the picture will result in a periodic VDS signal whereas such signal should only be proportional to the amplitude of such changes. The VDS signal S 7 is therefore applied to the VDS processor circuit 22 in FIG. 4a, and which is shown in more detail in FIG. 6. Signal S 7 is applied to an adder 191 the output S 71 of which is supplied to a rectifier 192 producing a unipolar signal S 72 which is low-pass filtered by a filter 193 to provide a smoothed output signal S 73 having low ripple even if input signal S 7 may be periodic. The signal S 73 is applied to a circuit 194 having a nonlinear transfer function as shown in FIG. 8, resulting in an output signal S 8 . For a non-complementary encoder according to FIG. 2b, having separate filters for the Y and C signal components, the VDS signal S 7 at the output of the VDS detector 20 of each such filter will also be supplied to the adder 191 at the input to the VDS processor in the filter for the other of such signals, so as to combine both VDS signals into the signal S 71 in FIG. 6 which is then processed. In this way, processing of the respective luminance and chrominance components each takes into account vertical changes in both luminance and chrominance. The dotted line S 55 in FIG. 6 denotes the VDS signal S 55 which will be supplied from the VDS detector of the adaptive filter for the C signal when the processor in FIG. 6 is the Y processor. If the processor in FIG. 6 is the C processor, then such dotted line would signify the VDS signal S 54 supplied from the Y processor. The second non-linear transfer circuit 195 in FIG. 6 and the dotted line thereto for signal S 73 represents the case in which FIG. 6 is the processor in the C filter, and such processor will also have a non-linear transfer function as in FIG. 8 resulting in an output signal S 9 . The signals S 8 and S 9 are the adaptive control signals (ACS) for controlling fading circuit 23 in FIGS. 4a-4c.
It should be particularly noted that since the adaptive control signals (ACS) are derived by the same non-linear transfer functions and processing parameters at both the encoder and decoder, coordination is achieved at the transmitter and receiver without necessitating transmission of any special control signal to the receiver for that purpose.
The adaptive fading circuit 23 in FIGS. 4a-c is shown in FIG. 9, wherein the dotted lines are applicable only in the case where such circuit is employed in a non-complementary encoder as in FIG. 4c, which provides an ACS signal S 9 as well as an ACS signal S 8 as described above with reference to the VDS processor in FIG. 6. In the case of a decoder, the signals S 9 and S 11 in FIG. 10 will not be present. The input signal S 5 , which is the delayed unfiltered line signal S 2 including the Y and C signal components, and the input signal S 6 , which is a comb filtered signal such as the filtered C signal component, are applied to a subtractor circuit 101. The result of such subtraction is multiplied by a factor corresponding to the magnitude of ACS signal S 8 by means of a multiplier 102. The so-multiplied signal is then added to the signal S 6 by an adder 103, the resulting sum signal S 10 effectively being a mixture of signals S 5 and S 6 in proportions determined by the magnitude of ACS signal S 8 . In the non-complementary decoder case, wherein there will also be a second control signal S 9 , it is similarly combined with signals S 5 and S 6 by means of a multiplier 104 and adder 105 to produce a resulting sum signal S 11 which represents a mixture of signals S 5 and S 6 in proportions determined by the magnitude of signal S 9 . Thus, signals S 8 and S 9 provide an adaptive variable proportioning or "fading" of the combination of signals S 5 and S 6 . If, for example, the ACS signal S 8 is zero, as will occur when the processed VDS signal S 72 is below the lower threshold FL of the non-linear transfer function in FIG. 8 of the VDS processor circuit in FIG. 6, the output signal S 10 of the fading circuit in FIG. 10 will be just the delayed line-combed signal S 6 provided by line-combed filter 17 in FIGS. 4a-4c at the input of fading circuit 23. If the ACS signal S 8 is at its maximum value, as will occur when the processed VDS signal S 72 is at or above the upper threshold FH of the non-linear transfer function in FIG. 8, the output signal S 10 of fading circuit 23 will be just the signal S 5 which is the delayed second line signal S 2 in FIGS. 4a-4c. Between those extremes, dependent on the magnitude of the ACS signal, a variable degree of mixing or "fading" is produced of comb filtered line signal S 6 with unfiltered line signal S 5 in varying proportions. Thus, the contribution of the comb filtered signal to the output of fading circuit 23 is faded out upon occurrence of high frequency vertical components in the line signals S 1 and S 2 and S 3 signifying sudden vertical changes in the scanning lines corresponding thereto.
Referring back to FIGS. 4b-4c, in the case of a complementary encoder as in FIG. 2a only one adaptive filter as in FIG. 4a is required. Consequently in FIG. 4a the signal S 10 at the output of fading circuit 23 carries both luminance and chrominance information. The band-limited output signals S 13 from bandpass filter 24a is then the filter output signal S 50 in FIG. 2a. In the case of the Y-filter of the non-complementary encoder in FIG. 2b, which filter is shown in FIG. 4a, therein the band-limited output signal S 12 from bandpass filter 24a is supplied to the subtractive input of a subtractor 25. The other input of subtractor 25 is coupled to line signal S 2 by pixel delay 21a, so that the delayed signal S 4 at such input has the same phase delay as the signal S 12 . The result of the subtraction performed by subtractor 25 is the output signal S 14 of the adaptive filter.
In FIG. 4c (the filter for a complementary decoder) the output signal S 10 of the fading circuit of the Y filter and the output signal S 11 of the fading circuit for the C filter are respectively supplied to respective bandpass filters 24a and 24b. Each such filter has a passband centered at the color subcarrier frequency and a bandwidth approximating the 3 to 4.2 MHz chrominance bandwidth of an NTSC video signal, although such filters may have somewhat different bandwidths in order to reduce spectral overlap of the luminance and chrominance passbands. The output signal S 13 from bandpass filter 24b is the output of the C filter of the decoder, which will a signal C2 as in FIG. 3. The output signal S 12 from bandpass filter 24a of the Y filter of the decoder is subtracted by subtractor 25 from the phase adjusted line signal S 4 , resulting in an output signal S 14 which is the output of the Y filter and so will be a signal Y2 in FIG. 3.
The operation of adaptive filtering according to the invention is illustrated in FIGS. 10-12. FIGS. 10b and 10c show how the vertical detection signal VDS is converted into the adaptive control signal ACS via several different possible non-linear transfer functions. Such functions are readily generated by 10a shows the amplitude of the detected VDS signal as a function of the vertical frequency fy. The amplitude is dependent on the occurrence of vertical detail (changes in the picture in the vertical direction). Since the VDS signal is fed to the inputs of the non-linear transfer function circuits 194 and 195 in FIG. 6 (after rectification in rectifier 192 and lowpass filtering in filter 193) the output ACS signal of each of such circuits consists of modified amplitude values of the VDS signal as shown in FIGS. 10b and 10c.
In FIGS. 10a to 10c a maximum peak-to-peak value of the input signal is assumed. As illustrated, a change in the adaptive control signal (ACS) is possible by changing the shape of the transfer function. With a steep transfer function a sudden change of ACS level is produced as the vertical frequency components increase. With smooth functions the change in ACS level is also smooth, resulting in a gradual fading operation. If the thresholds T L and T H of the non-linear transfer function in FIG. 8 are relatively low, the fading or reduction of the proportion of comb filtering will commence at relatively low values of vertical frequency fy.
The effect of different adaptive control signals on the bandwidth of the chrominance signal is illustrated in FIGS. 11, in which H CO refers to the unfiltered signal, H CCF is the amplitude response of the comb filter as shown in FIG. 5c, H VDS is the amplitude response of the VDS detector the frequency response of which is shown in FIG. 7, H ACS is the shaped amplitude response of the VDS signal after processing, and H CAF is the chrominance passband after adaptive filtering and which is calculated from the following equation applicable to the adaptive fading circuit:
H.sub.CAF =H.sub.CCF +H.sub.ACS ·(H.sub.CO -H.sub.CCF)
It is to be noted that due to the processing steps in FIG. 6 maximum values of the VDS and ACS signals, respectively, will result in equal amplitudes of the frequency responses H VDS and H ACS . For this reason, the graphs of H VDS and H ACS in FIG. 11 can be recognized partly in FIG. 10b and 10c, respectively.
With varying transfer functions according to FIG. 10b and 10c a variation of bandwidths is achieved and the slopes of the filter passbands are steeper than they are with non-adaptive comb filtering, as a comparison of H CCF and H CAF in FIG. 11 clearly shows.
One example of utilization of variable passbands with steep slopes is illustrated in FIGS. 12a-e, showing the cross-talk reduction which is achieved by an adjustment of the adaptive filter behavior of an encoder and decoder. In such figures, H E/Y denominates the encoder luminance frequency response and H E/C is the encoder chrominance frequency response. H D/Y is the decoder luminance frequency response and H D/C the decoder chrominance response. H CY and H CC indicate the amount of residual cross-luminance and cross-color components, respectively. In this example, complementary adaptive filters are employed at the decoder. Consequently, H E/Y =1-H E/C .
At the decoder, non-complementary filtering is preferably employed, which provides less spectral overlap.
The cross-luminance function H CY in FIG. 12b is given by H CY =H E/C ·H D/Y'
whereas the cross-chrominance function H CC is given by H CC =H E/Y ·H D/C .
Due to the shapes of the pass-bands of the non-complementary decoder filters, cross-talk components are reduced substantially. The area of residual overlap of the encoded Y and C components can be disregarded because due to the steep filter slopes this area is very small, resulting in only a small waste of spectrum. The loss of resolution of the luminance and chrominance signals is therefore also very small.
It will be clear from the above description that different shapes of the filter passbands can be achieved by a variation of the adaptive filter ACS signal. Therefore, a reduction of cross-talk is achievable which is even more complete than that shown in the example of FIG. 12. On the other hand, in certain applications a higher level of cross-talk is acceptable and permits use of more gradual filter slopes. This has the advantage of slightly better resolution of luminance and chrominance.
Besides use in a transmission system which includes both pre- and post-filtering at the encoder and decoder, respectively, the basic teachings of the invention can also be usefully applied for encoding alone or for decoding alone. In such cases, different adaptive adjustments of the filter may be desirable.
While the invention has been described with reference to certain preferred embodiments thereof, it will be apparent to those skilled in the art that various modifications and adaptations thereof may be made without departing from the teachings and scope of the invention as defined in the ensuing claims.
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A color television system wherein the transmitter and receiver each include at least one adaptive filter for minimizing crosstalk between the frequency interleaved luminance (Y) and chrominance (C) components of a received video signal due to vertical changes in luminance or chrominance on successive scanning lines of the video picture. Each such adaptive filter includes a line comb filter which comb-filters from the input signal thereto frequencies which belong to one of the video signal components, and a fading circuit for combining the comb-filtered signal with the unfiltered signal in continuously variable relative proportions. Such proportioning is established by an adaptive control signal derived from a vertical detection signal which corresponds to the degree of vertical correlation of luminance and/or chrominance of vertically corresponding pixels on successive scanning lines. Crosstalk between the luminance and chrominance signals is thereby minimized consistent with retention of high frequency components thereof which provide fine detail in the video picture.
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TECHNICAL FIELD
This disclosure relates to internal combustion engines, especially diesel engines in motor vehicles, that use exhaust gas recirculation (EGR) as a component of tailpipe emission control strategy.
BACKGROUND OF THE DISCLOSURE
A typical EGR system of an engine includes one or more EGR valves for controlling the flow of engine exhaust gas from the engine's exhaust system to the engine's intake system to meter an appropriate amount of exhaust gas into fresh air passing through the intake system where the air supports combustion of fuel in the engine's cylinders. The metered exhaust gas in effect dilutes the air so that in-cylinder temperature rise resulting from combustion is limited from that which would occur in the absence of such dilution. As a consequence, the quantity of oxides of nitrogen (NOx) in the exhaust gas that results from combustion is also limited.
Some EGR systems, especially those designed for compression ignition (i.e. diesel) engines, have one or more heat exchangers for cooling recirculated exhaust gas. Cooling of the exhaust gas can further limit the generation of NOx.
It is recognized in the industry that cooling of recirculated exhaust gas creates the potential for condensation of certain gaseous constituents of the exhaust gas. Control of condensation may be a factor in the design of various engine systems.
SUMMARY OF THE DISCLOSURE
This disclosure relates to an internal combustion engine comprising engine structure comprising engine cylinders within which fuel is combusted to operate the engine and coolant passageways, an intake system for conveying air to the engine cylinders to support fuel combustion and comprising a charge air cooler for cooling conveyed air, an exhaust system for conveying combustion-created exhaust gas from the cylinders, an EGR system for recirculating some exhaust gas from the exhaust system successively through a first heat exchanger and a second heat exchanger to the intake system for entrainment with air being conveyed to the cylinders and a cooling system for circulating liquid coolant in multiple loops and comprising first and second radiators.
A first of the loops comprises the coolant passageways where heat from the engine structure is transferred to coolant and the first radiator where heat in coolant that has passed through the coolant passageways is rejected.
A second of the loops comprises one of the first and second heat exchangers.
A third of the loops comprises the other of the first and second heat exchangers, the second radiator, the charge air cooler, a first valve that is selectively operable to first and second conditions, and a second valve that is operable to selectively apportion coolant flow entering an inlet of the second valve to parallel flow paths, one of which includes the second radiator and the other of which bypasses the second radiator, and which merge into confluent flow downstream of the second radiator to convey coolant to both an inlet of the charge air cooler and a first inlet of the first valve. The first valve has an outlet communicated an inlet of the other of the first and second heat exchangers.
The first condition of the first valve closes a second inlet of the first valve to coolant flowing toward both the second inlet of the first valve and the first inlet of the second valve while opening the first inlet of the first valve to the outlet of the first valve.
The second condition of the first valve opens the second inlet of the first valve to coolant flowing toward the second inlet of the first valve and the first inlet of the second valve while closing the first inlet of the first valve to the outlet of the first valve.
The disclosure also relates to a circuit for cooling both exhaust gas being recirculated through an EGR system of an internal combustion engine and charge air for supporting combustion in engine combustion chambers.
The circuit comprises a first loop comprising coolant passageways in engine structure containing where coolant absorbs heat from the engine structure and a first radiator where heat absorbed by coolant is rejected, a second loop comprising a first EGR cooler, and a third loop comprising a second EGR cooler, a second radiator, a charge air cooler for cooling charge air entering the engine, a first valve that is selectively operable to first and second conditions, and a second valve that is operable to selectively apportion coolant flow entering an inlet of the second valve to parallel flow paths, one of which includes the second radiator and the other of which bypasses the second radiator, and which merge into confluent flow downstream of the second radiator to convey coolant to both an inlet of the charge air cooler and a first inlet of the first valve. The first valve has an outlet communicated an inlet of the second EGR cooler.
The first condition of the first valve closes a second inlet of the first valve to coolant flowing toward both the second inlet of the first valve and the first inlet of the second valve while opening the first inlet of the first valve to the outlet of the first valve.
The second condition of the first valve opens the second inlet of the first valve to coolant flowing toward the second inlet of the first valve and the first inlet of the second valve while closing the first inlet of the first valve to the outlet of the first valve.
The disclosure also relates to a method for cooling both exhaust gas being recirculated through an EGR system of an internal combustion engine and charge air for supporting combustion in engine combustion chambers.
The method comprises: circulating liquid coolant in a first loop comprising coolant passageways in engine structure where heat from the engine structure is transferred to coolant and a first radiator where heat in coolant that has passed through the coolant passageways is rejected; circulating liquid coolant in a second loop comprising a first EGR cooler; and circulating liquid coolant in a third loop comprising a second EGR cooler, a second radiator, a charge air cooler for cooling charge air entering the engine, a selectively operable first valve, and a second valve for selectively apportioning coolant flow entering an inlet of the second valve to parallel flow paths, one of which includes the second radiator and another of which bypasses the second radiator, and which merge into confluent flow downstream of the second radiator to convey coolant to both an inlet of the charge air cooler and a first inlet of the first valve, the first valve having an outlet communicated an inlet of the second EGR cooler.
The method further comprises selectively operating the first valve to a first condition closing a second inlet of the first valve to coolant flowing toward both the second inlet of the first valve and the first inlet of the second valve while opening the first inlet of the first valve to the outlet of the first valve, and to the second condition opening the second inlet of the first valve to coolant flowing toward the second inlet of the first valve and the first inlet of the second valve while closing the first inlet of the first valve to the outlet of the first valve, and operating the second valve to selectively apportion coolant flow entering the inlet of the second valve to the parallel flow paths.
The foregoing summary is accompanied by further detail of the disclosure presented in the Detailed Description below with reference to the following drawings that are part of this disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a first embodiment of the disclosed system in an engine.
FIG. 2 is a schematic diagram showing a second embodiment of the disclosed system in an engine.
FIG. 3 is a schematic diagram showing a third embodiment of the disclosed system in an engine.
DETAILED DESCRIPTION
FIG. 1 shows a diesel engine 10 that comprises structure 12 containing engine cylinders 14 within which combustion of fuel occurs to operate the engine, such structure typically comprising a cylinder block 16 and one or more cylinder heads 18 depending on the particular type of engine block (such as an I-engine or a V-engine block). Engine 10 also comprises an air intake system 20 for conveying fresh air/EGR to cylinders 14 where the air supports the combustion of fuel. Engine 10 further comprises an exhaust system 22 for conveying combustion-created exhaust gas from cylinders 14 to a tailpipe through which the gas is discharged.
Engine 10 also comprises a turbocharger 24 shown as a two-stage turbocharger having a high-pressure turbine 24 HPT and a low-pressure turbine 24 LPT both operated by exhaust gas from cylinders 14 for operating respective high-pressure and low-pressure compressors 24 HPC and 24 LPC that draw fresh air into intake system 20 to create charge air for the engine. Because the compression of the air elevates its temperature, the compressed air leaving the low-pressure compressor stage flows first through a low-pressure charge air cooler (LPCAC) 26 LP (sometimes also called an inter-stage cooler or ISC) where some heat is rejected before the charge air is further compressed by high-pressure compressor 24 HPC. A high-pressure charge air cooler (HPCAC) 26 HP cools the air coming from the high-pressure compressor stage before it is delivered to a mixer where it may mix with recirculated exhaust gas before finally entering cylinders 14 through an intake manifold.
Engine 10 comprises a liquid cooling system that includes a system of coolant passageways 28 in block 16 and a system of coolant passageways 30 in head 18 . Liquid coolant is circulated through the cooling system by a pump 32 , which by way of example is an engine-driven coolant pump. The circulating coolant absorbs engine heat as it passes through the systems of passageways 28 , 30 and rejects absorbed heat to air passing through a high-temperature (HT) radiator 34 . When engine 10 is the powerplant of a motor vehicle such as a large truck, radiator 34 is typically a liquid-to-air heat exchanger. The cooling system also comprises a low-temperature (LT) radiator 36 that may also be a liquid-to-air heat exchanger.
Coolant circulates through various loops that include passageways in block 16 and/or head 18 but do not include either radiator 34 or 36 . Loops 38 , 40 , and 42 are examples of such loops. An expansion tank 44 can collect overflow coolant from various locations in the cooling system, such as those shown, and provide for return of coolant to a suction inlet 32 S of pump 32 .
The flow in any flow loop passing through HT radiator 34 leaves HT radiator 34 at a temperature T HTR .
Engine 10 also comprises an EGR system for recirculating some exhaust gas from exhaust system 22 in succession through a first heat exchanger 48 , sometimes called a high-temperature (HT) EGR cooler, and a second heat exchanger 50 , also sometimes called a low-temperature (LT) EGR cooler, to the mixer in intake system 20 for entrainment with the charge air flowing to cylinders 14 . An EGR valve 52 controls the recirculation flow. Although the recirculation flow path and the pierce points to intake system 20 and to exhaust system 22 are not specifically shown in FIG. 1 , the pierce point to exhaust system 22 can be upstream of high-pressure turbine 24 HPT and the pierce point to intake system 20 can be downstream of high-pressure compressor 24 HPC. The recirculation flow path may comprise EGR valve 52 , HT EGR cooler 48 and LT EGR cooler 50 in that order from the pierce point to exhaust system 22 to the pierce point to intake system 20 . The overflow coolant path from (LPCAC) 26 LP that is shown passing through EGR valve 52 passes through a passageway in the EGR valve body to provide some cooling for the EGR valve which happens to be close-coupled to an engine exhaust manifold.
Pump 32 pumps coolant in parallel paths through HT EGR cooler 48 , coolant passageways 28 , and coolant passageways 30 . Flows through those parallel paths confluently enter an inlet 54 of a temperature-controlled valve 56 , such as a thermostat, that comprises two outlets 58 , 60 . Outlet 58 is in fluid communication with the suction inlet 32 S of pump 32 , and outlet 60 is in fluid communication with an inlet 62 of HT radiator 34 . HT radiator 34 has an outlet 63 also in communication with suction inlet 32 S. Coolant for a heater core 61 that heats the interior of an occupant compartment in a motor vehicle that is powered by engine 10 is shown being supplied from the outlet of HT EGR cooler 48 , but could be supplied from any other source that provides suitably high temperature.
An outlet 32 P outlet of pump 32 is in fluid communication both with an inlet 64 A of a CCV valve 64 and with an inlet 66 A of a switch valve 66 . CCV valve 64 comprises an outlet 64 B that is in fluid communication with an inlet 68 of LT radiator 36 and an outlet 64 C that is in fluid communication both with an inlet 66 B of switch valve 66 and an inlet of low-pressure charge air cooler 26 LP. LT radiator 36 has an outlet 70 that is in fluid communication both with inlet 66 B of switch valve 66 and with the inlet of low-pressure charge air cooler 26 LP.
Switch valve 66 has an outlet 66 C that is in fluid communication with an inlet of LT EGR cooler 50 . Outlets of LT EGR cooler 50 and low-pressure charge air cooler 26 LP are in fluid communication with suction inlet 32 S of pump 32 .
Switch valve 66 is selectively operable to a first state in which inlet 66 A communicates with outlet 66 C while inlet 66 B is closed to inlet 66 A and outlet 66 C, and to a second state in which inlet 66 B communicates with outlet 66 C while inlet 66 A is closed to inlet 66 B and outlet 66 C.
Before engine 10 attains operating temperature, temperature-controlled valve 56 blocks flow of coolant from block 16 and head 18 to HT radiator 34 and returns the flow directly to suction inlet 32 S of pump 32 . When engine 10 attains operating temperature, valve 56 forces flow of coolant from block 16 and head 18 through HT radiator 34 before the flow returns to suction inlet 32 S.
Coolant leaving HT radiator 34 via outlet 63 flows to pump suction inlet 32 S, through pump 32 , to inlet 66 A of switch valve 66 and inlet 64 A of CCV valve 64 . While there may be some differences in actual coolant temperature at various points along this flow path, coolant temperature at any point may be considered to be T HTR , as marked in FIG. 1 . An orifice OR provides a proper flow rate for balancing flow along this flow path in this relation to other coolant system flows.
CCV valve 64 can apportion coolant entering inlet 64 A between two parallel branches from the respective outlets 64 B, 64 C. The branch from outlet 64 B contains LT radiator 36 and the other branch from outlet 64 C is a bypass around LT radiator 36 . CCV valve 64 controls the temperature of coolant flowing through LT EGR cooler 50 for managing exhaust gas condensation.
CCV valve 64 is controlled to apportion the flows through the respective branches as a function of certain variables related to air, coolant, and exhaust gas properties. The variables that are used may be measured in any suitably appropriate way such as by sensors (real and/or virtual) and/or estimated or inferred using suitable models. Any particular control strategy will depend on the particular engine and particular objective(s) to be achieved at various engine operating conditions. Different strategies may be used in different engines and to accomplish different control objectives. CCV valve 64 can function to apportion the branch flows such that 100% of the entering flow passes through one branch and 0% through the other, and vice versa. It can also divide the flows such that some percentage less than 100% of the entering flow passes through one branch and the remainder through the other branch.
When switch valve 66 is placed in its first state (inlet 66 A communicating with outlet 66 C while inlet 66 B is closed to inlet 66 A and outlet 66 C), the system of FIG. 1 functions in the following manner.
Coolant entering switch valve 66 from pump 32 has a temperature T HTR . The temperature of coolant entering the inlet of low-pressure charge air cooler 26 LP is designated T MIX and that temperature is controlled by CCV valve 64 .
If CCV valve 64 closes outlet 64 B to flow, the entire flow entering inlet 64 A exits via outlet 64 C and passes through low-pressure charge air cooler 26 LP, causing the temperature of coolant entering charge air cooler 26 LP to be the temperature T HTR .
The temperature of coolant coming from outlet 70 of LT radiator 36 is marked T LTR . The quantity of coolant heat that is being rejected at LT radiator 36 determines how much lower the temperature T LTR is than the temperature T HTR . If CCV valve 64 is closing outlet 64 C to flow, the entire flow entering inlet 64 A exits via outlet 64 B and passes through LT radiator 36 before entering low-pressure charge air cooler 26 LP, causing the temperature T MIX of coolant entering charge air cooler 26 LP to equal the temperature T LTR .
If CCV valve 64 is apportioning the entering flow between outlets 64 B and 64 C, one portion of the flow is cooled by LT radiator 36 while the remainder is not. In this instance the temperature T MIX of coolant entering charge air cooler 26 LP will be lower than the temperature T HTR but higher than the temperature T LTR , with the specific temperature being a function of the extent to which CCV valve 64 is apportioning the flow through the respective branches.
When switch valve 66 is placed in its second state in which inlet 66 B communicates with outlet 66 C while inlet 66 A is closed to inlet 66 B and outlet 66 C, coolant entering switch valve 66 has the same temperature T MIX as coolant entering low-pressure charge air cooler 26 LP. With the value of T MIX being controlled by CCV valve 64 , the temperature of coolant entering both charge air cooler 26 LP and LT EGR cooler 50 is controlled by controlling CCV valve 64 in the same manner as described above.
Placing switch valve 66 in its second state, allows switch valve 66 to concurrently control both EGR cooling and charge air cooling. When EGR needs less cooling, such as to mitigate EGR condensation, placing switch valve 66 in its first state allows coolant having temperature T HTR to pass through LT EGR cooler 50 for mitigating EGR condensation, while the temperature T MIX of coolant entering charge air cooler 26 LP can still be controlled by CCV valve 64 to cause the temperature of coolant passing through charge air cooler 26 LP to be lower than that of coolant passing through LT EGR cooler 50 continuing the greater cooling of charge air that increases charge air density, and hence improves performance of turbocharger 24 .
FIG. 1 shows HT EGR cooler 48 to be in parallel flow relationship to passageways 28 , 30 before the parallel flows merge to confluently pass through temperature-controlled valve 56 before returning either directly or through radiator 34 to suction inlet 32 S of pump 32 as determined by temperature of coolant leaving block 16 /head 18 (that temperature corresponding to engine operating temperature).
The flow from pump outlet 32 P through passageways 28 , 30 and either directly, or through HT radiator 34 , back to suction inlet 32 S may be considered a first flow loop.
The flow from pump outlet 32 P through HT EGR cooler 48 and either directly, or through HT radiator 34 , back to suction inlet 32 S as controlled by valve 56 , may be considered a second flow loop.
Flow from pump outlet 32 P to valves 64 , 66 , and subsequently as controlled by valves 64 , 66 before returning to suction inlet 32 S may be considered a third flow loop.
FIG. 2 shows an embodiment in which the same reference numerals designate the same elements shown and described in connection with FIG. 1 . FIG. 2 differs from FIG. 1 in that the flow to HT EGR cooler 48 has passed through engine passageways 28 , 30 rather than coming directly from pump outlet 32 P. Consequently, when engine 10 is running at operating temperature, hotter coolant is delivered to HT EGR cooler 48 than when coolant is supplied directly from pump outlet 32 P. Flow to CCV valve 64 and switch valve 66 continues to come directly from pump outlet 32 P. Coolant for heater core 61 is supplied from the outlets of engine passageways 28 , 30 .
FIG. 3 shows an embodiment in which the same reference numerals designate the same elements shown and described in connection with FIG. 1 . FIG. 3 differs from FIG. 1 in that the flows to HT EGR cooler 48 and to CCV valve 64 and switch valve 66 have passed through passageways 28 , 30 rather than coming directly from pump outlet 32 P. Consequently, when engine 10 is running at operating temperature, hotter coolant is delivered to HT EGR cooler 48 and to CCV valve 64 and switch valve 66 than when coolant is supplied directly from pump outlet 32 P. Coolant for heater core 61 is supplied from the outlets of engine passageways 28 , 30 .
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A first loop contains engine coolant passageways ( 28, 30 ) and a first radiator ( 34 ). A second loop contains a first EGR cooler ( 48 ). A third loop contains a second EGR cooler ( 50 ), a second radiator ( 36 ), a charge air cooler ( 26 LP), a first valve ( 66 ), and a second valve ( 64 ). Valve ( 64 ) apportions coolant flow entering an inlet ( 64 A) to parallel flow paths, one including second radiator ( 36 ) and the other being a bypass around radiator ( 36 ). The apportioned flows merge into confluent flow to both an inlet of charge air cooler ( 26 LP) and a first inlet ( 66 B) of valve ( 66 ). Valve ( 66 ) has an outlet ( 66 C) communicated to an inlet of second EGR cooler ( 50 ). The first condition of valve ( 66 ) closes a second inlet ( 66 A) to coolant flowing toward both the second inlet ( 66 A) and inlet ( 64 A) while opening inlet ( 66 B) to outlet ( 66 C). The second condition of valve ( 66 ) opens second inlet ( 66 A) to coolant flowing toward second inlet ( 66 A) and inlet ( 64 A) of the valve ( 64 ) while closing first inlet ( 66 B) of valve ( 66 ) to outlet ( 66 C) of valve ( 66 ).
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a vertical lift gate used to control access to certain areas, roadways and corrals. More specifically, this invention relates to an electrically or manually powered vertical lift gate which may be activated manually or through the use of remote controls.
[0002] The use of a vertical style lift gate has been found to be advantageous in many situations where swinging gates can not be used for a variety of reasons, such as the presence of cattle, trees, landscaping, buildings or other obstructions that prevent the swinging of a gate. When used in a ranch or farm type setting, a typical gate requires a rancher to pull up, stop their tractor or pickup, exit the vehicle, open the gate, drive the vehicle through, once again exit the vehicle and close the gate. From this it can be seen that it would be advantageous to provide a gate that could be operated from within the vehicle or by a device easily carried in the pocket or belt of a worker, thus allowing easy access to gate areas, minimizing the amount of time a gate is open which can prevent the unwanted escape of livestock or entrance of other unwanted animals or people and promote a safe and efficient workplace.
[0003] Further, it can be seen that it would be necessary for this gate to securely lock and close when in the closed position and to easily be unlocked and opened either remotely or manually.
[0004] From this it can be seen that it would be advantageous to provide a gate that lifts vertically rather than swinging side to side and lifts on a simple mechanism that is both inexpensive to build and install as well as simple to maintain.
SUMMARY OF THE INVENTION
[0005] It is the primary objective of the present invention to provide a method by which a fence gate can be opened to allow for the passage of people, livestock, or machinery from one side of a fence-line to the other.
[0006] It is an additional objective of the present invention to provide such a method which clears the gate from the fence opening by lifting it around a pivot point in a vertical fashion which allows it to operate in a smaller area than the conventional swinging gate.
[0007] It is a further objective of the present invention of providing a method of opening wide span gates in a manner that will allow for its effective opening and closing and which reduces the stresses placed on its pivot point due to the width of the span of the gate.
[0008] It is a further objective of the present invention to provide such a method of clearing a fence opening which can be adapted to use a variety of energy sources, from hand cranked to electrically driven, to raise and lower the pivotally mounted gate.
[0009] It is a still further objective of the present invention to provide such a method of opening gates that can use remote activation devices, much like those used in garage door opener applications, which will allow the user to control the position of the gate from a remote location such as the driver's seat of his vehicle.
[0010] These objectives are accomplished by the use of a steel framed gate that is pivotally mounted at one of its lower corners to a specifically designed inner fence post which is securely positioned in the proper location within the ground. This method of pivotally mounting the gate allows one end of it to be swung up and out of the way thereby effectively opening the fence gap and allowing passage from one side of the fence line to the other. Additionally, the positioning of the pivotal mount on one of the lower corners of the gate ensures that as it is pivoted around the mount to the fully upright position, the body of the fence will entirely clear the fence gap which in turn allows for the clear passage through the fence line.
[0011] Outside of the inner fence post, in relation to the gate, is located the primary post which provides the point of attachment for the winch and other components which are necessary for the operation of the invention. The primary post is significantly taller than the inner post and this additional height adds a degree of leverage to the lifting and lowering of the gate as the winch device is mounted on this post at a relatively high location in relation to the upper surface of the gate. The winch is connected to the upper surface of the gate by the winch cable which is attached to the far upper corner of the gate. This arrangement of the winch in relation to its point of attachment to the gate provides the necessary leverage to the lifting mechanism to ensure for the proper operation of the invention. The space between the primary post and the inner post is spanned by the gate mesh which closes off that space and ensures that nothing can pass through the fence line between these components of the invention.
[0012] Additionally, the primary post provides the point of attachment for the upper end of the gate spring which spans the distance between the primary post and the upper corner of the gate that is located directly above the pivotal mount of the gate to the inner post. The purpose of the gate spring is to keep a certain degree of pressure on the gate as it passes through its range of motion in the opening and closing process. This pressure ensures that these processes operate smoothly through all stages of the present invention's opening and closing actions.
[0013] On the opposite side of the fence opening from the inner post is located the outer post. The outer post defines the dimensions of the fence opening and provides the point of attachment for the outer end of the gate when it is in the closed position. The closing mechanism is made up of a gate catch which engages and guides the edge of the gate as it is lowered into the closed position and holds it securely once the closed position has been properly obtained. Conversely, the open ended design of the upper end of the gate catch ensures that it will not interfere with the lifting of the gate during the opening operations.
[0014] The manner in which the operator of the present invention raises and lowers the gate depends largely on the power source used to drive the winch. In its simplest form there is simply a crank handle attached to the winch which the operator rotates to raise or lower the gate. While this method is effective, it can be laborious and requires that the operator approach the winch to operate it which may involve exiting a vehicle. A second manner of winch operation is to use electricity provided by a battery or by live feed electrical wires. This resolves the laborious aspect of the hand operated winch as the operator only needs to engage a switch to raise or lower the gate. Finally, the electrically driven winch can also be fitted with a sensing device much like those used with garage door openers which allow the operator to raise and lower the gate from remote locations such as the driver's seat of their vehicle which makes the operation of the invention as simple as possible.
[0015] The present invention can also employ a specially designed gate latch which is used to lock the gate in a downward and closed manner when the operator chooses to close off the gate opening. The gate latch is made up of a plunger that is horizontally mounted at the upper outside corner of the gate in a manner that allows it to slide laterally in relation to the upper surface of the gate. Additionally, the latch assembly incorporates the use of a compressible spring that is mounted in conjunction with the plunger and operates on it to force it outward in relation to the gate. The tip of the plunger in its most outward orientation engages the catch housing which is fixedly attached to the outer post on the far side of the gate opening. This positioning of the plunger serves to lock the gate to the outer post in the closed position where it will remain until the plunger is disengaged from its position of contact with the catch housing.
[0016] The gate latch is disengaged from the closed position by an inward force (in relation to the body of the gate) being placed on the plunger by the movement of the attached winch cable. This inward force serves to compress the spring and retract the plunger from the contact with the catch housing. With the plunger disengaged, the winch cable is then free to lift the gate out of the gate opening as described above. Conversely, when the gate is lowered back into the closed position, the resulting removal of the weight of the gate off of the winch cable allows the latch spring to force the plunger back into contact with the catch funnel which again locks the gate into the closed position across the gate opening.
[0017] An additional method of constructing the gate hinge is also available which employs the use of a dual slatted inner post which contains a gap into which the hinge is built and into which the gate fits in both the open and closed positions. The inner post gate hinge provides a more secure mounting for the gate than that provided by the previous embodiment which in turn provides a more durable and effective mechanism by which the gate can be opened and closed in conjunction with the stated purpose of the present invention.
[0018] For a better understanding of the present invention reference should be made to the drawings and the description in which there are illustrated and described preferred embodiments of the present invention.
DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a front elevation view of the present invention which illustrates the manner in which it is employed in conjunction with a typical gate being used to close off a fence opening.
[0020] [0020]FIG. 2 is a front elevation view of the present invention which illustrates how the gate is pulled upward in a vertical manner to clear the fence opening to allow for the passage through the fence line.
[0021] [0021]FIG. 3 is a front elevation view of the gate hinge component of the present invention illustrating its general manner of construction.
[0022] [0022]FIG. 4 is a side elevation view of the gate hinge component of the present invention illustrating the manner in which the sleeve shoulder is employed to keep the gate at a specified distance from the fence posts which enables the gate to move freely within its designed parameters.
[0023] [0023]FIG. 5 is a front elevation view of the gate catch component of the present invention illustrating the manner in which it engages the leading portion of the gate as it drops into place to close the fence opening.
[0024] [0024]FIG. 6 is a side elevation view of the gate catch component of the present invention illustrating the manner in which the catch prongs are used to guide the leading portion of the gate as it drops into the closed position.
[0025] [0025]FIG. 7 is a front elevation view of an alternative embodiment of the present invention which illustrates the manner in which it is employed in conjunction with a typical gate being used to off close a fence opening.
[0026] [0026]FIG. 8 is a front elevation cut-away view of the double slat inner post component of an alternative embodiment the present invention illustrating the manner in which the gate fits within the inner post and the general manner of construction of the inner gate hinge.
[0027] [0027]FIG. 9 is a side elevation view of the double slat inner post component of an alternative embodiment of the present invention illustrating the manner in which the gate fits and is attached within the centrally located gap of the double slat inner post.
[0028] [0028]FIG. 10 is a close up side elevation view of the double slat inner post component of an alternative embodiment of the present invention illustrating the manner in which the gate fits and is attached within the centrally located gap of the double slat inner post.
[0029] [0029]FIG. 11 is a front elevation cut-away view of the connection of the gate to the inner gate hinge in the alternative embodiment of the present invention and details the hinge's manner of construction.
[0030] [0030]FIG. 12 is a side elevation cut-away view of the connection of the gate to the inner gate hinge in the alternative embodiment of the present invention and details the hinge's manner of construction.
[0031] [0031]FIG. 13 is a front elevation view of the gate latch assembly component of the alternative embodiment of the present invention illustrating the manner in which the plunger is used to engage the catch housing to lock the gate in a downward or closed orientation.
[0032] [0032]FIG. 14 is a front elevation view of the gate latch assembly component of the alternative embodiment of the present invention illustrating the manner in which the plunger is disengaged from its contact with the catch housing to release the gate and allow it to be drawn up to the open position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] Referring now to the drawings, and more specifically to FIGS. 1 and 2, the vertically opening gate apparatus 10 is made up of a gate 12 that is used to close a fence opening 64 of a typical fence 20 . Fence openings 64 are a common feature of almost every fence 20 in use throughout the world as they allow objects to pass from one side of the fence 20 to the other. Additionally, these fence openings 64 are closed off by the use of a swinging gate 12 which is pivotally mounted to the fence 20 on one side of the fence opening 64 and can therefore be swung open or closed to allow or restrict passage depending upon the desire of the user.
[0034] With the present invention, the fence opening 64 is defined by the positioning of the inner post 16 and the outer post 18 . The distance between is spanned by the gate 12 which is slightly shorter than the distance between the inner and outer posts, 16 and 18 . The gate 12 is typically made of a framework of horizontal gate rails 26 and vertical gate rails 28 which are fastened together in a manner that will restrict the passage of specified objects from one side of the fence 20 to the other and as a whole runs just above and parallel to the surface of the ground 24 . Additionally, the variance in the width of the gate 12 in relation to the fence opening allows the gate 12 to swing freely between the inner and outer posts, 16 and 18 , during normal operations and for each of the components to independently adjust to changing temperatures without effecting the performance of the invention as a whole.
[0035] The present invention also employs the use of a primary post 14 which is located on the opposite side of the inner post 16 in relation to the location of the gate 12 . Additionally, the primary post 14 is positioned so that the distance between ths primary post 14 and the inner post 16 is slightly more the distance between the bottom and top of the gate 12 . This positioning is important as it allows for the free movement of the gate 12 during opening and closing operations. The gap between the inner post 16 and the primary post 14 is closed off by the use of the gate mesh 22 which maintains the integrity of the fence 20 without interfering with the operation of the gate 12 .
[0036] The primary post 14 is implanted in the ground 24 in much the same manner as the inner and outer posts, 16 and 18 , but is significantly taller than the other two. This additional height of the primary post 14 is significant as it also provides the point of attachment for the winch 30 which is the component of the present invention that is directly responsible for opening and closing the gate 12 . The relatively high position of the winch 30 on the primary post 14 in relation to the inner post 16 is important as the angle created in the winch cable 44 , used to lift and drop the gate 12 , helps to create leverage which adds to the overall effectiveness of the winch 30 . Additionally, the winch 30 is also commonly fitted with an opener sensor 32 which can be used to allow a user to activate the present invention from a remote location such as the driver's seat of his vehicle or other equipment.
[0037] The opening and closing operations of the gate 12 are controlled through the winch 30 by the winch cable 44 which extends from the winch 30 to the far corner of the gate 12 where it is attached through the use of a gate bracket 36 . In the down or closed position, the front end of the gate 12 is engaged with the gate catch 40 located on the inner surface of the outer post 18 . The activation of the winch 30 draws the winch cable 44 in which in turn lifts the far end of the gate 12 out of the gate catch 40 and forces the gate 12 as a whole to pivot around the gate hinge 42 located at its lower inner corner on the lower portion of the inner post 16 . This pivoting action continues until the gate 12 obtains an orientation in which is upper edge is generally perpendicular to the inner surface of the primary post 14 . With the gate 12 in this upright position the fence opening 64 is clear and objects are left to freely pass from one side of the fence 20 to the other.
[0038] The primary post 14 also provides the point of attachment for the upper end of the gate spring 34 by the use of the upper spring mount 38 . Additionally, the lower end of the gate spring 34 is connected to the upper inside corner of the gate 12 through the use of a gate bracket 36 much like that used to attach the winch cable 44 . The purpose of the gate spring 34 is to place a degree of tension on the gate 12 in the opening and closing processes which ensures that the gate 12 will move easily and smoothly through its intended functions.
[0039] With reference to the function of the gate spring 34 , it is tensioned when the gate 12 is in its down position which has the effect of placing a force upon the inside upper corner of the gate 12 which would tend to help it open. Conversely, when the gate is open, the gate spring is tensioned in a manner which places a force on the inside upper corner of the gate 12 which would tend to help it return to the closed position. This transition in the force applied by the gate spring 34 is a function of the placement of its upper end on the primary post 14 . That is to say, the point of gate spring 34 attachment on the gate 12 moves through an arch during the opening and closing process with the apex of that arch being at its closest point to the upper spring mount 38 at the midway point between the gate 12 being fully open and fully closed. Any further movement away from this midway point in either direction tensions the gate spring 34 which therefore aids in the opening or closing process respectively.
[0040] The manner of construction of the gate hinge 42 component of the present invention is further detailed in FIGS. 3 and 4. The gate hinge 42 is the component of the invention which both attaches the gate 12 to the inner post 16 and allows it to pivot between the open and closed position which is the primary function of a gate 12 . The gate hinge 42 is made up of two primary components. The first of these is the hinge mount bracket 46 which is generally a section of V-shaped metal that fits over the corner of the inner post 16 . This is the point of attachment which fastens the gate 12 in the desired location within the invention. Additionally, the hinge mount bracket 46 has a perpendicularly extending hinge mount pin 48 from its outwardly oriented (in relation to the inner post 16 ) surface which allows for the mounting of the gate corner 52 to the hinge mount bracket 46 .
[0041] The second primary component of the gate hinge 42 is the gate corner 52 which serves to pivotally attach the gate 12 to the hinge mount bracket 46 . The gate corner 52 is generally a block which encloses the joint of the horizontal and vertical gate rails, 26 and 28 , and which has attached to its lower surface a pin sleeve 50 . The pin sleeve 50 is a tube-like apparatus which has an inside diameter that is slightly larger than the outside diameter of the hinge mount pin 48 . The connection is made by slipping the pin sleeve 50 over the hinge mount pin 48 and retaining it there in a manner that allows it to pivot freely around the hinge mount pin 48 . Thus, the gate hinge 42 attaches the gate 12 to the inner post 16 that allows it to pivot in its vertical axis.
[0042] Additionally, the pin sleeve 50 has a sleeve shoulder 51 which is simply a portion of the pin sleeve 50 that extends beyond the inner surface of the gate corner 52 in relation to the hinge mount bracket 46 . The purpose of the sleeve shoulder 51 is to provide a degree of separation between the gate 12 and the inner post 16 . This gap allows the gate 12 to pivot freely during the opening and closing operations without contacting the inner post 16 . Thus, the sleeve shoulder 51 allows the gate 12 to move freely without interference from the other components of the invention.
[0043] The manner of construction and the method of operation of the gate catch 40 are further detailed in FIGS. 5 an 6 . As previously stated, the gate catch 40 is attached to the inner surface of the outer post 18 in a position that ensures it will engage the gate 12 as it is lowered into the closed position. In furtherance of its purpose of directing and holding the closed gate 12 , the upper end of the gate catch 40 is equipped with a pair oppositely oriented diagonally extending catch prongs 54 which serve to direct a lowering gate 12 that is slightly offline into the centrally located catch channel 60 of the gate catch 40 . The catch channel 60 is enclosed by the catch sides 58 Which maintain the gate 12 within the gate catch 40 when it is closed. Finally, the downward gate travel 56 is effectively limited by the gate stop 62 which closes off the bottom of the gate catch 40 . Therefore, when the gate 12 is in its closed position it rests on the gate stop 62 between the catch sides 58 of the gate catch 40 which hold it in the proper location until the gate is opened at a later time.
[0044] An alternative embodiment of the present invention is also provided which employs a different method of pivotally attaching the gate 12 to the remaining components of the vertically opening gate apparatus 10 . This embodiment of the present invention is constructed in much the same fashion as the previous embodiment which is illustrated in FIG. 7 and therefore also operates in much the same manner. However, the alternative embodiment utilizes a double slat inner post 84 in place of the inner post 16 of the previous. Additionally, in conjunction with the double slat inner post 84 , the present embodiment uses an inner gate hinge 86 to pivotally attach the gate 12 within the fence opening 64 .
[0045] The general manner of construction of the double slat inner post 84 and the inner gate hinge 86 , as well as many other components of this embodiment of the invention, are further detailed in FIGS. 8, 9, 10 , 11 , and 12 . The double slat inner post 84 is made up of two parallel members, the inner and outer slats, 88 and 90 , which are separated by an interior gap 89 . The double slat inner post 84 also contains a downwardly extending post mount 92 which is used to anchor the double slat inner post 84 to the ground. This serves to orient the double slat inner post 84 in a vertical fashion which provides a solid base onto which the remaining components of this embodiment of the present invention can be attached.
[0046] The inner gate hinge 86 fits within the lower portion of the interior gap 89 between the inner and outer slats, 88 and 90 , and is itself made up of two parallel oriented hinge brackets 96 that are each separately mounted to the inside of the inner and outer slats, 88 and 90 . This method of construction allows the lower corner of the gate 12 to be placed between the hinge brackets 96 and pivotally positioned there by the use of the pivot bolt 94 which passes through this arrangement from the outside surface of one of the hinge brackets 96 to the outside surface of the other. This configuration provides a solid mounting for the gate 12 which allows it to freely pivot allowing it to swing open and closed as dictated by the design of this and other embodiments of the present invention.
[0047] This embodiment of the present invention also employs the use of gate spring 34 in much the same manner as the previous embodiment which is used to aid in the opening and closing processes of the gate 12 . The primary difference is that this embodiment uses an upper and lower spring brackets, 66 and 68 , which are located in slightly different positions on the components of the invention which enhances the overall performance of the gate spring 34 . Additionally, these FIGS. also illustrate the use of a plurality of fence bars 70 that are used to close off the space between the double slat inner post 84 and the primary post 14 as opposed to the gate mesh 22 that was used in the previous embodiment.
[0048] This embodiment of the present invention is also illustrated in FIGS. 13 and 14 using a gate latch assembly 74 which is employed to lock the gate 12 in the downward position in which the fence opening 64 is closed off. The gate latch assembly 74 is positioned on the upper corner of the body of the gate 12 in a location that allows it to interact with components positioned on the outer post 18 . The gate latch assembly 74 is operated by its connection with the winch cable 44 which is in turn connected to the winch 30 through the cable idler bracket 72 located about midway in the body of the gate 12 . The cable idler bracket 72 is equipped with a pair of cable idler wheels 98 which engage the winch cable 44 as it passes through the cable idler bracket 72 . The use of the cable idlers wheels 98 allows the direction of travel of the winch cable 44 to change from the diagonal orientation it assumes between the winch 30 and the cable idler bracket 72 to the horizontal orientation (in relation to the upper surface of the gate 12 ) it assumes between the cable idler bracket 72 and the gate latch assembly 74 . This system allows the winch cable 44 to be manipulated to operate the gate latch assembly 74 and to raise and lower the gate 12 in a smooth manner that allows the invention to operate as designed.
[0049] The gate latch assembly 74 is made up of a gate latch plunger 100 that is horizontally mounted at the upper corner of the gate 12 by the use of the two vertically oriented plunger mount tabs 102 located on the inner end of the gate latch plunger 100 on the upper surface of the gate 12 and also at its outer end by the vertical latch bracket 78 . The gate latch plunger 100 is also fitted with a latch spring 76 which encircles it between the plunger mounts tabs 102 and the spring stop 104 which, under normal circumstances, rests against the inner surface of the vertical latch bracket 78 .
[0050] The positioning of the latch spring 76 between the plunger mounts tabs 102 and the spring stop 104 places a load on the latch spring 76 which in turn operates to force the gate latch plunger 100 in an outward manner in relation to the upper surface of the gate 12 . In this orientation, the gate latch plunger 100 extends beyond the outward edge of the vertical latch bracket 78 . This allows it to engage the catch housing 80 which is a component of the gate catch 40 that extends above the catch funnel 82 used to guide the gate 12 into the proper position during the closing phase of the present invention's operations.
[0051] During gate 12 opening procedures, the winch cable 44 is retracted which in turn draws out the gate latch plunger 100 and compresses the latch spring 76 (a condition which is illustrated in FIG. 14). The compression of the latch spring 76 is accomplished because the spring stop 104 is pulled back with the gate latch plunger 100 which compresses the latch spring 76 against the plunger mounts tabs 102 . The resulting increase in the amount of load that is placed on the gate latch spring 76 ensures that when the tension of the winch cable 44 is released it will return to its extended position where it can engage the catch housing 80 to ensure that the gate 12 will remain in the desired closed position.
[0052] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A framed gate that is pivotally mounted at one of it's lower corners to a specially designed fence or base post securely positioned in the ground. The pivotal mounting of the gate allows one end of the gate to swinging up and out of the way thereby effectively opening a gap and allowing passage from one side of the fence line to the other. A primary post is provided outside of the inner fence post in relation to the gate. This post contains the necessary components for the lifting of the invention and may be either a manual winch device or a powered winch type device. Further, this device may be equipped with a remote control mechanism for remote operation of the gate. On the opposite side of the gate from the inner post is located the outer post which contains a catch mechanism to engage a locking mechanism on the gate to securely lock and hold the gate in a closed position. This mechanism is connected to the lifting mechanism whereby such that when the lifting is performed, the lock is automatically released.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This patent application is based on and entitled, under 35 USC 120, to the benefit of the filing date of U.S. provisional application 60/053,664 filed 24 Jul. 1997 by James F. McGuckin, Jr. and entitled “Minimal Access Breast Surgery Apparatus and Method”.
FIELD OF THE INVENTION
[0002] This invention relates to surgical apparatus and methods for obtaining a subcutaneous target mass having varied shape and dimension.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF THE PRIOR ART
[0003] Modern medical diagnostics increasingly rely on complex imaging technologies to identify abnormal conditions and/or masses within the human body. Such technologies as magnetic resonance imaging (MRI), ultrasonics, computerized axial tomography (CAT scan), and mammogram x-rays, aid medical personnel in the initial identification of areas within the body exhibiting potentially dangerous, abnormal biological activity. The beneficial aspect of these technologies is their ability to image biological structures interior to the human body, providing a non-invasive tool useful in facilitating preliminary diagnosis and treatment of detected anomalies.
[0004] Detected subcutaneous biological growths, masses, etc. once identified generally require complete surgical excision or at the very least an open biopsy procedure.
[0005] Small masses such as calcifications encountered in breast tissue are generally removed in their entirety. The process of excising the mass is an invasive process, performed either during exploratory surgery or utilizing specifically designed surgical apparatus. The retrieved specimen is subsequently pathologically analyzed to determine its biological properties, i.e. benign or malignant.
[0006] Several types of apparatus are known for use in removing portions of subcutaneous masses in breast tissue targeted by these imaging techniques. However, these apparatus generally either obtain only small tissue specimens from the main mass or cause significant surface scarring due to the size of the incision necessary to remove the mass with a safe resection margin.
[0007] One type of specimen retrieval is performed with needle aspiration devices. These devices have a needle with an end hole. The needle is advanced to a desired location where a sample specimen is obtained via suction. Size and quality of specimens obtained by these devices are often poor, requiring multiple sampling of each desired target mass. Moreover, tissue encountered along the path to the desired location is unavoidably removed. A hollow channel is created upon withdrawal of the device from the patient, thereby allowing “seeding” of the hollow channel removal tract with abnormal cells. Some needle systems utilize an enlarged needle end hole, creating a boring probe which obtains a greater portion of tissue. This lessens the likelihood that the specimen will be too small but increases the amount of surface scarring due to the larger size incision required.
[0008] The percutaneous incisions needed when multiple needle channels or large needle bore channels are used often result in significant scarring, dimpling and disfigurement of surface tissue.
[0009] Needle side cutting devices have a blade extending around the circumference of a hollow needle shaft. The shaft and blade are axially rotated around the skin entry site, allowing a larger overall specimen to be excised. Target tissue is sliced and a non-contiguous specimen is obtained due to the spiral blade path. While these needle side cutting devices facilitate capture of larger sample specimens, they require resection of a relatively large core of tissue between the incision and the specimen desired to be resected. Additionally, needle side cut devices result in irregularly shaped specimens and subcutaneous cavities having irregular and/or bleeding margins.
[0010] Hence, the known devices are particularly ill suited in retrieving tissue masses from the female breast, due to the interest in preserving cosmetic integrity of the surface tissue as well as the inability of the known devices to remove most masses/calcifications during a single application.
SUMMARY OF THE INVENTION
[0011] This invention provides surgical apparatus and methods where size and shape of subcutaneous tissue identified for excision is minimally dependent on dimensions of the percutaneous incision. The apparatus and methods have specific utility in breast surgery.
[0012] In one of its aspects this invention provides apparatus for excision of the subcutaneous target tissue mass through a cutaneous incision smaller than maximum transverse dimension of the tissue mass excised where the apparatus includes an axially elongated member including cutaneous tissue piercing means at one end and means connected to the elongated member and being radially expandable relative thereto for cutting a circumferential swath of radius greater than maximum transverse dimension of the elongated member and greater than maximum transverse cross-sectional dimension of the target tissue mass in order to separate the target tissue mass from surrounding tissue for excision thereof through the incision. The apparatus may further include an expandable aseptic shield concentric with the elongated member and axially slidably advanceable over the cutting means when in the radially expanded configuration, to collectibly bag the target tissue mass detached from the patient by the cut circumferential swath, for aseptic removal in an axial direction together with the elongated member through the incision resulting from entry of the cutaneous tissue piercing means.
[0013] The apparatus may yet further include a sheath which is axially slidably concentric with the elongated member and connected to first ends of the cutting means for expanding the cutting means from generally linear and axial orientation to a curved basket-like orientation by axial movement relative to the elongated member.
[0014] In yet another of its aspects the invention provides apparatus for excision of a sub-cutaneous target tissue mass through a cutaneous incision smaller than maximum transverse dimension of the tissue mass excised where the apparatus includes an axially elongated member through which cutaneous tissue piercing means may be extended to emerge at one end thereof. The apparatus further includes means insertable through the elongated member which is radially expandable relative to the elongated member for cutting a conical swath having base radius greater than maximum transverse dimension of the elongated member and greater than maximum transverse cross-sectional dimension of the target tissue mass, for separating the target tissue mass from surrounding tissue for removal thereof through the incision. In this embodiment of the invention the apparatus further preferably includes expandable aseptic shield means insertable through the elongated member and advanceable over the path of the cutting means to radially expand and collectibly bag the tissue mass detached from a patient by the conical swath cutting for aseptic removal in an axial direction through the elongated member and the incision resulting from entry of the cutaneous tissue piercing means.
[0015] In one of its aspects this invention preferably provides such apparatus having a piercing segment for penetrating a percutaneous entrance incision. The forward edge of the piercing segment preferably separates breast tissue in the path of the target tissue to be excised. The piercing segment preferably passes through the specimen to be excised, delivering an associated preferably circular array of preferably highly flexible cutting blades to the interior identified subcutaneous breast growth.
[0016] The circular array of preferably flexible cutting blades is preferably radially expanded by action of an attached actuating shaft. The blades radially expand to preferably cut by electro-cauterizing the breast tissue as they rotate around a defined periphery. The blades preferably outwardly expand to envelope the target tissue specimen and axially rotate to separate the target tissue growth from surrounding breast tissue. The target tissue growth is excised from surrounding breast tissue outisde the periphery of the circular blade path and is preferably secured by a snaring membrane placed riding over the circular array of flexible cutting blades.
[0017] The membrane is preferably secured over the blade array through an integral drawstring assembly contracting the mouth of the snaring membrane. The membrane-encased blade array is preferably drawn into a recovery sheath and compressed for aseptic removal from the excision site.
[0018] In a method aspect this invention removes subcutaneous breast growths. A percutaneous surface incision is prepared for reception of surgical apparatus. Through use of suitable medical imaging technologies, the cutting apparatus device is guided to the area of the target subcutaneous breast growth while preferably maintaining a fixed subcutaneous reference point. A circular array of blades is then preferably radially expanded, preferably forming a cutting basket having dimensions larger than the target subcutaneous breast growth. Radial expansion and rotation of the electro-cauterizing blades separates the targeted growth from surrounding tissue. A snaring membrane advances over the blade array and is secured by an integral drawstring assembly. A recovery sheath compresses the membrane, encasing the target growth as it is withdrawn from the subcutaneous breast cavity. As a result, a growth which is large relative to the entrance incision is excised. In another of its method aspects this invention provides a procedure for excision of a sub-cutaneous target tissue mass through a cutaneous incision which is smaller than maximum transverse dimension of the target tissue mass to be excised where the procedure includes an advancing tissue piercing means towards a patient to create an incision in the patient's skin, slidably advancing cutting means through the incision and into sub-cutaneous tissue until in position to radially expand and cut a circumferential swath around the target tissue mass larger than the incision, cutting a circumferential swatch around the target tissue mass thereby separating the target mass from the surrounding tissue, slidably advancing flexible aseptic containment means over the separated target tissue mass to a position of closure about the target tissue mass and withdrawing the flexible aseptic containment means, with the target tissue mass aseptically contained therewithin, through the incision. The method may further include collapsing the cutting means after cutting the swath.
[0019] In yet another of its method aspects, this invention provides a procedure for excision of sub-cutaneous target tissue mass through a cutaneous incision smaller than maximum transverse dimension of the target tissue mass to be excised where the procedure includes advancing tissue piercing means towards the patient to create an incision in the patient's skin, slidably advancing cutting means through the incision and into sub-cutaneous tissue until in position to gradually radially expand and cut a conical swath about the target tissue mass larger than the incision thereby separating the target tissue mass from the surrounding tissue, slidably advancing flexible aseptic containment means over the separated target tissue mass to a position of closure around the target tissue mass and withdrawing the flexible aseptic containment means with the target tissue mass aseptically contained therewithin through the incision. The invention in this aspect preferably further includes radially inwardly collapsing the cutting means, which is preferably wire, after cutting the conical swath and may yet further include radially inwardly cutting tissue along the base of said cone by a passage of the cutting wire therethrough and thereafter closing flexible aseptic containment means over about the periphery of the cone and the target tissue mass contained therewithin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a side view one embodiment of apparatus manifesting aspects of the invention with the cutting blades in radially expanded condition.
[0021] FIG. 2 is a side view of the surgical-apparatus illustrated in FIG. 1 of the cutting blades in their non-expanded condition.
[0022] FIG. 3 is a front view of a modified version of the apparatus illustrated in FIGS. 1 and 2 with the cutting blades in a non-expanded condition as illustrated in FIG. 2 .
[0023] FIG. 4 is a front view of a modified version of the apparatus illustrated in FIGS. 1 through 3 with the cutting blades in their radially expanded condition as illustrated generally in FIG. 1 .
[0024] FIG. 5 is a broken schematic partially sectioned view of female breast tissue with the apparatus illustrated in FIGS. 1 through 4 in position within the breast in the process of removing a target tissue mass from the breast with the target tissue mass encased within an aseptic shield portion of the apparatus.
[0025] FIG. 6 is a side view of a portion of apparatus according one preferred embodiment of the invention shown in the course of practicing a preferred method aspect of the invention.
[0026] FIG. 7 is a side view of a part of the apparatus illustrated in FIG. 6 showing additional parts of one preferred apparatus embodiment of the invention in the course of practicing the inventive method.
[0027] FIG. 8 is a side view of the apparatus illustrated in FIG. 7 showing the support struts deployed.
[0028] FIG. 9 is a side view of the preferred embodiment of the apparatus showing the struts deploying about a percutaneous growth.
[0029] FIG. 10 is a side view of the preferred embodiment of the apparatus showing advancement of the cutting wire along a strut margin.
[0030] FIG. 11 is a side view of the apparatus shown in FIG. 10 with the cutting wire fully deployed.
[0031] FIG. 12 is a side view of the preferred embodiment of the apparatus depicting a new cutting wire retraction.
[0032] FIG. 13 is a side view of the preferred embodiment of the apparatus showing advancement of the bagging structure.
[0033] FIG. 14 is a side view of the preferred embodiment with tissue containment bagging completed.
[0034] FIG. 15 is a side view of the preferred embodiment of the apparatus showing the containment sheath deploying.
[0035] FIG. 16 is a side view of the preferred embodiment of the apparatus showing the containment sheath normally deployed.
[0036] FIG. 17 is an isometric view of the apparatus shown in FIG. 16 .
[0037] FIG. 18 is a broken view of the tissue containment bag showning the drawstring tissue.
[0038] FIG. 19 is a side view similar to FIG. 16 but showing the containment sheath fully deployed.
[0039] FIG. 20 is a side view similar to FIG. 19 but showing the containment sheath being withdrawn.
[0040] FIG. 21 is a side view similar to FIG. 19 showing optional use of a medicament bag and a radiological marker FIG. 22 is a side view similar to FIG. 19 showing optional use of liquid medication supported in part by the containment sheath.
[0041] FIG. 23 is an elevation of a support member.
[0042] FIG. 24 depicts the female breast and illustrated the incision resulting from practice of the method.
[0043] FIG. 25 is partial end elevation taken looking from the right in FIG. 8 .
[0044] FIG. 26 is partial end elevation taken looking from the right in FIG. 10 .
[0045] FIG. 27 is partial end elevation taken looking from the right in FIG. 16 .
[0046] FIG. 28 is a side elevation of a second preferred embodiment of apparatus embodying the invention with hook and rod structure facilitating simultaneous performance of the cutting and bagging steps.
[0047] FIG. 29 is a partially sectioned side elevation of the embodiment of apparatus illustrated in FIG. 28 prior to deployment of the hook and rod structure facilitating simultaneous performance of the cutting and bagging steps.
[0048] FIG. 30 is a partially sectioned side elevation of the embodiment of apparatus illustrated in FIG. 28 showing deployment of the hook and rod structure facilitating simultaneous performance of the cutting and bagging steps.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0049] This invention provides surgical apparatus and methods for excision of percutaneous breast tissue. The apparatus has the capability to pass through an incision substantially smaller than the maximum percutaneous target specimen dimension occupying an excision site.
[0050] In one embodiment the surgical apparatus preferably cuts the target tissue with an electro-cauterizing, circular array of flexible cutting blades, preferably collecting the specimen within the periphery of an expandable blade path; thus the complete growth is preferably obtained in a single procedure. The tissue is preferably returned as a complete specimen or, alternatively, in segments within a snaring membrane. A recovery sheath is preferably positioned to further encase and compress the blade array upon contraction.
[0051] Referring to FIG. 1 , the illustrated embodiment of surgical apparatus 10 includes an inner rotatable shaft 20 , a tubular recovery sheath 25 , a snaring membrane 30 , a circular array of radially flexible and expandable cutting blades generally designated 50 , a membrane drawstring 80 , a membrane mouth section 27 of recovery sheath 25 , a power source 15 and a tissue piercing member 65 .
[0052] Membrane 30 preferably has an inner surface 32 coaxially parallel with shaft 20 , and an outer surface 34 . Inner surface 32 of membrane 30 preferably slidably facingly contacts the outside surface 22 of shaft 20 . Membrane 30 is adjustably positioned in either the distal or proximate direction through the proximate end of shaft 20 .
[0053] Tubular recovery sheath 25 preferably includes a distal pleated mouth section 27 , an outer surface 45 , and an inner surface 60 facingly coaxially contacting membrane 30 . Inner surface 60 slidably engages outer surface 34 of membrane 30 . Shaft 20 defines a rotational axis 12 .
[0054] Shaft 20 rotates as denoted by arrow 12 . Rotatable shaft 20 of surgical apparatus 10 is preferably rotated manually, through mechanical hand control. However, shaft 20 may be operably linked with an electrical motor, not shown, which may be driven by power source 15 .
[0055] Circular cutting blade 50 includes individual flexible blades 55 which are preferably anchored between piercing member 65 and proximate end of shaft 20 . Blades 55 are preferably electro-cauterizing, heated by electrical power source 15 .
[0056] The materials utilized to construct surgical apparatus 10 are preferably radiopaque to be visible using modern medical imaging systems.
[0057] Referring to FIG. 2 , surgical apparatus 10 is shown with individual flexible blades 55 in their non-expandable, tissue insertion orientation. In this insertion orientation the blades are parallel with and of slightly smaller diameter than tubular recovery sheath 25 . Tubular recovery sheath 25 includes a snaring membrane 30 having a mouth section 27 and a drawstring 80 , for drawing membrane 30 closed once it has been opened. Drawstring 80 is positioned along the distal margin of mouth section 27 .
[0058] Mouth section 27 of membrane 30 expands outwardly in response to pulling of a polyvinyl tab or ripcord upon reaching the excision site. The polyvinyl tab or ripcord is preferably at the end of shaft 20 to the right, which is not shown in the drawing. The polyvinyl tab or ripcord is not visible in the drawing.
[0059] Recovery sheath 25 is preferably advanced over circular array of cutting blades 50 and preferably secured in place around the cutting blades and the excised specimen by pulling the drawstring towards the proximate end of shaft 20 .
[0060] Referring now to FIG. 3 , piercing segment 65 is formed to separate subcutaneous tissue in the path between the surface incision and the growth.
[0061] FIG. 3 and FIG. 4 show a modification of the embodiment of surgical apparatus 10 illustrated in FIGS. 1 and 2 . In the modification illustrated in FIGS. 3 and 4 , shaft 20 includes an interior channel 21 extending forwardly through the center of the cutting blade circular array 50 and connecting with piercing membrane 65 . A shaft stem section which is not shown connects to a dye port 70 in piercing member 65 for optional delivery of marking fluid to subcutaneous areas. Dye port 70 enables operators of apparatus 10 to deliver marking substances to the subcutaneous excision site. Alternatively, a titanium clip can be ejected from a clip fastening surface 75 for marking excision sites for future medical imaging analysis.
[0062] As shown in FIG. 4 , the circular array 50 of cutting blades 55 expands radially upon relative moment of shaft 20 in the direction of piercing member 65 , defining a cutting orientation. Flexible cutting blades 55 are preferably electro-cauterizing, cutting as they outwardly expand and as they rotate after radially outward expansion. Upon rotation of flexible cutting blades 55 in the direction indicated by arrow A in FIG. 4 , the target tissue growth is separated from the surrounding subcutaneous breast tissue and remains within the periphery of the circular blade path.
[0063] As variations, the circular array of flexible cutting blades 50 may employ radially expandable ultrasonic cutting means, referred to as “harmonic scalpels”, or laser cutting means.
[0064] The method of excising subcutaneous breast target tissue growths is shown in FIG. 5 . In FIG. 5 the edges of a surgical site where a growth has been removed is indicated as 100 ; removal of the growth has created subcutaneous cavity 105 . As shown, subcutaneous cavity 105 is separated from a surface incision 126 by an excision distance 95 .
[0065] In preparation for removing the subcutaneous breast tissue growth, percutaneous tissue is cut to produce an incision 126 . A piercing member 65 of surgical apparatus 10 is placed at incision 126 . An excision path is created by forcing piercing member 65 through the subcutaneous breast tissue between the percutaneous incision 126 and the identified target tissue growth. The target tissue growth is the desired excision site which is visualized via a medical imaging system such as ultrasound or mammography. The tip of surgical apparatus 10 is advanced until the piercing segment passes through the growth to be excised.
[0066] Once apparatus 10 is properly positioned relative to the target tissue mass as indicated by the medical imaging system, the proximate end of shaft 20 is urged towards piercing member 65 . Flexible cutting blades 55 radially expand to define subcutaneous margin 100 . The array of flexible cutting blades 50 is then rotated about the shaft axis as indicated by arrow 12 , separating the target tissue growth along margin 100 .
[0067] Membrane 30 is then advanced over the circular array of cutting blades 50 and secured by pulling integral drawstring 80 to the right in FIG. 5 towards the end of shaft 20 . Drawstring 80 secures the distal margin of membrane 30 . The mouth 27 of sheath 25 is expanded by the polyvinyl pull tab when drawn towards the end of shaft 20 .
[0068] Circular array of cutting blades 55 , now encased by membrane 30 , is drawn into the mouth of snaring sheath 25 and removed from subcutaneous cavity 105 .
[0069] In the preferred embodiment shown in FIG. 6 , a plurality of guide struts generally designated 150 are advanced through a skin surface incision 126 and past a target tissue mass 115 via a tubular housing defining an extrication channel 26 . As shown in FIGS. 7 and 8 , guide struts 150 are inserted through surface incision 126 and moved to a position to define a conically shaped desired excision margin 100 respecting the target tissue mass 115 , shown in FIG. 11 . As shown in FIGS. 8 through 10 , the extension and configuration of struts 150 from surface incision 126 past target mass 115 creates a gradually expanding subcutaneous retrieval path referred to as a conical penumbra 95 .
[0070] As shown in FIGS. 11 through 13 , an electro-cauterizing cutting snare 155 is advanced along guide struts 150 , creating a conically shaped excision margin.
[0071] Referring to FIG. 14 , the cutting snare 155 is advanced beyond the length of the guide struts 150 to where cutting snare 155 is drawn closed by pulling an integral drawstring 160 towards the exterior of the skin. As shown in FIGS. 15 through 17 , mouth 27 of sheath 25 is advanced along the defined extrication channel 26 and expanded by pulling the polyvinyl pull tab which is not shown. As shown in FIGS. 18 through 24 , guide struts 150 are enveloped by snaring sheath 25 and may be removed from subcutaneous cavity through extrication channel 26 .
[0072] In one preferred practice of the invention as depicted in FIGS. 6 through 27 and using the apparatus shown therein, apparatus 200 includes a support conduit designated generally 202 and axially elongating skin cutting means 204 having a cutting blade 205 which is insertable through support conduit 202 as illustrated generally in FIG. 6 . Skin cutting means 204 and particularly cutting blade 205 to make a suitable incision in the skin, preferably in the human breast designated generally 246 in FIG. 24 where the skin is designated 224 in the drawing figures including FIG. 6 and FIG. 24 . The incision is made to provide access to a target tissue mass designated generally 228 in the drawings which has been previously identified preferably using x-ray mammographic techniques as being dangerous and hence to be removed.
[0073] Once a skin incision, designated generally 248 in the drawings, has been made by skin cutting means 204 and appropriate use of cutting blade 205 thereof, skin cutting means 204 is preferably withdrawn axially through support conduit 202 , moving to the left in FIG. 6 , and support means designated generally 207 and having a plurality of support members designated generally 206 is inserted axially through support conduit 202 and into the sub-cutaneous tissue 226 of the breast as indicated generally in FIG. 7 , with the direction of travel of support means 207 indicated generally by arrow A in FIG. 7 .
[0074] As support members 206 of support means 207 are inserted into the sub-cutaneous tissue 226 , support members expand 206 radially due to influence of resilient spring means 210 , illustrated in dotted lines in FIG. 8 and forming a portion of support means 207 to a position where support members 206 define a conical penumbra enveloping target tissue mass 228 . The conical penumbra 208 defines planes of incision for removal of target tissue mass 228 and a medically advisable amount of surrounding sub-cutaneous healthy tissue 226 .
[0075] As support members 206 radially diverge one from another due to the influence of resilient spring means 210 , remote tips 209 of support members 206 define a circle which in turn defines the base of conical penumbra 208 . Remaining, proximate ends of support members 206 are pivotally connected to a supporting shaft, not numbered in the drawings, for pivoting rotation thereabout in response to spring 210 .
[0076] Once support members 206 have been deployed, into the position illustrated in FIG. 8 , the target tissue mass is well within the conical penumbra defined by support members 206 .
[0077] A pair of tissue cutting wire loops 214 are positioned about the bases of support members 206 , as illustrated generally in FIG. 9 , and are supported by and emerge from respective support catheters 212 , also illustrated in FIG. 9 . Support catheters 212 are sufficiently rigid that when force is applied in the axial direction to support catheters 212 is indicated by arrows B and B′ in FIG. 9 , support catheters 212 move to the right in FIG. 9 advancing tissue cutting wire loops 214 along the outer periphery of support members 204 as depicted generally in FIG. 10 .
[0078] As support catheters 212 are moved to the right in FIGS. 9 and 10 , additional lengths of tissue cutting wires 214 is supplied through support catheters 212 so that tissue cutting wires 214 , which are in the form of loops about the exterior surfaces of support members 206 as illustrated in FIG. 10 , can enlarge as the circumference of the conical penumbra, measured about the slant surface of the conical penumbra defined by support members 206 as illustrated in FIG. 10 , increases.
[0079] Support catheters 212 are urged to the right in FIG. 10 until tissue cutting wire loops 214 pass the remote tips 209 of support members 206 and define a pair of essentially coincident and in any event concentric circles forming the base of conical penumbra 208 .
[0080] Once tissue cutting wire loops 214 have reached this position due to movement of support catheters 212 , the wire forming tissue cutting wire loops 214 are drawn to the left, through respective support catheters 212 . This causes the respective tissue cutting wire loops 214 each to cinch together as the wires are withdrawn as indicated generally by arrows C, C′ in FIG. 11 . As the tissue cutting wires are drawn to the left in FIG. 11 through respective support catheters 212 , the wire loops each cinch together thereby cutting circular incisions through the sub-cutaneous tissue; this action is illustrated generally in FIG. 11 where the respective tissue cutting wire loops are shown partially, but not completely, cinched. Two wire loops are preferable, for symmetrical application of force.
[0081] Once tissue cutting wire loops 214 have been completely cinched and the wires withdrawn to the position illustrated in FIG. 12 by continually drawing the respective tissue cutting wires 214 in the directions indicated by arrows D, D′ in FIG. 12 , the conical penumbra 208 defines planes of incision created by action of tissue cutting wire loops 214 where those planes of incision are shown in dotted lines in FIG. 12 . Note that two dotted lines are shown at the extreme right of FIG. 12 to indicate that two circular planar incisions created by action of respective tissue cutting wire loops 214 . Desirably, these two circular planar incisions are essentially congruent one with another.
[0082] Once tissue cutting wire loops 214 have been completely withdrawn into the position illustrated in FIG. 12 , a suitable tissue containment bag structure 216 is advanced outwardly of support conduit 202 , around the outer periphery of support means 207 and particularly support members 206 . Tissue containment bag 216 preferably has a pair of drawstrings 218 , which may be metal, suture material, suitable plastic monofilaments and the like, which are sewn or threaded into tissue containment bag 216 proximate the vertical right-hand margin thereof appearing in FIG. 13 . Drawstrings 218 have extremity portions 219 illustrated in FIG. 13 .
[0083] Once tissue containment bag 216 has been advanced so that its margin 217 has traveled inwardly with respect to the breast past the remote tips 209 of members 206 , to the position generally corresponding to the base of conical penumbra 208 , drawstring extremities 219 are pulled to the right in FIGS. 13 and 14 , thereby causing looped drawstrings 218 , 218 ′ to close margin 217 of bag 216 , causing margin 217 to circularly gather as shown in FIG. 14 .
[0084] Once margin 217 of bag 216 has been circularly gathered thereby effectively closing bag 216 about the target tissue mass 228 of interest, an expandable sheath 230 is advanced through the interior of support conduit 202 about tissue containment bag 216 with expandable sheath 230 moving in the direction indicated by arrow F in FIG. 15 . Expandable sheath 230 has a pleated expandable portion 231 , which is resilient and seeks to expand radially outwardly to relieve internal stresses such that upon expandable portion 231 reaching terminus 203 of support conduit 202 which is within sub-cutaneous tissue 226 , expandable portion 231 expands radially into the configuration illustrated generally in FIG. 16 . Expandable portion 231 of sheath 230 is preferably pleated, as depicted in FIG. 17 .
[0085] Expandable sheath 230 and particularly expandable portion 231 thereof provides support in the form of radially inwardly directed force on tissue containment bag 216 as bag 216 with target tissue mass 228 enveloped therein is pulled to the left in FIGS. 16, 19 and 20 as indicated generally by arrows G in FIG. 19 and arrow H in FIG. 20 . The radially inward force provided on tissue containment bag 216 and target tissue mass 228 contained therein by expandable sheath 230 , as tissue containment bag 216 is pulled to the left in FIG. 19 , compresses tissue mass 228 into a smaller volume and essentially squashes tissue mass 228 into a longitudinally elongated form for passage through support conduit 202 . Application of the radial force to tissue mass 228 reduces the transverse cross-sectional dimension of tissue mass 228 to at least the diameter of support conduit 202 as tissue containment bag 216 is drawn through the funnel-shaped expandable portion 231 of sheath 230 and into the interior of support conduit 202 .
[0086] Once bag 216 and tissue mass 228 contained therein have been removed from the sub-cutaneous tissue, expandable sheath 230 may be removed by pulling it in the direction indicated by arrow H in FIG. 20 .
[0087] Optionally, while expandable sheath 230 is in position and perhaps only part way removed from the resected area of interest, a medicament bag 232 may be inserted into the resected area through the interior of support conduit 202 and through expandable sheath 230 , as indicated in FIG. 21 . This may provide means for supplying radioactive gas to provide radiation therapy to the resected area. Additionally, a radiographic marker depicted as 236 may be implanted into the resected area of interest, using the balloon or otherwise while expandable sheath 230 remains in the area of the resection. As an additional option while expandable sheath remains in position thereby maintaining a void in the resected area of the sub-cutaneous tissue, liquid medication indicated schematically as 234 in FIG. 22 may be supplied to the resected area. In such case expandable sheath maintaining the resected tissue in a spaced-apart condition facilitates application of the liquid medication to all parts of the resected volume.
[0088] Utilizing the method and apparatus as described hereinabove results in a small, tunnel like incision approaching the skin of the breast with a larger, resected mass being removed therefrom; the resulting internal incision is depicted 244 in FIG. 24 .
[0089] Support members 206 preferably have metallic tips to provide radiopaque characteristics as indicated by 230 in FIG. 23 and may also have metallic or other radiopaque marker bands indicated as 248 in FIG. 23 . Central portions 242 of support members 206 are preferably radiolucent as indicated by the stippling in FIG. 23 .
[0090] In FIGS. 28 thorugh 30 the curring wire and bag are connected by hook and rod structure as illustrated.
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A surgical apparatus for cutting a tissue mass comprising an elongated housing having a distal portion, a rotatable shaft positioned in the elongated housing, and a plurality of flexible electrocautery cutting blades extending from the housing, wherein the plurality of cutting blades are radially expandable from a first position defining a first diameter to a second larger diameter and the blades are rotatable and transmit electrical energy to cut the tissue mass.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 09/942,400 filed 29 Aug. 2001 now U.S. Pat. No. 6,863,159.
BACKGROUND
1. Field of the Invention
The invention relates to a lifting platform and more particularly to a vehicle lifting platform having a flexible traction cable coupling an electric motor to support arms.
2. Background Discussion
Conventional lifting platforms for motor vehicles generally function according to the lifting strut principle, the lifting shear principle or the toothed rack or jack screw principle. Even though such lifting platforms fully satisfy the operational and safety technical requirements, the manufacturing costs are substantial, which are caused by the technically complex lifting systems.
Accordingly, there is a need for a vehicle lifting platform with reduced complexity and manufacturing costs. The present invention satisfies these needs and provides related advantages as well.
SUMMARY OF THE INVENTION
It is a primary purpose of the invention to provide a technically simple lifting platform for vehicles which requires little space, can be produced at low cost, can be operated with little maintenance, and at the same time fully satisfies the prevailing safety requirements.
According to the invention these purposes are achieved by providing the transmission of the lifting system with at least one flexible traction cable coupled to a rotating member disposed at the upper end of the column and to the support arm. Suitable traction cables may be steel cables, belts, link chains and the like, all of which are commonly available and can be purchased at low cost in a multitude of embodiments and thicknesses. The same applies to the other components of the lifting system.
To enable the utilization of small-sized electric motors it is efficient to provide a reduction gear between the motor shaft and the rotating member for the traction cable, the reduction gear having simple pairs of gears or a chain drive.
For single-track vehicles, such as motorcycles, motor-scooters or the like, the lifting platform according to the invention may have a single column design and, if required, may be provided with a chassis for a mobile application. In this case, it is efficient to arrange the prime mover and the transmission elements in a box-shaped closed container, below or adjacent to the support arm, and to provide an access ramp for moving the vehicle to be lifted in its lifting position on at least one side of the container. For light-weight two-track vehicles, for example, passenger cars, a correspondingly larger dimension single-column lifting platform having the lifting system according to the invention may be used.
A lifting platform according to the invention having a two-column design is characterized in that a separate traction cable is provided for each column, respectively, in which case, when only one single prime mover is used. The torque of the prime mover is uniformly distributed to the driving members of the two traction cables to apply uniform traction forces to the respective support arms and to secure their synchronism. This torque branching is realised in a simple manner by providing a shaft extending between the columns and being driven by a driving member, for example, a sprocket wheel, coupled to the prime mover either directly or via a gear train. To ensure a sufficient free space for the vehicles, the shaft may either be provided on upper extensions of the two columns or at the lower column end, if required on or below the floor level. The same applies to the prime mover which may, together with its gear elements, either be provided at the upper end of a column or at its lower part.
An efficient further development of the invention is characterized in that the prime mover itself or an auxiliary drive may also be operated manually. This allows a lifted vehicle to be lowered manually in case of a defect of the motor-driven lifting system.
According to another embodiment of the invention, brake means are provided for each support arm to be automatically activated to stop the support arms when a critical operating state occurs. An example of this is in case of a breakage of the traction cable or in case of excessive lowering speed.
An additional synchronism control may also be provided which may, for example, effect an emergency stop. The emergency stop may be initiated when the two support arms are moved with different speeds, are positioned at different heights or both.
The so called pulley principle may be applied to the lifting system according to the invention. The traction cable is guided on a relay member provided on the support arm, running on a roller or a sprocket wheel provided at the upper end of the column and being wound up on a driven drum or the like disposed at the lower end of the column. Aside from that the utilization of a closed-loop chain as a traction element is possible.
BRIEF DESCRIPTION OF THE DRAWING
The objects, advantages and features of the invention will be more clearly understood from the following detailed description, when read in conjunction with the accompanying drawing, in which:
FIG. 1 is a schematic front view of a two-column lifting platform;
FIG. 2 is a schematic front view of another embodiment of the lifting platform; and
FIG. 3 is a schematic front view of an underfloor lifting platform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The two-column lifting platform according to FIG. 1 is designed for two-track vehicles, particularly passenger cars, and comprises two columns, 1 a and 1 b , which are fixedly anchored in floor foundation 3 with associated bases 2 a and 2 b . On each of columns 1 a and 1 b is a horizontal support arm, 4 a and 4 b , respectively, arranged so as to be vertically shiftable. Each of support arms 4 a and 4 b is extensible in a telescope-like manner and each is provided with a support 5 a and 5 b respectively, at its end. Each of the support arms is attached to a vertical guide, 6 a and 6 b , respectively, at its end which at least partly encloses the respective columns 1 a and 1 b in the illustrated embodiment. The length of guides 6 a and 6 b ensures a tilt-free support of the support arms even with a vehicle driven on, as well as ensuring their free movement.
On each of columns 1 a and 1 b, a stable elongation beam 7 a and 7 b, respectively, is provided comprising upper bearing 8 a and 8 b, respectively, for transverse shaft 9 provided with a sprocket wheel on its right end according to FIG. 1 . In the upper end portion of the embodiment in FIG. 1 , on right elongation beam 7 b, a prime mover in the shape of an electric motor 11 is installed which rotates transverse shaft 9 by means of sprocket wheel 12 and a closed-loop chain 13 running on two sprocket wheels 10 and 12 . Traction cables 15 a and 15 b, which may be steel cables, belts or link chains, run on disks 14 a and 14 b, respectively. Traction cables 15 a and 15 b are preferably sheathed. Disks 14 a and 14 b are fixedly mounted on transverse shaft 9 . In the embodiment shown, each of traction cables 15 a and 15 b is a steel cable fixed to associated vertical guides 6 a and 6 b, respectively, via terminals 16 a and 16 b with its one end while its other end portion is fixed on associated disks or drums 14 a and 14 b, respectively.
By turning on electric motor 11 , transverse shaft 9 is rotated together with the two disks or drums 14 a and 14 b by means of chain drive 10 to 13 , so that both traction cables 15 a and 15 b are wound up with a uniform speed and, thus, two support arms 4 a are 4 b are synchronously lifted. The lowering movement of support arms 4 a and 4 b is efficiently effected by their own weight or the additional weight of a supported vehicle and also with a speed determined by a brake or electric motor 11 .
In FIG. 2 only the right part of a lifting platform is schematically shown, the second column of said lifting platform including the auxiliary assemblies being formed identically in accordance with the embodiment of FIG. 1 . In this embodiment electric motor 11 , together with chain drive 10 , is disposed in box-shaped housing 20 provided at the lower end of column 1 b formed as a hollow profile. Correspondingly, transverse shaft 9 extends in groove 21 formed in floor foundation 3 and covered by plate 22 . At both end portions of the transverse shaft, drums secured against rotation are provided, only the right side drum 14 b being shown here. In the present embodiment, as in the embodiment according to FIG. 1 , the corresponding portions of the respectively associated torsion cable 15 b are wound up on drum 14 b , provided at least partly inside the hollow profile of the column when support arm 4 b is lifted or lowered. In this embodiment, also steel cable 15 b running inside the hollow profile is used as the traction cable, the one end of the traction cable being fixed to the lower part of vertical guide 6 b at 16 b while the traction cable runs over relay disk 23 turnably supported in the upper end portion of column 1 b . The cable portion indicated by broken lines is wound up on drum 14 b provided on the floor side.
Particularly in the embodiment according to FIG. 2 , the so-called pulley principle may be applied in a simple way by fixing the one end of traction cable 15 b in the upper part of column 1 b and by providing another relay roller in longitudinal guide 6 b , on which the steel cable then runs to upper relay disk 23 .
This embodiment requires increased manufacturing expenses due to groove 21 to be formed in the floor foundation as well as its cover. It is, however, advantageous in that the free space between the two columns is not limited by the transversely extending shaft 9 of the embodiment according to FIG. 1 , and in that the columns themselves are not provided with extensions.
Even though two-column lifting platforms are shown in the drawing, each embodiment can also be formed as a single-column lifting platform, in which case transverse shaft 9 is omitted. Particularly, the embodiment according to FIG. 2 is preferably suitable as a single-column lifting platform also applicable for light-weight two track motor vehicles, for example, passenger cars, in which case two support arms 4 b are provided which can be swung relative to each other at the same height.
The lifting platform according to the embodiments shown in FIGS. 1 and 2 may, in one or other embodiment, also be applied to mobile single-column lifting platforms preferably used for the repair of motorcycles. In such an embodiment, the column may also consist of a plurality of parts that can be shifted into each other in a telescope-like manner, and it may be mounted on a chassis together with the other assemblies.
The underfloor lifting platform shown in FIG. 3 comprises two vertical beams, 25 a and 25 b , to the upper ends of which horizontal support arms, 4 a and 4 b , respectively, each also comprising supports 5 a and 5 b , respectively, are adjustable in a telescope-like manner. In the upper part of pit 26 in floor foundation 3 , schematically indicated support scaffold 27 is fixed to which guides 28 a and 28 b , each for vertical beams 25 a and 25 b , are attached. Efficaciously, support scaffold 27 is provided as a pre-assembled constructional unit together with guides 28 a and 28 b and the other components so that it may be installed and anchored in pit 26 in a simple manner. The lower ends of two vertical beams 25 a and 25 b are fixedly connected to each other by dimensionally stable transverse bar 29 ensuring the synchronism of the vertical beams during their lifting and lowering motions. The lower ends of two traction cables formed as steel cables 30 a and 30 b are attached to transverse bar 29 , the steel cables extending parallel to the associated vertical beams 25 a and 25 b . The upper ends of the steel cables are fixed to drums 31 a and 31 b , respectively, both being fixed to common shaft 32 . Shaft 32 runs in stationary end side bearings 33 a and 33 b , which may be mounted on support scaffold 27 . For driving shaft 32 , electric motor 34 is provided which is mounted on support scaffold 27 , if required together with an integrated gear box, and connected to shaft 32 via chain drive 35 . Pit 26 is provided with upper cover 36 .
The underfloor lifting platform described above and shown in FIG. 3 may also be provided with only one vertical beam 25 lifted and lowered by only one traction cable 30 formed, for example, as a rope, a chain or a belt. In accordance with the embodiments of FIGS. 1 and 2 , the underfloor lifting platform of FIG. 3 may be provided with components effective under safety or operation technical points of view, such as an electronic control with or without position sensors, a cable brake, etc.
Furthermore the embodiments shown may be provided with a manually operable auxiliary drive enabling a slow descent of the vehicle to the foundation floor in case of a defect of the electric prime mover.
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A lifting platform for vehicles having at least one column, at least one support arm shiftable on the column by vertical guides and having supports. The lifting platform also includes a prime mover having switching and control elements and a transmission disposed between the prime mover and the associated support arm, the transmission having at least one flexible traction cable coupled to a rotating member positioned at the upper end of the respective column and to the associated support arm.
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CROSS REFERENCES TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/813,518 which was filed on Mar. 20, 2001, (U.S. Pat. No. 6,419,226, Jul. 16, 2002), which was a continuation of U.S. patent application Ser. No. 09/128,218, filed Aug. 3, 1998, (U.S. Pat. No. 6,203,008, Mar. 20, 2001), which was a continuation of U.S. patent application Ser. No. 08/649,821, filed May 17, 1996 (U.S. Pat. No. 5,788,230, Aug. 4, 1998). Priority under 35 U.S.C. §120 is claimed with regard to said prior applications. Said prior applications are also incorporated by reference hereinto in their entirety.
FIELD OF THE INVENTION
The present invention relates generally to an electro-mechanical gaming machine, and more particularly to a combination slot machine and pachenko game machine which has drop zones created by zone deflectors and scoring positions which vary from game to game.
BACKGROUND OF THE INVENTION
Slot machines have been a dominant part of the gaming industry world wide for over 50 years. While pachenko machines have seen a great deal of popularity in Asia, they are not as well suited for gaming as the traditional slot machine.
Slot machines have changed very little over the years. Whether mechanical or electronic, they still have reels spinning and coming to stop on a potential jackpot. It appears that a large part of the appeal of slot machines is the “mechanical” nature of the spinning reels which induces a belief in players that they are witnessing a truly random event and that the “big” jackpot is always just around the corner. While the big jackpot may or may not be just around the corner, slot machines maintain a very accurate payout percentage, usually between 92 and 99 percent with the house retaining the rest as profit.
The public perception of the “mechanical” nature of a slot machine is a critical part of their acceptance of the fairness of the machine. When slot machines with video displays showing simulated reels were introduced, the public rejected them in favor of the older slot machines with mechanical reels. Even though the new machines simulated the mechanical slots in every way and used the same random number generating circuit and yielded the same percentages as the mechanical slot machines, they were less attractive to the gaming public.
The biggest problem with the mechanical or electronic slot machines that have mechanical reels is that they have higher mechanical maintenance costs than machines with video displays in place of spinning reels. While prior art machines that replaced the spinning reels with video displays had lower mechanical maintenance costs they were also less attractive to gamers.
Another problem with traditional slot machines is their size, due to the space requirements of the mechanical reels. Traditional slot machines take up a great deal of floor space and are generally not well suited to being wall mounted. Smaller machines would allow the machines' owners to generate more revenue per square foot. The option of wall mounting a machine is attractive because this allows greater flexibility in the placement of machines.
Yet another problem with traditional slot machines is the limited number of possible combinations of symbols limits the size of a jackpot that can be offered. In order to provide larger jackpots, gaming establishments link multiple machines together in order to offer a progressive jackpot.
Finally, the very randomness which makes slot machines attractive also deters some people from playing them because they do not perceive there to be any skill involved in playing the game. Additionally, some people are looking for a more interactive experience than is provided by traditional slot machines. Too much interactivity, such as that involved with video and pinball games, would slow down the cycle rate of the machines to an unacceptable level.
There is a demand for a gaming machine that is as attractive to gamers as slot machines but at lower mechanical maintenance costs. There is a further demand for a gaming machine which would allow for the chance at a large jackpot with a small investment without having to link together multiple machines. There is yet a further demand for a gaming machine which creates a perception of skill while maintaining an accurate payout percentage and a fast cycle rate.
SUMMARY OF THE INVENTION
The present invention is a drop slot game machine that utilizes falling balls which drop from the upper part of the playing field, which is divided into user or randomly selectable drop zones, and into exit positions at the bottom of the playing field. The balls encounter deflector pegs which randomly change the path of the balls during their fall. As each passes through an exit position it is detected by sensor (photoelectric, infra-red, etc). Each exit position has a corresponding symbol which is represented on a liquid crystal display, the exit position symbol display, which lights up when a ball passes through that position. A small LED above each symbol reflects how many balls fell into a particular position (providing some did) so there can be no doubt to the player to which position and to how many balls passed through the associated exit position. A larger LCD payline display, simulating the payline of a traditional slot machine, shows the series of symbols selected by the balls passing through the exit positions.
If, for example, three balls are dropped, then the symbols representing the three exit positions which the balls pass through are displayed on the larger payline display. The symbols used in traditional slot machines as well as new symbols can be displayed on the exit position symbol display and the payline display. If all three balls fall into a single exit position, then the same symbol will be represented three times on the payline.
Payout in the present invention is controlled by electrical circuits similar to the those controlling payout in traditional slot machines, thereby ensuring the same payout percentages.
After passing through the exit positions, the balls recirculate by rolling into a launching position where they will be ejected back to the top of the game machine to drop through the playing field. It is likely that the balls will be launched by electrical solenoid or pneumatic ejector system.
A microprocessor/random number generator determines which symbols appear on which exit positions at the time of each pull. More than three balls can be used and more than three symbols can be represented on the payline (such as a four or greater reel machine). Furthermore, multiple paylines can be used using the appropriate number of balls (i.e. three paylines, three symbols per payline, nine balls would drop). In general, it is possible to simulate almost all current slot machine pay variations.
An additional feature of the machine is to have drop zones so that the balls may be deflected into one specific zone at the upper starting position. These zones may be either randomly selected by the machine itself, or selected by the player just prior to the symbols being shown on the LCD.
Other features may include bonus payouts such as: symbols designated by the LCD as “double”, “triple” etc. if balls fall in those individual or group of holes. Another bonus may be available if all the balls fall through the same hole. Yet another bonus may be available based upon what is displayed on the exit position display in combination with the payline display.
From a players standpoint, there is an element of anticipation not present in traditional slot machines. A player can see a jackpot developing and “wish” balls into the jackpot positions. The present invention also creates a perception of “true” randomness not found in traditional slot machines. The player sees balls freely dropping through the playing field as opposed to reels jerkily moving symbols in or out of the payline.
The present invention also creates a perception of skill, by being able to select drop zones, a player can exert a distinct influence on the outcome (not at all present in current slot machines). In reality, the percentages will run the same, but there is little doubt that the perception of skill on the player's behalf will exist.
Another aspect that is unique to the present invention is what may be called the “if only I had” aspect which is evident in other gambling sport/games, i.e. horse racing “if only I had bet on the number two horse”, roulette “if only I had bet the red or seven”, craps, etc. In the case of the present invention, “if only I had selected number two drop zone”.
Yet another advantage to the player is their ability to experience the excitement of a “high probability of win” round when they look down and see many symbols which may be “high” jackpot oriented. In these cases, the player will actually be at an advantage to win during that round, and he/she will know it. This situation never exists on a traditional slot machine.
The machine of the present invention also allows for a greater number of symbols to be displayed than a traditional, reel based, slot machine. The reel based machines are limited to displaying the number of symbols that can be fit on the reel. In a three (3) reel machine with eleven (11) symbols per reel there are 1331 possible combinations that can ever be displayed on the payline. In the present invention it is easy to store many symbols for electronic display. In a machine with eight (8) exit positions and 25 possible symbols per exit position there are over 150 billion combinations for display on the exit position display. This larger number of possible combinations makes it possible for the present invention to payout over a larger range of combinations and would allow a single machine to have the potential to payout a very large jackpot.
The present invention should have a very wide appeal to the gaming establishments as it has an overtly visible “mechanical” element, balls launching and freely dropping through the playing field, yet very low maintenance. The maintenance is low because other than simple mechanical switches and a ball ejecting system, the machine is dependent on non-mechanical hardware and software for most of its operation.
These and other features of the present invention will be more fully appreciated when considered in light of the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a functional diagram of the drop slot game machine of the present invention.
FIG. 2 is an functional diagram of the upper portion of the playing field of the present invention.
FIG. 2 a illustrates a close up cutaway cross-sectional view of a portion of FIG. 2 .
FIG. 3 illustrates the exit positions, payline display, and symbol selector display of the present invention in isolation.
FIG. 3 a is a cross-sectional close up of a portion of FIG. 3 .
FIG. 4 is an isometric view of the game machine of the present invention.
FIG. 5 is a flow chart diagraming the operational sequence of the drop slot game machine of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The game machine of the present invention is shown generally at 2 in FIG. 1 . The present invention comprises a generally upright gaming cabinet 4 , the upper portion of which houses the playing field 6 which in turn is covered by a transparent front glass 44 . The playing field is inclined, more preferably vertical, so that the balls may fall under the force of gravity. At the top of playing field 6 , there are three zone deflectors 8 a, 8 b, and 8 c, just below and slightly to the right of each deflector there is a zone divider wall 10 a, 10 b, and 10 c. Zone deflectors 8 a, 8 b, and 8 c along with zone divider walls 10 a, 10 b, and 10 c divide the upper portion of the playing field into drop zones I, II, III and IV.
The middle portion of playing field 6 is comprised of a maze of deflector pegs 12 . Generally, the maze of deflector pegs 12 is arranged so it would take a ball 2-4 seconds to fall through the maze. There are eight exit positions 20 at the bottom of playing field 6 under the maze of deflector pegs 12 . Each exit position 20 has an exit position sensor 22 associated with it and each exit position sensor 22 has an exit position symbol display 24 associated with it. Each exit position symbol display 24 is also comprised of a ball count display 26 . Beneath the exit position symbol display 24 , there is a payline display 28 .
The exit positions 20 lead to ball return ramp 30 which in turn leads to ball holder 32 which is connected to ball ejector 14 . Ball ejector 14 is provided with a ball ejector sensor 34 that will cause the ball holder 32 to load the ball ejector 14 when no balls are detected.
The drop slot game machine 2 is also provided with four zone select buttons 36 and a play handle 38 . The player may use the zone select buttons 36 to chose which zone the balls should drop into when launched by the ball ejector 14 . Play handle 38 is modeled after a traditional slot machine handle.
FIG. 2 illustrates the drop zone portion of the present invention. Referring to FIG. 2 a, we can see that zone deflectors 8 have two positions, retracted 8 r, and extended 8 e. When extended, there is not enough room for a ball to pass between zone deflector 8 e and zone divider wall 10 . Front glass 44 and playing field 6 also limit the ball's travel. In addition, the upper interior edge 42 of playing field 6 is curved in order to guide the ball along a path intersecting the deflectors 8 e. The extension and retraction of the zone deflectors is controlled by deflector peg retractor/extender 40 which is a solenoid in one of the preferred embodiments.
FIGS. 3 and 3 a illustrate a front and side view of the exit positions 20 . In FIG. 3 a deflector peg 12 , exit position sensor 22 , and exit position symbol display 24 , and payline display 28 can be clearly seen. In the present preferred embodiment, exit position sensor 22 is an infra-red (IR) sensor. The IR sensor 22 detects a ball passing through the exit position 20 and illuminates the corresponding symbol on the exit position symbol display 24 and payline display 28 .
Referring to FIG. 4, in a typical playing cycle the player will put coins in the machine at coin input or receptacle 60 , or play existing credits indicated by credit display 64 , the same as regular slot machines. At this point all LCDs go blank. The player then hits a drop zone button 36 once and new symbols are selected and displayed on the exit position symbol display 24 . The player can now pull the traditional slot machine handle 38 or push a play button 62 or a zone select button 36 again to launch the balls along a path of travel 16 shown in FIG. 1 . Upon first push of a zone select button 36 , a zone deflector 8 is also activated and moves into an extended position 8 e.
A separate play button 62 will exist for people who just want to put their money in and push a button, allowing play similar to traditional slot machines. Alternatively, people may put their money in and pull the handle 38 . In these cases the zone will be selected randomly by the machine itself. As soon as this button is pushed, or handle pulled, the symbols are immediately selected and displayed on the exit position symbol display 24 and the ball is launched (perhaps simultaneously). Balls are launched, deflected into zones selected or random, fall and drop into holes and appropriate symbols are displayed on the payline display 28 . Balls proceed to launch positions for next pull or launch. If the player wins, coins drop or credits register like a traditional slot machine.
All other features that are available in a traditional slot machine, i.e. bill validator, personalized card tracking, cash or credit, number of coins played display, are available in present invention.
In FIG. 5 the operational sequence of the for the present invention begins with the machine in standby 70 . In standby 70 the machine can carry out any number of actions to attract players such as lighting and sound effects. If the machine detects a coin drop or credit deposit 72 the machine is initialized for gameplay 74 . Also referring to FIG. 1, when initialized for gameplay 74 the present invention may randomly displays symbols on the exit position symbol display 24 , clears the payline display 28 , and moves all the zone deflectors 8 to their starting position, either extended or retracted.
Gameplay continues with either the player selecting a drop zone I, II, III, IV when a zone select button is pressed 76 or the machine randomly selecting a drop zone when the play handle is pulled 78 or the play button is pushed 80 . As the play handle is pulled 78 or the play button is pushed 80 the selected zone deflector is extended and the balls are launched and the game is played 88 . If a drop zone I, II, III, IV was selected when a zone select button is pressed 76 the balls are launched and the game is played 88 with a second pressing of the zone select button 82 , the play handle is pulled 78 , or the play button is pushed 80 .
In the preffered embodiment, the symbols on the exit position symbol display 24 that are to be used for scoring in a game are be selected and displayed simultaneously with the launching of the balls. Alternatively, the symbols on the exit position symbol display 24 may be selected and displayed when the drop zones are selected 76 , the play handle is pulled 78 , or the play button is pushed 80 .
If a coin drop or credit deposit is detected 72 and no further gameplay events occur after a specified amount of time the machine may randomly select a drop zone and play the game 88 or reset 96 .
After the balls are launched and the game is played 88 the present invention determines scoring 90 . If the game is a winner the invention provides the appropriate payout response 92 and returns the machine to standby 94 ( 70 ). If the game is not a winner the machine is returned to standby 94 ( 70 ).
It is within the scope of the present invention to use any number of balls launched one at a time or in groups. It is advantageous to use a smaller number of balls launched simultaneously in order to keep the cycle rate on the game as short as possible. It is also within the scope of the present invention to use balls that have an offset center of mass.
The present invention may also be configured for lottery or pull tab usage in areas where slot machines are prohibited. Any number of balls could be dropped to select any number of randomly selected symbols. The selected symbols would be displayed and any winning combination would be printed out on a validated ticket for redemption.
From the foregoing teachings, it can be appreciated by one skilled in the art that a new, novel, and nonobvious gaming machine has been disclosed. It is to be understood that numerous alternatives and equivalents will be apparent to those of ordinary skill in the art, given the teachings herein, such that the present invention is not to be limited by the foregoing description but only by the appended claims.
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The present invention is a game machine comprising a playing field having an upper interior edge and a lower interior edge with at least one drop zone deflector located adjacent to the upper interior edge of the playing field. The present invention also has a number of exit positions located along the lower interior edge of the playing field. A payline display and a payline symbol selector display are also part of the present invention. Balls passing through the exit positions select symbols for display in the payline display determined in part upon the movement of a ball on said playing field. The game also has a ball ejector capable of propelling a ball in a path that intersects the drop zone deflector.
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BACKGROUND OF THE INVENTION
The present invention relates to the field of matter and/or heat exchange columns, particularly columns for scrubbing or distilling gas mixtures. More specifically, it relates to manifolds that collect the liquid descending down inside these columns and distribute it over the upper surface of the active zone of the column that they overhang.
During the processes of separating the various constituents of a gaseous mixture inside a column, it may be necessary to extract the gases ascending up inside this column so as to subject them to a treatment such a heat exchange operation intended to return them to a given temperature. This is the case in particular when scrubbing the ascending gases inside the column using a liquid constituent. As an example of such a method, mention may be made of the operation of separating hydrogen from mixtures containing hydrogen, CO and methane which are obtained by the reforming of methane with steam. During the separation operation aimed at collecting pure hydrogen at the top of the column, the hydrogen may be scrubbed with liquid methane that is introduced into the upper part of the column.
For such a scrubbing operation to be as effective as possible, a temperature as close as possible to −180° C. needs to be maintained throughout the column, even though the scrubbing is exothermal. For this purpose, it is a known practice to extract the ascending gases at various points on the column, to pass them through a heat exchanger aimed at cooling them, and to reintroduce them into the column at a level above the level at which they were tapped. The drop in temperature of the collected gases after they have passed through the exchanger causes the less volatile compounds of the gaseous mixture to condense. This condensed liquid is collected by liquid traps which pour it out into manifold containers. These manifold containers have a perforated bottom which allows them to distribute the liquid they contain over the upper surface of an active zone, such as a packing, that they overhang.
These liquid trap-manifold assemblies constitute relatively bulky members, the overall height of which can be as much as a few meters. As the column generally has a number of packings and stages where the ascending gases are extracted, cooled and then reintroduced into the column, this construction of necessity entails building very tall columns, therefore having a high cost price. In addition, these liquid trap-manifold assemblies are of complex structure and are in themselves costly to produce.
SUMMARY OF THE INVENTION
The object of the invention is to provide users of matter and/or heat exchange columns with liquid-gas manifolds which are appreciably less complicated than the existing manifolds, so as to allow a reduction in the cost of construction of the column, and possibly in its overall height.
To this end, a subject of the invention is a liquid-gas manifold for a matter and/or heat exchange column, characterized in that it comprises a single container of roughly cylindrical overall external shape, designed to define an annular space between its side wall and the interior wall of the said column and having a perforated bottom, means for connecting the container to the interior wall of the column, and means allowing the gases to be transferred from the said annular space to the space located above the container.
The latter means may consist of openings formed in an upper lip of the said manifold, or in the side wall of the container.
As a preference, the container has a narrowing of its internal cross section in its central part.
Another subject of the invention is a matter and/or heat exchange column comprising at least one liquid-gas manifold collecting the descending liquid to distribute it to an active zone that it overhangs, characterized in that the said manifold is in accordance with the type described above.
According to one variant of the invention, the said means allowing the transfer of the ascending gases from the said annular space into the space located above the container comprise a pipe for tapping the ascending gases from the said annular space and a pipe for reintroducing the said gases into the column above the container.
According to another variant of the invention, openings are made in an upper lip of the container, and open into an heat exchanger incorporated into the said column.
As will have been appreciated, the invention consists in incorporating into the liquid-gas manifold, a single container of cylindrical overall shape with a perforated bottom, with which no separate liquid trap is associated. According to the various variants of the invention, the container collaborates with the wall of the column to send the ascending gases to undergo a treatment in apparatus located outside or inside the column, or allows the ascending gases to pass through.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from reading the description which follows, which is given with reference to the following appended figures:
FIG. 1 which depicts, in longitudinal section, one portion of a gaseous mixture separation column of the prior art;
FIG. 2 which depicts, in longitudinal section, one portion of a gaseous mixture separation column equipped with a liquid-gas manifold according to the invention;
FIG. 3 which depicts, in longitudinal section, one portion of a gaseous mixture separation column equipped with a liquid-gas manifold according to a variant of the invention;
FIG. 4 which depicts, from above, a liquid-gas manifold according to another variant of the invention;
FIG. 5 which depicts, in longitudinal section, a portion of a gaseous mixture separation column equipped with a liquid-gas manifold according to another variant of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The portion of gaseous mixture separation column according to the prior art which is depicted in FIG. 1 comprises a cylindrical wall or barrel 1 . It is filled over a portion of its height with a packing 2 constituting an active zone of the column. In the installation given by way of example, the gases leaving the packing 2 are at a temperature higher than the desirable temperature for performing a gas scrubbing operation with the greatest possible efficiency. This is the case, for example, when the column has to treat a hydrogen/CO/methane mixture resulting from a reaction for the reforming of methane with steam, which the column is supposed to separate into pure gaseous hydrogen, on the one hand, collected at the top of the column, and a liquid CO/methane mixture, on the other hand, collected at the bottom of the column. For this purpose, it is often desirable to carry out an operation of scrubbing the ascending gaseous mixture with liquid methane introduced at the top of the column. For this scrubbing operation to have maximum effectiveness, it needs to take place at a temperature close to −180° C. As the gases leave the packing 2 at a temperature slightly higher than the desired temperature, these gases are tapped off using a pipe 3 tapped into the wall 1 of the column. The gases thus collected are sent to a heat exchanger 4 where they are cooled (for example using liquid CO). Once the temperature of the gases has been brought back down to −180° C., the gases and the liquid which has condensed during the heat transfer operation are reintroduced into the column by a pipe 5 . The latter opens into the column at a level higher than the level at which the gas extraction pipe 3 was located. The liquid fraction of the matter reintroduced into the column is collected by a liquid trap 6 . This liquid trap 6 is in the form of a funnel, the circumference of the upper part of which is secured to the periphery of the internal wall 1 of the column at a level located between that of the gas tapping pipe 3 and that of the pipe 5 for reintroducing the gases and condensed liquid into the column. The funnel-shaped part of the liquid trap 6 opens onto a cylindrical portion 7 equipped with a solid bottom 8 . Liquid 9 can thus accumulate in the bottom of the liquid trap 6 . Pipes 10 , 11 allow this liquid 9 to be introduced into a manifold 12 located under the liquid trap 6 . This manifold 12 may conventionally be in the form of a container of complex shape, the bottom of which has perforations 13 , 14 , 15 , 16 , 17 , 18 . The liquid 19 present in the manifold 12 flows through the perforations 13 , 14 , 15 , 16 , 17 , 18 of said manifold towards the packing 2 . The heads of liquid 9 , 19 present in the liquid trap 6 and in the manifold 12 correspond to the pressure drops of the gas between the upper and lower levels of these liquids. The bottom of the manifold 12 is also equipped with domes 20 which have perforations 21 allowing the ascending gases leaving the packing 2 to pass through the manifold 12 .
The separation column according to the invention and depicted in FIG. 2 comprises, placed between the respective levels of the gas tapping pipe 3 and the pipe 5 for reintroducing the gases and the condensed liquid, a support 22 which runs around the inside of the wall 1 of the column around its entire circumference. Resting on this support 22 is an upper lip 23 of a container 24 which forms part of a liquid-gas manifold according to the invention. This container 24 has a cylindrical overall shape and its bottom 25 has perforations 26 . Its outside diameter d is smaller than the inside diameter D of the column. These perforations 26 distribute the liquid 27 present in the container 24 over the upper surface of the packing 2 which the container 24 overhangs. The ascending gases leaving the packing 2 pass through the annular space defined, on the one hand, by the internal wall 1 of the column and, on the other hand, by the external wall of the container 24 . They are directed towards the gas tapping pipe 3 , because the support 22 on which the upper lip 23 of the container 24 rests delimits, in collaboration with the side wall of the container 24 , a zone which is impervious to the ascending gases. As in the prior art, these ascending gases pass through a heat exchanger 4 which drops their temperature to the desired level. After they have been reintroduced into the column by the pipe 5 , the cooled gases continue to rise, while the condensed liquid and the scrubbing liquid flow into the container 24 , without a separate liquid trap or any other member comparable to the liquid trap 6 of FIG. 1 being provided. The head of liquid 27 present in the container 24 corresponds to the pressure drop of the gases between the upstream and downstream sides of the container 24 .
By comparison with the configuration according to the prior art and illustrated in FIG. 1, the exemplary configuration according to the invention in FIG. 2 is about 1 m less tall, therefore an appreciably reduced height. This makes it possible to give the column height which is smaller than it would usually be, this being all the more advantageous if the stages of extracting, cooling and reintroducing the gases into the column are numerous.
As a variant, as depicted in FIG. 3, the container 24 may have a narrowing 28 of its inside diameter in its central part. The amount of liquid 27 retained in the container 24 can thus be reduced. To make the liquid 27 easier to collect, it is also possible to envisage giving the container 24 the shape of a funnel above the narrowing 28 of its cross section.
As a variant, as depicted in FIG. 4, the upper lips 23 of the containers 24 may have openings 29 . In collaboration with similar openings made in the supports 22 , these openings 29 allow the gases to rise up inside the column. These openings 29 may thus open into heat exchangers similar in their function to the exchanger 4 of FIGS. 1 to 3 , but incorporated into the wall 1 of the column. Once the gases have passed through these exchangers and have been reintroduced into the column, the liquid which has condensed drops back down to be collected in the containers 24 .
The manifolds according to the invention may also be used in scenarios where there is no desire to cause the ascending gases to undergo a particular treatment but where there is simply a desire to distribute the descending liquid uniformly over the surface of the packing (or, in general, the active zone) that the manifold overhangs. For this purpose, it is possible to use the variant of the container 24 which is depicted in FIG. 5 . It is installed in a column, the wall 1 of which has no means for causing the ascending gases to be subjected to a particular treatment, whether outside or inside the column. As in the variants depicted in FIGS. 2 and 3, the annular space between the container 24 and the wall 1 of the column is closed off at its upper end by a lip 22 secured to the wall 1 of the column collaborating with an upper lip 23 of the container, both being devoid of openings through which the ascending gases could pass. By contrast, such openings 30 are to be found on the side wall of the container 24 . In this way, all the condensed liquid descending from the upper stages of the column passes through the container 24 , and does not impede the ascending movement of the gases in the annular space.
As a variant, the orifices 30 could be made in the lip 23 .
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A liquid-gas manifold includes a single container of roughly cylindrical overall external shape, designed to define an annular space between a side wall of the container and an interior wall of a heat exchange column. The container also has a perforated bottom and a connection between the container and the interior wall of the column. Gases from the annular space are transferred to a space located above the container.
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FIELD OF THE INVENTION
The present invention relates to food processing equipment and more particularly to apparatus for manufacturing twisted pretzels.
BACKGROUND OF THE INVENTION
Pretzels were traditionally formed by hand rolling dough into a rope and then manually twisting and folding the rope over on itself to create the common twisted pretzel. Although there is a certain appeal to the unique appearance of handmade pretzels, as one is not identical to the other, the production of such food products is very labor intensive and involves operations which are very monotonous to workers. As a result, various types of equipment have been created to form pretzels automatically with minimal human intervention.
One of the drawbacks of automated pretzel forming equipment is that each individual pretzel is virtually indistinguishable from all of the other pretzels produced by that machine. As a consequence, the pretzels lack the unique individualized appearance of a handmade product. Although the automated machinery can produce large quantities of pretzels very rapidly, it is desirable to produce them in a manner in which the pretzels have a unique appearances resembling the handmade product.
SUMMARY OF THE INVENTION
The general object of the present invention is to provide an automated apparatus for forming twisted pretzels.
Another object is to provide such an automated apparatus that is capable of forming twisted pretzels having different sizes ann shapes.
A further object of the present invention is to provide an automated apparatus in which the operation can be varied from pretzel to pretzel to provide a unique appearing product similar to that which occurs when the pretzels are made by hand.
These and other objectives are satisfied by an apparatus which comprises a conveyor system that has a surface for receiving and transporting a rope of dough. An anvil is moveable with respect to the conveyor to engage the rope of dough which becomes bent about the anvil by continued movement of the conveyor surface to form a curved portion of dough. A twister head is movable along the conveyor with the dough and includes an effector for grabbing two ends of the rope of dough. The twister head is rotatable to form a twisted section of the rope of dough adjacent the two ends. A mechanism is provided to press the two ends against the curved portion to complete the formation of a twisted pretzel.
The location of and degree to which the ends are pressed against the curved portion can be varied randomly among a plurality of pretzels being manufactured. Due to this random variation, the pretzels do not have identical appearances as typically results from machine made products. Instead, the pretzels vary in appearance so that they resemble handmade products.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of an automated assembly line for manufacturing twisted pretzels;
FIG. 2 is a side elevation view of the portion of the assembly line for twisting the pretzels;
FIG. 3 is a cross sectional view taken along line 3--3 in FIG. 1;
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 1; and
FIG. 5 is a side view of an assembly for twisting a rope of dough moving down the assembly line.
DETAILED DESCRIPTION OF THE INVENTION
With initial reference to FIG. 1, an apparatus 10 for manufacturing twisted pretzels comprises an extruder, or laminator 12, which produces eight continuous strands 14 of pretzel dough, for example. The strands of dough 14 drop lengthwise in parallel onto a first conveyor 16 which moves in a direction indicated by arrow 17. A cutter 18 passes across the first conveyor 16 and severs the continuous strands of dough into ropes of dough 19 having the appropriate length for the size of pretzel being produced.
The ropes of dough 19 continue along the first conveyor 16 ultimately reaching the remote end which terminates in a shuttle conveyor 20. As is well known in the art, shuttle conveyors retract and extend along directions indicated by double arrow 22. The shuttle conveyor 20 extends over a metering tray 24 which is mounted above one end of a second conveyor 26 that is oriented orthogonally to the first conveyor 16 and moves in a direction indicated by arrow 28.
The shuttle conveyor 20 oscillates back and forth along directions 22 so that the cut ropes of dough 19 drop into troughs of the metering tray 24. Each trough in the metering tray 24 has a trap door through which its dough rope can drop onto the second conveyor 26. First, every other trap door is opened to drop four of the ropes of dough 19 onto the second conveyor 26. This action arranges the four dough ropes transversely across the second conveyor. Once those four ropes have passed from beneath the tray 24, the remaining four ropes of dough are dropped from the tray onto the second conveyor.
Ultimately the second conveyor 26 moves four of the dough rope beneath a bending assembly. As shown in FIG. 3, the bending mechanism comprises support pillar 32 on which an elevator 34 is mounted to raise and lower an anvil assembly 36 with respect to the surface of the second conveyor 26. The anvil assembly 36 has four anvils 38. Each anvil depends from the assembly 36 and has a curved surface facing toward the tray 24. Initially, four dough ropes 40 are arranged in straight lines across the width of the conveyor 26 upon reaching the bending mechanism 30. A proximity sensor (not shown) located on the bending mechanism 30 detects when one of the dough ropes 40 is between each of the anvils 38, and a controller 35 for the apparatus 10 responds by activating the elevator 34 to lower the anvils against the surface of the conveyor 36. Further movement of the second conveyor 26 along direction 28 pushes the linear dough ropes 40 against the curved surface of each anvil 38. Thereafter, further movement of the second conveyor 26 causes the ends of the dough ropes 40 to bend around the stationary anvils 38 until each dough rope assumes a U-shape, as shown in FIG. 1. This orientation of the dough ropes is detected by another proximity sensor which causes the elevator 34 to raise the anvils 38 away from the surface of the second conveyor 26, thus releasing the now U-shaped dough ropes 40 to travel farther along the second conveyor.
Eventually the group of four U-shaped ropes 40 pretzel dough travels under the head 44 of a twister mechanism 42 where the head is indicated in phantom in FIG. 1 so that the dough ropes 40 will be visible. The twisting mechanism 42 is shown in detail in FIGS. 2 and 4 and comprises two support pillars 46 which are spaced apart along the one side of the second conveyor 26. Two horizontal rails 48 extend between the pair of support pillars 46 with a pair of vertical rails 50 slidably mounted on the horizontal rails. A first motor 52 drives separate chains or belts which extend the length of each horizontal rail 48 and are linked to move the vertical rails 50 horizontally along the second conveyor 26. Another motor 54 drives a pair of chains or belts that extend the length of each vertical rail 50 to raise or lower the twister head 44 that is mounted there. This assembly of rails and drive mechanisms form a Cartesian robot that moves the twister head 44 along the length of the second conveyor 26 and vertically in relation thereto.
The head 44 of the twister mechanism 42 comprises four twisting units 56 spaced along the longitudinal axis over the second conveyor 26 as shown in FIGS. 2 and 4. Referring to FIG. 5, the twisting units 56 are driven in unison by a motor 58. Each twister unit 56 comprises an effector formed by two pairs of opposing fingers 60 and 61 which move together or apart to grasp ends of the dough ropes 40, as will be described. The two pairs of fingers 60 and 61 are spaced apart by an amount equal to the distance between the ends of the U-shaped dough ropes on the second conveyor 26. Above each pair of fingers 60 and 61 is a separate plunger 62 or 64, respectively, which is driven by an actuator 66 (with only one such actuator being visible in FIG. 5). The pairs of opposing fingers are operated by clutch assemblies connected to a series of belts and pulleys 68 which are linked by additional belts, pulleys and shafts to the twister motor 58.
With reference again to FIGS. 1 and 2, the twister mechanism 42 is initially in a rest position with the twisting units 56 located at the end of the horizontal rails 48 closest to the bending mechanism 30. A proximity sensor (not showing) detects the presence of four U-shaped dough ropes 40 under the twister head 44. This detection causes the controller 35 to activate the twister mechanism which begins traveling horizontally along the conveyor 26 in synchronism with the ropes of dough 40. At the same time, the four twisting units 56 are lowered until an end of a dough rope is between each pairs of opposing fingers 60 and 61. Those fingers then close to grasp the ends of the dough ropes and then lift those ends above the surface of the conveyor 26.
A clutch mechanism 70 within each of the twister units 56 then engages to produce a 360° rotation of the pairs of opposed fingers 60 and 61 which produces a twisted segment of each dough rope 40. While the operation occurs the twisting heads 44 continue to move along the conveyor 26 at the same rate as the dough ropes. After the twisted rope segments have been formed, motor 52 slows the horizontal movement of the twister head 44 with respect to the rate of the conveyor 26 causing the curved portion of what was previously the U-shaped dough rope 40 to pass beneath the pairs of fingers 60 and 61 which still grasp the rope ends. This causes the twisted segment to be folded over the top of the curved portion of the dough rope. While this folding is occurs, the twisting unit 56 is lowered so that the ends of the dough rope come into contact with the curved portion.
Next the two pairs of opposed fingers 60 and 61 open and the plungers 62 and 64 are lowered to press the ends of the dough firmly into the curved portion thereby completing the finished pretzel shape. This plunger action depresses the ends of the dough rope in much the same way as depressions were produced by fingers when pretzels are made by hand. The depth and location of the depressions can be varied randomly so that the pretzels are not uniform, thereby giving the appearance of handmade pretzels. Specifically, the amount to which the ends of the pretzel rope are twisted and the exact location at which the ends are pressed against the curved portion are varied randomly from pretzel to pretzel by the assembly line controller 35 governing the amount of twister head rotation. Thus, sometimes the ends of the dough rope are centered about the curved portion while other times one or the other of the ends is placed closer to the mid point of the curve which providing a variation among the pretzels that resembles the non-uniformity of handmade products.
Once the ends have been pressed onto the curved portion, the twister head assembly 44 is raised above the surface of the second conveyor 26 and returned horizontally to the rest position illustrated in FIG. 2.
With continuing reference to FIG. 1, the group of four twisted pretzels continues to pass along the second conveyor 26 reaching the remote end at which another shuttle conveyor 72 is located. This shuttle conveyor 72 slowly retracts dropping each of the twisted pretzels 74 on to a third conveyor 76 positioned orthogonally to the second conveyor 26. This action produces rows of pretzels extending across the width of the third conveyor 76 which carries the pretzels in a direction 78 into a conventional oven 80.
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An twisted pretzel producing apparatus has a conveyor with a surface for receiving and transporting a rope of dough. An anvil engages the rope of dough so that continued conveyor movement form a curved dough portion. A twister assembly grabs the two ends of the rope of dough and rotates to form a twisted section of dough. The twister assembly includes a set of plungers that press the two ends against the curved portion to form a twisted pretzel. The exact location and degree to which the ends are pressed against the curved portion are randomly varied so that each pretzel has a different appearance as occurs with pretzels made by hand.
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FIELD
[0001] The present invention relates generally to paving bricks and specifically to road surfaces comprising paving bricks with improved wall and edge designs for increased durability when exposed to vehicle traffic and other environmental stresses.
BACKGROUND OF THE INVENTION
[0002] The use of artificial paving bricks with various geometric shapes and used as paving elements to form sidewalks, court yards, roads, streets, and the like is well known. Such paving bricks and the surfaces they form are expected to carry vehicle traffic, wheelchairs, bicycles and the like, and to endure mechanical forces caused by freezing, heating, and earth movements which can impart mechanical stresses on the paving bricks and cause long term degradation or sudden cracking and spalling at stress concentration points, particularly at the top surface edges.
[0003] In U.S. Pat. No. 3,969,851 the inventor describes several artificial paving stones with interlocking protrusions at the side surfaces to resist displacement when loads are applied. While effective at keeping the paving stones in place, the sharp edges and corners are known to create weak points for spalling and cracking, and are not durable under heavy vehicular loads.
[0004] In U.S. Pat. No. 5,707,698 the inventors describe a water permeable paving system with channels formed along the sides of the paving bricks which, when the bricks are placed together, create channels to allow water to pass through. While an effective means of increasing the water permeability of the paving system, these channels create stress concentration points that can lead to cracks and spalling when the bricks are subjected to environmental stresses and vehicle traffic.
[0005] In U.S. Pat. No. 4,761,095 the inventors describe an artificial paving stone with irregular sidewalls designed to engage with neighboring stones and anchor them against lateral shifting and displacement during vehicle motion. The inventors further describe a chamfered top edge which, while easy to manufacture, creates sharp corners that is known to cause cracks and spalling under heavy vehicle loads owing to the sharp angles created at the chamfer edges.
[0006] In addition to these problems of the paving bricks of the prior art, there is an increasing desire in the marketplace for paving bricks which are slightly porous and therefore permeable to moisture, and the porosity of such paving bricks further exposes them to damage at any sharp corners or edges owing to their methods of construction and, in some cases lack of solid reinforcement.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a paving brick of the kind described above with novel features designed to improve the load bearing capacity and durability of a surface made with such bricks. In one embodiment, paving bricks are provided with rounded edges in order to limit contact between adjacent bricks when laid adjacent to each other. The rounded edges begin approximately two thirds of the distance from the bottom of the paving brick, and in some embodiments have a radius of curvature from 1 mm to 4 mm, such as 3 mm, and such as 2 mm.
[0008] Another embodiment of the invention includes at least one sidewall which is angle inward such that the top surface of the paving brick is smaller in at least one of a width and length dimension than a bottom surface of a paving brick. The inward angle is such that the angle between the at least one sidewall and the bottom surface is less than 85 degrees and greater than 75 degrees, such as 80 degrees, and is defined as angle theta.
[0009] Another embodiment of the present invention is to provide a water permeable paving brick designed in such a way that the load bearing capacity and durability of a roadway or other surface made with such bricks is clearly improved. When porous artificial paving bricks are employed there is a risk of breakage and the top edges and corners, particularly for porous paving bricks having a compressive strength between 40 MPa and 70 MPa and a tensile strength of between 0.1 MPa and 0.2 MPa. In this range of compressive and tensile strengths a paving system made of bricks known in the prior art have been found by the inventors to be susceptible to cracking and spalling at the top edges when heavy vehicle traffic is applied.
[0010] A further mechanical strength property of paving stones is known as the modulus of rupture, or flexural strength, which is defined as the maximum stress the material can withstand under a three-point bend test. This is test is defined in ASTM standard C67-02 entitled, “Standard Test Method for Sampling and Testing Brick and Structural Clay Tile”, Section 6.0—Modulus of Rupture, and is a measure of the brittleness of a material under bending load. The inventors have found that porous stones of the kind used for permeable paving, having a dry modulus of rupture between 10 MPa and 20 MPa are particularly suited for the novel features of the present invention.
[0011] The compressive strength of paving stones may be tested according to ASTM standards C192 and C39, and the tensile strength of paving stones may be tested according to ASTM standard C190.
[0012] A more complete appreciation of the present invention and its scope can be obtained from the following detailed description of the invention, drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a top down view of a prior art paving system.
[0014] FIG. 2 is a perspective view of a novel brick design for paving.
[0015] FIG. 3 shows two adjacent paving bricks with a sloping edge design.
[0016] FIG. 4 shows two adjacent paving bricks with a rounded upper edge portions.
[0017] FIG. 5 is a perspective view of two adjacent paving bricks with rounded upper edge portions.
[0018] FIG. 6 is a top view of a paving system formed with bricks of the prior art adjacent to a paving system formed with bricks of the present invention.
[0019] FIG. 7 is a perspective view of a paving system formed with bricks of the prior art adjacent to a paving system formed with bricks of the present invention.
DETAILED DESCRIPTION
[0020] Reference will now be made in detail to specific embodiments of the invention. Examples of the specific embodiments are illustrated in the accompanying drawings. While the invention will be described in conjunction with these specific embodiments, it will be understood that it is not intended to limit the invention to such specific embodiments. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be practiced without some or all of these specific details.
[0021] As set forth below, a paving system is described comprising paving bricks with novel designs that limit mechanical stress build-up and chipping of the corners and edges of the paving bricks when heavy loads are applied to the paving system. In some embodiments, the paving bricks are porous to allow water to pass through at a rate of more than 1,000 grains per 24 hour per square meter, such as 1,500 grains per 24 hour per square meter, such as 3,000 grains per 24 hour per square meter, and such as 4,000 grains per 24 hour per square meter.
[0022] FIG. 1 is a top down view of a prior art paving system. Edge region 102 and corner region 101 depict the cracking and spalling that occurs on the sharp or chamfered edges of the prior art.
[0023] FIG. 2 is perspective view of one embodiment of the present invention. In this embodiment the width dimension of the bottom surface 203 is greater than the width dimension of the top surface 204 such that angle 207 is less than about 85 degrees and greater than 75 degrees, such as 80 degrees, and shall be defined as angle theta in the accompanying claims. The angle theta introduced therein allows adjacent paving bricks, as shown in FIG. 3 , to touch at their bottom edges 305 and lock in place, helping to resist movement under vehicle load while providing gap 304 between adjacent top surfaces to allow for expansion and contraction during heating and cooling cycles, and drastically reduce the stress applied to the top edge and corner surfaces of adjacent paving bricks under load. In a typical paving installation the gap between adjacent pacing bricks is filled with a porous or non-porous grout (not shown), as commonly known in the art.
[0024] FIG. 4 is an end view of one embodiment of the present invention showing two adjacent paving bricks with rounded top edges 407 . In one embodiment, the ratio of the height 402 of the paving brick to the height 401 of the unrounded edge is between 1.5 and 3. In other words, the rounded portion 407 should begin no more than two thirds of the total height 402 from the bottom surface 408 of the paving brick in order to allow sufficient contact between adjacent bricks to create friction and lock the brick in place. By introducing a rounded edge 407 the stress concentration at the edge 407 is reduced, and gap 406 is created to allow for expansion and contraction during heating and cooling, and to allow for movement of the bricks during heavy vehicular loads. In some embodiments, gap 406 may be filled with a porous or non-porous grout compound (not shown) as commonly known in the art.
[0025] FIG. 5 is a perspective view of the adjacent bricks as shown in FIG. 4 . In this example gap 505 created by rounded edge 507 provides spacing for the expansion and contraction during heating and cooling, and allows for movement of the bricks during heavy vehicular loads.
[0026] FIG. 6 is a top view of a paving system of the prior art with sharp edges constructed adjacent to one embodiment of the paving bricks of the present invention. Due to the dramatically reduced stress concentration from the rounded edges of 407 , the distance between adjacent bricks 601 is greatly reduced without adversely affecting the durability of the paving system. In contrast, the distance 602 between paving bricks of the prior art is required to be much larger, in some cases two to three times larger, in order to minimize cracking and spalling at the top edges to an acceptable level. This required extra spacing adds cost due to the additional filler material (not shown) that must mixed and poured at the installation site. In some instances the additional spacing requiring reduces the aesthetic value of the paving system, and in other instances limits the types of vehicle travel that are acceptable on the paved surface.
[0027] FIG. 7 is a perspective view of a paving system of the prior art adjacent to the paving bricks and system of the present invention. In this experimental example, several vehicles weighing in the range of 2,000 to 4,000 pounds travelled over each surface, and the corners of the prior art bricks exhibited cracked corners and edges 701 due to the stress concentration at the sharp edges, whereas the bricks of the instant invention having rounded edges were observed to remain intact. In a separate experiment, not shown, the inventors have found a similar result for bricks having trapezoidal shapes wherein the angle formed between the side wall and bottom surface was less than about 85 degrees and greater than 75 degrees, for example 80 degrees as depicted in FIGS. 2 and 3 .
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A paving brick with a means for reducing mechanical stress on at least one edge of a top surface, particularly when used in a paving system for roads, streets, sidewalks and like when heavy vehicle load applies a force on the top surface. In one embodiment the means for reducing mechanical stress is a rounded edge. In another embodiment the means for reducing mechanical stress is an angle sidewall having an angle theta between 75 and 85 degrees.
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CROSS REFERENCE OF RELATED APPLICATIONS
This application claims priority to, and incorporates by reference herein in its entirety, pending U.S. Provisional Patent Application Ser. No. 60/632,094, filed 1 Dec. 2004. This application is a continuation in part of U.S. patent application Ser. No. 10/997,654, filed 24 Nov. 2004, the entirety of which is incorporated by reference.
FIELD OF INVENTION
This invention relates to pressure control devices in general and more particularly, a pressure control device comprising a valve assembly including a ceramic valve element used in automotive fuel systems.
BACKGROUND
Most modern automotive fuel systems use fuel injectors to deliver fuel to the engine cylinders for combustion. The fuel injectors are mounted on a fuel rail to which fuel is supplied by a pump. The pressure at which the fuel is supplied to the fuel rail must be metered to ensure the proper operation of the fuel injector. Metering is carried out using pressure regulators which control the pressure of the fuel in the system at all engine r.p.m. levels.
Most pressure regulator valves use an upper valve member made of stainless steel or other metallic material and a lower valve member or valve seat fabricated from a stainless steel or other metallic material. When the valve is open, the valve element lifts off the valve seat and may dither, making contact with the valve seat. When the valve closes, the valve element drops onto the valve seat. A high density metallic valve element has the potential to wear the sealing surface of the valve seat, which is also called galling. This wear can be attributed to the valve element impacting the valve seat and galling between the valve element and the valve seat.
Coining is a preferred method of improving the sealing surface on the valve seat. A metallic ball or the valve element is used to coin the metallic valve seat. With this process it is possible for galling to occur during coining. When the Young's Modulus of the valve element and the valve seat are similar, both parts can deform at a similar rate during the coining operation. The result may lead to poor leak performance.
Pressure regulators known in the art also use a valve biasing member biased to a valve seat with a longitudinal flow passage. At low fuel pressures, the valve seat is biased to a closed position to prevent the flow of fuel through the pressure regulator. As fuel pressure builds in the system, the pressure against the valve seat overcomes the biasing force of the valve biasing member, allowing fuel to flow through the valve seat, thereby controlling the fuel pressure in the system.
While such pressure regulators have been proven satisfactory, they require a substantial number of parts. In an ongoing effort to reduce the material and manufacturing costs of fuel pressure regulators as well as decrease poor leak performance there exists a need to develop a fuel pressure regulator that is small in size with fewer parts.
Thus, it is believed that there is a need to provide a pressure regulator to overcome the disadvantages of the known pressure regulator.
SUMMARY OF INVENTION
In accordance with one aspect of this invention, a flow through pressure regulator comprising: a lower housing having a fuel inlet wherein a flow of fuel through the fuel inlet communicates with a valve assembly through a fuel chamber; the valve assembly regulating the flow of fuel through the lower housing to a fuel outlet wherein a valve element rests on a valve seat in a closed position to prohibit the flow of fuel from the fuel chamber to the fuel outlet; a valve biasing member for biasing the valve element toward the fuel chamber in opposition to pressure exerted on the valve element by the fuel in the fuel chamber; and a fuel cover for directing the flow of fuel from the valve biasing member to the fuel outlet.
In accordance with another aspect of this invention, a valve biasing member for a flow through pressure regulator comprising: a flat disk; the flat disk affixed to a lower housing in a fixed relative position; and a flow of fuel in communication with the flat disk for controlling transmitted flow of fuel from a fuel inlet to a fuel outlet.
In accordance with another aspect of this invention, a method for reducing noise generation in a flow through pressure regulator, the method comprising: providing a passage for a fuel flow from a fuel inlet to a fuel outlet wherein a valve element prohibits the fuel flow through the passage; and communicating the fuel flow with a valve biasing member during flow through the passage.
It is therefore an object of the present invention to provide improved noise and flow characteristics of a fuel pressure regulator free of any additional parts. It is also an object of the present invention to reduce the materials and manufacturing costs of fuel pressure regulators.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a perspective view of the valve assembly.
FIG. 2 illustrates is a cross section view of the valve assembly with the upper valve element in the open position.
FIG. 3 illustrates a cross sectional view of the flow through pressure regulator that includes a valve biasing member.
FIG. 4 illustrates a perspective view of the flow through pressure regulator that includes a valve biasing member.
FIG. 5 illustrates a top view of the valve biasing member.
FIG. 6 illustrates a perspective view of a fuel cover.
FIG. 7 illustrates a top view of an alternative 3 point of contact embodiment of the valve biasing member.
FIG. 8 illustrates a top view of an alternative spiral embodiment of the valve biasing
DETAILED DESCRIPTION
FIGS. 1 , 2 , and 3 illustrate a flow through pressure regulator 10 according to the present invention. Flow through pressure regulator 10 includes a lower housing 20 that contains a fuel tube 30 . Fuel tube 30 houses a fuel chamber 40 which is generally cylindrical in shape and which channels the fuel into the pressure regulator 10 from the fuel pump (not shown). In the preferred embodiment, fuel tube 30 is made from stainless steel. Fuel will first pass through a fuel filter 50 into fuel chamber 40 . Fuel filter 50 , generally circular in shape, it is disposed around lower portion of fuel tube 30 and adjacent to an o-ring 60 . O-ring 60 is positioned below the lower housing 20 to seal and prevent any fuel leakages into other components in the system. O-ring 60 is made of an elastomeric material and is generally circular in shape. Others skilled in the art may select not to use an o-ring 60 .
Flow through pressure regulator 10 also includes a valve seat 70 which cooperates with valve element 80 that is movably disposed between a closed and open position. In the closed position, the valve element 80 contacts and seals against the seating surface of the valve seat 70 and prevents fuel flow through the valve seat 70 . The valve element 80 is biased into the closed position by valve biasing member 90 . Valve biasing member 90 is held in place by lower housing 20 which crimps over the outer edge of valve biasing member 90 . Others skilled in the art may choose to affix the valve biasing member 90 to lower housing 20 with a weld or clip. Pressurized fuel flows through and accumulates in fuel chamber 40 until the pressurized fuel contacts the bottom surface of the valve element 80 . The pressurized fuel will then push valve element 80 off of valve seat 70 into an open position. The fuel flows through the valve seat 70 . In manufacturing the valve seat 70 , the sealing surface is coined to assure smooth sealing between the valve element 80 and the valve seat 70 .
Once the pressurized fuel is released, the valve element 80 is then biased back into the closed position by the valve biasing member 90 . Valve biasing member 90 functions to hold the valve element 70 of the flow through pressure regulator 10 in a closed position at a predetermined amount of pressure that is related to the pressure desired by the flow through pressure regulator 10 specification.
In the preferred embodiment, the valve element 80 is shaped as a sphere and maintains a free floating design. The valve element 80 is made of a ceramic consisting of alumina oxide, to prevent galling from occurring during coining and reduce wear on the valve seat. The valve element 80 performs in wear, heat, corrosive environments and maintains dimensional stability of temperatures up to 2000 degrees F. The valve element 80 is not retained by other components of the flow through pressure regulator 10 and therefore does not share a permanent contact with the valve biasing member 90 . The valve element 80 is free to move both axially and radially when displaced from the valve seat 70 . Valve biasing member 90 is positioned on the upper surface of the valve element 80 to assist with movement of the valve element 80 in an axial direction away from the valve seat 70 . When the pressure of the inlet fuel is greater than the force exerted by the valve biasing member 90 , the fuel pushes the valve element 80 in an axial upward direction and the valve element 80 leaves the valve seat 70 . Fuel flows through the flow through pressure regulator 10 until the pressure of the valve biasing member 90 is strong enough to return the valve element 80 to the valve seat 70 thus closing the opening in the valve seat 70 . Others skilled in the art may wish to select different shapes for the valve element 80 including a truncated sphere or cone. Others skilled in the art may also choose to weld the valve element 80 to the valve biasing member 90 .
Referring to FIGS. 3 , 4 and 5 , the geometry of the valve biasing member 90 provides the force to close the valve element 80 and seal the opening of the valve seat 70 . Valve biasing member 90 also provides the spring rate necessary to regulate the fuel pressure in the system. The geometry of valve biasing member 90 consists of at least two co-axial concentric rings 100 and 110 adhered together by at least one bridge 120 . The preferred shape of the valve biasing member is annular, however, others skilled in the art may select other shapes including oval. From this geometry, balanced slot openings 130 are formed. In the preferred embodiment, the balanced slot openings 130 are arc shaped. Others skilled in the art may select a balanced slot opening 130 to be shaped as a circle, tubular, triangular or angled. Each concentric ring 110 has a beam length used to calculate the spring rate under Hookes law. The effective beam length is defined as the total length of the valve biasing member 90 . The effect of changing the length of the beams, with all other factors remaining constant, will result in changes to performance criteria. At the same time, by decreasing the open area of balanced slot openings 130 where the ratio of surface area to open area is increased, the fluid flowing though the valve biasing element meets more resistance. Therefore, by increasing the effective beam length of the valve biasing member 90 and decreasing the open area of inner balanced slot opening 130 , to a length greater than the radius of its largest ring, the spring rate decreases making the valve biasing member 90 less stiff. The bridge 120 connects first ring 100 with its adjacent neighbor ring 110 in a reticulated network fashion. Bridge 120 increases the effective length of the beams of valve biasing member 90 which achieves desirable spring rates for the flow through pressure regulator 10 .
The valve biasing member 90 applies a balanced force to the valve element 80 that allows the valve element 80 to lift straight in an upright manner without any bias. The balanced openings 130 serve as a homogenous diffuser to direct the flow of fuel from the opening of the valve seat 70 to various directions. The balanced openings 130 disperse the fuel flow with improved flow characteristics and less noise.
The center aperture 140 of the valve biasing member 90 preferably centers on the lower housing 20 and on the central axis of valve seat 70 . In the preferred embodiment, the center aperture 140 provides a three-point contact with the valve element 80 . Others skilled in the art may contact the valve biasing member 90 with the valve element 80 with less than or more than three reference points. This feature centers the valve element 80 and achieves low flow linearity of the flow through pressure regulator 10 resulting in regulation at a low flow at the right pressure. There is no valve element to valve seat alignment problem with present invention and therefore, a floating valve element 80 design which typically requires an additional part and that is in common in other regulator designs is not required. Others skilled in the art may allow the valve element 80 to float in a radial direction by reducing the diameter of or eliminating entirely the center aperture 140 of the valve biasing member 90 .
Referring to FIGS. 3 and 6 , flow through pressure regulator 10 also includes a fuel cover 150 . The fuel cover 150 is made of a plastic molded material and generally houses the flow through pressure regulator 10 . Fuel cover 150 includes fuel passageway 160 for directing and turning the flow of fuel from the valve biasing member 90 to fuel outlet 170 . The fuel outlet 170 is generally circular in shape and located on the outer edge of cover 150 . Fuel cover 150 also includes at least one snap mechanism 180 allowing ease when being affixed to the flow through pressure regulator 10 . The snap mechanism 180 may be directly molded into the fuel cover 150 as an integral clip. This eliminates the need for separate clip attachments. In the preferred embodiment, the snap mechanism 180 is a tab acting as a clip to hold the flow through pressure regulator 10 in place. One skilled in the art may choose not to affix fuel cover 150 to the flow through pressure regulator 10 and use flow through regulator 10 free of fuel cover 150 . Fuel cover 150 also acts to keep the valve biasing member 90 submerged in fuel at all times during fuel flow which enhances durability of the valve biasing member 90 as well as dampen any vibrating noise of the valve biasing member 90 . After exiting valve biasing member 90 , the fuel builds in the cover chamber 190 above the valve biasing member 90 and climbs over internal wall 200 and then flows to fuel outlet 170 . By this process, the flow of fuel exits in an organized flow and does not discharge in various directions. Similarly, submergence of the valve biasing member 90 in the fuel ensures that the fuel is located on both the top portion and the bottom portion of the valve biasing member 90 . Submergence of the valve biasing member 90 in fuel also ensures that the fuel is not aerated which consequently lessens noise in the flow through pressure regulator 10 . Lastly, the fuel cover 150 protects the valve biasing member 90 during shipping and handling.
FIGS. 7 and 8 illustrate alternative embodiments of the valve biasing member 90 . In these embodiments, all the various elements of the flow through pressure regulator 10 are identical with exception to the valve biasing member 90 . In FIG. 7 , the geometry of valve biasing member 90 is a flat disk including at least a three point of contact aperture 140 with no concentric ring geometry. In FIG. 8 , the geometry of valve biasing member 90 is a flat disk with a spiral shape having center aperture 140 .
While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present invention. Accordingly, it is intended that the present invention not be limited to the described embodiments and equivalents thereof.
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A flow through pressure regulator apparatus and method for directing a flow of fuel within a fuel system. Present invention includes a lower housing having a fuel inlet where fuel flows through the fuel inlet and communicates with a valve biasing member through a fuel chamber and lower valve element with fuel passages. The valve biasing member permits or inhibits fuel flow through a fuel chamber by opening and closing a ceramic valve element. The valve biasing member comprises a flat disk having at least two reticulated concentric rings coupled by at least one bridge. The fuel flows past an open valve element through the lower valve element fuel passages to the valve biasing member. The valve biasing member then diffuses the flow of fuel. A fuel cover directs the flow of fuel from the valve biasing member to the fuel outlet.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a window operating mechanism for opening and closing a casement window.
[0003] 2. Discussion of the Prior Art
[0004] Casement windows have been in existence for a great many years. In the last forty or fifty years, operating or activating mechanisms have become standard equipment in casement window assemblies. Casement windows commonly open in one or two directions, depending upon whether the hinges are mounted on the left or the right hand side of the window. Typical operators for such windows are described in Canadian Patent No. 1,301,202, issued to D. A. Nolte et al on May 19, 1992; and in U.S. Pat. No. 3,044,311, issued to G. W. Gagnon on Jul. 17, 1962.
[0005] A problem inherent to existing window operating mechanisms is reversibility, i.e. the ability to adapt the mechanism to windows opening in the opposite directions. In existing devices, it is necessary to disassemble and then reassemble a substantial portion of the devices in order to be able to use the devices with windows opening in opposite directions.
GENERAL DESCRIPTION OF THE INVENTION
[0006] An object of the present invention is to provide a solution to the above-identified problem in the form of a relatively simple window operating mechanism which can be quickly and easily modified for use on windows opening in opposite directions.
[0007] Accordingly, the invention relates to an operating mechanism for a casement window comprising:
[0008] (a) a hollow, closed housing for mounting on a casement window frame, said housing including:
[0009] (i) an opening in one side thereof;
[0010] (b) a worm shaft rotatable in said housing for manual actuation of the mechanism;
[0011] (c) an inner gear in said housing for rotation by said worm shaft;
[0012] (d) an annular outer gear in said housing for rotation by said inner gear, said outer gear including
[0013] (i) a flange extending out of said opening in the housing;
[0014] (e) spaced apart pins on said flange; and
[0015] (f) a crank arm releasably mounted on said pins for extending in one of two opposed directions,
[0016] whereby the operating mechanism can be readily adapted to windows opening in opposite directions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention is described below in greater detail with reference to the accompanying drawings, which illustrate a preferred embodiment of the invention, and wherein:
[0018] [0018]FIG. 1 is an isometric view of a window operating mechanism in accordance with the invention as seen from above and an outer end;
[0019] [0019]FIG. 2 is an isometric view of the mechanism of FIG. 1 with parts removed;
[0020] FIGS. 3 to 5 are isometric views of a cover used on the mechanism of FIGS. 1 and 2 as seen from above (FIGS. 3 and 4) and below (FIG. 5);
[0021] [0021]FIG. 6 is a top view of the mechanism of FIGS. 1 and 2;
[0022] [0022]FIG. 7 is a cross section taken generally along line 7 - 7 of FIG. 6;
[0023] [0023]FIG. 8 is an inner end view of the mechanism of FIGS. 1 and 2;
[0024] [0024]FIG. 9 is a cross section taken generally along line 9 - 9 of FIG. 8;
[0025] [0025]FIG. 10 is an exploded, isometric view of interior elements of the mechanism of FIGS. 1 and 2; and
[0026] [0026]FIG. 11 is a cross section taken generally along line 11 - 11 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] With reference to FIGS. 1 and 2 of the drawings, a window operating mechanism in accordance with the present invention includes a hollow, one-piece housing indicated generally at 1 , which is covered by a cover 2 .
[0028] The one-piece hollow cover 2 (FIGS. 3 to 5 ) is defined by a top wall 4 , an outer end wall 5 , side walls 6 and a flange 7 extending upwardly from the inner end of the top wall 4 and outwardly from the side walls 6 . A sleeve 8 extends upwardly from the top wall 4 , and a hole 9 (FIG. 3) is provided in the otherwise closed top end of the sleeve.
[0029] The housing 1 (FIG. 2, where the cover 2 is omitted) includes a top wall 10 , a bottom wall 11 , an outer end wall 12 and side walls 13 extending between the top and bottom walls 10 and 11 ; respectively. The inner end 14 of the housing 1 is open for receiving various elements of the mechanism as described below. The bottom wall 11 extends outwardly a substantial distance beyond the open inner end 14 of the housing 1 . A plurality of holes 15 are provided in the outer end 16 of the bottom wall 11 for receiving screws (not shown) for securely mounting the housing 1 on the ledge of a window in the conventional manner. Because a large number of window frames are made of plastic, it is sometimes necessary to use many screws to ensure a secure mounting of the operating mechanism. When mounting the mechanism on a window frame, the outer end 16 of the bottom wall 11 and the inner free ends of the top and side walls of the housing 1 are housed in a socket (not shown) in the window frame. A flange 18 near the inner end of the housing 1 limits movement of the housing into the socket. Actually, the flange 18 bears against a vertical surface of the window frame around the socket to stabilize the mechanism, i.e. reduce or eliminate torque on the screws holding the housing 1 in position during operation of the mechanism.
[0030] Rectangular notches 20 and 21 are provided in the centers of the interiors of the top and bottom walls 10 and 11 , respectively of the housing for slidably receiving rectangular projections 22 and 23 on the top and bottom ends, respectively of a core body 27 of the mechanism. When the core body 27 is mounted in the housing 1 , mating of the projections 22 and 23 with the notches 20 and 21 prevents rotation of the core body in the housing. As best shown in FIGS. 8 to 10 , the core body 27 is generally-cylindrical for rotatably supporting an annular outer gear or gear ring 29 which is sandwiched between annular upper and lower spacers 30 and 31 , respectively. The upper spacer 30 is seated on a shoulder 32 on the core body 27 . The outer gear 29 has a larger interior diameter than the lower spacer 31 . Inclined teeth 34 extend around the interior of the outer gear 29 for meshing with similarly shaped and inclined teeth 35 on an inner, disc-shaped gear 36 , which is, in effect, a sun gear.
[0031] The inner gear 36 is rotatably mounted on a pin 38 on the flat base 39 of a semicircular recess 40 in one side of the core body 27 . Rotation of the inner gear 36 results in a corresponding rotation of the outer gear 29 around the longitudinal axis of the core body 27 . The recess 40 intersects an inclined passage 42 through the center of the core body 27 . The inner gear 36 is rotated by a worm shaft 43 which is rotatably mounted in the passage 42 . Helical threads 44 on the shaft 43 mesh with the inner gear 36 . The cylindrical bottom end 46 of the shaft 43 is rotatable in an inclined recess 47 in the bottom wall 10 of the housing 1 . The shaft 43 is held in the housing 1 by a cylindrical lock screw 49 , which bears against a shoulder 50 on the shaft 43 . External threads on the screw 49 engage the threaded upper end of a passage 51 through an inclined projection 53 on the center of the housing top wall 9 .
[0032] A handle assembly, which is indicated generally at 55 , is mounted on the splined upper end 56 of the shaft 43 . The assembly 55 includes a base 57 with a splined socked 58 for mounting on the shaft 43 , and a handle 60 pivotally connected to the base 57 by a pin 61 . A convex, transversely extending rib 62 on the cylindrical, body end of the handle 60 limits rotation of the handle when the latter is rotated from a non-use, storage position (not shown) on the base 57 to the use position (FIGS. 1, 6 and 7 ). A knob 64 secured to the outer, free end 65 of the handle 60 by a screw 66 facilitates manual manipulation of the handle.
[0033] Immediately prior to mounting the handle assembly 55 on the housing 1 , the thin, plastic rover 2 is mounted on the housing. An arm 66 , which forms part of a conventional lever system (not shown) for opening and closing a window, is mounted on a rectangular projection 67 on the outer gear 29 . The projection 67 extends outwardly from the open end 14 of the housing 1 . Spaced apart snap pins 69 on the projection 67 mate with holes in the arm 66 .
[0034] Snap rings 70 placed in annular grooves 72 (FIG. 11) near the outer free ends of the pins 69 hold the arm 66 on the outer gear 29 . Obviously, it is a simple matter to reverse the arm 66 on the pins 69 . The arm is lifted off the pins 69 causing the snap rings 71 to compress and then expand, the arm is rotated 180°, and the arm 66 is again placed on the pins 69 . When the arm 66 is reinstalled, the rings 71 compress and again expand to hold the arm on the pins 69 . This process applies to a retrofit situation. Normally, the operating mechanism is installed in a window frame when a window is being produced. Depending upon the intended opening direction, i.e. which side of the window sash carries the hinges, the arm 66 is installed to point in the appropriate direction.
[0035] Thus, it will be appreciated that the above described mechanism is much simpler in terms of structure than other assemblies intended for the same purpose. Moreover, the mechanism of the present invention makes it substantially easier to change the direction of window opening.
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An operating mechanism of a casement window includes a handle for rotating a worm shaft, which in turn rotates an inner gear, an annular gear and a crank arm to open a window. The crank arm is mounted on spaced apart pins on a flange or extension of the outer gear, so that the arm can be reversed on the pins to change the direction of window opening.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a system and method for managing an online social network, and more specifically, to a system and method for managing information exchange between members of an online social network.
2. Description of the Related Art
Online social networking sites have been rapidly gaining in popularity, and operators of online social networking sites have been adding servers and switches to their infrastructure to keep up with the increasing demand. Keeping up with the increasing demand has, however, proved to be difficult for two reasons. First, online social networking sites are virally marketed, as current members actively solicit nonmembers to sign up and join the network, and as a result, its growth has been very rapid. Second, the load on the social networking site is dependent not only on the total number of members but also on the total number of relationships. Because a member typically has multiple relationships, this means that the load increase associated with each new member is much greater than typical.
SUMMARY OF THE INVENTION
The present invention deals with the system load demands by improving the processing efficiencies of the online social networking site. The improvement in the processing efficiencies is achieved by providing one or more graph servers to be used in combination with the site's application server. The application server is configured to handle database management tasks, and the graph servers are configured to handle CPU-intensive computational tasks.
More specifically, the application server manages a database that contains member profile information and member relationship information. The graph servers keep track of how the members are socially connected to one another (hereinafter referred to as, “social network map”) in a dedicated memory device, and process and respond to queries from the application server using the social network map stored in the dedicated memory device. The social network map that is stored in the dedicated memory device of the graph servers is updated to reflect any changes to the member relationship information that are made in the database.
Because the present invention processes relationship information using a social network map that is stored in a dedicated memory device, the number of database lookups is decreased and an improvement in the processing speed is achieved. Depending on the number of relationships that are tracked, a dramatic improvement in the processing speed might be achieved with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram that conceptually represents the relationships between members in a social network;
FIG. 2 is a block diagram illustrating the system for managing an online social network according to an embodiment of the present invention;
FIG. 3 is a sample adjacency list that is maintained by the graphs servers of the present invention;
FIG. 4 is a flow diagram illustrating the method for processing a request by one member to view the profile of another member in the system of FIG. 2 ;
FIG. 5 is a flow diagram illustrating the method for determining whether a member can be contacted by another member in the system of FIG. 2 ; and
FIG. 6 is a flow diagram illustrating the method for processing a search request in the system of FIG. 2 .
DETAILED DESCRIPTION
A social network is generally defined by the relationships among groups of individuals, and may include relationships ranging from casual acquaintances to close familial bonds. A social network may be represented using a graph structure. Each node of the graph corresponds to a member of the social network. Edges connecting two nodes represent a relationship between two individuals. In addition, the degree of separation between any two nodes is defined as the minimum number of hops required to traverse the graph from one node to the other. A degree of separation between two members is a measure of relatedness between the two members.
FIG. 1 is a graph representation of a social network centered on a given individual (ME). Other members of this social network include A-U whose position, relative to ME's, is referred to by the degree of separation between ME and each other member. Friends of ME, which includes A, B, and C, are separated from ME by one degree of separation (1 d/s). A friend of a friend of ME is separated from ME by 2 d/s. As shown, D, E, F and G are each separated from ME by 2 d/s. A friend of a friend of a friend of ME is separated from ME by 3 d/s. FIG. 1 depicts all nodes separated from ME by more than 3 degrees of separation as belonging to the category ALL.
Degrees of separation in a social network are defined relative to an individual. For example, in ME's social network, H and ME are separated by 2 d/s, whereas in G's social network, H and G are separated by only 1 d/s. Accordingly, each individual will have their own set of first, second and third degree relationships.
As those skilled in the art understand, an individual's social network may be extended to include nodes to an Nth degree of separation. As the number of degrees increases beyond three, however, the number of nodes typically grows at an explosive rate and quickly begins to mirror the ALL set.
FIG. 2 is a block diagram illustrating a system for managing an online social network. As shown, FIG. 2 illustrates a computer system 100 , including an application server 200 and distributed graph servers 300 . The computer system 100 is connected to a network 400 , e.g., the Internet, and accessible over the network by a plurality of computers, which are collectively designated as 500 .
The application server 200 manages a member database 210 , a relationship database 220 and a search database 230 . The member database 210 contains profile information for each of the members in the online social network managed by the computer system 100 . The profile information may include, among other things: a unique member identifier, name, age, gender, location, hometown, a pointer to an image file, listing of interests, attributes, etc. The profile information also includes VISIBILITY and CONTACTABILITY settings, the uses of which are described below in connection with FIGS. 4 and 5 .
The relationship database 220 stores member relationship information in the following format: (MemberID — 1, MemberID — 2, Time, Add/Delete). MemberID — 1 and MemberID — 2 identify the two members whose relationship is defined by this input. Time is a variable corresponding to the time stamp of this input. Add/Delete is a variable indicating whether the friendship between MemberID — 1 and MemberID — 2 is to be added or deleted.
In addition, the contents of the member database 210 are indexed and optimized for search, and stored in the search database 230 . The member database 210 , the relationship database 220 , and the search database 230 are updated to reflect inputs of new member information and edits of existing member information that are made through the computers 500 .
The member database 210 , the relationship database 220 , and the search database 230 are depicted separately in the block diagram of FIG. 2 to illustrate that each performs a different function. The databases 210 , 220 , 230 may each represent a different database system, module, or software; or any two of the three or all three may be parts of the same database system, module, or software.
The application server 200 also manages the information exchange requests that it receives from the remote computers 500 . The information exchange requests may be a request to view a member's profile ( FIG. 4 ), a request to send messages to a member ( FIG. 5 ), or a search request ( FIG. 6 ). The application server 200 relies on the distributed graph servers 300 to process certain CPU-intensive tasks that are part of the information exchange request. The graph servers 300 receive a query from the application server 200 , process the query and return the query results to the application server 200 .
The graph servers 300 have a dedicated memory device 310 , such as a random access memory (RAM), in which an adjacency list that reflects the member relationship information is stored. A sample adjacency list that reflects the social network map of FIG. 1 is shown in FIG. 3 . A list item is generated for each member and contains a member identifier for that member and member identifier(s) corresponding to friend(s) of that member. As an alternative to the adjacency list, an adjacency matrix or any other graph data structure may be used.
The graph servers 300 , on a fixed interval, e.g., every five minutes, check the relationship database 220 for any incremental changes to the member relationship information. If there is, e.g., if (current time—5 minutes) is less than or equal to the time stamp corresponding to an entry in the relationship database 220 , the adjacency list stored in the dedicated memory device 510 is updated to reflect such incremental change. If a friendship is to be added, the adjacency list item for MemberID — 1 is amended to add MemberID — 2 and the adjacency list item for MemberID — 2 is amended to add MemberID — 1. If a friendship is to be deleted, the adjacency list item for MemberID — 1 is amended to delete MemberID — 2 and the adjacency list item for MemberID — 2 is amended to delete MemberID — 1. Alternatively, the adjacency list can be updated in real time, i.e., synchronously with the updates to the relationship database 220 .
The queries processed by the graph servers 300 include:
List_of_Members (M 1 , N d/s), which returns a list of member identifiers of all members who are exactly N d/s from member M 1 ; No_of_Members (M 1 , N d/s), which returns a raw number indicating the number of members who are exactly N d/s from member M 1 ; Get_Network (M 1 , N d/s), which returns a list of member identifiers of all members that are within N d/s from member M 1 ; Shortest_Path (M 1 , M 2 ), which returns the shortest path, if any, between member M 1 and member M 2 (the shortest path is displayed in the form of member identifiers of those members disposed in the shortest path between member M 1 and member M 2 ); and Are_Connected? (M 1 , M 2 , degrees), which returns the degree of separation corresponding to the shortest path between member M 1 and member M 2 , if the two are connected. If the two are not connected, an error code indicating that the two members are not connected is returned.
For the calculation of the shortest path in the queries listed above, any of the shortest path algorithms for a node network defined by an adjacency list may be used, e.g., breadth first search algorithm. The algorithms for carrying out other calculations that are necessary to process the queries listed above are programmed using conventional techniques.
In FIG. 2 , a plurality of distributed graph servers 300 are depicted, and is preferred over a single graph server because the distributed structure permits resources to be shared. However, the present invention may also be practiced with a single graph server.
The application server 200 and the graphs servers 300 are depicted separately in the block diagram of FIG. 2 to illustrate that the two are performing separate processes. The application server 200 and the graphs servers 300 may be housed within a single physical structure, or they may be parts of a single processor that is programmed to carry out their separate processes in parallel.
FIG. 4 is a flow diagram illustrating the method for processing a request by one member (e.g., M 1 ) to view the profile of another member (e.g., M 2 ) in the system of FIG. 2 . In Step 610 , the application server 200 receives a request by member M 1 to view the profile of member M 2 . As an example, this happens when member M 1 clicks on a hyperlink associated with member M 2 . The full profile of member M 2 will be displayed if the d/s between M 1 and M 2 is less than or equal to the VISIBILITY setting set by member M 2 or if the VISIBILITY setting set by member M 2 is ALL. (VISIBILITY setting may be set at 1, 2, 3 or ALL.) Otherwise, only the mini-profile of member M 2 will be displayed. In Step 620 , the application server 200 retrieves M 2 's VISIBILITY setting from the member database 210 . If M 2 's VISIBILITY setting is ALL, the full profile of M 2 will be transmitted to M 1 for display at M 1 's computer (Steps 630 and 640 ). If not, the application server 200 sends the Are_Connected? query to the graph servers 300 to determine the d/s between member M 1 and member M 2 (Steps 630 and 650 ). The graph servers 300 execute this query and return the d/s that it computed to the application server 200 . If the computed d/s is greater than the VISIBILITY setting or if member M 1 and member M 2 are not connected, the mini-profile of member M 2 and a message indicating that member M 2 's full profile can only be viewed by members in his or her personal network is transmitted to M 1 for display at M 1 's computer (Steps 660 and 670 ). Otherwise, the full profile of member M 2 is transmitted to M 1 for display at M 1 's computer (Steps 660 and 640 ).
FIG. 5 is a flow diagram illustrating the method for determining whether a member can be contacted by another member in the system of FIG. 2 . In the example given herein, it is assumed that member M 1 is attempting to send a message to member M 2 . In Step 710 , the application server 200 retrieves the CONTACTABILITY setting of member M 2 . (CONTACTABILITY setting may be set as 1, 2, 3 or ALL.) If M 2 's CONTACTABILITY setting is ALL, this means that member M 2 is permitting contact from anyone, and consequently, when member M 1 views member M 2 's profile, a “Send Message” hyperlink will appear through which member M 1 will be able to send messages to member M 2 (Steps 720 and 730 ). If M 2 's CONTACTABILITY setting is not set to ALL, the application server 200 sends the Are_Connected? query to the graph servers 300 to determine the d/s between member M 1 and member M 2 (Steps 720 and 740 ). The graph servers 300 execute this query and return the d/s that it computed to the application server 200 . If the computed d/s is greater than the CONTACTABILITY setting or if member M 1 and member M 2 are not connected, this means that member M 2 is not permitting contact from member M 1 and the “Send Message” hyperlink will not be displayed when member M 1 views member M 2 's profile (Steps 750 and 760 ). If the computed d/s is less than or equal to the CONTACTABILITY setting, this means that member M 2 is permitting contact from member M 1 , and consequently, when member M 1 views M 2 's profile, a “Send Message” hyperlink will appear through which member M 2 will be able to send messages to member M 1 (Steps 750 and 730 ).
FIG. 6 is a flow diagram illustrating the method for processing a search request in the system of FIG. 2 . In Step 810 , the application server 200 receives a search query input by member M 1 . The search query is divided into two parts. The first part specifies search terms for pre-selected categories such as gender, age, interests and location. The second part specifies a d/s setting, which may be set at 1, 2, 3 or ALL. For example, the search query may be: [gender (female), age (less than 30), d/s (at most 2)]. The first part of this search query is [gender (female), age (less than 30)] and the second part of this search query is [d/s (at most 2)]. In Step 820 , the application server 200 issues the first part of the search query to the search database 230 to obtain member identifiers for those members whose profiles meet the specified criteria. In Step 830 , the application server 200 issues a Get_Network query to the graph servers 300 to obtain a list of member identifiers of all members that are within the d/s specified in the second part of the search query. The application server 200 merges the results from the search database 230 and the graph servers 300 (Step 840 ), and transmits the merged results to member M 1 (Step 850 ). After the merged results are delivered to member M 1 , the member may click on any of the results to view that member's profile and, if the “Send Message” hyperlink is displayed, attempt to send a message to that member through that hyperlink.
While particular embodiments according to the invention have been illustrated and described above, it will be clear that the invention can take a variety of forms and embodiments within the scope of the appended claims.
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An online social network is managed using one server for database management tasks and another server, preferably in a distributed configuration, for CPU-intensive computational tasks, such as finding a shortest path between two members or a degree of separation between two members. The additional server has a memory device containing relationship information between members of the online social network and carries out the CPU-intensive computational tasks using this memory device. With this configuration, the number of database lookups is decreased and processing speed is thereby increased.
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CROSS-REFERENCE
[0001] This application refers to the provisional patent application No. 61/621,547 dated 2012 Apr. 8.
BACKGROUND OF THE INVENTION
[0002] In a typical communication between a web browser and a web server, a network entity designed for serving web pages or files implements a server program that accepts incoming network connections, such that clients or browsers connect to the server's network service port. In such a scenario the server opens a passive listening port (e.g. TCP port number 80 for incoming HTTP connections or TCP port number 443 for incoming HTTPS connections) and clients connect to the server by actively connecting to the server's listening port.
[0003] In a typical communication between a web browser and a web server through a web proxy, the network traffic between a client and a server is intercepted by an intermediate web proxy. A web proxy is a network entity designed to function as a server to clients and as a client to servers. From the client's point of view, a proxy acts as a server to receive incoming connections from clients. From the server's point of view, it acts as a client by forwarding the incoming connections to the server. A typical set of proxies add value to a network service by load balancing network traffic to the server and/or by off-loading server load by serving locally cached data to clients.
[0004] A firewall is a network entity that is typically placed at the entry/exit point of a computer network as a protection device, and can be configured to allow/disallow network connections based on connection attributes. For instance, a firewall can be placed at the entry point of a server farm or data center and it could be configured to let incoming connections destined to the server's TCP port 80 (IANA Internet Assigned Numbers Authority's default HTTP port) to transit through the firewall to the server, whilst dropping incoming connection packets that are unwanted (for example connections with destination port not equal to 80). Another wide spread use of a firewall is at the entry/exit point of small residential networks. For instance, firewall functionality usually comes built-in with home routers used in multitude of human residences. The default role of a home firewall is to disallow incoming network connections whilst allowing outgoing network connections. Such a setup prevents rogue hackers from crafting network attacks on home networks. If a residential user intends to accept incoming connections for a server then the firewall would have to be configured to allow incoming connections for that particular listening port (e.g. TCP protocol port 80).
[0005] One of the current methods uses direct peer to peer connections, wherein a residential computer serves files to users over the interne by running a network server program to listen to incoming requests. This solution may or may not allow a peer to browse the remote peer (hereby termed ‘live browsing’). This solution has the following four disadvantages:
a. The peer that serves files has to configure a firewall to allow incoming connections, b. The peer that serves files has to run a program that listens to incoming connections, thereby opening it up to the possibility of various attacks, such as port scanning, denial of service, and hacking, from anyone on the internet, c. The peer that accesses (or browses) the files connects to the IP address of the serving peer, requiring it to ‘trust’ that it is connected to the correct IP address, and that the IP addresses has not been spoofed, d. The peer that accesses (or browses) the files has to rely on the provider's implementation of algorithms for security of the data that travels such connections, given that a web browser will not display the familiar SSL security padlock.
[0010] One of the current methods uses server assisted peer to peer connections, wherein peers locate each other's location or IP address using an intermediate server, after which the connections are established in a direct peer to peer mode as above. This method will have the same disadvantages as mentioned in the direct peer to peer case above.
[0011] One of the current methods uses cloud storage based file sharing, wherein one peer uploads files to an intermediate server for storage, and an accessing-peer downloads from the intermediate server, a typical scenario being a server supplied program that downloads it automatically to the peer's computer. Methods similar to these are currently implemented by various online sites. While these services overcome the disadvantages of a peer to peer network, they still do not solve the ‘live browsing’ feature, and they require their users to store user files at the service provider. There is a subset of users who do not wish to relinquish their data to a service provider's storage farm.
[0012] There is a need for a solution that overcomes all the disadvantages of a peer to peer network, and does not require a user to upload their data to a storage farm, and still maintains the advantages of live browsing. The present invention solves this problem by using secure (SSL based) connections, which ensures DNS security, IP address security, Data Security, Live Browsing, without the need to upload files, while providing a secure browsing experience over HTTPS (Secure HTTP protocol).
[0013] The following is a list of items describing how the present invention differs from other inventions:
1) While U.S. Pat. No. 7,161,947 by the current inventor describes a method of transparently intercepting protocols such as FTP that utilize control and data connections; in contrast, the present invention describes a method of serving a protocol such as HTTP that utilizes one connection per request in a manner such that both the accessing computer and serving computer set up active connections to an intermediate rendezvous server. 2) While patent application Ser. No. 11/871,032 describes a method of sharing computer display screens; in contrast, the present invention describes a method for sharing file folders. 3) While patent application Ser. No. 13/644,659 describes a method of integration between local and remote computing environments for the purpose of sharing remote application; in contrast, the present invention describes a method for sharing file folders and for serving files from remote computers. 4) Patent application Ser. No. 13/595,472 describes a method for mobile devices to negotiate a dynamic rendezvous point using a notification, thereby creating a set of ephemeral rendezvous points. Such a method would require connection initiation from a first mobile device for each rendezvous with a second mobile device. Furthermore, such a method would imply that a rendezvous point is negotiated for each transfer. Furthermore, such a method would imply that the first mobile device and the second mobile device negotiate a rendezvous point sporadically on an as-needed basis. Furthermore, such a method would imply that such transfers occur in a non-continuous form, wherein even during two consecutive transfers there would a small time window (during negotiation) where the first mobile device is unavailable. In contrast, the present invention describes a method for continuously serving files and folders from a publisher computer utilizing a rendezvous server, using a control connection and a data connection, such that the control connection always remains connected to a rendezvous server, and data requests are handled using a combination of control and data connections, such that data transfer between the publisher and the rendezvous server occurs using a separate data connection. In the present invention, all the clients utilizing the system connect to a well-known server and browse web pages as though it is served from the rendezvous server, such that publisher computers act as a pseudo servers that serve content for channels through the rendezvous server. Furthermore, in the present invention, published data and associated channels are continuously available for the life of the control connection, such that publisher data is available online for extended periods of time, as long as the publisher program stays connected to the rendezvous server (typically for tens of thousands of requests over many days or weeks).
SUMMARY OF THE INVENTION
[0020] In the context of this document, for the purposes of computer networking the use of the term ‘rendezvous’ is meant to imply a network location where the user of a resource and the publisher of a resource meet up by connecting over network connections, such that the user can locate the publisher and the publisher can serve the user with a representation of the resource.
[0021] The present invention organizes users as owners, publishers and/or subscribers of virtual channels; wherein requested URLs (Uniform Resource Locators) contain a channel identifier and resource identifier as part of the URL; additionally organizing publishers to dynamically publish resource sets to channels, and subscribers to access and/or update resources published to such channels. For the purpose of this document, the term ‘resource’ implies collected bits of computer data.
[0022] The present invention organizes and allows desktop computers and other mobile devices to register as resource publishers with a rendezvous server in the Internet by actively connecting to the rendezvous server (hereby termed ‘control connection’); such that client users (using web browsers) can fetch or update the content residing on a resource publisher by connecting to the rendezvous server (hereby termed ‘subscriber connection’), wherein the rendezvous server forwards the user's request over a control connection to the resource publisher, and the resource publisher in turn sends a content response over an active network connection (hereby termed ‘data connection’) to the rendezvous server, which in turn forwards it to the user over the subscriber connection. Additionally, a publisher control connection is kept open across multiple data connections (from the same publisher), such that it handles multiple subscriber requests, such that published data is available online continuously for the life of the control connection.
[0023] As described above, a rendezvous server listens for incoming connections from resource publishers as well as from requesting resource subscriber clients, and it patches the connections together for request and response flows. Thus allowing for content to be served from resource publishers without needing resource publishers to open passive listening ports on resource publisher computers.
[0024] A key difference between the present invention and a generic proxy based solution is that in the present invention the publisher actively connects to a rendezvous server, as opposed passively listening for incoming connections, making it firewall friendly, and enabling easy deployment at a multitude of residential customers.
[0025] A key difference between the present invention and a peer to peer file sharing network is that the present invention uses standard secure protocol (HTTPS), is not open to IP spoofing, is not open to DNS spoofing, does not open a publisher to attacks from the internet.
[0026] A key difference between the present invention and a cloud storage based sharing network is that the present invention allows live browsing of published files without requiring the files to be uploaded and stored at a service provider's server.
[0027] Such a scheme, therefore, allows for the arrangement of a multitude of resource publishers connected to a set of distributed rendezvous servers, wherein the content resides at various resource publishers, without requiring the content to be placed in a remote data center, or so called cloud of computer servers.
[0028] Additionally, such an arrangement when used for digitally encrypted secure connections, would require Public Key Infrastructure (PKI) digital security certificates (SSL certificates) to be installed only at rendezvous servers instead of at each resource publisher, thereby simplifying the security architecture of the arrangement.
[0029] Such a scheme, allows maximum control of the content by a resource publisher by ensuring that bits of private data are not placed on huge computers in a data center or server cloud, whilst providing a dynamic control over the availability and unavailability of content.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The foregoing and other objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, with the emphasis instead being placed upon illustrating the embodiments, principles and concepts of the invention.
[0031] FIG. 1 is a block diagram of a rendezvous server based data communications system, configured according to one embodiment of the invention.
[0032] FIG. 2 is a flow chart of the process of a request and response flow at a rendezvous server of the data communications system, when the system is configured as per FIG. 1 .
[0033] FIG. 3 is a block diagram of the modules of a rendezvous server, configured according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0034] The present invention relates to techniques for arranging resource publishers and rendezvous servers to provide a dynamically controllable resource publication system that is accessible over the interne without the need to set up full scale servers at the various resource publishers. A typical server on the Internet requires a valid domain name, a firewall for protection, and a host of other supporting networking gear. The present invention allows resource publishers to publish resources like software files and directories by simply registering with a rendezvous server, without the need for additional networking gear. The present invention also provides security of the resources at a resource publisher by actively connecting to a rendezvous server, as opposed to passively listening to incoming connections.
[0035] FIG. 1 shows a data communications system configured to operate according to the principles of this invention. The data communications system includes a first computerized device, such as client computer 20 , a computer server device 50 , a second computerized device, such as publisher computer 60 , a third computerized device, such as publisher computer 70 . The direction of arrows in FIG. 1 indicate the direction in which a connection is initiated, such that the arrowhead is at the listener end of a TCP connection.
[0036] As illustrated in FIG. 1 , during a typical operation of the data communications system, the user operating the client computer 20 uses a web browser 21 to connect to the rendezvous server 50 . The rendezvous server shows the online or offline status of the various resource publishers that the user has authority to access. If a resource publisher is offline, the user cannot access or browse the associated resources or files.
[0037] Publisher computer 60 can initiate a network connection, hereby termed ‘control connection’ 65 to the rendezvous server 50 . By doing so it registers with the rendezvous server 50 , after which point the status of the resource publisher changes to ‘online’.
[0038] Publisher computer 70 can initiate a network connection, hereby termed ‘control connection’ 75 to the rendezvous server 50 . By doing so it registers with the rendezvous server 50 , after which point the status of the resource publisher changes to ‘online’.
[0039] If the user has access rights to the resource set 62 published by the publisher computer 60 , the user can access or update the resources in resource set 62 .
[0040] If the user does not have access rights to the resource set 72 published by the publisher computer 70 , the rendezvous server 50 does not allow the user to access the resources in resource set 72 .
[0041] Access rights to resource sets can be implemented in various ways. The method described in this invention implements access rights by associating various resource sets to virtual channels, wherein users who are subscribers of certain channels can access those resources, and users who are publishers of certain channels can publish resource sets to those channels.
[0042] After receiving the HTTP request from web browser 21 over subscriber connection 25 to read a resource belonging to resource set 62 ; if the user has access rights to that set, the rendezvous server 50 forwards the request to the resource publisher 61 over control connection 65 . The resource publisher 61 generates a response and sends the resource (e.g. software copy of a file) to the rendezvous server 50 over data connection 67 . The rendezvous server 50 in turn forwards the response to the web browser 21 over subscriber connection 25 .
[0043] After receiving the HTTP request from web browser 21 over subscriber connection 25 to read a resource belonging to resource set 72 ; if the user does not have access rights to that set, the rendezvous server 50 rejects the request by sending an error response to the web browser 21 over subscriber connection 25 .
[0044] FIG. 2 illustrates a procedure 200 for managing connections at a rendezvous server for a request from a client user, such as web browser 21 , for a resource located at a publisher computer such as 70 .
[0045] In step 202 , the rendezvous server receives a control connection request from the publisher computer 70 . The rendezvous server accepts the connection and adds connection information about resource publisher 71 to its software registry.
[0046] In step 204 , the rendezvous server receives a request from the client web browser 21 over subscriber connection 25 . The rendezvous server accepts the connection and parses the request to find that it is a request to fetch a resource located at the publisher computer 70 in the resource set 72 which can be served by the resource publisher 71 .
[0047] In step 206 , the rendezvous server consults a channel publish-subscribe module to check whether the user is authorized to access the resource. If the user is authorized to access the aforementioned resource the rendezvous server proceeds to step 208 , else it proceeds to step 214 .
[0048] In step 208 , the rendezvous server forwards the subscriber request to the resource publisher 71 over control connection 75 .
[0049] In step 210 , the rendezvous server accepts an incoming data connection 77 from the resource publisher 71 containing a response. A response can contain either a successful result with associated data or an error result with associated error information.
[0050] In step 212 , the rendezvous server forwards the response to the client web browser 21 over the subscriber connection 25 .
[0051] In step 214 , the rendezvous server forwards an authorization failure error response to the client web browser 21 over the subscriber connection 25 .
[0052] In a related embodiment, the rendezvous server can allocate a specific time interval for receiving a response from the resource publisher 71 . In case a response is not received within the specified time interval, the rendezvous server can abort the request processing and send an error response to the client web browser 21 over the subscriber connection 25 .
[0053] FIG. 3 shows a block diagram of a rendezvous server 50 configured according to one embodiment of the invention. The server system includes a database 80 hereby termed ‘channel publish-subscribe module’ for storing various association tables, such as registry 81 for storing user authentication, channel, and resource-set entries, user to channel associations 82 , resource-set to user associations 83 , resource-set to channel associations 84 ; a rendezvous connection table 91 ; a network layer 100 to accept incoming network connections such as subscriber connection 25 , control connection 75 , data connection 77 . FIG. 3 also depicts publisher computer 70 and web browser 21 which are external to the rendezvous server. The direction of arrows in FIG. 3 indicate the direction in which a connection is initiated, such that the arrowhead is at the listener end of a TCP connection.
[0054] The rendezvous server 50 receives an incoming control connection 75 from a resource publisher user at the network layer 100 , upon which it validates the user by checking the registry 81 . It further checks if the user is a channel publisher by searching the user to channel association 82 . It further checks if there are any published resource-sets by the user by searching the resource-set to channel association 83 . If all these checks succeed an entry is added to the rendezvous connection table 91 , else the control connection is rejected.
[0055] The rendezvous server 50 receives a request over an incoming subscriber connection 25 from a subscriber user using a web browser client 21 at the network layer 100 , upon which it validates the user by checking the registry 81 . It further checks if the user is allowed to access the requested channel by searching the user to channel association 82 . It further searches the rendezvous connection table 91 to locate a resource publisher control connection 75 associated with the requested channel, upon which it forwards the request along with a unique request identifier to resource publisher 71 over control connection 75 . It further adds a uniquely identifiable entry to the rendezvous connection table 91 for subscriber connection 25 .
[0056] The rendezvous server 50 receives an incoming data connection 77 from resource publisher 71 at the network layer 100 , upon which it searches the rendezvous connection table 91 to find the uniquely identified entry for subscriber connection 25 . If the request on subscriber connection 25 has a data payload it forwards it to the publisher over the data connection 77 . Additionally, it forwards the response received on data connection 77 to the user over subscriber connection 25 .
[0057] In a related embodiment, publisher control connections, publisher data connections, and subscriber connections use encrypted network service, such as SSL (Secure Sockets Layer), further ensuring security of the data.
[0058] In a related embodiment, the subscriber connection request is for storing data to the publisher's resource-set (e.g. an HTTP POST request), wherein data payload of a request is forwarded to the resource publisher over the data connection and stored in the resource-set at the publisher. Such a configuration can be used to dynamically update the resource set mapped to the channel. Furthermore, such a configuration can be used to distribute data to multiple channel users across multiple computers.
[0059] In a related embodiment, a publisher computer has one resource publisher, but multiple resource sets, such that one resource set is available on one channel, whereas a second resource set is available on a different channel. In such a scenario, the rendezvous server checks whether the client web browser is allowed access to the specific channel before forwarding the request to the resource publisher.
[0060] In a related embodiment, resource publishers are full scale servers located within a network of computers equipped to safely handle incoming traffic, wherein resource publishers dynamically publish content by utilizing a rendezvous server as a means for redirecting client traffic to the appropriate resource publisher. Such a configuration can be deployed for high performance content publishing.
[0061] In a related embodiment, multiple full scale servers with duplicate data are set up as resource publishers connected as slave servers to a main rendezvous server. Such a configuration can be used for a high redundancy web service or for load balancing web content.
[0062] In a related embodiment, multiple full scale servers with differing data are set up as resource publishers connected as slave servers to a main rendezvous server. Such a configuration can be used across geographic regions, wherein various regional resource publishers feed into a centralized rendezvous server. Such a configuration can be used for deploying a content aggregation system.
[0063] In a related embodiment, multiple rendezvous servers are set up within a server cluster, such that they load balance incoming publisher and subscriber connections based on the connection load of the cluster.
[0064] In a related embodiment, multiple rendezvous servers are set up across geographically diverse locations, such that publishers are assigned to a rendezvous server based on the proximity of the publisher with the rendezvous server.
[0065] It is to be understood that the above-described embodiments are simply illustrative of the principles of the invention. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit of and scope thereof.
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A system and method for interconnecting a plurality of resource publisher computers with a plurality of rendezvous servers, facilitating resource publishers to dynamically publish content with little or no configuration, further facilitating web based access to the published resources by clients through a rendezvous server. The system organizes users as owners, publishers and/or subscribers of virtual channels, allowing publishers to dynamically publish resource sets to channels, and subscribers to access and/or update resources published to such channels. Resource sets reside at resource publishers, with a rendezvous server facilitating a network path to the resources, enabling resource publishers to have full control over their resources. The system facilitates subscriber clients to connect to a rendezvous server to view the status of the resource sets and access and/or update online resource sets.
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BACKGROUND OF THE INVENTION
Prior Art
[0001] Generally, cellulose fibers are suitable for use in the treatment of wounds and also in the hygiene sector because cellulose is very compatible with skin and wounds. Apart from natural cellulose fibers such as cotton, synthetic cellulose fibers such as viscose, lyocell, cupro or polynosic are commercially available and known in these applications. According to the BISFA definition, Lyocell is a fiber spun from an organic solvent. Possible methods of producing it are described, inter alia, in U.S. Pat. No. 4,246,221 and U.S. Pat. No. 4,196,282. Processes for producing the other cellulosic synthetic fibers have been known much longer.
[0002] The use of absorbent cellulosic materials in medical applications, for example in wound dressings has long been known, inter alia, from U.S. Pat. No. 4,203,435.
[0003] AT 363578 describes the production of absorbent cellulose-based fibers by spinning of carboxymethyl cellulose and other cellulose derivatives in viscose.
[0004] Also, chemically modified polysaccharides find use as absorbent components of wound dressings and padding, for example according to EP 0092999 in the form of water-dispersible hydrocolloids made from carboxymethyl cellulose or according to EP 0680344 in the form of cellulose fibers which have been carboxymethylated following the extrusion from an NMMO solution.
[0005] Wound dressings which contain carboxymethyl cellulose fibers, however, have the disadvantage that the derivatization of the fibers is performed using monochloroacetic acid, leading to a reduction in strength of the fibers and thus later to insufficient cohesion of the gel layer swollen due to liquid absorption.
[0006] Methods for producing carboxyethyl cellulose have also already been described in the prior art. For example, US20060137838 proposes the production of carboxyethyl cellulose from wood pulp in the same manner as from carboxymethyl cellulose using the appropriate chloroalkyl acids as reagent. This method is well suited for producing carboxymethyl cellulose. However, the analogous preparation of carboxyethyl cellulose fibers in this way is economical not possible. By reworking these procedures, no economically relevant yield of carboxyethyl cellulose fibers could be obtained. The fibers did not have any significantly higher water retention capacity compared to underivatized control fibers. It is therefore likely that the relevant information to carboxyethyl production is merely theoretical in nature and has not been checked technically.
[0007] U.S. Pat. No. 5,667,637 discloses the production of carboxyethyl cellulose, starting from wood pulp with acrylamide for paper applications.
[0008] In the literature, the use of carboxyethyl cellulose is often suggested for wound dressings, but always only in lists of various theoretically possible alternatives to carboxymethylcellulose. Practice-relevant properties of such carboxyethyl celluloses or concrete examples are not listed. Also, information on the strength of such fibers is nowhere to be found.
SUMMARY OF THE INVENTION
[0009] In view of the prior art, the object was to provide an alternative cellulose-based material for the absorption of fluids and in particular body fluids, for example for use in wound dressings and other products for medical applications or hygiene applications, and particularly for producing a surface to be in contact with the body and a method for producing it. In the swollen state, this material must have greater cohesion than previously known materials, which allows, for example, that a wound dressing produced therefrom can be peeled off from the wound in one piece.
[0010] This problem could be solved by the first provision of water insoluble carboxyethyl cellulose fibers that have a strength in the conditioned state of at least 15 cN/tex, and have a water retention capacity of at least 400% while maintaining their fibrous form.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Preferably, the carboxyethyl cellulose fibers have a water retention capacity of at least 600%, particularly preferably at least 800%.
[0012] The strength of these carboxyethyl cellulose fibers in the conditioned state is preferably at least 20 cN/tex. In principle, strengths up to those of the underivatized fibers are possible to obtain, i.e., up to about 40 cN/tex.
[0013] It has surprisingly been found that carboxyethyl cellulose fibers suitable for these applications have sufficient mechanical properties if they were prepared by derivatization of lyocell, viscose or modal fibers. These mechanical properties allow, for example, that a wound dressing produced from the fibers according to the invention after contact with water or wound fluid forms a transparent gel, while it still retains a high strength, which allows for it to be peeled off from a wound without residues. Also, for hygiene items it is of great importance that fibers used have sufficient mechanical cohesion after the absorption of body fluids and the associated swelling with gel formation.
[0014] Since, as already stated above, the processes for producing carboxyethyl cellulose fibers proposed in the prior art are practically unsuccessful, initially there was a need to develop a suitable production method.
[0015] The present invention therefore also provides a process for producing these water-insoluble carboxyethyl cellulose fibers, wherein cellulosic synthetic fibers are reacted with acrylamide in strong alkali.
[0016] Basically, the titer of the fibers used may be selected arbitrarily and is determined by the application. For many applications a not too rough structure of the body-facing surface may be preferred. Preferred is therefore a single fiber titer of 0.5 dtex-6.0 dtex, more preferably 1.4 to 3.3 dtex. Fibers having a single fiber titer of less than 0.5 dtex are practically not relevant.
[0017] The cellulosic synthetic fibers can be used in the form of cut individual fibers—also referred to as staple fibers—, filaments, continuous filament tow, nonwoven fabrics, woven fabrics, knitted fabrics and/or other textile fabrics. As the cellulosic synthetic fibers, preferably lyocell, viscose or modal fibers are used.
[0018] Preferred alkali is sodium hydroxide. However, the use of any strong alkali is possible. The alkali concentration should be 2-10%, preferably, however, 4-6%. Surprisingly, it has been found that the aqueous solution may contain 1 to 75% of ethanol, preferably 15 to 30% of ethanol.
[0019] The amount of acrylamide used is closely related to the desired degree of substitution. Per anhydroglucose unit 2-10 molecules of acrylamide can be used in the reaction. Preferably, 6-10 molecules of acrylamide are used per anhydroglucose and particularly preferably 7 or 8 molecules of acrylamide. The reaction takes 30 to 120 min, preferably 50-70 min, at a temperature of 30-90° C., preferably at 40-60° C. Additionally, after this reaction, the reaction temperature can be increased up to 90° C. and treatment may continue for additional 30 to 120 min. Preferred is an increase of 10-40° C. Most preferably, the temperature is increased to 60-80° C., and the reaction is continued for additional 50-70 min. The values of water retention capacity in 0.9% NaCl solution achieved in this manner reach 200-600%.
[0020] These values are surprisingly increased significantly by a post-treatment of the fibers with a 3-10% alkali, preferably with a 4-6% alkali. Preferably, sodium hydroxide is used as alkali, but in principle, any solution of an alkali metal hydroxide is suitable. The aqueous alkali solution may contain 1 to 75% ethanol, preferably 30 to 70%. This post-treatment takes 30-120 min, preferably 50-70 min at a temperature of 30-90° C., preferably at 60-80° C.
[0021] If no ethanol is added during the reaction and/or during the post-treatment step, the final product has a much lower water retention capacity than if the procedure is performed in accordance with the invention.
[0022] The CEC fibers are washed and dried after the post-treatment. For washing, a mixture of ethanol, water and a weak acid is used. Preferred is a solution of 20-80% of ethanol, 19-79% of water and 1-10% of a weak acid, preferably 40-70% of ethanol, 29-59% of water and 1-10% of a weak acid. As a weak acid, preferably citric or acetic acid is used. Finally, the fibers are washed with a solution of a fatty acid ester in ethanol, preferably polyoxyethylene sorbitan fatty acid ester, for example, 1% Tween 20, in ethanol, and then dried.
[0023] The final fibers have a neutral to slightly acidic pH value (pH 5.5 to 7.5) and a water retention capacity of 400% up to over 1200% in 0.9% saline.
[0024] The fibers thus produced can be used in particular for producing products for absorbing liquids and body fluids, for example for use in products for medical applications or hygiene applications. These fibers can also be used for products for maintaining of moisture of wounds, e.g. with saline. The use takes place in the contact area, which faces the body, i.e., which is in contact with the body. In the case of wound dressings, band aids, bandages, swabs and the like, it is usually the wound to be treated or any other open area of the body. In the case of hygiene items such as baby diapers and incontinence products and feminine hygiene products, it is a skin surface or body part appropriate for the intended application. Only in hygiene items, frequently a layer of PP or PES, a so-called top sheet, is inserted between the skin and the fiber layer. Surprisingly, it has been found that it is critical for a successful application that the carboxyethyl cellulose fibers have a strength in the conditioned state of at least 15 cN/tex, preferably at least 20 cN/tex and a water retention capacity of at least 400%. According to the current state of the art for this purpose only the above described method according to the invention is suitable.
[0025] Preferably, the carboxyethyl cellulose fibers can be used in the form of cut individual fibers—also referred to as staple fibers—, filaments, continuous filament tow, nonwoven fabrics, woven fabrics, knitted fabrics and/or other textile fabrics.
[0026] For use in wound dressings the carboxyethyl cellulose fiber itself or another part of the wound dressing may be provided with additives of Ag, Cu and Zn compounds, chitosan and other antimicrobial components.
EXAMPLES
[0027] The invention will now be explained using examples. These are understood to be possible embodiments of the invention. By no means is the invention limited to the extent of these examples.
[0028] Determination of water retention capacity (according to standard DIN 53814):
[0029] The water retention capacity as a measure of the absorbency of the fibers according to the invention is defined as the liquid absorption by swelling of a certain amount of fiber as a percentage of the dry weight and is determined as follows: In a centrifuge vessel, 0.5 g of fibers are mixed with sufficient 0.9% saline until the fluid leaks from the bottom. Thereafter, again saline is added and allowed to stand for 2 hours. The centrifuge vessels are then spun at 3400 rpm (=9500 m/s 2 ) for 20 min and then the fibers are weighed in weighing bottles. Then, the fibers are dried at 105° C. for 16-18 hours, and after cooling, they are weighed again (according. The difference between the two masses is multiplied by 100 and divided by the dry weight yields the water retention capacity as a percentage. The CEC fibers reach values of water retention capacity of at least 400%, preferably at least 600% and more preferably at least 800% in 0.9% saline.
Example 1
[0030] Lyocell fibers having a single fiber titer of 1.4 dtex are added into 5.6% aqueous NaOH solution. The solution further contains 25% ethanol and 240 g/l acrylamide. The mixture is heated to 50° C. and is allowed to react for 60 min. Thereafter, the temperature in increased to 70° C. and is allowed to react for additional 60 min. After the reaction, the fibers are pressed with a pressing roller to a moisture content of 100%. The pressed fibers are treated with 4% aqueous NaOH solution containing 50% ethanol, at 70° C. for 60 min. Following this second treatment, the fibers are again pressed and washed with a solution of 55% ethanol, 42% water and 3% citric acid. Washing once with 1% Tween® 20 in ethanol follows as the final treatment step. The fibers are then dried. The resulting fibers have a water retention capacity of 900% in 0.9% NaCl solution and conditioned a strength of 22 cN/tex.
Example 2
Comparative Example
[0031] To show clearly the impact of the addition of ethanol during the reaction and the post-treatment step, the ethanol addition was omitted in the following experiment. Everything else was repeated as in Example 1 without change.
[0032] Lyocell fibers having a single fiber titer of 1.4 dtex are added into 5.6% aqueous NaOH solution. The solution further contains furthermore and 240 g/l acrylamide. The mixture is heated to 50° C. and allowed to react for 60 min. Thereafter, the temperature in increased to 70° C. and allowed to react for additional 60 min. After the reaction, the fibers are pressed with a pressing roller to a moisture content of 100%. The pressed fibers are treated with 4% aqueous NaOH solution, at 70° C. for 60 min. Following this second treatment, the fibers are again pressed and washed with a solution of 55% ethanol, 42% water and 3% citric acid. As the final treatment step, washing once with 1% Tween® 20 in ethanol follows. The resulting fibers have a water retention capacity of 300% in 0.9% NaCl solution. Since the fibers thus obtained were always stuck to each other, the single fiber strength could not be determined.
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The present invention relates to carboxyethyl cellulose fibers, to a method for producing the same and their use for wound treatment, especially in wound dressings, in other products for medical applications such as swabs, bandages and the like, and in hygiene items, and in all these applications, particularly for producing a surface to be in contact with the body. The products produced from the fibers according to the invention do not stick to the wounds or to the skin despite being extremely absorbent and have such good cohesion in the swollen state that especially the wound dressings produced therefrom can be peeled off from the wound in one piece without injuring the same.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 10/198,546, filed on Jul. 18, 2002; which is a divisional of application Ser. No. 09/575,634, filed on Dec. 17, 2002 now U.S. Pat. No. 6,495,721; and claims the benefit of provisional application Ser. No. 60/182,159, filed Feb. 14, 2000; and is a continuation-in-part of application Ser. No. 09/448,985, filed Nov. 24, 1999, which claims the benefit of provisional application No. 60/147,888, filed Aug. 9, 1999. The contents of each of these applications are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel crystalline form of sertraline hydrochloride, and reproducible methods for its preparation.
BACKGROUND OF THE INVENTION
[0003] Sertraline hydrochloride, (1S-cis)-4-(3,4 dichlorophenyl)-1,2,3,4-tetrahydro-N-methyl-1-naphthalenamine hydrochloride, having the formula
is approved, under the trademark Zoloft®, by the U.S. Food and Drug Administration, for the treatment of depression, obsessive-compulsive disorder and panic disorder.
[0004] U.S. Pat. 4,536,518 (“the '518 patent”) describes the preparation of sertraline hydrochloride with a melting point of 243-245° C. by treating an ethyl acetate/ether solution of the free base with gaseous hydrogen chloride. The solid state properties of the sertraline hydrochloride so produced are not otherwise disclosed.
[0005] U.S. Pat. No. 5,734,083 describes the preparation of a form of sertraline hydrochloride denominated polymorph “T1.”
[0006] According to U.S. Pat. No. 5,248,699 (“the '699 patent”), the sertraline hydrochloride produced by the method of the '518 patent has a crystalline form denominated “Form II.” The '699 patent discloses four other polymorphs of sertraline hydrochloride designated Forms I, III, IV, and V, and characterizes them by single crystal x-ray analysis, powder x-ray diffraction, infra-red spectroscopy, and differential scanning calorimetry. The '699 patent reports that Form II is produced by rapid crystallization of sertraline hydrochloride from an organic solvent, including isopropyl alcohol, ethyl acetate or hexane, and generally describes methods for making sertraline hydrochloride Forms I-V. According to this patent, the preferential formation of Forms I, II or IV in an acidic solution consisting of isopropyl alcohol, hexane, acetone, methyl isobutyl ketone, glacial acetic acid or, preferably, ethyl acetate, depends on the rapidity of crystallization. The only method described in this patent for making Forms II and IV is by the rapid crystallization of sertraline hydrochloride from an organic solvent such as those listed above.
[0007] The experimental procedure for the preparation of sertraline hydrochloride described in the '518 patent, was repeated in the laboratory. According to the '699 patent, the '518 procedure produces sertraline hydrochloride Form II. Four experiments were performed according to the description in the '518 patent. By following the procedures described in the '699 patent for preparation of sertraline hydrochloride Form II, we were unable to obtain sertraline hydrochloride Form II. Thus there remains a need for reproducible methods for the preparation of sertraline hydrochloride Form II.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a process for making sertraline hydrochloride Form II comprising the steps of dissolving sertraline base or sertraline mandelate in an organic solvent to form a solution; adding hydrogen chloride to the solution; heating the solution to a temperature between about room temperature and about reflux for a time sufficient to induce the formation of sertraline hydrochloride Form II; and isolating sertraline hydrochloride Form II.
[0009] The present invention also relates to a process for making sertraline hydrochloride Form II comprising the steps of dissolving sertraline hydrochloride in dimethylformamide, cyclohexanol, acetone or a mixture thereof; heating the solution for a time sufficient to effect transformation to sertraline hydrochloride Form II; and isolating sertraline hydrochloride Form II.
[0010] The present invention further relates to a process for making sertraline hydrochloride Form II comprising the steps of granulating sertraline hydrochloride Form V in ethanol or methanol; and stirring the mixture of sertraline hydrochloride Form V and ethanol or methanol for a time sufficient to induce transformation to sertraline hydrochloride Form II.
[0011] The present invention still further relates to a process for making a mixture of sertraline hydrochloride Form II and Form V comprising the steps of heating sertraline hydrochloride ethanolate Form VI at up to 1 atmosphere pressure; and isolating a mixture of sertraline hydrochloride Form II and Form V.
[0012] The present invention still further relates to a process for making sertraline hydrochloride Form II comprising the steps of suspending a water or solvent adduct of sertraline hydrochloride in a solvent selected from the group consisting of acetone, t-butyl-methyl ether, cyclohexane, n-butanol, and ethyl acetate such that a slurry is formed, for a time sufficient to effect transformation to sertraline hydrochloride Form II; and filtering the slurry to isolate sertraline hydrochloride Form II.
[0013] The present invention still further relates to sertraline hydrochloride Form II, characterized by an x-ray powder diffraction pattern comprising peaks at about 5.5, 11.0, 12.5, 13.2, 14.7, 16.4, 17.3, 18.1, 19.1, 20.5, 21.9, 22.8, 23.8, 24.5, 25.9, 27.5, and 28.0 degrees two theta; pharmaceutical compositions for the treatment of depression comprising sertraline hydrochloride Form II together with a pharmaceutically acceptable carrier, and a method for treating depression comprising the step of administering to a subject in need of such treatment a therapeutically effective amount of the such a pharmaceutical composition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a characteristic x-ray powder diffraction spectrum of sertraline hydrochloride prepared by the methods of U.S. Pat. No. 4,536,518.
[0015] FIG. 2 is a characteristic x-ray powder diffraction spectrum of sertraline hydrochloride prepared by the methods of U.S. Pat. No. 5,248,699.
[0016] FIG. 3 is a characteristic x-ray powder diffraction spectrum of sertraline hydrochloride Form II prepared by the methods of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Form II from Sertraline Base or Sertraline Mandelate
[0017] The present invention provides new processes for making sertraline hydrochloride Form II from sertraline base or sertraline mandelate. Sertraline base may be made by methods known in the art, including the methods of the '518 patent. Sertraline base is dissolved in a suitable solvent. Suitable solvents include ethyl acetate, acetone, t-methyl-butyl ether, isopropyl alcohol, n-butanol, t-butanol, iso-butanol, hexane, and cyclohexane, and mixtures thereof. The pH of the sertraline base solution is lowered by the addition of hydrogen chloride, which may result in a temperature increase. As used herein, “hydrogen chloride” includes both gaseous hydrogen chloride and aqueous hydrogen chloride (i.e. hydrochloric acid). Hydrogen chloride also may be added as a solution with an organic solvent, such as a solution of isopropyl alcohol and hydrogen chloride, n-butanol and hydrogen chloride, acetone and hydrogen chloride, or the like. The solution of sertraline base or sertraline mandelate in the solvent is heated to a temperature between about room temperature and the reflux temperature of the solvent and maintained at that temperature for a period of time sufficient to effect the transformation to sertraline hydrochloride Form II. Preferably the solution is heated to a temperature between about 45° C. and the reflux temperature of the solvent. Most preferably the solution is heated to at or about the reflux temperature of the solvent. Upon cooling of the mixture, for example to room temperature, sertraline hydrochloride Form II is isolated by filtration.
[0018] In a preferred variation of this method, the solution of sertraline base or sertraline mandelate in a solvent is heated to the reflux temperature of the solvent. The mixture is refluxed for a time sufficient to effect the transformation to sertraline hydrochloride Form II. Preferably the mixture is refluxed for about 1 to 4 hours.
[0019] Numerous experiments were performed in an attempt to repeat the procedure described in U.S. Pat. No. 4,536,518 for preparing Form II wherein sertraline base was dissolved in ethyl acetate, ether was added and the solution was acidified with gaseous hydrogen chloride. The material obtained after filtration and air drying was sertraline hydrochloride amorphous, not Form II as was expected. These experiments are set forth in Examples 13-16 below.
[0020] The x-ray powder diffraction graphs for the products of each of these experiments are equivalent, containing peaks at 11.0, 12.0, 15.4, 16.2, 22.4, 22.9 degree two-theta (See FIG. 1 for a representative example). FIG. 1 does not contain the typical peaks of sertraline hydrochloride Form II, indicating an absence of sertraline hydrochloride Form II in those samples. Thus, none of these experiments, which follow the procedure described in the '518 patent for preparation of sertraline hydrochloride Form II, leads to sertraline hydrochloride Form II.
[0021] The '699 patent provides experimental procedures for preparation of sertraline hydrochloride. The '699 patent does not provide experimental procedure for preparation of sertraline hydrochloride Form II, but it is mentioned that sertraline hydrochloride Form II may be prepared by “rapid crystallization” from the same solvents.
[0022] The procedure of the '699 patent was repeated in an attempt to prepare sertraline hydrochloride form II from ethyl acetate. In a trial of the methods according to the '699 patent: An aqueous solution of sodium hydroxide, 10%, was added to a slurry of sertraline mandelate crystals (44.6 g) in ethyl acetate (290 mL), until complete dissolution. The organic phase was separated and the aqueous phase was extracted with ethyl acetate (280 mL) and combined with the organic phase. The resulting organic solution was washed with water (5×100 mL) then with brine (100 mL) and concentrated on a rotavapor to a volume of 356 mL. The concentrated solution was cooled to 58° C. and seeded with sertraline hydrochloride Form II. Concentrated hydrochloric acid (32%, 8.1 mL) was added to this solution. The solution was then rapidly cooled to 30° C. over 5 minutes. A heavy gel was obtained and the stirring was continued overnight. The solid was filtrated, washed with ethyl acetate and dried at 50° C. The dried solid, sertraline hydrochloride, was not sertraline hydrochloride Form II, as shown by the x-ray diffraction pattern of FIG. 2 .
[0023] By following the procedures described in the '699 patent for preparation of sertraline hydrochloride Form II, we did not obtain sertraline hydrochloride Form II. It is thus apparent that neither the '699 patent nor the '518 patent disclose a useful method for the preparation of sertraline hydrochloride Form II.
[0000] Form II from Sertraline Hydrochloride
[0024] The present invention also provides new processes for making sertraline hydrochloride Form II from sertraline hydrochloride Form V by granulation. In the conversion of sertraline hydrochloride Form V to sertraline hydrochloride Form II, sertraline hydrochloride Form V is combined with a small amount of ethanol or methanol. The mixture of sertraline hydrochloride Form V and ethanol or methanol is stirred for at least a period of at least a few hours, up to several days, preferably about two days, to induce the transformation of Form V to Form II. Sertraline hydrochloride Form II is then isolated by filtration.
[0025] The present invention also provides new processes for making sertraline hydrochloride Form II by recrystallization of sertraline hydrochloride under heating conditions. In the conversion of sertraline hydrochloride to sertraline hydrochloride Form II, sertraline hydrochloride is dissolved in a suitable organic solvent. The solution is then heated for a time sufficient to effect transformation to sertraline hydrochloride Form II. Suitable solvents include dimethylformamide, cyclohexanol and acetone. Dimethylformamide is preferred. The suspension may be heated to a temperature between about 70° C. and 120° C. Sertraline hydrochloride Form II is then isolated by filtration.
[0026] The present invention provides new processes for making sertraline hydrochloride Form II from sertraline hydrochloride Form VI, Form VII or Form VIII by reslurry in organic solvents at temperatures between 25-80° C., followed by drying. Sertraline hydrochloride Form VI may be made following the methods of Examples 2 and 3. Sertraline hydrochloride Form VII is a water adduct and may be made by the methods of Examples 19 and 20. Sertraline hydrochloride Form VIII may be made by the methods of Examples 17 and 18. The methods provided in the present invention have advantages over the rapid recrystallization method of U.S. Pat. No. 5,248,699. The method of the present invention does not require complete dissolution of sertraline hydrochloride, controlling the rate of heating or cooling of a sertraline solution, or controlling the rate of crystallization. The present method utilizes less solvent than the method of the '699 patent, since the sertraline hydrochloride starting material need not be completely dissolved.
[0027] In the conversion of sertraline hydrochloride Form VI, Form VII or Form VIII to sertraline hydrochloride Form II, according to the present invention, sertraline hydrochloride Form VI, Form VII water adduct, or Form VIII is combined with an aprotic organic solvent to form a slurry. Suitable solvents include n-butanol, acetone, t-butyl-methyl ether (MTBE), ethyl acetate and cyclohexane. The conversion may take place at room temperature, but preferably the sertraline hydrochloride Form VI, Form VII water adduct, or VIII and solvent are heated to temperatures between 25° C. and 80° C. About 1 to about 10 volumes of solvent are preferred, based on the weight of the sertraline hydrochloride starting material. See Examples 8 (3 volumes of solvent) and 9 (5 volumes of solvent) below. Smaller amounts of solvent will also effect the transformation, albeit in some instances more slowly. The reaction is carried out for a time sufficient to convert the Form VI, Form VII or Form VIII to Form II. We have not observed any further conversion of Form II upon treatment under these conditions for times longer than the minimum time necessary to effect the transformation.
[0028] The present invention also provides new processes for making a mixture of sertraline hydrochloride Form II and sertraline hydrochloride Form V. In this embodiment of the present invention, sertraline hydrochloride Form VI is heated to induce the transformation of sertraline hydrochloride Form VI to a mixture of both sertraline hydrochloride Form II and sertraline hydrochloride Form V. In this embodiment of the present invention, the heating of sertraline hydrochloride Form VI may be done under reduced pressure or atmospheric pressure.
[0000] Pharmaceutical Compositions Containing Sertraline Hydrochloride Polymorphs
[0029] In accordance with the present invention, sertraline hydrochloride Form II as prepared by the new methods disclosed herein may be used in pharmaceutical compositions that are particularly useful for the treatment of depression, obesity, chemical dependencies or addictions, premature ejaculation, obsessive-compulsive disorder and panic disorder. Such compositions comprise at least one of the new crystalline forms of sertraline hydrochloride with pharmaceutically acceptable carriers and/or excipients known to one of skill in the art.
[0030] For example, these compositions may be prepared as medicaments to be administered orally, parenterally, rectally, transdermally, bucally, or nasally. Suitable forms for oral administration include tablets, compressed or coated pills, dragees, sachets, hard or gelatin capsules, sub-lingual tablets, syrups and suspensions. Suitable forms of parenteral administration include an aqueous or non-aqueous solution or emulsion, while for rectal administration suitable forms for administration include suppositories with hydrophilic or hydrophobic vehicle. For topical administration the invention provides suitable transdermal delivery systems known in the art, and for nasal delivery there are provided suitable aerosol delivery systems known in the art.
[0031] Suitable non-toxic pharmaceutically acceptable carriers and/or excipients will be apparent to those skilled in the art of pharmaceutical formulation, and are discussed in detail in the tet entitled Remington's Pharmaceutical Science, 17 th edition (1985), the contents of which are incorporated herein by reference. Obviously, the choice of suitable carriers will depend on the exact nature of the particular dosage form, e.g. for a liquid dosage form, whether the composition is to be formulated into a solution, suspension, gel, etc, or for a solid dosage form, whether the composition is to be formulated into a tablet, capsule, caplet or other solid form, and whether the dosage form is to be an immediate- or controlled-release product.
[0000] Experimental Details
[0032] The powder X-ray diffraction patterns were obtained by methods known in the art using a Philips X-ray powder diffractometer, Goniometer model 1050/70 at a scanning speed of 2° per minute, with a Cu radiation of λ=1.5418 Δ
EXAMPLES
[0033] The present invention will now be further explained in the following examples. However, the present invention should not be construed as limited thereby. One of ordinary skill in the art will understand how to vary the exemplified preparations to obtain the desired results.
Example 1
Preparation of Sertraline Base
[0034] Sertraline mandelate was prepared according to procedures in U.S. Pat. No. 5,248,699. Sertraline mandelate (5 g) was stirred at room temperature with 50 mL ethyl acetate. Aqueous sodium hydroxide was added dropwise until the sertraline mandelate was completely neutralized. The phases were separated and the organic phase was dried over MgSO 4 and filtered. The solvent was removed under reduced pressure resulting sertraline base as an oil (3.2 g).
Example 2
Preparation of Sertraline Hydrochloride Ethanolate Form VI by Reslurry of Form I
[0035] Sertraline hydrochloride Form I (1 g) and absolute ethanol (20 mL) were stirred at room temperature for 24 hours. Filtration of the mixture yielded sertraline hydrochloride ethanolate Form VI.
Example 3
Preparation of Sertraline Hydrochloride Ethanolate Form VI by Reslurry of Form V
[0036] Sertraline hydrochloride Form V (1 g) and ethanol absolute (20 mL) were stirred at room temperature for 24 hrs. Filtration of the mixture yielded sertraline hydrochloride ethanolate Form VI.
Example 4
Preparation of Sertraline Hydrochloride Form II
[0037] Sertraline base (3 g) was dissolved in acetone (10 mL). Isopropanol containing hydrogen chloride (20 mL) was added to the solution until the pH is 2. The stirring was continued overnight at room temperature. The resulting solid was filtered, washed with acetone and dried to yield sertraline hydrochloride Form II (2.61 g, yield 77.6%).
Example 5
Preparation of Sertraline Hydrochloride Form II in N-Butanol
[0038] HCl (g) was bubbled through a solution of sertraline base (33 g) in n-butanol (264 mL). The temperature rose to about 45° C. A gel-like solid was formed. The addition of HCl (g) was continued until pH 0.5 was reached. Then the stirring was continued at room temperature for 2.5 h. During the stirring the solid became a fine crystalline solid. The solid was filtered, washed with n-butanol (2×10 mL) and dried at 80° C. for 24 h. The product is sertraline hydrochloride Form II. The x-ray powder diffraction spectrum obtained is FIG. 3 .
Example 6
Preparation of Sertraline Hydrochloride Form II
[0039] Sertraline hydrochloride Form V (10 g) was suspended in dimethylformamide (DMF) (30 mL). Heating was started and at about 70° C. a clear solution is obtained. The solution was cooled to room temperature and the solid was filtered. After drying at 80° C. for 24 hrs., sertraline hydrochloride Form II was obtained (6.6 g, yield 66%).
Example 7
Preparation of Sertraline Hydrochloride Form II by Granulation of Form V
[0040] Sertraline hydrochloride Form V (2 g) and absolute ethanol (0.5 mL) were stirred in a rotavapor at room temperature for 2 days. At the end of two days, the material contained sertraline hydrochloride Form II.
Example 8
Preparation of Sertraline Hydrochloride Form II from Form VI
[0041] A slurry of sertraline hydrochloride Form VI (50 g) and t-butyl-methyl ether (150 mL) were heated to reflux and the reflux was continued for 1 hour. The slurry was then allowed to cool to room temperature and filtered. The solid was washed with t-butyl-methyl ether (50 mL) and dried in a reactor under vacuum of 30 mm Hg with stirring. The dried solid so obtained is sertraline hydrochloride Form II (38.26 g: yield 86.7%).
Example 9
Preparation of Sertraline Hydrochloride Form II from Form VI
[0042] Sertraline hydrochloride Form VI (25 g) was stirred with acetone (250 mL) at room temperature for 2 hours. The solid material was filtered and washed twice with acetone (25 mL). The wet solid was dried in a vacuum agitated drier to afford sertraline hydrochloride Form II (20.09 g: yield 98.6%).
Example 10
Preparation of Sertraline Hydrochloride Form II and Sertraline Hydrochloride Form V by Drying Form VI
[0043] Sertraline hydrochloride ethanolate Form VI was dried at 105 C under vacuum (<10 mm Hg) over 24 hours. The resulting dried material was sertraline hydrochloride Form II mixed with sertraline hydrochloride Form V.
Example 11
Preparation of Sertraline Hydrochloride Form II from Sertraline Mandelate in N-Butanol
[0044] Sertraline mandelate (20 g) and n-butanol were stirred at room temperature. The mixture was acidified with hydrogen chloride until pH 0 was reached. During the acidification the temperature of the reaction mixture rose to ˜50° C. After the natural cooling to room temperature, the mixture was stirred at room temperature for two hours. The solid was filtrated, washed with n-butanol and dried at 80° C. to afford sertraline hydrochloride Form II (9.02 g).
Example 12
Preparation of Sertraline Hydrochloride Form II from Sertraline Hydrochloride Form VIII
[0045] Sertraline hydrochloride Form VIII (13 g) was heated in acetone (130 mL) at reflux for 1 hour. The slurry was than cooled to room temperature and the solid was filtrated and washed with acetone (2×10 mL). After drying sertraline hydrochloride Form II was obtained (7.9 g).
Example 13
[0046] An aqueous sodium hydroxide solution, 10%, was added drop-wise to a slurry of sertraline mandelate crystals (10 g) in ethyl acetate (650 mL), until complete dissolution was obtained (25 mL). After separation of the phases, the organic phase was washed with water (300 mL) and then dried with MgSO 4 . The organic solution was diluted with ether (690 mL) and gaseous hydrochloric acid was bubbled through the solution until pH 1.3 was reached. The addition of hydrogen chloride resulted in a temperature increase to about 30° C. The resulting slurry of sertraline was stirred at room temperature overnight. The solid was then isolated by filtration, washed twice with ether (2×20 mL) and air dried. The dried solid, sertraline hydrochloride, was not sertraline hydrochloride Form II, as shown in FIG. 1 .
Example 14
[0047] An aqueous sodium hydroxide solution, 10%, was added drop-wise to a slurry of sertraline mandelate crystals (15 g) in ethyl acetate (810 mL), until complete dissolution was obtained (35 mL). The organic and aqueous phases were separated and, the organic phase was dried over MgSO 4 . The organic solution was then diluted with ether (820 mL) and gaseous hydrogen chloride (2.36 g, 2 eq.) was bubbled through the solution until pH 1.5 was reached. The temperature was about 25° C. The slurry was stirred at room temperature overnight. The solid was filtrated, washed with ether (2×15 mL) and air-dried. The dried solid, sertraline hydrochloride, was not sertraline hydrochloride Form II.
Example 15
[0048] An aqueous sodium hydroxide solution, 10%, was added drop-wise to a slurry of sertraline mandelate crystals (15 g) in ethyl acetate (810 mL), until complete dissolution was obtained. The organic and aqueous phases were separated and the organic phase was dried over MgSO 4 and diluted with an equal volume of ether (820 mL). Gaseous hydrochloric acid (4.82 g) was bubbled through the solution until pH 1 was reached. The slurry was stirred at room temperature overnight. The solid was filtrated, washed with ether (2×15 mL) and air-dried. The dried solid, sertraline hydrochloride, was not sertraline hydrochloride Form II.
Example 16
[0049] An aqueous sodium hydroxide solution, 10%, was added drop-wise to a slurry of sertraline mandelate crystals (15 g) in ethyl acetate (810 mL), until complete dissolution is obtained. The phases were separated and the organic phase was dried over MgSO 4 and diluted with an equal volume of ether (820 mL). Gaseous hydrogen chloride was slowly bubbled through the solution (over about 3 hours) until pH 1.5 was reached. The slurry was stirred at room temperature over night. The dried solid, sertraline hydrochloride, was not sertraline hydrochloride Form II.
Example 17
Preparation of Sertraline Hydrochloride Form VIII
[0050] Sertraline base (2.7 g) was suspended in 27 mL of water. This mixture was heated to 80° C. and treated with hydrochloric acid until about pH 1 was reached. A clear solution was obtained which on cooling gave a precipitate. After 2 hours stirring at room temperature the solid was isolated by filtration. This solid was characterized by powder x-ray diffraction and found to be sertraline hydrochloride Form VIII.
Example 18
Preparation of Sertraline Hydrochloride Form VIII
[0051] Sertraline hydrochloride ethanolate (Form VI) (40 g) was stirred with water (80 mL) for 1 hour at room temperature. The slurry was filtrated and washed with water to yield sertraline hydrochloride hydrate Form VIII.
Example 19
Preparation of Sertraline Hydrochloride Form VII
[0052] Sertraline hydrochloride Form V (1.003 g) was stirred for 24 hours at room temperature in 20 mL water (HPLC grade). At the end of the stirring the mixture looked like a jelly suspension. The suspension was filtrated and the compound obtained was kept at cold conditions (4° C.) until analyzed by x-ray diffraction.
Example 20
Preparation of Sertraline Hydrochloride Form VII from Form VI
[0053] A solution of sertraline hydrochloride ethanolate (Form VI) (40 g) in water (400 mL) was heated at 80 C and complete dissolution of sertraline hydrochloride ethanolate (Form VI) was obtained. The pH was adjusted to about 1 and the solution was allowed to cool to room temperature and then stirred for 2 additional hours. The solid was isolated by filtration and washed with water to yield sertraline hydrochloride Form VII.
[0054] Although certain presently preferred embodiments of the invention have been described herein, it will be apparent to those skilled in the art to which the invention pertains that variations and modifications of the described embodiments may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law.
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The present invention is directed to Form II of sertraline hydrochloride and novel methods for its preparation. According to the present invention, sertraline hydrochloride Form II may be produced directly form sertraline base or sertraline mandelate. It may also be produced from sertraline hydrochloride solvate and hydrate forms, and crystallized from new solvent systems. Pharmaceutical compositions containing sertraline hydrochloride Form II and methods of treatment using such pharmaceutical compositions are also disclosed.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is a division of application Ser. No. 09/694,163, filed Oct. 23, 2000, the complete disclosure of which is hereby incorporated by reference now U.S. Pat. No. 6,428,619.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of heat treating a silicon wafer prepared by a Czochralski method (hereinafter, referred to as “a CZ method”) to be used for manufacturing a semiconductor integrated circuit, a wafer to be used in such a method, and a heat-treated wafer obtained by such a heat treatment method.
2. Description of the Related Art
Recently, causes of deterioration of yields in processes for manufacturing semiconductor integrated circuits include existence of: micro defects of oxygen precipitations which lead to nuclei of oxidation induced stacking faults (hereinafter referred to as “OSF's”); crystal-originated particles (hereinafter referred to as “COP's”); and an interstitial-type large dislocation (hereinafter referred to as “L/D”). Micro defects as nuclei of OSF's are introduced into a silicon ingot during crystal growth, and actualize such as in an oxidation process on manufacturing semiconductor devices, leading to malfunctions such as increase of leakage current of fabricated devices. Meantime, cleaning mirror-polished silicon wafers by a mixed solution of ammonia and hydrogen peroxide leads to formation of pits on the wafer surface, and such pits are detected as particles similarly to real or intrinsic particles. Such pits are referred to as COP's, to distinguish them from real particles. COP's which are pits on a wafer surface cause deterioration of electric characteristics such as a time dependent dielectric breakdown (TDDB) characteristic and a time zero dielectric breakdown (TZDB) characteristic. Further, existence of COP's in a wafer surface causes physical steps during a wiring process of devices, and these steps cause wire breakage. In addition, it causes troubles such as leakage on a device separating portion, so that the yield of products is reduced.
On the other hand, an L/D is called a dislocation cluster, or a dislocation pit since a pit is formed when a silicon wafer having this defect is immersed in a selective etching solution containing hydrofluoric acid as a main ingredient. Such an L/D also causes deterioration of electric characteristics such as a leak characteristic and an isolation characteristic.
From the above, it is required to reduce OSF's, COP's and L/Ds from a silicon wafer to be used for manufacturing a semiconductor integrated circuit.
As a method for reducing such OSF's and L/Ds, there has been conventionally disclosed a defect-free silicon wafer free of OSF's, COP's and L/Ds in Japanese Patent Application Laid-Open Nos. HEI 8-330316 (1996) and HEI-11-1393 (1999).
In the method disclosed in Japanese Patent Application Laid-Open No. HEI 8-330316 (1996), a silicon monocrystal is grown at a lower speed so that OSF's being formed like a ring is disappeared from a center of the wafer and L/Ds are removed from the whole surface of the wafer, while OSF to be caused like a ring at the time of heat-treating the silicon monocrystal as a silicon wafer.
However, the range of speed for pulling a silicon monocrystal and the range of temperature gradation in the crystal in the axial direction for making a non-defective silicon monocrystal by the method disclosed in the above reference are confined in comparatively narrow limits, respectively. Manufacturing the non-defective silicon monocrystal will become more difficult with increasing diameter of a silicon monocrystal being pulled. In some cases, OSF's may be occurred as a mass on the central part of the wafer but not as a ring by the variations in the pulling speed or the like. The OSF's lead to deterioration of the leak characteristic as described above, so that the improvements on the process of manufacturing a silicon monocrystal have been demanded.
The method disclosed in Japanese Patent Application Laid-Open No. HEI-11-1393 (1999) including the step of pulling a single silicon crystal ingot comprising a perfect domain [P] from a silicon melt, where the perfect domain [P] is supposed to be free of agglomerates of vacancy point defects and free of agglomerates of interstitial silicon point defects within the ingot. The silicon wafer sliced out from the ingot consists of the perfect domain region [P]. The perfect domain [P] exists between an interstitial silicon point defect dominant domain [I] and a vacancy point defect dominant domain [V] within the single silicon crystal ingot. The silicon wafer comprising the perfect domain [P] is formed by determining a value of V/G (mm 2 /minute ° C.) such that OSF's generated in a ring shape during a thermal oxidization treatment disappears at the center of the wafer, in which V (mm/minute) is a pulling-up speed of the ingot, and G (° C./minute) is a vertical temperature gradient of the ingot near the interface between a silicon melt and the ingot.
On the other hand, some semiconductor device manufacturers may demand silicon wafers which are free of OSF's, COP's and L/Ds but have abilities for gettering metal contamination caused in the device process. Metal contamination of wafers having insufficient gettering abilities in the device process leads to junction leakage, and to occurrence of malfunctions of devices due to a trap level of metal impurities. To solve this problem, there has been demanded a silicon wafer that exerts the effect of intrinsic gettering (IG) by a heat treatment during the device process of the device maker.
The silicon wafer sliced out from the ingot comprising the perfect domain [P] described above is free of OSF's, COP's and L/Ds. However, oxygen precipitation is not necessarily caused within the wafer by the heat treatment in a device manufacturing process, leading to the disadvantage of causing an insufficient IG effect.
Conventionally, the step of treating a silicon wafer for making full use of the capabilities of. IG effect of the silicon wafer during the device process may be of making defections in the wafer in advance or adding impurities intentionally in advance. In the silicon wafer treated by such a step, contaminants generated by the subsequent steps are absorbed around the preformed defections of the wafer. Therefore, we can prevent the generation of any defection or contamination on an area in proximity to the wafer's surface on which a device is to be formed.
On the other hand, there is a tendency to decrease a heat treatment temperature to a temperature of 1,000° C. or less in the device process because of increasing the packing density of device in recent years. Therefore, it is strongly desirable to perform the IG treatment at a low temperature as a pretreatment in the device process.
Further, there has been proposed a heat treatment method for exhibiting an IG effect (Japanese Patent Application Laid-Open No. HEI-8-45945 (1996)), comprising the steps of: holding a silicon wafer just ground and polished after sliced out from a single silicon crystal ingot at 500 to 800° C. for 0.5 to 20 hours, to thereby introduce oxygen precipitation nuclei into the wafer; rapidly heating the silicon wafer including the oxygen precipitation nuclei from a room temperature to temperatures of 800-1,000° C. and holding the wafer for 0.5 to 20 minutes; leaving the silicon wafer rapidly heated and held for 0.5 to 20 minutes, down to a room temperature; and heating the thus cooled silicon wafer from temperatures of 500 to 700° C. up to temperatures of 800 to 1,100° C. at a rate of 2 to 10° C./minute, and holding the silicon wafer at this temperature for 2 to 48 hours.
In this treating method, at the surface as well as the interior of the wafer rapidly heated under the aforementioned temperature condition, the concentration of interstitial silicon atoms temporarily becomes lower than a thermal equilibrium concentration, leading to a depleted condition of interstitial silicon atoms to thereby provide an environment where oxygen precipitation nuclei tend to stably grow. Simultaneously, generation of interstitial silicon atoms are caused at the wafer surface so as to fill the depleted interstitial silicon atoms into a stable condition, so that the generated interstitial silicon atoms start to diffuse into the interior of the wafer. The area near the wafer surface which has been in the depleted condition of interstitial silicon atoms immediately falls into a saturated condition so that oxygen precipitation nuclei start to disappear. However, it will take some period of time for interstitial silicon atoms grown in the wafer surface to diffuse into the wafer interior. Thus, the deeper the distance from the wafer surface into the wafer interior, the longer the period of time over which an environment for easy growth of oxygen precipitation nuclei is maintained. Therefore, the closer to the wafer surface, the lower the density of oxygen precipitation nuclei. Further, the longer the heat treatment time (0.5 to 20 minutes), the greater the thickness of a denuded zone (hereinafter referred to as a “DZ”) in which oxygen precipitation nuclei, i.e., defects are not formed. Moreover, the higher the temperature in the range of 800 to 1,000° C., the larger the diffusion coefficient of interstitial silicon atoms, so that the thickness of the DZ becomes large in a short time.
Rapidly heating, leaving at a room temperature and then heating again the wafer up to temperatures of 800 to 1,100° C. results in that those oxygen precipitation nuclei within the wafer, which have survived with the rapid heating, grow into oxygen precipitation and become stable IG sources. In the following description, the oxygen precipitation will be referred to as “bulk micro defect(BMD)”.
However, the aforementioned heat treatment method requires, as a pre-treatment for generating IG sources, introducing oxygen precipitation nuclei into a silicon wafer just ground and polished by holding the wafer at 500 to 800° C. for 0.5 to 20 hours, and heat treating after rapid heating so as to render oxygen precipitation nuclei within the wafer to grow into BMD. This causes a problem of unnecessarily many times of heat treatment in the state of wafer.
SUMMARY OF THE INVENTION
The present invention is implemented to solve the foregoing problems. It is therefore a first object of the present invention is to provide a method of heat-treating a silicon wafer in the type of OSF free and COP free by avoiding the generation of OSF to be caused by the heat-treatment in spite of using a silicon wafer that is characterized in that OSF's manifests itself at the center of the wafer by the conventional OSF-manifesting heat treatment.
A second object of the present invention is to provide a silicon wafer with a polysilicon layer and a method of fabricating such a silicon wafer, where the silicon wafer exerts a uniform gettering effect between the peripheral edge and center of the silicon wafer as a result of a uniform oxygen precipitation occurred at the entire surface of the silicon wafer.
A third object of the present invention is to provide a method of heat-treating a silicon wafer, where a silicon wafer sliced from an ingot consisting of a mixed domain of [P V ] and [P I ] and having an oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) not only has no agglomerates of point defects, but also generates oxygen precipitation nuclei higher than a desired density by the heat treatment in the device manufacturing process to exert the IG effect.
A fourth object of the present invention is to provide a method of heat-treating a silicon wafer, where an oxygen donor killer treatment is not required.
A fifth object of the present invention is to provide a method of heat-treating a silicon wafer that exerts a high IG effect by subjecting the wafer to a heat treatment at a temperature of 950° C. or less and allows a reduction in the number of heat treatments on the silicon wafer.
A sixth object of the present invention is to provide a silicon wafer fabricated by the above novel method and exerting a high IG effect.
A seventh object of the present invention is to provide a silicon monocrystal ingot to produce the above silicon wafer capable of exerting a high IG effect.
In the first aspect of the present invention, a method of heat-treating a silicon wafer comprises the steps of: preparing a silicon wafer having an oxygen concentration of 1.2×10 18 atoms/cm 3 or less (old ASTM) without generating COP's and L/D; forming a polysilicon layer of 0.1 μm to 1.6 μm in thickness on a back of the silicon wafer by a chemical-vapor deposition at a temperature of 670° C.±30° C.; and heat-treating the silicon wafer having the polysilicon layer in an oxygen atmosphere at 1000° C.±30° C. for 2 to 5 hours and subsequently at 1130° C.±30° C. for 1 to 16 hours, wherein the silicon wafer before the formation of the polysilicon layer thereon is the type of a wafer in which OSF's manifest itself at a center of the wafer when the wafer is subjected to the heat-treatment.
In the second aspect of the present invention, a silicon wafer having a polysilicon layer comprises: a silicon wafer having an oxygen concentration of 1.2×10 18 atoms/cm 3 or less (old ASTM) without generating COP's and L/D, and a polysilicon layer of 0.1 to 1.6 μm in thickness formed on a back of the wafer, wherein the silicon wafer before the formation of the polysilicon layer thereon is the type of a wafer in which OSF's manifest itself at a center of the wafer when the wafer is heat-treated in an oxygen atmosphere at 1000° C.±30° C. for 2 to 5 hours and subsequently at 1130° C.±30° C. for 1 to 16 hours.
The silicon wafers according to the first and second aspects are the type of a wafer prepared by the CZ method so as to appear OSF's at the center of the wafer, and having comparatively many precipitation nuclei of oxygen at the center but hardly having precipitation nuclei of oxygen at the rest which is COP free. When forming a polysilicon layer on a back of the silicon wafer by the CVD method, BMD is formed at the entire surface of the wafer during the process of CVD. As a result of a uniform oxygen precipitation occurred at the entire surface of the wafer, the wafer obtains a uniform IG between the center and the rest thereof.
In the third aspect of the present invention, a method of heat-treating a silicon wafer sliced out from an ingot consisting of a perfect domain [P], comprises the steps of: pulling up a silicon monocrystal ingot consisting of a mixed domain of [P V ] and [P I ] and having an oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) from a silicon melt; slicing the ingot into silicon wafers; and holding the sliced silicon wafer in a gaseous atmosphere selected from the group consisting of nitrogen, argon, hydrogen, oxygen, and mixtures thereof at a temperature of 600 to 850° C. for 30 to 90 minutes, where [P I ] is a domain neighboring with a domain [I], is classified into the perfect domain [P], and has a concentration of interstitial silicons lower than the lowest concentration of interstitial silicons capable of forming interstitial dislocations, and where [P V ] is a domain neighboring with a domain [V], is classified into the perfect domain [P], and has a concentration of vacancies equal to or lower than a concentration of vacancies capable of forming COP's or FPD's, where the domain [I] is a domain dominated by interstitial silicon point defects and including agglomerates of interstitial silicon point defects within an ingot, the domain [V] is a domain dominated by vacancy point defects and including agglomerates of vacancy point defects within the ingot, and the perfect domain [P] is a domain including no agglomerates of vacancy point defects and no agglomerates of interstitial silicon point defects.
In the fourth aspect of the present invention, a method of heat-treating a silicon wafer sliced out from an ingot consisting of the above perfect domain [P], comprises the steps of: pulling up a silicon monocrystal ingot consisting of the above mixed domain of [P v ] and [P I ] and having an oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) from a silicon melt; slicing the ingot into silicon wafers; and holding the sliced silicon wafer in a gaseous atmosphere selected from the group consisting of nitrogen, argon, hydrogen, oxygen, and mixtures thereof at a temperature of 600 to 850° C. for 120 to 250 minutes.
In the fifth aspect of the present invention, a method of heat-treating a silicon wafer sliced out from an ingot consisting of the above perfect domain [P], comprises the steps of: pulling up a silicon monocrystal ingot consisting of the above mixed domain of [P V ] and [P I ] and having an oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) from a silicon melt; slicing the ingot into silicon wafers; heating the sliced silicon wafer in a gaseous atmosphere selected from the group consisting of nitrogen, argon, hydrogen, oxygen, and mixtures thereof at rising temperatures from room temperature to a predetermined temperature of 1150° C. to 1200° C. at a rate of 10 to 150° C./second; and holding the heated silicon wafer at the predetermined temperature of 1150° C. to 1200° C. for 0 to 30 seconds.
In the third to fifth aspects of the present invention, the ingot has an oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) and consists of the mixed domain of [P V ] and [P I ]. When a silicon wafer sliced out from the above ingot is heat-treated in the above condition, not only a density of precipitation nuclei of oxygen enhances at the domain [P V ] in which precipitation nuclei of oxygen introduce during crystal growth but also precipitation nuclei of oxygen emerge at the domain [P I ] in which precipitation nuclei of oxygen do not introduce during crystal growth. Accordingly, when the above heat-treated wafer is subjected to the heat treatment in the device manufacturing process of a semiconductor device maker, the above precipitation nuclei of oxygen grow up to BMD to thereby exert the IG effect at the entire surface of the wafer even if the wafer consists of the mixed domain of [P V ] and [P I ].
In the sixth aspect of the present invention, a method of heat-treating a silicon wafer comprises the steps of: pulling up a silicon monocrystal ingot from a silicon melt; forming a silicon wafer from the ingot; and rapidly heating the silicon wafer from a room temperature to a predetermined temperature of 650 to 950° C. at a rate of 10° C./minute or over and holding the silicon wafer for 0.5 to 30 minutes, wherein the silicon wafer generates OSF's in an area wider than 25% of the entire area thereof and an oxygen precipitation of 1×10 5 to 3×10 7 /cm 3 without an occurrence of dislocation when the wafer is subjected to the heat-treatment.
The method in the sixth aspect of the present invention exerts a high IG effect by rapidly heating the polished wafer which is obtained the ingot under the above condition without conventional processes of pre-annealing to introduce precipitation nuclei of oxygen into the wafer and growing up precipitation nuclei of oxygen to BMD's.
The above and other objects, effects, features and advantages of the present invention will become more apparent from the following description of embodiments thereof taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a relationship between a V/G ratio and a vacancy point defect density or an interstitial silicon point defect density in a first embodiment of the present invention, based on a Voronkov theory;
FIG. 2 is a characteristic diagram showing a transition of a pulling-up speed for determining a desired pulling-up speed profile;
FIG. 3 is a schematic view of an X-ray tomographic image showing a vacancy point defect dominant domain, an interstitial silicon point defect dominant domain, and a perfect domain of a reference ingot according to the first embodiment of the present invention;
FIG. 4 is a view showing a situation where OSF's appear in a silicon wafer W 1 corresponding to a position P 1 in FIG. 3;
FIG. 5 is a cross sectional view showing an ingot sliced along in the axial direction through an axial center of the ingot, correspondingly to a position P 2 in FIG. 3;
FIG. 6 is a plan view showing a situation where OSF's appear at the center of a silicon wafer W 2 according to the first embodiment of the present invention, corresponding to the position P 2 in FIG. 3;
FIG. 7 is a view showing a relationship between a V/G ratio and a vacancy point defect density or an interstitial silicon point defect density in second and third embodiments of the present invention, based on the Voronkov theory;
FIG. 8 is a schematic view of an X-ray tomographic image showing a vacancy point defect dominant domain, an interstitial silicon point defect dominant domain, and a perfect domain of a reference ingot according to the second and third embodiments of the present invention;
FIG. 9 is a plan view showing a situation where OSF's appear in a silicon wafer W 3 corresponding to a position P 3 in FIG. 8;
FIG. 10 is a schematic view of an X-ray tomographic image showing a vacancy point defect dominant domain, an interstitial silicon point defect dominant domain, and a perfect domain of a reference ingot according to the fourth embodiment of the present invention;
FIG. 11 is a plan view showing a situation where OSF's appear in a silicon wafer W 1 corresponding to a position P 1 in FIG. 10;
FIG. 12 is a cross sectional view showing an ingot sliced along in the axial direction through an axial center of the ingot, correspondingly to a position P 2 in FIG. 10;
FIG. 13 is a plan view showing a situation where OSF's appear in the center of a silicon wafer W 2 corresponding to a position P 2 in FIG. 10;
FIG. 14 is a view showing a situation of Δ[Oi] in the wafer surface at the time of before or after the first heat treatment depending on the heat treatment in the semiconductor device process for each of the silicon wafers of the first example and the first comparative example;
FIG. 15 is a view showing a situation of Δ[Oi] in the wafer surface at the time of before or after the second heat treatment depending on the heat treatment in the semiconductor device process for each of the silicon wafers of the first example and the first comparative example;
FIG. 16A is a microscopic photograph of the silicon wafer W 3 of the second embodiment prepared by the process including the step of contaminating the wafer W 3 with Fe for determining the presence or absence of haze after the diffusion of Fe into the bulk;
FIG. 16B is a microscopic photograph of the silicon wafer W 3 of the second embodiment prepared by the process including the step of contaminating the wafer W 3 with Cr for determining the presence or absence of haze after the diffusion of Cr into the bulk;
FIG. 16C is a microscopic photograph of the silicon wafer W 3 of the second embodiment prepared by the process including the step of contaminating the wafer W 3 with Ni for determining the presence or absence of haze after the diffusion of Ni into the bulk;
FIG. 16D is a microscopic photograph of the silicon wafer W 3 of the second embodiment prepared by the process including the step of contaminating the wafer W 3 with Cu for determining the presence or absence of haze after the diffusion of Cu into the bulk;
FIG. 17A is a microscopic photograph of the silicon wafer W 3 of the second comparative embodiment prepared by the process including the step of contaminating the wafer W 3 with Fe for determining the presence or absence of haze after the diffusion of Fe into the bulk;
FIG. 17B is a microscopic photograph of the silicon wafer W 3 of the second comparative embodiment prepared by the process including the step of contaminating the wafer W 3 with Cr for determining the presence or absence of haze after the diffusion of Cr into the bulk;
FIG. 17C is a microscopic photograph of the silicon wafer W 3 of the second comparative embodiment prepared by the process including the step of contaminating the wafer W 3 with Ni for determining the presence or absence of haze after the diffusion of Ni into the bulk;
FIG. 17D is a microscopic photograph of the silicon wafer W 3 of the second comparative embodiment prepared by the process including the step of contaminating the wafer W 3 with Cu for determining the presence or absence of haze after the diffusion of Cu into the bulk; and
FIG. 18 is a microscopic photograph showing a situation of oxygen precipitation (BMD) in the silicon wafer after the rapid heating process of the example 18.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[A] First Embodiment of the Present Invention
Each of silicon wafers according to first through fourth embodiments of the present invention is fabricated by pulling up an ingot from a silicon melt within a hot zone furnace by a CZ method at a predetermined pulling-up speed profile based on a Voronkov theory, and by slicing the ingot.
Generally, when an ingot of single crystal of silicon is pulled up from a silicon melt within a hot zone furnace by a CZ method, there are caused point defects and agglomerates (three-dimensional defects) as defects in the single crystal of silicon. Point defects are classified into two general types, i.e., a vacancy point defect and an interstitial point defect. The vacancy point defect is a type where one silicon atom is omitted from a normal position within a silicon crystal lattice. Such a vacancy leads to a vacancy point defect. Meanwhile, the presence of a silicon atom at a non-lattice point (interstitial site) leads to an interstitial silicon point defect.
Further, point defects are generally formed at an interface between a silicon melt (melted silicon) and an ingot (solid silicon). However, as the ingot is pulled up, the portion having been the interface starts to be cooled. During the cooling, vacancy point defects or interstitial point defects diffuse to be mutually merged to thereby form vacancy agglomerates or interstitial agglomerates, respectively. In other words, agglomerates are three-dimensional structures generated by the combination of point defects.
Agglomerates of vacancy point defects include defects called “LSTD (Laser Scattering Tomograph Defects)” or “FPD (Flow Pattern Defects)” in addition to the aforementioned COP's, while agglomerates of interstitial silicon point defects include defects called “L/D” as noted above. Further, FPD's are sources of traces which exhibit a unique flow pattern which appears when a silicon wafer fabricated by slicing an ingot is subjected to a Secco etching (i.e., etching by a mixed solution of K 2 Cr 2 O 7 :50% HF:pure water=44 g:2,000 cc:1,000 cc) for 30 minutes without agitation. LSTD are sources which have refractive indexes different from that of silicon and which generate scattered light upon radiation of infrared rays into a single crystal of silicon.
The aforementioned Voronkov theory is to control a V/G ratio (mm 2 /minute ° C.) so as to grow a high purity ingot having fewer defects, where V (mm/minute) is a pulling-up speed of an ingot and G (° C./mm) is a temperature gradient at an interface between an ingot and silicon melt in a hot zone structure. According to this theory, the relationship between V/G and point defect density is diagramatically represented as shown in FIG. 1 in which the abscissa represents V/G and the ordinate represents a vacancy point defect density and an interstitial silicon point defect density, to thereby demonstrate that the boundary between a vacancy domain and an interstitial silicon domain is determined by the V/G ratio. More specifically, an ingot dominated by a vacancy point defect density is formed when the V/G ratio is greater than a critical point, while an ingot dominated by an interstitial silicon point defect density is formed when the V/G ratio is smaller than the critical point.
The predetermined pulling-up speed profile for the first embodiment of the present invention is determined such that the ratio (V/G) of a pulling-up speed to a temperature gradient largely exceeds a first critical ratio ((V/G) 1 ) for avoiding occurrence of agglomerates of interstitial silicon point defects, and lessens a second critical ratio ((V/G) 2 ) for restricting vacancy agglomerates to a vacancy point defect dominant domain at the center of an ingot, when the ingot is pulled up from a silicon melt within a hot zone furnace.
This pulling-up speed profile is determined by a simulation based on the Voronkov theory, such as by empirically slicing a reference ingot in an axial direction, by empirically slicing a reference ingot into wafers, or by combining these techniques. Namely, this determination is performed by confirming the axial slice of the ingot and sliced wafers after the simulation, and then repeating the simulation. There are determined a plurality of kinds of pulling-up speeds in a predetermined range, and a plurality of reference ingots are grown. The pulling-up speed profile for the simulation is adjusted from a higher pulling-up speed such as 1.2 mm/min as shown in FIG. 2 ( a ) via a lower pulling-up speed such as 0.5 mm/min as shown in FIG. 2 ( c ) to a pulling-up speed as shown in FIG. 2 ( d ). The aforementioned lower pulling-up speed may be 0.4 mm/min or less, and the pulling-up speeds (b) and (d) are preferably made to be linear.
Multiple reference ingots pulled up at different speeds are sliced in axial directions, respectively. There is determined an optimum V/G ratio based on a correlation between the axial slices, confirmation of wafers, and the result of the simulation, then an optimum pulling-up speed profile is determined, and ingots are manufactured based on such a profile. The actual pulling-up speed profile depends on various parameters such as a diameter of a desired ingot, a specific hot zone furnace to be used, and a quality of a silicon melt, without limited thereto.
FIG. 3 actually shows a cross-sectional view of an ingot obtained by gradually decreasing the pulling-up speed to thereby continuously lower the V/G ratio. In FIG. 3, the mark [V] represents a domain dominated by vacancy point defects and including agglomerates of vacancy point defects within an ingot, the mark [I] represents a domain dominated by interstitial silicon point defects and including agglomerates of interstitial silicon point defects, and the mark [P] represents a perfect domain including no agglomerates of vacancy point defects and no agglomerates of interstitial silicon point defects.
Note, agglomerates of COP's and L/Ds may present different values of detection sensitivities and detection lower limits, depending on detection methods. As such, the phrase “agglomerates of point defects do not exist” herein means that the number of agglomerates of point defects is less than a detection lower limit (1×10 3 pieces/cm 3 ) which is determined where one piece of defect agglomerate of a flow pattern (vacancy defect) and dislocation cluster (interstitial silicon point defect) is detected for a testing volume of 1×10 −3 cm 3 upon observing, as the testing volume, a product of an observing area and an etching allowance by an optical microscope after Secco etching a mirror-machined single crystal of silicon without agitation.
As shown in FIG. 3, the axial position P 1 of the ingot is a domain entirely dominated by vacancy point defects. The position P 2 includes a center domain dominated by vacancy point defects, compared with that of the position P 1 . The position P 4 includes a ring dominated by interstitial silicon point defects, and a center perfect domain. The position P 3 does not include vacancy point defects in the center and also interstitial silicon defects in the edge portion, so that it is an entirely perfect domain.
As apparent from FIG. 3, the wafer W 1 , corresponding to the position P 1 is a domain entirely dominated by vacancy point defects. The wafer W 2 corresponding to the position P 2 includes a center domain dominated by vacancy point defects, compared with that of the wafer W 1 . The wafer W 4 corresponding to the position P 4 includes a ring dominated by interstitial silicon point defects, and a center perfect domain. The wafer W 3 corresponding to the position P 3 does not include vacancy point defects in the center and also interstitial silicon defects in the edge portion, so that it is an entirely perfect domain.
In a minimal domain adjacent to the perfect domain in which such vacancy point defects are dominantly existed is a domain that does not generate any COP or L/D in the wafer surface. However, OSF's can be generated by the process depending on the conventional OSF manifesting heat treatment, when the silicon wafer is heat treated at temperatures in a range of 1,000° C.±30° C. for 2 to 5 hours and subsequently heat treatment at temperatures in a range of 1,130° C.±30° C. for 1 to 16 hours. That is, an OSF ring is generated near half the radius of the wafer W 1 as shown in FIG. 4 . The domain surrounded by the OSF's, in which the vacancy point defects are dominantly existed, tends to generate COP. In the wafer W 2 , on the other hand, the OSF's are not shaped like a ring. The OSF's are only generated at the center of the wafer W 2 . The silicon wafer W 2 to be used in the first embodiment is such a wafer W 2. In the silicon wafer W 2 of the first embodiment, the OSF's are not shaped like a ring as shown in FIG. 5 . It is formed by slicing a silicon ingot grown with the predetermined pulling-up speed profile so that the OSF's are only generated at the center of the wafer W 2 as shown in a plan view of FIG. 6 . In the silicon wafer W 2, the OSF is not shaped like a ring, so that the number of COP's in the entire wafer surface of which is zero (COP free) and also there is no occurrence of interstitial dislocation.
In the silicon wafer of the first embodiment, the oxygen concentration within the wafer is further controlled. In the CZ method, the oxygen concentration within a wafer can be controlled such as by changing a flow rate of argon to be supplied into a hot zone furnace, a rotational speed of a quartz crucible for storing a silicon melt, and a pressure within the hot zone furnace. The oxygen concentration within the wafer is adjusted to 1.2×10 18 atoms/cm 3 or less. For attaining such an oxygen concentration, for example, the flow rate of argon is controlled to be 80 to 150 liter/minute, the rotational speed of a quartz crucible for storing a silicon melt is controlled to be 4 to 9 rpm, and the pressure within a hot zone furnace is controlled to be 15 to 60 Torr. The reason for adjusting the oxygen concentration to 1.2×10 18 atoms/cm 3 or less (old ASTM) is to prevent an excess of oxygen precipitation nuclei.
A polysilicon layer of 0.1 to 1.6 μm in thickness is formed on the surface of a silicon wafer fabricated by slicing the ingot pulled up under the above condition by the CVD method using SiH 4 or the like at temperatures of 670° C.±30° C. If the thickness of the polysilicon layer is less than 0.1 μm, it produces little effect. If it is larger than 1.6 μm, it decrees productivity. Therefore, it is preferable that the thickness of the polysilicon layer is in the range of 1.0 to 1.6 μm. In spite of uniform distribution of oxygen concentration in the wafer surface before the step of forming a polysilicon layer, the oxygen precipitation may be easily occurred at the center of the wafer while it is hardly occurred on the other portions thereof. The polysilicon layer allows the uniform distribution of the oxygen precipitation in the wafer surface.
Accordingly, after the silicon wafer where the oxygen precipitation nuclei exist is provided with the polisilicon layer, if the silicon wafer with the polysilicon layer is subjected to heat treatment in the semiconductor device process, the growth of the nuclei is stopped. Thus, there is no OSF generation in spite of performing the conventional OSF-manifesting heat treatment.
[B] Second Embodiment of the Present Invention
In the second embodiment of the present invention, a silicon ingot is pulled up from a silicon melt based on the Voronkov theory, similarly to the first embodiment. As shown in FIG. 7, the predetermined pulling-up speed profile for the second embodiment of the present invention is determined such that the ratio (V/G) of a pulling-up speed to a temperature gradient is held at a predetermined value. In this case, the value is defined so as to be equal to or greater than a third critical ratio ((V/G) 3 ) for avoiding occurrence of agglomerates of interstitial silicon point defects, and also it is defined to be equal to or less than a fourth critical ratio ((V/G) 4 ) for restricting agglomerates of vacancy point defects within a center domain dominated by vacancy point defects, when the ingot is pulled up from a silicon melt within a hot zone furnace. In FIG. 7, the mark [I] represents a domain (a third critical ratio (V/G) 3 or less) dominated by interstitial silicon point defects and including interstitial silicon point defects, the mark [V] represents a domain (a fourth critical ratio (V/G) 4 or greater) dominated by vacancy point defects and including agglomerates of vacancy point defects within an ingot, and the mark [P] represents a perfect domain ((V/G) 3 to (V/G) 4 ) including no agglomerates of vacancy point defects and agglomerates of interstitial silicon point defects. The domain [V] neighboring with the domain [P] includes a domain [OSF] ((V/G) 4 to (V/G) 5 ) for forming OSF nuclei.
The perfect domain [P] is further classified into a domain [P I ] and a domain [P V ]. The domain [P I ] has the V/G ratio from the (V/G) 3 to the critical point, and the domain [P V ] has the V/G ratio from the critical point to the (V/G) 4 Namely, the domain [P I ] neighbors with the domain [I] and has an interstitial silicon point defect density lower than the lowest interstitial silicon point defect density capable of forming interstitial dislocations, and the domain [P V ] neighbors with the domain [V] and has a vacancy point defect density lower than the lowest vacancy point defect density capable of forming OSE's.
The facts shown in FIG. 8 can be recognized by drawing a cross-sectional view of an ingot prepared by the process in which the pulling-up speed is gradually lowered to thereby continuously lower the ratio (V/G). In FIG. 8, the mark [V] represents a domain dominated by vacancy point defects within an ingot, the mark [I] represents a domain dominated by interstitial silicon point defects, and the mark [P] represents a perfect domain including no agglomerates of vacancy point defects and no agglomerates of interstitial silicon point defects. As described above, the perfect domain [P] is further classified into a domain [P I ] and a domain [P v ]. The domain [P v ] includes vacancy point defects not progressed into agglomerates within the perfect domain [P], and the domain [P I ] includes interstitial silicon point defects not progressed into agglomerates within the perfect domain [P].
As shown in FIG. 8, the position P 1 in the axial direction of the ingot includes a center domain dominated by vacancy point defects. The position P 4 includes a ring dominated by interstitial silicon point defects and a center perfect domain. The position P 3 is an entirely perfect domain without including agglomerates of the vacancy point defects in the center and also without including agglomerates of the interstitial silicon point defects on the edge to be associated with the second embodiment.
As is evident from FIG. 8, the wafer W 1 corresponding to the position P 1 includes a center domain dominated by vacancy point defects. The wafer W 4 corresponding to the position P 4 includes a ring dominated by interstitial silicon point defects and a center perfect domain. The wafer W 3 corresponding to the position P 3 is an entirely perfect domain, where the domains [P v ] and [P I ] coexist together. A small domain ((V/G) 4 to (V/G) 5 in FIG. 7) adjacent to the perfect domain dominated by vacancy point defects is of without generating COP and L/D in the wafer surface. However, OSF's are generated if the wafer W 1 is subjected to the conventional OSF-manifesting heat treatment, where the wafer W 1 is heat treated at temperatures in a range of 1,000° C.±30° C. for 2 to 5 hours and subsequently heat treated at temperatures in a range of 1,130° C.±30° C. for 1 to 16 hours. As shown in FIG. 4 and described in the first embodiment, an OSF ring is generated near half the radius of the wafer W 1 . There is a tendency to generate COP in the domain dominated by vacancy point defects surrounded by such an OSF ring.
The wafer according to the second embodiment is the wafer W 3 and the plan view thereof is shown in FIG. 9 . The wafer W 3 is required to have its oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) so as to generate oxygen precipitation nuclei higher than a desired density by the heat treatment of the second embodiment.
Then, we will describe the heat treatment on the above silicon wafer W 3 in the following description. The heat treatment on the above silicon wafer W 3 comprises the steps of: holding the silicon wafer in an atmosphere of nitrogen, argon, hydrogen or oxygen or mixture thereof at temperatures of 600° C. to 850° C. for 30 to 90 minutes or at temperatures of 600° C. to 850° C. for 120 to 250 minutes. Heating is preferably conducted by introducing the wafer at a rate of 50 to 100° C./minute into a heat treatment furnace held at 600 to 850° C. Holding temperatures lower than 600° C. or holding times shorter than 30 minutes lead to insufficient increase of oxygen precipitation nuclei, resulting in failure of a BMD density required to exhibit an IG effect upon conducting the heat treatment in the process of fabricating a device by the semiconductor device manufacturer. Holding temperatures exceeding 850° C. results in failure of a BMD density required to exhibit an IG effect upon conducting the next second step heat treatment, due to the lower density of oxygen precipitation nuclei of the domain [P I ]. Holding temperatures between 600° C. to 850° C. and holding time exceeding 90 minutes and shorter than 120 minutes leads to restriction of a precipitation amount of oxygen precipitation nuclei, due to excess of interstitial point defects accompanying to formation of oxygen precipitation nuclei. Holding time of 250 minutes or longer leads to reduced productivity.
The above conditions of the heat treatment are included in the conditions of the heat treatment for forming a polysilicon layer on the back of the wafer (i.e., holding temperatures between 650° C.±30° C. and holding times 5 to 300 minutes). Thus, the object of the second embodiment of the present invention can be attained by the formation of polysilicon layer in accordance with the second embodiment of the present invention. In this case, the thickness of the polysilicon layer is in the rage of 0.1 to 2.0 μm. The amount of oxygen precipitation nuclei in the neighborhood of the back of the wafer in contact with the polysilicon layer is further increased. In this wafer configuration, by the way, the polysilicon layer may be left as it is or may be removed using an alkali etching liquid prepared by diluting KOH or NaOH with water or an acid etching liquid prepared by diluting a mixture of fluorine acid and nitric acid with water or acetic acid.
The above heat treatment eliminates the need for an oxygen donor killer treatment provided as one of the steps of the water process.
[C] Third Embodiment of the Present Invention
In the third embodiment of the present invention, a silicon ingot is pulled up from a silicon melt based on the Voronkov theory, similarly to the first embodiment. The predetermined pulling-up speed profile of the third embodiment is the same one as that of the second embodiment.
The silicon wafer according to the third embodiment is the wafer W 3 shown in FIG. 8 and FIG. 9 . The wafer W 3 is required to have its oxygen concentration of 0.8×10 18 to 1.4×10 18 atoms/cm 3 (old ASTM) so as to generate oxygen precipitation nuclei higher than a desired density by the heat treatment of the third embodiment.
The heat treatment of the third embodiment is rapid heating and is conducted by heating the wafer W 3 in an atmosphere of nitrogen, argon, hydrogen or oxygen or mixture thereof from a room temperature up to temperatures of 1,150° C. to 1,200° C. at a temperature elevating speed of 10° C./second to 150° C./second, and hold the wafer W 3 at temperatures of 1,150° C. to 1,200° C. for 0 to 30 seconds. That is, the heat treatment performed in the third embodiment is the type a rapid heating. Herein, a holding time of 0 second means that only temperature elevation is conducted, and holding is not conducted. Heating is conducted by introducing the wafer into a heat treatment furnace held at a room temperature or into the interior of a heat treatment furnace held at a temperature of several hundreds degrees by residual heat in case of a continuous operation, and temperature elevated to temperatures of 1,150° C. to 1,200° C. at a rate of 10° C./second to 150° C./second, preferably 50° C./second to 100° C./second. Temperature elevating speeds slower than 10° C./second leads to increase of oxygen precipitation nuclei but results in a deteriorated and thus impractical processing ability. Holding temperatures lower than 1,150° C. leads to insufficient increase of oxygen precipitation nuclei, resulting in failure of a BMD density required to exhibit an IG effect upon conducting the next second step heat treatment. Holding temperatures exceeding 1,200° C. or holding time exceeding 30 seconds results in a problem such as occurrence of slippage and deteriorated productivity of heat treatment and reduction. Temperature elevating speeds exceeding 150° C./second result in a problem of occurrence of slippage due to dispersion of tare stress and in-plane temperature distribution.
The above heat treatment eliminates the need for an oxygen donor killer treatment provided as one of the steps of the wafer process.
[D] Fourth Embodiment of the Present Invention
In the fourth embodiment the present invention, a silicon ingot is pulled up from a silicon melt based on the Voronkov theory, similarly to the first embodiment. The predetermined pulling-up speed profile of the fourth embodiment is the same one as that of the first embodiment. FIG. 10 that corresponds to FIG. 3 is provided for more detail description of the fourth embodiment. The reference numerals in FIG. 10 denote the same components as those in FIG. 3 . The characteristic advantage of the fourth embodiment is that the wafer W 2 that corresponds to the Position P 2 includes a center domain dominated by vacancy point defects over half (50%) of the entire area of the wafer, compared with the wafer W 1 .
A small domain adjacent to the perfect domain dominated by vacancy point defects is the region with no generation of both COP and L/D in the wafer surface. The OSE's are generated when the silicon wafer is subjected to a heat treatment at a temperatures in a range of 1,000° C.±30° C. for 2 to 5 hours and subsequently heat treated at temperatures in a range of 1,130° C.±30° C. for 1 to 16 hours in an oxygen atmosphere in accordance with the conventional OSF manifesting heat treatment. In the wafer W 1 , as shown in FIG. 11, OSF ring is generated around the peripheral edge of the wafer W 1 . In general, furthermore, larger COP's tend to appear from the domain dominated with vacancy point defects surrounded by the OSP ring. on the other hand, the OSF's are not generated like a ring in the wafer W 2 . It occurs only in a disk shape at the center of the wafer. The silicon wafer to be used in the fourth embodiment is the wafer W 2 . In this wafer, OSE's occur in an area wider than 25% of the entire area of the wafer. In the case that OSF's area is less than 25% of the entire area of the wafer, BMD only generates in a narrower area, resulting in difficulty in exhibiting a sufficient IG effect. Therefor, a preferable area percentage of OSF's is 50 to 80%.
The silicon wafer W 2 of the fourth embodiment is fabricated by slicing an ingot grown by a pulling-up speed profile selectively determined such that OSF's actualize not in a ring shape but over the center of the wafer as shown in FIG. 12 . FIG. 13 is a plan view of the wafer W 2 . This wafer W 2 is free of COP, since OSF's do not form a ring shape. Further, no interstitial-type large dislocation (L/D) occurs. The ingot for providing the wafer W 2 of the present invention includes BMD without dislocation generation, at a rate of 1×10 5 to 3×10 7 pieces/cm 3 . Therefore, it becomes unnecessary to introduce oxygen precipitation nuclei at a high density into a wafer by holding the wafer state at relatively lower temperatures of 500 to 800° C. for 0.5 to 20 hours before rapidly heating such as described in the Japanese Patent Application Laid-Open No. HEI-8-45945. BMD densities less than 1×10 5 pieces/cm 3 results in difficulty in exhibiting a sufficient IG effect upon rapid heating in a wafer state. Further, the value of 3×10 8 pieces/cm 3 is the maximum density of BMD allowed to occur within the OSF domain.
The heat treatment method of the fourth embodiment may be the method in which the silicon wafer W 2 including BMD without dislocation generation at the aforementioned percentage at a room temperature is swiftly placed in a furnace heated to temperatures of 650° C. to 950° C. Another method is to arrange the silicon wafer including BMD without dislocation generation at the aforementioned percentage at a room temperature in a fast heating furnace using a lamp capable of generating higher temperatures, to turn on a lamp switch to start heating to thereby rapidly heat up to temperatures of 650 to 950° C. That is, the heat treatment of the fourth embodiment is also in the type of rapidly heating a wafer. The term “rapidly heat” herein means to conduct a heat treatment at a temperature elevating speed of 10° C./minute or over, preferably 30° C./minute or over. Rapidly heating the wafer by lamp light radiation enables uniform heating of the wafer, to thereby provide an advantage that the wafer warps lesser than a situation of introduction thereof into a pre-heated furnace. Final temperatures lower than 650° C. reached by rapid heating lead to insufficient disappearance of BMD near the wafer surface, thereby failing to ensure a sufficient DZ. Further, exceeding 950° C. leads to occurrence of dislocation before disappearance of BMD near the wafer surface, thereby failing to ensure a sufficient DZ. Therefore, the preferable temperatures may be in the range of 800° C. to 900° C. Moreover, holding time less than 0.5 minute is too short to shrink BMD near the wafer surface, resulting in insufficient disappearance of BMD near the wafer surface and failing to ensure a sufficient DZ. Exceeding 30 minutes leads to a DZ having an excessive thickness and to affection on productivity. Therefore, the preferable holding times may be in the range of 0.5 minutes to 30 minutes, preferably 10 minutes to 30 minutes. The rapidly heating treatment may be performed in a nitrogen or oxygen atmosphere or in the air. Preferably, it is performed in a nitrogen atmosphere.
Leaving the silicon wafer at a room temperature after the rapid heating leads to formation of a DZ over a depth of 1 to 100 μm from the wafer surface, to thereby provide a wafer having a BMD density of 1×10 5 to 3×10 7 pieces/cm 3 in a portion deeper than this DZ. This wafer exhibits a higher IG effect.
EXAMPLES
There will be described hereinafter examples of the present invention together with comparative examples.
<Example 1>
An ingot is pulled up from a silicon melt to grow the domain corresponding to the position P 2 shown in FIG. 3 throughout the length of the ingot. To control the oxygen concentration within the ingot at this time, the flow rate of argon was kept at about 110 liter/minute, the rotational speed of a quartz crucible for storing the silicon melt was kept at about 5 to 10 rpm, and the pressure within the hot zone furnace was kept at about 60 Torr.
Silicon wafers sliced out from the thus pulled up ingot were lapped, chamfered, and then mirror-polished to thereby prepare silicon wafers. Each of the silicon wafers is subjected to the step of removing any damage on the surface thereof, followed by forming the polysilicon layer of 1.5 μm in thickness on the back of the wafer by the CVD method using SiH 4 at 680° C. Subsequently, the silicon wafer is polished to a mirror-smooth state, resulting in the finished silicon wafer having a diameter of 8 inches and a thickness of 725 μm.
<Comparative Example 1>
For comparison, there was prepared to comparative example 1 from the same silicon wafer as that of the example 1 except that the polysilicon layer is not formed on the silicon wafer of the comparative example 1.
<Comparative Evaluation 1>
The silicon wafer of the example 1 and the silicon wafer of the comparative example 1 are subjected to a first heat treatment in imitation of the heat treatment in the semiconductor device process. That is, each of these silicon wafers is heat treated in an atmosphere of oxygen at temperatures of 800° C. for 4 hours and subsequently heat treated at temperatures of 1,000° C. for 16 hours. Oxygen concentrations of an area extending from the center to the outer edge of the surface of each of the silicon wafers of the example 1 and the comparative example 1 are measured by Fourier transform infrared spectroscopic analysis (FT-IR). The difference Δ[Oi] between oxygen concentrations before and after the heat treatment are shown in FIG. 14 .
Another silicon wafer of the example 1 and another silicon wafer of the comparative example 1 are subjected to a second heat treatment in imitation of the heat treatment in the semiconductor device process. That is, each of these silicon wafers is heat treated in an atmosphere of oxygen at temperatures of 700° C. for 8 hours and subsequently heat treated at temperatures of 1,000° C. for 12 hours. Oxygen concentrations of an area extending from the center to the outer edge of the surface of each of the silicon wafers of the example 1 and the comparative example 1 are measured by Fourier transform infrared spectroscopic analysis (FT-IR). The difference Δ[Oi] between oxygen concentrations before and after the heat treatment are shown in FIG. 15 .
As shown in FIG. 14 and FIG. 15, there are large fluctuations in the difference Δ[Oi] between oxygen concentrations before and after the heat treatment on the area from the center to a point 40 mm away of the wafer of the comparative example 1. On the other hand, the mild slope of the difference Δ[Oi] between oxygen concentrations before and after the heat treatment is observed on the area from the center to a point 90 mm away of the wafer of the example 1, so that it is substantially uniform in the wafer surface as a whole.
Furthermore, still another silicon wafer of the example 1 and still another silicon wafer of the comparative example 1 are subjected to a heat treatment. That is, each of them is heat treated at a temperature of 1000° C. for 4 hours and subsequently at a temperatures of 1300° C. for 3 hours (pyrogenic oxidation treatment), followed by making a visual check on the presence or absence of OSF actualization. As a result, whitish OSF's are observed at the center of the silicon wafer prepared in the conventional example 1. On the other hand, there is no OSF found on the wafer surface of the example 1.
<Example 2>
Boron (B) doped p-type silicon ingots each having a diameter of 8 inches were pulled up by a single crystal of silicon pulling up apparatus. Each ingot had a straight body length of 1,200 mm, a crystal orientation of (100), a specific resistance of about 10 Ωcm, and an oxygen concentration of 1.0×10 18 atoms/cm 3 (old ASTM). These ingots were two in number, and grown under the same condition while continuously decreasing the V/G upon pulling up from 0.24 mm 2 /minute ° C. to 0.18 mm 2 /minute ° C. One of the ingots was cut at its center in the pulling up direction as shown in FIG. 8 to check positions of respective domains, and the other ingot was sliced to provide, as a specimen, a silicon wafer W 3 corresponding to the position P 3 in FIG. 8 . The wafer as the specimen in this example is the wafer W 3 shown in FIG. 9 and includes a center domain [P v ], a domain [P 1 ] that surrounds the domain [P v ], and a domain [P v ]that surrounds these domains.
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by heating the wafer in a nitrogen atmosphere at a temperature of approximately 650° C. and holding the wafer for 30 seconds.
<Example 3>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 650° C. with the holding time of 90 seconds.
<Example 4>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 650° C. with the holding time of 210 seconds.
<Example 5>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 750° C. with the holding time of 60 seconds.
<Example 6>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 750° C. with the holding time of 90 seconds.
<Example 7>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 850° C. with the holding time of 30 seconds.
<Example 8>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 850° C. with the holding time of 120 seconds.
<Comparative Example 2>
The wafer W 3 sliced out from the same ingot as that of the example 2 except that the mirror-polished wafer W 3 was not subjected to the heat treatment.
<Comparative Example 3>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 650° C. with the holding time of 100 seconds.
<Comparative Example 4>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 750° C. with the holding time of 20 seconds.
<Comparative Example 5>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 2 except that the heat treatment was performed at a temperature of approximately 800° C. with the holding time of 100 seconds.
<Comparative Evaluation 2>
Four pieces of silicon wafers W 3 of each of the examples 2 to 8 and the comparative examples 2 to 5 were prepared. Then, four different solutions that respectively contain Fe, Cr, Ni, and Cu were dropped on the surfaces of the respective wafers by means of a spin coating, obtaining four wafers being entirely contaminated with Fe, Cr, Ni, Cu respectively. All of the contaminated wafers W 3 were subjected to sequential heat treatments at 900° C. for 2 hours, 1000° C. for 0.5 hours, and 800° C. for 1.5 hours in that order. In each wafer, the metal element was dispersed in the bulk of the wafer. The heat treatment after the step of contaminating the wafer were carried out as the same way as that of the device manufactunng process in the semiconductor manufacturing industry.
For confirming the IG effects of the metal contaminants, those contaminated wafers were etched to about 2 μm in thickness by a secoetching solution. the presence or absence of haze under a light-gathering light was detected. The results of the presence or absence of haze with respect to the examples 2 to 8 and the comparative examples 2 to 5 are listed in Table 1. In addition, optical microscope photographs of the example 2 are shown in FIG. 16A to FIG. 16D, while optical microscope photographs of the compatible example 2 are shown in FIG. 17A to FIG. 17 D. In FIG. 16A, a quarter of the Fe-contaminated wafer of the example 2 is shown. In FIG. 17A, the Fe-contaminated wafer of the comparative example 2 is shown. Likewise, FIGS. 16B and 17B, FIGS. 16C and 17C, and FIG. 16 D and FIG. 17D show quarters of the Cr—, Ni—, and Cu-contaminated wafers of the example 2 and the comparative example 2, respectively.
TABLE 1
Heat Treatment
Presence or Absence
Condition
of Haze
Temperature
Time
Domain
Domain
(° C.)
(min.)
[P v ]
[P I ]
Exp. 2
650
30
Absence
Absence
Exp. 3
650
90
Absence
Absence
Exp. 4
650
210
Absence
Absence
Exp. 5
750
60
Absence
Absence
Exp. 6
750
90
Absence
Absence
Exp. 7
850
30
Absence
Absence
Exp. 8
850
120
Absence
Absence
Comp. 2
—
—
Absence
Presence
Comp. 3
650
100
Absence
Presence
Comp. 4
750
20
Absence
Presence
Comp. 5
800
100
Absence
Presence
* In Table 1, “Exp.” is an abbreviation for “Example” and “Comp.” is an abbreviation for “Comparative Example”.
As is evident from Table 1, FIG. 16A to FIG. 16D, and FIG. 17A to FIG. 17D, haze is only observed in the domain [P I ] of the wafer prepared in each of the comparative examples 2 to 5. It is conceivable that the densities of oxygen precipitation nuclei under the heat treatment conditions of the comparative examples 2 to 5 are low so that the IG effects cannot be exerted by the heat treatment after the contamination. On the other hand, the wafers of the examples 2 to 8 do not show any haze, so that each of them allows a high density of the oxygen precipitation nuclei on the whole surfaces of both the domains [P V ] and [P I ], resulting that they exert their IG effect.
<Example 9>
Boron (B) doped p-type silicon ingots each having a diameter of 8 inches were pulled up by a single crystal of silicon pulling up apparatus. Each ingot had a straight body length of 1,200 mm, a crystal orientation of (100), a specific resistance of about 10 Ωcm, and an oxygen concentration of 1.0×10 18 atoms/cm 3 (old ASTM). These ingots were two in number, and grown under the same condition while continuously decreasing the V/G upon pulling up from 0.24 mm 2 /minute ° C. to 0.18 mm 2 /minute ° C. One of the ingots was cut at its center in the pulling up direction as shown in FIG. 8 to check positions of respective domains, and the other ingot was sliced to provide, as a specimen, a silicon wafer W 3 corresponding to the position P 3 in FIG. 8 . The wafer as the specimen in this example is the wafer W 3 shown in FIG. 9 and includes a center domain [P v ], a domain [P I ] that surrounds the domain [P v ], and a domain [P v ] that surrounds these domains.
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by heating the wafer at room temperature to 1,150° C. at a temperature elevating speed of 50° C./second without holding the silicon wafer at a temperature of 1,150° C.
<Example 10>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated at a temperature of 1,150° C. by the same way as that of the example 9 except that the wafer W 3 was held for 5 seconds.
<Example 11>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated at a temperature of 1,150° C. by the same way as that of the example 9 except that the wafer W 3 was held for 30 seconds.
<Example 12>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,200° C. without holding the wafer W 3 at 1,200° C.
<Example 13>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,200° C. and held for 5 seconds.
<Example 14>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,200° C. and held for 30 seconds.
<Comparative Example 6>
The wafer W 3 was sliced out from the ingot and then mirror-polished by the same way as that of the example 9 except that the wafer W 3 was not subjected to the heat treatment.
<Comparative Example 7>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,100° C. and held for 5 seconds.
<Comparative Example 8>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,100° C. and held for 30 seconds.
<Comparative Example 9>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,100° C. and held for 60 seconds.
<Comparative Example 10>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated at a temperature of 1,500° C. by the same way as that of the example 9 except that the wafer W 3 was held for 60 seconds.
<Comparative Example 11>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,200° C. and held for 60 seconds.
<Comparative Example 12>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,250° C. and held for 5 seconds.
<Comparative Example 13>
The wafer W 3 sliced out from the ingot and then mirror-polished was heat treated by the same way as that of the example 9 except that the wafer W 3 was heated at a temperature of 1,250° C. and held for 30 seconds.
<Comparative Evaluation 3>
Heat treatment was carried out in imitation of the heat treatment in the device manufacturing process in the semiconductor manufacturing industry. That is, silicon wafers of the examples 9 to 14 and the comparative examples 6 to 13 were subjected to a heat treatment in an oxygen atmosphere at 800° C. for 4 hours and subsequently in an oxygen atmosphere at 1,000° C. for 16 hours. After the heat treatment, each waver was truncated and then subjected to the process of selective etching on the wafer surface using a Wright etching solution. Optical microscopic observations were performed for the purpose of detecting the presence or absence of slip and measuring the BMD surface density of each of the portions corresponding to the domains [P V ] and [P I ] at a depth of 350 μm from the wafer surface. The results are listed in Table 2.
TABLE 2
Heat Treatment
BMD Area
Condition
Density
Presence or
Temp.
Time
(× 10 4 /cm 2)
Absence of
(° C.)
(Second)
[P V ]
[P I ]
Slip
Exp. 9
1150
0
3.6
3.5
Absence
Exp. 10
1150
5
2.4
2.3
Absence
Exp. 11
1150
30
1.2
1.0
Absence
Exp. 12
1200
0
532.0
411.0
Absence
Exp. 13
1200
5
412.0
356.0
Absence
Exp. 14
1200
30
37.7
77.3
Absence
Comp. 6
Untreated
40.0
0.1
Absence
Comp. 7
1100
5
1.0
0.1
Absence
Comp. 8
1100
30
2.2
0.1
Absence
Comp. 9
1100
60
2.2
0.1
Absence
Comp. 10
1150
60
0.5
0.1
Presence
Comp. 11
1200
60
125.0
0.5
Presence
Comp. 12
1250
5
73.5
68.5
Presence
Comp. 13
1250
30
65.4
58.8
Presence
* In Table 2, “Exp.” is an abbreviation for “Example” and “Comp.” is an abbreviation for “Comparative Example”.
As is evident from Table2, the portion corresponding to the domain [P I ] of the wafer of each of the comparative examples 6 to 11 could not attain the BMD surface density (1×10 4 /cm 2 , preferably 2×10 4 /cm 2 ) responsible for exerting the IG effect. Regarding the wafers of the comparative examples 12 and 13, portions corresponding to the domains [P V ] and [P I ] caused slips in spite of permitting the BMD area densities of more than 2×10 4 /cm 2 . Regarding the wafers of the examples 9, 10, 12 to 14, on the other hand, the portions corresponding to the domains [P V ] and [P I ] permitted the higher BMD area densities. In the case of the wafer of the example 11, by the way, the distribution of precipitation in the wafer surface was uniform in spite of the BMD surface density of less than 2×10 4 /cm 2 .
<Example 15>
A silicon ingot was pulled up from a silicon melt such that the ratio (V/G) of a pulling-up speed to a temperature gradient was held at a value equal to or greater than a second critical ratio ((V/G) 2 ) and equal to or less than a third critical ratio ((V/G) 3 ), as shown in FIG. 1, for generating OSF in an area that corresponds to 25% of the entire area of the wafer when the wafer was subjected to a heat treatment in an oxygen atmosphere at 1,000° C. for 2 hours and subsequently at 1,100° C. for 12 hours. The total length of the ingot corresponded to the position P 2 shown in FIG. 10 . Each of the silicon wafer was sliced out from the thus pulled up ingot. Then, the wafer was lapped, chamfered and then mirror-polished, to thereby prepare a mirror-finished silicon wafer.
The mirror-finished wafer was heated up to 850° C. from room temperature at an elevating speed of 30° C., and held for 5 minutes. Subsequently, the temperature was lowered to a room temperature.
<Example 16>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 50% of the entire area of the wafer.
<Example 17>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 0.5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 18>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 19>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 10 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 20>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 20 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 21>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 30 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 22>
The silicon wafer was subjected to the heat treatment at a temperature of 700° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 23>
The silicon wafer was subjected to the heat treatment at a temperature of 800° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Example 24>
The silicon wafer was subjected to the heat treatment at a temperature of 950° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Comparative Example 14>
The silicon wafer was subjected to the heat treatment at a temperature of 850° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 15% of the entire area of the wafer.
<Comparative Example 15>
The silicon wafer was subjected to the heat treatment at a temperature of 640° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Comparative Example 16>
The silicon wafer was subjected to the heat treatment at a temperature of 1000° C. for 5 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Comparative Example 17>
The silicon wafer was subjected to the heat treatment at a temperature of 85° C. for 40 minutes elevated at the same speed as that of the example 15, except that the ingot was pulled up so as to generate the OSF's in an area that corresponds to 80% of the entire area of the wafer.
<Comparative Evaluation 4>
Optical microscopic observations were performed for the purpose of measuring the width of DZ and detecting the presence or absence of slip and measuring the BMD density at a depth of 250 μm from the wafer surface. The results are listed in Table 3. In addition, FIG. 8 shows a microscopic photograph of BMD in the wafer after the rapid heating of the example 18, magnified 50,000 times.
TABLE 3
Total Area
IG Heat Treatment
Ratio (%)
Condition
BMD
of Domain
Temp.
Time
density
DZ Width
OSF
(° C.)
(min.)
(× 10 6 /cm 3 )
(μm)
Exp. 15
25
850
5
2.6
40
Exp. 16
50
850
5
3.4
40
Exp. 17
80
850
0.5
10.0
15
Exp. 18
80
850
5
10.0
35
Exp. 19
80
850
10
11.0
45
Exp. 20
80
850
20
10.0
65
Exp. 21
80
850
30
12.0
85
Exp. 22
80
700
5
23.0
20
Exp. 23
80
800
5
22.0
35
Exp. 24
80
950
5
24.0
55
Comp. 14
15
850
5
less than
100 or over
1.0
Comp. 15
80
640
5
20.0
0
Comp. 16
80
1000
5
5.0
100 or over
Comp. 17
80
850
40
12
100 or over
* In Table 1, “Exp.” is an abbreviation for “Example” and “Comp.” is an abbreviation for “Comparative Example”.
As is evident from Table 3, regarding the comparative example 15, the OSF domain occupies too small area, i.e., only 15% of the total area of the silicon surface after the IG heat treatment, so that the BMD density cannot reach the order of 10 6 /cm 3 to be required for exerting the IG effect. Regarding the comparative example 15, the heat treatment temperature is too small, i.e., only 640° C., so that the DZ cannot be formed on the wafer surface. Regarding the comparative example 16, the heat treatment temperature is too high, i.e., 1000° C., so that the width of DZ is too wide more than necessary. Regarding the comparative example 17, furthermore, the heat treatment temperature is too long, i.e., 40 minutes, so that the width of DZ is too wide more than necessary. On the other hand, the silicon wafers of the examples 15 to 24 have their respective BMD densities on the order of 10 6 to 10 7 /cm 3 . Among them, each of the examples 17 to 22 has the OSF domain that occupies 80% of the total area of the wafer surface, so that the BMD density is on the order of 10 7 /cm 3 . Particularly, the examples 19 to 21 in which the heat treatment time is 10 to 30 minutes and the example 24 in which the heat treatment temperature is 950° C. attains the wide DZ of 45 to 85 μm in thickness.
The microscopic photograph shown in FIG. 18 reveals that the dislocation of BMD is also occurred in the wafer after performing the rapid heat treatment.
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A method of heat-treating a silicon wafer has the steps of: preparing a silicon wafer having an oxygen concentration of 1.2×10 18 atoms/cm 3 or less (old ASTM) without generating crystal originated particles(COP'S) and interstitial-type large dislocation(L/D); forming a polysilicon layer of 0.1 μm to 1.6 μm in thickness on a back of the silicon wafer by a chemical-vapor deposition at a temperature of 670° C.±30° C.; and heat-treating the silicon wafer having the polysilicon layer in an oxygen atmosphere at 1000° C.±30° C. for 2 to 5 hours and subsequently at 1130° C.±30° C. for 1 to 16 hours. In this method, the silicon wafer before the formation of the polysilicon layer thereon is the type of a wafer in which oxidation induced stacking faults(OSF's) manifest itself at a center of the wafer when the wafer is subjected to the heat-treatment. Accordingly, the resulting silicon wafer with a polysilicon layer is of OSF fee and COP free, even when the wafer is subjected to the conventional OSF-manifesting heat treatment. The wafer with the polysilicon layer exerts a uniform gettering effect between the peripheral edge and center of the silicon wafer as a result of a uniform oxygen precipitation occurred at the entire surface of the silicon wafer.
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BACKGROUND OF THE INVENTION
1. Technical Field
This application relates generally to increasing performance in a multiprocessor system. More specifically, the application relates to speeding up synchronization and least recently used (LRU) operations on a multiprocessor system. More specifically still, the application relates to increasing the speed of these operations by improving the locality of file systems involved in these operations.
2. Description of Related Art
Cache
A cache, as defined in the dictionary is simply “a secure place of storage”. As used in the computer industry, a cache has come to mean the fast memory in which pages of information are temporarily stored for quick retrieval by the system. This type of cache, which is used for increasing the virtual memory of a system, is generally managed by the hardware and its use is transparent to the operating system. There is, however, another type of cache, which is administered by software, such as the operating system of a computer. The operating system needs to access a number of objects such as inodes and metadata, which are pieces of information that provide information about files and exactly where to find them. Since the operating system needs to keep this metadata accessible, it will have a cache of metadata, which the operating system itself will administer. However, like main cache memory, the cache administered by the operating system is limited in space, so that old metadata must be periodically flushed out to make way for new metadata. Rather than try to search the entire operating system cache when space must be found, the cache can be separated into a number of cache classes. Each cache class will be associated with the metadata for a specific set of objects and will be allocated a given amount of cache space. This space will be allocated to the cache class in “pages” of a given size, although these are not the same as the pages used by the hardware to administer virtual memory. When a page in the software-administered cache must be freed for new metadata, only the pages belonging to the appropriate cache class are searched, not the entire cache.
While a number of algorithms can be used to decide which page is to be replaced at any given time, a commonly used method is one of the forms of the least recently used (LRU) algorithm. Using this algorithm, every time a packet of information is accessed, its access is noted. Then, when it is necessary to bring in a new page of information, the cache page that has gone the longest time without use (or some approximation of this) will be located. One such approximation method is to add to a counter within a page whenever that page is accessed. At intervals, the counters can be checked; any counter having a zero value has not been used in that interval. Once the unused pages have been located, the counters can be reset to zero for a new interval. Any available pages that have been modified will be written back to storage, then the space reused for the new page.
Multiprocessors
Large computers can be formed using multiple processors that divide the work between themselves. FIG. 1 demonstrates a typical arrangement of two multi-chip modules MCM 0 , MCM 1 , which between them contain eight processors CPU 0 –CPU 7 and sixteen memories MEM 0 –MEM 15 . These multi-chip modules are connected together to form a multiprocessor system.
It is known that access between a processor and an on-chip memory is faster than between the processor and a memory on another chip, e.g. access from CPU 4 to MEM 11 is faster than access from CPU 4 to MEM 0 . However, it is also known that most accesses to the cache memory are fairly random access. It has been recognized that it would be extremely difficult to provide any optimization of memory use in such a shared memory environment.
FIG. 2 demonstrates a prior art physical distribution of the pages that are allocated to three different cache classes in a shared operating system cache memory, which is distributed across the various memories on the two multi-chip modules. The memory is separated into regions, the exact nature of which is determined by the memory dynamics of the system. For a segmented architecture, such as Advanced Interactive eXecutive (AIX), the regions can be segments. AIX is a version of UNIX, available from International Business Machines Corporation. As can be seen in this figure, cache class CC 0 has four pages of cache memory allocated in Region 0 xF 0 , three pages of cache memory allocated in Region 0 xF 1 , and one page of cache memory allocated in Region 0 xF 2 . The other two cache classes CC 1 , CC 2 are likewise spread across the three regions. When any of these cache classes needs to synchronize (i.e., to write back to disk any pages that have been changed) or to locate the least recently used page to replace, it will need to search within three different regions of memory to find all the available pages.
When accessing an address within a segment in the segment-based architecture of AIX, the effective address used by software must be translated into the real address used by hardware. Because this requires several clock cycles, a number of the most recently accessed addresses are stored in the segment-lookaside-buffer (SLB). The SLB can be associatively searched (i.e., all at once), and if the address is found, clock cycles are saved in translating the address. However, an SLB miss results in the need to calculate the necessary address. If the cache spans a considerable number of segments, any other threads accessing the cache during the synchronize operation will cause context switching and require more SLB loads, incurring a penalty for the LRU/synchronize operation. A filesystem synchronize operation, for instance, may end up visiting most of the memory in the cache and may be context switched many times, losing the association of what segments it already visited.
Therefore, it would be advantageous to have a method, apparatus, and computer instructions to synchronize the cache without incurring the high overhead.
SUMMARY OF THE INVENTION
The present invention presents a method, apparatus, and computer instructions in which a cache class in a software-administered cache is assigned cache space that is localized to a single region of a memory, both physically and virtually, and is contiguous. Synchronization and LRU operations can step sequentially through the given region, removing the need for SLB searches or the penalty for a miss, while other threads remain random access. The threads that manage each virtual memory area can then be attached to specific processors, maintaining physical locality as well.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 demonstrates a known physical distribution of processors and memory on a typical multi-chip module in which the invention can be implemented.
FIG. 2 demonstrates a prior art distribution of cache memory for three cache classes.
FIG. 3 demonstrates a distribution of cache memory for three cache classes according to a preferred embodiment of the invention.
FIG. 4 shows an exemplary inode structure in accordance with a preferred embodiment of the present invention.
FIG. 5 demonstrates how the LRU-locating and synchronizing threads can be run independently for each cache class or synchronously and shows the flow of these threads according to an exemplary embodiment of the invention.
FIG. 6 demonstrates the physical locality of a cache class bound to a memory and of a thread handling that cache class that is bound to a processor according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the figures, and in particular, reference to FIG. 3 , a diagram demonstrating the allocation of operating system cache memory is depicted according to an exemplary embodiment of the present invention. In this figure, each of the cache classes CC 0 , CC 1 , CC 2 have the same amount of cache memory available to them as in FIG. 2 , but rather than being scattered across the three regions of cache memory, CC 0 is completely contained within region 0 xF 0 . Likewise, CC 1 is contained within region 0 xF 1 ; and CC 2 is contained within region 0 xF 2 . In the presently preferred embodiment, the pages of virtual memory given to each cache class are contiguous memory. Then, whenever the least recently used page must be located or the pages synchronized, a thread spawned by the operating system can step through the allocated region sequentially without the overhead of SLB accesses.
EXAMPLE
Inode Cache
In this illustrative example, an AIX operating system is running on the multichip modules MCM 0 , MCM 1 of FIG. 1 . For each file stored on the multichip modules, there is an inode, giving information such as file size and time of last modification. FIG. 4 shows an exemplary structure of a single file inode 410 , in accordance with a preferred embodiment of the present invention. The inode 410 contains, in addition to information regarding the entire file, either (a) pointers 416 to the addresses of all disk blocks 418 that comprise the file data or (b) pointers 412 to one or more levels of indirect blocks 414 that are deep enough to hold all of the data block addresses. As files are used, their inodes are being continually read and, in some cases, written. The operating system maintains an inode cache to speed up accesses to all of the files. If an inode is found in the cache, a count associated with the inode is incremented to show that it has another user. If the inode is not located in the cache, another location must be freed up so that the operating system can read the inode from memory. Inodes that have a usage count of zero are not currently being used and thus are candidates for reuse. Once a candidate for reuse has been located, the resident inode is written back to disk, if it has changed, then the space is made available. A routine is then called to read the new inode from the file. To get the node that is actually needed, the file system may need to access several other nodes in this tree before reaching the needed node. Thus, more than one free page may be needed.
With reference now to FIG. 5 , the illustrative example has eight cache classes CC 0 , CC 1 , CC 2 , CC 3 , CC 4 , CC 5 , CC 6 , CC 7 . It will be recognized that respective threads can be launched to search any one of the cache classes CC 0 , CC 1 , CC 2 , CC 3 , CC 4 , CC 5 , CC 6 , CC 7 , either independently or simultaneously. Alternatively, a single thread can search each cache class's location in turn. Whenever a thread is spawned to synchronize a cache class, the thread will follow the flowchart shown under CC 1 , in which the thread starts at the beginning of the cache class allocation(step 510 ). The thread will check to see if the page is dirty (step 512 ). A “dirty” page is one that has been changed; a dirty page will be synchronized or written back to the disk (step 512 ). The thread checks to see if there are more pages or if it has reached the end of the cache class allocation (step 516 ). If there are remaining pages, the thread will increment to the address of the next page (step 518 ) and continue checking pages (return to step 512 ); if no further pages remain on the list, the thread terminates (step 518 ). Similarly, the flowchart under CC 5 demonstrates the flow for searching for the LRU pages. The thread in this flow first moves to the first page of the cache class' allocated space (step 530 ). The usage count for the page is checked (step 532 ). If the usage count is zero, the page is available for reallocation and the operating system is so notified (step 534 ). If the usage count is greater than zero, it will be reset to zero (step 536 ) to start a new period. The thread checks to see if any pages remain (step 538 ). If there are further pages, the thread will increment to the address of the next page (step 540 ) and continue (return to step 532 ).
Binding Threads to Domains
Localizing the memory allocated to a cache class also allows the cache class to be optimized in terms of physicality. Since the cache memory allocated to the cache class will all be located within a single region of memory, it is easy to be sure that the thread that synchronizes and releases pages within the cache class is localized or bound to a CPU near the physical memory location. Specifically, the processor that synchronizes and releases pages within the cache class should be bound to a processor that is physically located on the same multi-chip module as the memory containing the cache class.
Even though the synchronization thread in this example is bound to a local processor (i.e., one sharing the chip with the cache memory), other types of access, being random, are not bound to a local processor. FIG. 6 demonstrates that the cache class CC 0 has been physically located on MEM 0 . Although the inodes stored in CC 0 can be accessed by any of the CPUs, the thread that will synchronize CC 0 would preferably be bound to one of the processors on MCM 0 . For all other types of accesses, the inodes in CC 0 can be accessed by any of the processors, including those processors on the module MCM 1 .
While this example has been explained in terms of an operating system inode cache, the invention is not limited to this example. Rather, the invention is applicable to any cache that is maintained by software (rather than hardware) and needs to be scanned frequently.
It is important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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A cache class in a software-administered cache of a multiprocessor is assigned cache space that is localized to a single region of a memory and is contiguous. Synchronization and LRU operations can step sequentially through the given region, removing the need for SLB searches or the penalty for a miss, while other threads remain random access. The threads that manage each virtual memory area can then be attached to specific processors, maintaining physical locality as well.
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SUMMARY OF THE INVENTION
Cultivation of a strain of the microorganism Pseudomonas cepacia SC11,783, which has been deposited in the American Type Culture Collection as A.T.C.C. No. 39356, yields a novel antibiotic substance cepacin.
Cepacin has been analyzed and found to be made up of two compounds; i.e., 5-[3-[3-(hepta-1,2-dien-4,6-diynyl)oxiran-2-yl]-3-hydroxy-1-propenyl]dihydro-2(3H)-furanone, a compound of the formula ##STR1## referred to as cepacin A, and 5-[[3-[3-(hepta-1,2-dien-4,6-diynyl)-2-oxiranyl]-2-oxiranyl]hydroxymethyl]dihydro-2(3H-furanone, a compound having the formula ##STR2## referred to as cepacin B.
Each of the above compounds exhibits activity against gram-positive bacteria. Cepacin A shows activity against some gram-negative bacteria and cepacin B shows activity against a wider range of gram-negative bacteria.
DETAILED DESCRIPTION OF THE INVENTION
The Microorganism
The microorganism used for the production of cepacin is Pseudomonas cepacia, SC 11,783. A subculture of the microorganism can be obtained from the permanent collection of the American Type Culture Collection, Rockville, Md. Its accession number in the repository is A.T.C.C. No. 39356. In addition to the specific microorganism described and characterized herein, it should be understood that mutants of the microorganism (e.g., mutants produced through the use of x-rays, ultraviolet radiation or nitrogen mustards) can also be cultivated to produce cepacin.
Isolation of Pseudomonas cepacia SC 11,783 from a soil sample (obtained in West Windsor, N.J.) in which it is present can be accomplished by plating the soil onto an agar of the following composition:
1 Synthetic Sea Salts--1.0 grams
Aspartic Acid--0.05 grams
Asparagine--0.05 grams
Yeast Extract--1.0 grams
KH 2 PO 4 --0.02 grams
K 2 HPO 4 --0.02 grams
2 Compost Extract--300.0 ml
Distilled Water--700.0 ml
Glycerol--5.0 ml
The medium is adjusted to pH about 6.5 and sterilized in an autoclave at 121° C. for 30 minutes. After cooling to room temperature, the sterile and cooled medium is supplemented with the following:
3 Biotin (0.1% solution)--1.0 ml
3 Thiamin (0.2% solution)--1.0 ml
3 Actidione (1.0% solution)--10.0 ml
After 24-72 hours incubation at 28° C., the colonies of Pseudomanas cepacia SC 11,783 are isolated from the plated soil. The isolated colonies are picked off and maintained on an agar medium composed of:
Yeast Extract--1 gram
Beef Extract--1 gram
NZ Amine A--2 grams
Glucose--10 grams
Agar--15 grams
Distilled Water to --1000 ml
The medium is adjusted to pH 7.3 and sterilized in an autoclave at 121° C. for 30 minutes.
Pseudomonas cepacia SC 11,783 is a gram negative rod, motile by means of multitrichous polar flagella. It is non-fluorescent, oxidase positive, accumulates poly β-hydroxybutyrate as intracellular reserve material. Arginine dihydrolase is lacking, nitrate is reduced to nitrate, and growth occurs at 41° C.
The following compounds are utilized as the sole carbon source on the basal medium described in Stanier et al., J. Gen. Microbiol, 43:159 (1966): glucose, xylose, arabinose, fructose, sucrose, ribose, mannitol, sorbitol, salicin, acetate, citrate, d-tartrate, and putrescine. Rhamnose, maltose, lactose, erythritol are not utilized.
Pseudomonas cepacia SC 11,783 is identical to Pseudomonas cepacia A.T.C.C. No. 17759 and matches the published description of this species (Ballard et al., J. Gen. Microbiol, 60:199 (1970)) except for the failure to produce a yellow intracellular pigment.
Production of the Antibiotic
Pseudomonas cepacia SC 11,783 produces cepacin. To form cepacin according to the preferred methodology, the microorganism is grown at, or near, room temperature (25° C.) under submerged aerobic conditions in an aqueous nutrient medium containing an assimilable carbohydrate and nitrogen source. The fermentation is carried out until substantially activity is imparted to the medium, usually about 12 to 40 hours, preferably about 18 to 20 hours.
At harvest, cells can be removed by centrifugation. Cepacin can be extracted from the supernate into moderately polar organic solvents (e.g., n-butanol, ethyl acetate, chloroform, and dichloromethane) and can then be purified by normal-phase chromatography on silica gel or silicic acid or by partition chromatography on Sephadex LH-20 in methanol-chloroform-heptane (1:3:6) to give cepacin A and cepacin B in approximately equal amounts. These antibiotics can also be separated by reverse-phase chromatography on a Waters C 18 μBondapak column eluting with acetonitrile-water (3:7), and monitoring the effluent at 261 nm.
Cepacin A and cepacin B are very unstable when all the solvent is removed and decompose rapidly to give a dark brown insoluble solid. They should, therefore, be stored in dilute solution. They are also very base labile, rearranging to a triyne-ene system. This rearrangement has been observed in ethanol-water (1:9) without added base, presumably catalyzed by traces of base on the glassware. The γ-lactone ring is subject to methanolysis so storage in methanol should be avoided.
The following examples further illustrate the preparation and isolation of cepacin A and cepacin B.
EXAMPLE OF FERMENTATION OF PSEUDOMONAS CEPACIA
SC 11,783
Pseudomonas cepacia SC 11,783 was maintained on the following sterilized agar medium (A):
______________________________________ Grams______________________________________Yeast Extract 1.0Beef Extract 1.0NZ Amine A 2.0Glucose 10.0Agar 15.0Distilled H.sub.2 O to 1 liter______________________________________
The pH was adjusted to 7.3 before sterilization at 121° C. for 30 minutes. A loopful of surface growth from an agar slant (Medium A) of Pseudomonas cepacia SC 11,783 was used to inoculate each of four 500 ml Erlenmeyer flasks containing 100 ml each of the following sterilized medium (B):
______________________________________ Grams______________________________________Yeast Extract 4.0Malt Extract 10.0Dextrose 4.0Distilled H.sub.2 O to 1 liter______________________________________
The pH was adjusted to 7.3 before sterilization at 121° C. for 15 minutes. After inoculation, the flasks were then incubated at 25° C. on a rotary shaker (300 rpm; 2 inch stroke) for approximately 24 hours. After incubation as described above, 1% (vol/vol) transfers were made from the grown culture flasks to thirty 500 ml Erlenmeyer flasks each containing 100 ml of sterilized medium (B), as described above. After inoculation, the flasks were once again incubated at 25° C. on a rotary shaker (300 rpm; 2 inch stroke) for approximately 24 hours. After incubation as described above, a 1% transfer (vol/vol) was made to a 380-liter stainless steel fermentation tank containing 250 liters of sterilized medium (B). After inoculation the fermentation was continued under the following conditions: temperature 25° C.; pressure 10 psig; aeration--10 CFM; agitation 155 rpm. Ucon LB-625 (polypropylene glycol; Union Carbide) was added as needed as an antifoam agent. After approximately 18-20 hours, the fermentation was completed. The fermentation broth was then adjusted to pH 5.0 using hydrochloric acid and the broth contents of the tank was centrifuged yielding approximately 240 liters of supernatant broth.
EXAMPLE OF ISOLATION OF CEPACIN FROM A 50 LITER FERMENTATION
The broth supernate (pH 6) from a 50 liter fermentation of Pseudomonas cepacia SC 11,783 was extracted with 16 liters of dichloromethane and the extract was concentrated in vacuo to 700 ml. The concentrate was dried (sodium sulfate), taken to dryness, and the residue immediately redissolved in chloroform-heptane-methanol-water (2:3:4:1) (system I). The lower (water rich) phase was separated, washed once with an equal volume of the upper phase of system I, and then concentrated to 50 ml in vacuo. The concentrate was extracted with 25 ml of chloroform, giving 45 ml of lower phase, LP-1, that was stored in the freezer until further purification.sup.(1). The solution contained 180 mg of non-volatile material, ca. 50 mg. of which was cepacin A and cepacin B judging from the UV absorbance at 263 nm.
LP-1 was concentrated in vacuo and the residue immediately dissolved in 5 ml of methanolchloroform-heptane (1:3:6) (system II). The solution was chromatographed on a 2.5×90-cm (450 ml) column of Sephadex LH-20 in system II, eluting at 2 ml/minute and collecting 20 ml fractions. Cepacin A and cepacin B were located by UV absorbance at 263 nm. Fractions 95 to 103 were combined, concentrated in vacuo to 5 ml and diluted with chloroform to give 35 ml of solution which contained 6.8 mg of cepacin A: UV max in CHCl 3 (E 1% ) 248.5 (613), 262.0 (827), 276.8 nm (672); nmr in CDCl 3 +CD 3 OD δ2.05 (1H, m), 2.47 (1H, m), 2.50 (1H, m. J<1 Hz), 2.58 (1H, m), 3.02 (1H, J=4.6, 2.1 Hz, Δδ=0.01 ppm), 3.47 (1H, J=7.8, 2.0, 0.6 Hz), 4.17 (1H, m), 5.03 (1H, m), 5.33 (1H, J=7.9, 6.8, 0.6 Hz), 5.68 (1H, J=6.7 Hz), 5.91 ppm, (2H, m); ir in CHCl 3 3291, 2218, 1944, 1770, 1177 cm -1 ; [α] D (c=0.23 in CHCl 3 ) -129°. Similarly, fractions 108 to 119 gave 35 ml of solution which contained 10.7 mg of cepacin B: UV max in CHCl 3 (E 1% ) 250.5 (399), 263.7 (575), 279.0 (465); nmr in CDCl 3 +CD 3 OD δ2.31 (1H, m), 2.52 (1H, m, J<1 Hz), 2.55 (1H, J=17.9, 9.6, 8.2 Hz), 2.66 (1H, J=17.9, 9.8, 5.7 Hz), 3.01 (1H, J=4.3, 1.8 Hz), 3.15 (1H, J=4.3, 2.1 Hz), 3.21 (1H, J=4.0, 2.1 Hz), 3.46 (1H, J=7.9, 1.9, 0.6 Hz), 3.69 (1H, J=4.0, 4.0 Hz), 4.61 (1H, J= 7.0, 7.0, 3.6 Hz), 5.31 (1H, J=7.9, 6.7, 0.6 Hz), 5.70 ppm (1H, J=6.7, 0.9, 0.9 Hz); ir in CHCl 3 3295, 2217, 2197, 1946, 1773, 1180 cm -1 .
EXAMPLE OF ISOLATION OF CEPACIN A FROM A 250 LITER FERMENTATION
Cepacin was extracted with dichloromethane from 200 liters of broth supernate, partitioned in chloroform-heptane-methanol-water (2:3:4:1), and extracted into chloroform as described in the previous example. The chloroform extract was applied to a 1 liter column of Whatman LPS-1 silica gel. The column was washed with 1 liter of chloroform and then eluted with chloroform-ethyl acetate (3:1), collecting 250 ml fractions. The effluent was monitored by TLC on silica gel (chloroform-ethyl acetate (1:1), detection, with phosphomolybdic acid; cepacin A, R f 0.19; cepacin B, R f 0.13). Fractions 6 and 7 contained cepacin A and fractions 9 to 12 contained cepacin B. Both of the compounds were about 50% pure at this stage and were further purified by partition chromatography on Sephadex LH-20 in methanol-chloroform-heptane (1:3:6) as described in the previous example.
Biological Activity
The following methodology is used to determine the minimum inhibitory concentration (hereinafter referred to as MIC) of the compounds of this invention.
The test organisms are grown in approximately 15-20 ml of Antibiotic Assay broth (Difco) by inoculating (in tubes) the broth with a loopful of the organism from a BHI (Difco) agar slant. The inoculated tubes are incubated at 37° C. for 18 to 20 hours. These cultures are assumed to contain 10 9 colony forming units (hereinafter CFU) per milliliter. The cultures are diluted 1:100 to give a final inoculum level of 10 7 CFU; dilutions were made with K-10 broth*.
The compounds are dissolved in the appropriate diluent at a concentration of 1000 μg/ml. Two-fold dilutions are made in K-10 broth resulting in a range from 1000 μg/ml to 0.5 μg/ml. 1.5 ml of each dilution is placed into individual square petri dishes to which 13.5 ml of K-10 agar** is added. The final drug concentration in the agar ranges from 100 μg/ml to 0.05 μg/ml. Organism growth control plates containing agar only are prepared and inoculated before and after the test plates. The organisms are applied to the agar surface of each plate with the Denley Multipoint Inoculator (which delivers approximately 0.001 ml of each organism) resulting in a final innoculum level of 10 4 CFU on the agar surface.
Beef extract--1.5 g
Yeast extract--3.0 g
Peptone--6.0 g
Dextrose--1.0 g
Distilled water q.s. 1 liter
Beef extract--1.5 g
Yeast extract--3.0 g
Peptone--6.0 g
Dextrose--1.0 g
Agar--15.0 g
Distilled water q.s. 1 liter
The plates are incubated at 37° C. for 18 hours and the MIC's are determined. The MIC is the lowest concentration of compound inhibiting growth of the organism.
The tables that follow are tabulated results obtained when the compounds of this invention were tested against various organisms. The number following each organism refers to the number of the organism in the collection of E. R. Squibb & Sons, Inc., Princeton, N.J. A dash (-) in the tables means that the compound tested did not show activity against the particular organism at 50 μg/ml.
______________________________________ M.I.C. (μg/ml)Organism SC#* Cepacin A Cepacin B______________________________________Staphylococcus aureus 1276 0.2 <0.05Staphylococcus aureus 2399 0.1 <0.05Staphylococcus aureus 2400 0.2 <0.05Staphylococcus aureus 10165 0.2 <0.05Streptococcus faecalis 9011 50 --Streptococcus agalactiae 9287 50 --Micrococcus luteus 2495 0.2 3.13Escherichia coli 8294 50 0.78Escherichia coli 10857 1.6 0.1Escherichia coli 10896 12.5 0.4Escherichia coli 10909 6.3 0.2Klebsiella aerogenes 10440 -- 0.78Klebsiella pneumoniae 9527 -- --Proteus mirabilis 3855 -- 6.3Proteus rettgeri 8479 >25 6.3Proteus vulgaris 9416 1.6 <0.05Salmonella typhosa 1195 25 0.4Shigella sonnei 8449 50 0.8Enterobacter aleacae 8236 -- 25Enterobacter aerogenes 10078 -- 3.1Citrobacter freundii 9518 50 0.8Serratia marcescens 9783 -- --Pseudomonas aeruginosa 9545 -- --Pseudomonas aeruginosa 8329 -- --Acinetobacter calcoacetieus 8333 -- --______________________________________ *Organisms from the culture collection of E. R. Squibb & Sons, Inc.
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Cultivation of a strain of the microorganism Pseudomonas cepacia SC 11,783, A.T.C.C. No. 39356 yields a novel antibiotic substance which is made up of two compounds, i.e., 5-[3-[3-(hepta-1,2-dien-4,6-diynyl)oxiran-2-yl]-3-hydroxy-1-propanyl]dihydro-2(3H)-furanone and 5-[[3-[3-(hepta-1,2-dien-4,6-diynyl)-2-oxiranyl]-2-oxiranyl]hydroxymethyl]dihydro-2(3H)-furanone.
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INCORPORATION BY REFERENCE
[0001] The present application claims priority from Japanese patent application JP 2013-110830 filed on May 27, 2013, the content of which is hereby incorporated by reference into this application.
BACKGROUND
[0002] The subject matter disclosed herein relates to a system and method capable of identifying the extent of a failure quickly in a messaging system.
[0003] In recent years, a huge amount of data (big data) is sent/received over a network nowadays, and the importance of a messaging technology for processing big data efficiently is rising. With a common messaging technology, processing of relaying a message (for example, sensor data) to a destination server is executed by using a messaging system that includes a message receiving server, a message sending server, and backup storage where messages are stored.
[0004] The messaging system executes processing described below in the message relaying processing.
[0005] First, the receiving server receives a message from a sending terminal, stores the received message in the backup storage, and then sends a response to the sending terminal. Thereafter, the sending server obtains the message from the backup storage, relays the obtained message to a destination server, and then deletes the message from the backup storage.
[0006] By following the processing steps described above, a response to the sending terminal can be sent as soon as the storing of the message in the backup storage is finished, and the response performance is accordingly improved. Storing a message in the backup storage also guarantees the permanence of the stored message.
[0007] In recent years, messaging systems capable of processing a large amount of data efficiently and quickly by utilizing in-memory Key Value Store (KVS) are becoming popular.
[0008] In-memory KVS is a form of data store where data that is a pair of a key and a value is stored in a volatile memory. With in-memory KVS, high scalability is accomplished and, because data is stored on the memory, high processing performance is achieved as well. In-memory KVS is also capable of preventing data loss, which is a concern in an in-memory environment, through the replication (duplication) of data between a plurality of servers.
[0009] In the following description, processing of storing data that is a pair of a key and a value in a volatile memory is referred to as storing, processing of reading a value that is associated with a key out of the volatile memory is referred to as retrieval, and processing of erasing data that is a pair of a key and a value from the volatile memory is referred to as deletion.
[0010] In a messaging system that utilizes the in-memory KVS described above, data is managed on the in-memory (volatile memory) for quick processing, which has a possibility of complete data loss in the event of multiple failures. Further, when a data loss occurs, identifying the lost data is difficult because the receiving server, the sending server, and an in-memory KVS all handle different aspects of message processing from one another. The resulting problem is that grasping the extent of a failure (how many users have been affected by the message loss, how many messages have been lost, and the like) is difficult.
[0011] When a data loss occurs in a messaging system and a sending failure due to the data loss cannot be notified to the sender side, the failure is generally treated as a service failure. Accordingly, when dealing with a data loss by restoring lost data, or by identifying the extent of the failure and sending an error response to the sending terminal, is not possible in a messaging system that utilizes in-memory KVS, there is a chance of service failure, which makes the messaging system an unstable system.
[0012] A known method of preventing a service failure by restoring data is a technology described in U.S. Pat. No. 4,159,517 A.
[0013] The technology described in U.S. Pat. No. 4 , 159 , 517 A is commonly known as Write Ahead Logging (WAL), which is a DB technology. Write Ahead Logging is a technology used in in-memory DBs, typically, Hbase, and involves recording the specifics of processing in a non-volatile storage medium as a log when a piece of data is written so that the piece of data is restored by re-executing the processing recorded in the log. In Write Ahead Logging, each time the receiving server and the sending server execute processing that is related to in-memory KVS, the in-memory KVS records in a non-volatile storage medium a log of the processing including the specifics of the stored data. In the case where a failure occurs in the in-memory KVS, the in-memory KVS is reactivated, and the processing recorded in the log is executed to recover to the state that precedes the failure. By following these steps, the system can return to the state prior to data loss and Write Ahead Logging is thus capable of preventing a service failure due to data loss.
[0014] A known method of preventing a service failure by ensuring that the extent of a failure can be identified is a technology described in JP 2004-227360 A.
[0015] JP 2004-227360 A includes the following description: “Session information, which is assigned to each execution of processing in log information held by a server, is recorded in a session information management table, and a session information association relation between different pieces of log information is recorded in a session information association table. The session information association table is searched recursively for a piece of session information that is specified by a user through a display target entering part, to thereby identify a series of pieces of session information related to processing that is of interest to the user. For each piece of session information out of the series of related pieces of session information, an associated piece of information is collected from the log information. The collected pieces of information are integrated by the date of recording of the log and formatted so that it is easy to understand the flow of processing. The formatted information is then presented to the user.”
SUMMARY
[0016] However, with the technology of U.S. Pat. No. 4,159,517 A, where a log is written in the in-memory KVS for each execution of processing and for every piece of data stored, the in-memory KVS performance drops and, consequently, the advantage of in-memory KVS which is fast processing is impaired.
[0017] The technology of JP 2004-227360 A needs to check hours of logs for all receiving servers and all sending servers, and takes long to identify the extent of a failure.
[0018] This invention has been made to solve the problems described above. Specifically, this invention provides a system and method capable of preventing a performance drop due to the writing of a log in an in-memory KVS, and capable of identifying the extent of a failure quickly.
[0019] The present invention can be appreciated by the description which follows in conjunction with the following figures, wherein: a computer system comprises a plurality of computers to be coupled to one another through a network, and is configured to receive a plurality of messages from a terminal and send each of the plurality of messages to a destination apparatus. Each of the plurality of computers includes a processor, a memory coupled to the processor, and a network interface coupled to the processor. The computer system comprises at least one first computer, at least one second computer, at least one third computer, and at least one fourth computer. The at least one first computer includes a message receiving part configured to receive the plurality of messages from the terminal, a first log output part configured to output a plurality of receiving logs which are logs of the received plurality of messages, and a first memory part configured to store receiving log data including the plurality of receiving logs. The at least one second computer including a data store management part configured to manage a data store which is built from a storage area of the memory and stores the plurality of messages, a first search part configured to search for at least one of the plurality of messages that meets a given condition from among the plurality of messages stored in the data store, a second log output part configured to output a data store log which is a log of the searched at least one of the plurality of messages, and a second memory part configured to store data store log data including a plurality of data store logs. The at least one third computer including a message sending part configured to retrieve the plurality of messages stored in the data store and send the plurality of messages to the destination apparatus, a third log output part configured to output a plurality of sending logs which are logs of the plurality of messages sent to the destination apparatus, and a third memory part configured to store sending log data including the plurality of sending logs. The at least one fourth computer including a first monitoring part configured to monitor a state of the data store, a first log collecting part configured to obtain the receiving log data from the first memory part, the data store log data from the second memory part, and the sending log data from the third memory part, respectively, in a case where a failure in the data store is detected, a second search part configured to search for at least one of the plurality of messages which has been lost due to the failure in the data store by comparing the obtained receiving log data, data store log data, and sending log data, and a fourth memory part configured to store the receiving log data, the data store log data, and the sending log data.
[0020] According to the aspect of this invention described above, only data store logs of messages that fulfill a given condition are written in the memory part, and a performance drop due to the writing of a log in the data store is thus prevented successfully. With only a small number of logs written, fast identification of the extent of a failure is accomplished as well.
[0021] According to the disclosure, a performance drop due to the writing of a log may be prevented. The extent of a failure may also be identified quickly.
[0022] Other objects, configurations, and effects than those described above are revealed through the following description of embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The present invention can be appreciated by the description which follows in conjunction with the following figures, wherein:
[0024] FIG. 1 is an explanatory diagram for illustrating an example of the configuration of a mail system according to a first embodiment of this invention,
[0025] FIG. 2 is a block diagram for illustrating an example of the configuration of an incoming mail server in the first embodiment,
[0026] FIG. 3 is a block diagram for illustrating an example of the configuration of an outgoing mail server in the first embodiment,
[0027] FIG. 4 is a block diagram for illustrating an example of the configuration of a data store server in the first embodiment,
[0028] FIG. 5 is a block diagram for illustrating an example of the configuration of a collection/search server in the first embodiment,
[0029] FIG. 6A is an explanatory diagram for illustrating an example of the contents of receiving log data stored on the collection/search server in the first embodiment,
[0030] FIG. 6B is an explanatory diagram for illustrating an example of the contents of sending log data stored on the collection/search server in the first embodiment,
[0031] FIG. 6C is an explanatory diagram for illustrating an example of the contents of data store log data stored on the collection/search server in the first embodiment,
[0032] FIG. 7 is a sequence diagram for illustrating an example of mail receiving processing of the first embodiment,
[0033] FIG. 8A and FIG. 8B are sequence diagrams for illustrating an example of mail sending processing of the first embodiment,
[0034] FIG. 9 is a flow chart for illustrating mail data search processing that is executed by a data search processing part of the data store server in the first embodiment,
[0035] FIG. 10 is a sequence diagram for illustrating processing that is executed when a failure occurs on the data store server in the first embodiment,
[0036] FIG. 11 is an explanatory diagram for illustrating log data that is used by the collection/search server to identify the extent of a failure in the first embodiment,
[0037] FIG. 12 is an explanatory diagram for illustrating an example of a terminal screen, which is used by the operator to operate the collection/search server of the first embodiment,
[0038] FIG. 13 is a flow chart for illustrating mail data search processing that is executed by the data search processing part of the data store server in a modification example of the first embodiment,
[0039] FIG. 14 is an explanatory diagram for illustrating an example of the configuration of a mail system according to a second embodiment,
[0040] FIG. 15 is a block diagram for illustrating an example of the configuration of a log management server in the second embodiment, and
[0041] FIG. 16 is a sequence diagram for illustrating processing that is executed in the second embodiment when a failure occurs in one of carrier networks.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0042] Embodiments of this invention are described below with reference to the accompanying drawings.
[0043] The description of the embodiments uses a mail system, which is a typical messaging system.
First Embodiment
[0044] FIG. 1 is an explanatory diagram for illustrating an example of the configuration of a mail system according to a first embodiment of this invention.
[0045] The mail system, namely, messaging system, of this embodiment includes a mobile terminal 101 , a destination server 105 , an incoming mail server 106 , an outgoing mail server 107 , a data store server 108 , and a collection/search server 109 . The mail system also includes, as networks that couple the constituent apparatus of the mail system, a mobile network 102 , a carrier network 103 , and an internet 104 .
[0046] The mobile terminal 101 is a terminal handled by a user or other people, and is coupled to the carrier network 103 via the mobile network 102 . The mobile network 102 is a wireless network that couples the mobile terminal 101 and the carrier network 103 . The carrier network 103 is a network that couples the mobile network 102 , the internet 104 , the incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 .
[0047] The destination server 105 is coupled to the carrier network 103 via the internet 104 , and sends/receives mail to/from the outgoing mail server 107 .
[0048] The incoming mail server 106 is coupled to the carrier network 103 , receives mail sent from the mobile terminal 101 via the carrier network 103 , and stores the mail on the data store server 108 . While there is only one incoming mail server 106 in FIG. 1 , the mail system may include a plurality of incoming mail servers 106 .
[0049] The outgoing mail server 107 is coupled to the carrier network 103 , retrieves mail from the data store server 108 , and sends the mail to the destination server 105 . While there is only one outgoing mail server 107 in FIG. 1 , the mail system may include a plurality of outgoing mail servers 107 .
[0050] The data store server 108 is coupled to the carrier network 103 , and holds mail that is stored therein by the incoming mail server 106 . The data store server 108 is a message store, typically an in-memory KVS. While there is only one data store server 108 in FIG. 1 , the mail system may include a plurality of data store servers 108 .
[0051] The collection/search server 109 is coupled to the carrier network 103 , and monitors the situation of the data store server 108 . The collection/search server 109 also collects logs that are on the incoming mail server 106 , the outgoing mail server 107 , and the data store server 108 , and uses the collected logs to identify the extent of a failure.
[0052] The incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 are implemented as different apparatus in the example of FIG. 1 . However, this embodiment is not limited thereto, and the functions of two or more of the servers may be implemented by a single apparatus. For example, a single apparatus may implement the functions of the incoming mail server 106 and the outgoing mail server 107 . To give another example, a single apparatus may implement the functions of the incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 .
[0053] Alternatively, the incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 may be implemented with the use of a virtualization technology. For example, virtual computers corresponding to the incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 may be generated on a single computer.
[0054] FIG. 2 is a block diagram for illustrating an example of the configuration of the incoming mail server 106 in the first embodiment.
[0055] The incoming mail server 106 is implemented with the use of an information processing apparatus. The hardware configuration of the incoming mail server 106 includes a processor 201 , a volatile memory 202 , a non-volatile memory 203 , and a network I/F 204 , which are coupled to one another via an internal communication line such as a bus.
[0056] The processor 201 executes a program stored in the volatile memory 202 . By executing a program that is stored in the volatile memory 202 with the use of the processor 201 , the function of the incoming mail server 106 is implemented. In the following description, a program described as performing processing is actually being executed by the processor 201 .
[0057] The volatile memory 202 stores a program executed by the processor 201 , and includes a storage area in which data necessary to execute the program is temporarily stored. Specifically, the volatile memory 202 stores a program that implements a mail receiving processing part 210 , and includes a volatile memory part 220 .
[0058] The mail receiving processing part 210 includes a plurality of program modules, and controls receiving processing for receiving mail from the mobile terminal 101 . Specifically, the mail receiving processing part 210 includes a mail receiving part 211 , a data store server I/F 212 , and a log output part 213 .
[0059] The mail receiving part 211 executes receiving processing for mail sent from the mobile terminal 101 .
[0060] The data store server I/F 212 executes storing processing for storing received mail on the data store server 108 .
[0061] The log output part 213 outputs, when received mail is stored on the data store server 108 , a receiving log in a data format that includes information for identifying the stored mail. The output receiving log is stored in receiving log data 231 of a non-volatile memory part 230 in this embodiment.
[0062] The mail receiving part 211 may include the function of the data store server I/F 212 .
[0063] The volatile memory part 220 stores data that is managed by the mail receiving processing part 210 .
[0064] The non-volatile memory 203 includes the non-volatile memory part 230 in which data is to be stored permanently.
[0065] The non-volatile memory part 230 stores data that is managed by the mail receiving processing part 210 , and also stores the receiving log data 231 . The receiving log data 231 is data that includes one or more receiving logs output by the log output part 213 .
[0066] The network I/F 204 is an interface for coupling to other apparatus via a network. The network I/F 204 in this embodiment is coupled to the carrier network 103 .
[0067] The program stored in the volatile memory 202 may instead be stored in the non-volatile memory 203 . The processor 201 in this case reads the program out of the non-volatile memory 203 , and loads the read program onto the volatile memory 202 .
[0068] FIG. 3 is a block diagram for illustrating an example of the configuration of the outgoing mail server 107 in the first embodiment.
[0069] The outgoing mail server 107 is implemented with the use of an information processing apparatus. The hardware configuration of the outgoing mail server 107 includes a processor 301 , a volatile memory 302 , a non-volatile memory 303 , and a network I/F 304 , which are coupled to one another via an internal communication line such as a bus.
[0070] The processor 301 executes a program stored in the volatile memory 302 . By executing a program that is stored in the volatile memory 302 with the use of the processor 301 , the function of the outgoing mail server 107 is implemented. In the following description, a program described as performing processing is actually being executed by the processor 301 .
[0071] The volatile memory 302 stores a program executed by the processor 301 , and includes a storage area in which data necessary to execute the program is temporarily stored. Specifically, the volatile memory 302 stores a program that implements a mail sending processing part 310 , and includes a volatile memory part 320 .
[0072] The mail sending processing part 310 includes a plurality of program modules, and controls sending processing for sending mail to the destination server 105 . Specifically, the mail sending processing part 310 includes a mail sending part 311 , a data store server I/F 312 , and a log output part 313 .
[0073] The mail sending part 311 executes sending processing for sending to the destination server 105 mail retrieved from the data store server 108 .
[0074] The data store server I/F 312 executes retrieval processing for getting mail from the data store server 108 .
[0075] The log output part 313 outputs, if send mail to the destination server 105 is completed, a sending log in a data format that includes information for identifying the sent mail. The output sending log is stored in sending log data 331 of a non-volatile memory part 330 in this embodiment.
[0076] The volatile memory part 320 stores data that is managed by the mail sending processing part 310 .
[0077] The mail sending part 311 may include the function of the data store server I/F 312 .
[0078] The non-volatile memory 303 includes the non-volatile memory part 330 in which data is stored permanently.
[0079] The non-volatile memory part 330 stores data that is managed by the mail sending processing part 310 , and also stores the sending log data 331 . The sending log data 331 is data that includes one or more sending logs output by the log output part 313 .
[0080] The network I/F 304 is an interface for coupling to other apparatus via a network. The network I/F 304 in this embodiment is coupled to the carrier network 103 .
[0081] The program stored in the volatile memory 302 may instead be stored in the non-volatile memory 303 . The processor 301 in this case reads the program out of the non-volatile memory 303 , and loads the read program onto the volatile memory 302 .
[0082] FIG. 4 is a block diagram for illustrating an example of the configuration of the data store server 108 in the first embodiment.
[0083] The data store server 108 is implemented with the use of an information processing apparatus. The hardware configuration of the data store server 108 includes a processor 401 , a volatile memory 402 , a non-volatile memory 403 , and a network I/F 404 , which are coupled to one another via an internal communication line such as a bus.
[0084] The processor 401 executes a program stored in the volatile memory 402 . By executing a program that is stored in the volatile memory 402 with the use of the processor 401 , the function of the data store server 108 is implemented. In the following description, a program described as performing processing is actually being executed by the processor 401 .
[0085] The volatile memory 402 stores programs executed by the processor 401 , and includes a storage area in which data necessary to execute the programs is temporarily stored. Specifically, the volatile memory 402 stores programs that implement a data store management part 410 and a data search processing part 420 , and includes a volatile memory part 430 .
[0086] The data store management part 410 controls data store processing procedures. The data store processing procedures include processing for storing a pair of a key and a value that is received from the incoming mail server 106 or from the outgoing mail server 107 in the volatile memory part 430 , processing for sending in response a value that is associated with a key received from the incoming mail server 106 or from the outgoing mail server 107 , and processing for deleting a value that is associated with a key received from the incoming mail server 106 or from the outgoing mail server 107 .
[0087] The data search processing part 420 includes a plurality of program modules, and controls processing for searching for mail data to be output as a data store log. Specifically, the data search processing part 420 includes a data search part 421 and a log output part 422 .
[0088] The data search part 421 executes processing for searching pieces of mail data 431 , which are stored in the volatile memory part 430 , for a piece of the mail data 431 that fulfills a particular condition.
[0089] The log output part 422 outputs a data store log of a piece of the mail data 431 that is found through the search by the data search part 421 . The output data store log is stored in data store log data 441 of the non-volatile memory part 440 in this embodiment.
[0090] The volatile memory part 430 stores data that is managed by the data store management part 410 . The volatile memory part 430 of this embodiment stores one or more pieces of the mail data 431 . The mail data 431 is data of mail stored by the data store management part 410 . The data store management part 410 in this embodiment manages the mail data 431 (a value) with a sending time and date, a unique ID, a domain name, or the like that is included in the header or other sections of the mail data 431 as a key.
[0091] The non-volatile memory 403 includes the non-volatile memory part 440 in which data is stored permanently.
[0092] The non-volatile memory part 440 stores data that is managed by the data store management part 410 and the data search processing part 420 . The non-volatile memory part 440 also stores the data store log data 441 . The data store log data 441 is data that includes one or more data store logs output by the log output part 422 .
[0093] The network I/F 404 is an interface for coupling to other apparatus via a network. The network I/F 404 in this embodiment is coupled to the carrier network 103 .
[0094] The program stored in the volatile memory 402 may instead be stored in the non-volatile memory 403 . The processor 401 in this case reads the program out of the non-volatile memory 403 , and loads the read program onto the volatile memory 402 .
[0095] FIG. 5 is a block diagram for illustrating an example of the configuration of the collection/search server 109 in the first embodiment.
[0096] The collection/search server 109 is implemented with the use of an information processing apparatus. The hardware configuration of the collection/search server 109 includes a processor 501 , a volatile memory 502 , a non-volatile memory 503 , and a network I/F 504 , which are coupled to one another via an internal communication line such as a bus.
[0097] The processor 501 executes a program stored in the volatile memory 502 .
[0098] By executing a program that is stored in the volatile memory 502 with the use of the processor 501 , the function of the collection/search server 109 is implemented. In the following description, a program described as performing processing is actually being executed by the processor 501 .
[0099] The volatile memory 502 stores programs executed by the processor 501 , and includes a storage area in which data necessary to execute the programs is temporarily stored. Specifically, the volatile memory 502 stores programs that implement a failure monitoring part 510 , a log collecting part 520 , and a failure extent searching part 530 , and includes a volatile memory part 540 .
[0100] The failure monitoring part 510 executes processing for monitoring a failure in the data store server 108 or other components. Specifically, the failure monitoring part 510 determines whether or not a loss of the mail data 431 stored in the volatile memory part 430 of the data store server 108 has occurred.
[0101] The log collecting part 520 executes processing for obtaining logs from the respective servers and storing the obtained logs in the non-volatile memory 503 . The log collecting part 520 in this embodiment obtains the receiving log data 231 , which is stored in the non-volatile memory part 230 of the incoming mail server 106 , the sending log data 331 , which is stored in the non-volatile memory part 330 of the outgoing mail server 107 , and the data store log data 441 , which is stored in the non-volatile memory part 440 of the data store server 108 . The log collecting part 520 stores the obtained logs in a non-volatile memory part 550 of the non-volatile memory 503 as receiving log data 551 , sending log data 552 , and data store log data 553 , respectively.
[0102] The failure extent searching part 530 executes processing for identifying mail that has been lost due to a failure in the data store server 108 , based on the receiving log data 551 , the sending log data 552 , and the data store log data 553 , which are stored in the non-volatile memory part 550 .
[0103] The volatile memory part 540 stores data that is managed by the failure monitoring part 510 , the log collecting part 520 , and the failure extent searching part 530 .
[0104] The non-volatile memory 503 includes the non-volatile memory part 550 in which data is stored permanently.
[0105] The non-volatile memory part 550 stores data that is managed by the failure monitoring part 510 , the log collecting part 520 , and the failure extent searching part 530 . The non-volatile memory part 550 also stores the receiving log data 551 , the sending log data 552 , and the data store log data 553 .
[0106] The receiving log data 551 includes a plurality of receiving logs obtained by the log collecting part 520 from the incoming mail server 106 . The sending log data 552 includes a plurality of sending logs obtained by the log collecting part 520 from the outgoing mail server 107 . The data store log data 553 includes a plurality of data store logs obtained by the log collecting part 520 from the data store server 108 .
[0107] The network I/F 504 is an interface for coupling to other apparatus via a network. The network I/F 504 in this embodiment is coupled to the carrier network 103 .
[0108] The program stored in the volatile memory 502 may instead be stored in the non-volatile memory 503 . The processor 501 in this case reads the program out of the non-volatile memory 503 , and loads the read program onto the volatile memory 502 .
[0109] FIG. 6A is an explanatory diagram for illustrating an example of the contents of the receiving log data 551 stored on the collection/search server 109 in the first embodiment. FIG. 6B is an explanatory diagram for illustrating an example of the contents of the sending log data 552 stored on the collection/search server 109 in the first embodiment. FIG. 6C is an explanatory diagram for illustrating an example of the contents of the data store log data 553 stored on the collection/search server 109 in the first embodiment.
[0110] A log stored in the receiving log data 551 , a log stored in the sending log data 552 , and a log stored in the data store log data 553 each include a plurality of pieces of data in a log format that includes time and date, a unique ID, the mail address of the sender, and the subject of the mail.
[0111] The unique ID is a value by which a piece of mail is always identified uniquely. By using a unique ID, the contents of mail that are included in the receiving log data 551 , the sending log data 552 , and the data store log data 553 can be associated with one another.
[0112] The logs are not limited to the log format described above, and, for example, may each include the body of the mail in addition to the items of the described log format. While this increases the load of processing at the time of outputting a log, in the case where mail data that has not been sent to the destination server 105 is lost due to a failure, the lost mail can be restored with the use of the mail body included in the log and the restored mail can be sent to the destination server 105 .
[0113] The logs may include information about coping processing for dealing with a failure in addition to the items of the described log format. Examples of the information about coping processing include “send a delivery failure notification to the mobile terminal” and “restore mail and send the restored mail to the destination server”. Flexible failure coping is accomplished by executing coping processing based on this information on the respective servers when a failure occurs.
[0114] The specifics of processing procedures in this embodiment are described next.
[0115] FIG. 7 is a diagram for illustrating processing that is executed when the incoming mail server 106 receives mail. FIG. 8A and FIG. 8B are diagrams for illustrating processing that is executed when the outgoing mail server 107 sends mail.
[0116] In mail sending and receiving processing, mail, various requests, and various notifications are sent/received between the data store server I/F 212 of the incoming mail server 106 and the data store server 108 , or between the data store server I/F 312 of the outgoing mail server 107 and the data store server 108 .
[0117] However, data that is actually sent/received between the incoming mail server 106 or the outgoing mail server 107 and the data store server 108 is in a data format that includes header information, a payload where the data main body is stored, or the like.
[0118] In the following description, mail, various requests, and various notifications that form the payload section of actually sent/received data are used instead of the data, in order to describe a sequence focused on mail receiving processing and mail sending processing.
[0119] The same applies to mail and various notifications that are sent/received between the mobile terminal 101 and the mail receiving part 211 of the incoming mail server 106 , and mail and various notifications that are sent/received between the mail sending part 311 of the outgoing mail server 107 and the destination server 105 .
[0120] When processing related to the storage, retrieval, or deletion of mail in/from the volatile memory part 430 of the data store server 108 is executed, various types of management information in addition to mail may need to be sent/received between the data store server I/F 212 of the incoming mail server 106 and the data store server 108 , or between the data store server I/F 312 of the outgoing mail server 107 and the data store server 108 .
[0121] In the following description, however, processing related to the storage, retrieval, or deletion of mail is described in the form of one request-one response by omitting a description about the sending/receiving of the management information, in order to describe a sequence focused on mail receiving processing and mail sending processing.
[0122] FIG. 7 is a sequence diagram for illustrating an example of mail receiving processing of the first embodiment.
[0123] First, the mobile terminal 101 sends mail to the incoming mail server 106 (Step S 701 ).
[0124] The mail receiving part 211 of the incoming mail server 106 receives the mail sent from the mobile terminal 101 (Step S 702 ), and stores the mail (mail data) in the volatile memory part 220 (Step S 703 ).
[0125] The data store server I/F 212 of the incoming mail server 106 next sends a mail storing request and the mail to the data store server 108 (Step S 704 ).
[0126] Though not shown in FIG. 7 , in the case where the mail storing request and the mail are not received properly by the data store server 108 and the subsequent processing is not executed as a result, the incoming mail server 106 notifies the mobile terminal 101 that the mail has not been sent normally.
[0127] Next, the data store management part 410 of the data store server 108 receives the mail storing request and the mail (Step S 705 ), and stores the received mail (the mail data 431 ) in the volatile memory part 430 as requested by the mail storing request (Step S 706 ). After storing the mail (the mail data 431 ) in the volatile memory part 430 , the data store management part 410 of the data store server 108 sends a mail storing completion notification to the incoming mail server 106 (Step S 707 ).
[0128] Though not shown in FIG. 7 , in the case where the storing of mail (the mail data 431 ) fails in Step S 706 , the data store management part 410 notifies the incoming mail server 106 that the mail (the mail data 431 ) has not been stored. Then, the incoming mail server 106 notifies the mobile terminal 101 that the mail has not been sent normally.
[0129] Next, the data store server I/F 212 of the incoming mail server 106 receives the mail storing completion notification (Step S 708 ). The log output part 213 of the incoming mail server 106 output a receiving log in a data format that includes information for identifying the mail that has been sent to the data store server 108 (Step S 709 ). The output receiving log is stored in the receiving log data 231 of the non-volatile memory part 230 .
[0130] The mail receiving part 211 of the incoming mail server 106 next sends a mail sending completion notification to the mobile terminal 101 (Step S 710 ). The mobile terminal 101 receives the mail sending completion notification (Step S 711 ).
[0131] After Step S 710 , the mail receiving part 211 of the incoming mail server 106 deletes from the volatile memory part 220 the mail (mail data) sent to the data store server 108 (Step S 712 ).
[0132] FIG. 8A and FIG. 8B are sequence diagrams for illustrating an example of mail sending processing of the first embodiment.
[0133] First, the data store server I/F 312 of the outgoing mail server 107 sends a mail getting request to the data store server 108 (Step S 801 ). The mail getting request includes a key for identifying mail.
[0134] The data store management part 410 of the data store server 108 receives the mail getting request (Step S 802 ), and searches the volatile memory part 430 for given mail (the mail data 431 ) as requested by the mail getting request (Step S 803 ). After finding the mail (the mail data 431 ), the data store management part 410 of the data store server 108 sends the getting completion notification and the mail to the outgoing mail server 107 (Step S 804 ).
[0135] The data store server I/F 312 of the outgoing mail server 107 receives the getting completion notification and the found mail (Step S 805 ), and stores the received mail in the volatile memory part 320 (Step S 806 ). After the received mail is stored in the volatile memory part 320 , the mail sending part 311 of the outgoing mail server 107 sends this mail to the destination server 105 (Step S 807 ).
[0136] The destination server 105 receives the mail sent from the outgoing mail server 107 (Step S 808 ), and sends a mail sending completion notification to the outgoing mail server 107 (Step S 809 ).
[0137] The mail sending part 311 of the outgoing mail server 107 receives the mail sending completion notification from the destination server 105 (Step S 810 ).
[0138] The log output part 313 of the outgoing mail server 107 outputs a sending log in a data format that includes information for identifying the mail that has been sent to the destination server 105 (Step S 811 ). The output sending log is stored in the sending log data 331 of the non-volatile memory part 330 .
[0139] The log output part 313 of the outgoing mail server 107 next deletes from the volatile memory part 320 the mail (mail data) sent to the destination server 105 (Step S 812 ). The data store server I/F 312 of the outgoing mail server 107 sends a mail deleting request to the data store server 108 (Step S 813 ).
[0140] The data store management part 410 of the data store server 108 receives the mail deleting request (Step S 814 ), deletes the mail (the mail data 431 ) from the volatile memory part 430 (Step S 815 ), and sends a deletion completion notification to the outgoing mail server 107 (Step S 816 ).
[0141] The data store server I/F 312 of the outgoing mail server 107 receives the deletion completion notification sent from the data store server 108 (Step S 817 ).
[0142] FIG. 9 is a flow chart for illustrating mail data search processing that is executed by the data search processing part 420 of the data store server 108 in the first embodiment.
[0143] In the mail data search processing, mail data stored in the volatile memory part 430 is searched for a given piece of data.
[0144] The data search processing part 420 executes processing described below periodically or when a given condition is fulfilled, such as when an instruction from an operator is received.
[0145] The data search part 421 of the data search processing part 420 starts loop processing for the mail data 431 stored in the volatile memory part 430 (Step S 901 ).
[0146] Specifically, at the time the processing is started, the data search part 421 selects one piece of the mail data 431 to be processed out of the mail data 431 stored in the volatile memory part 430 , and executes Steps S 902 to S 904 for the selected piece of the mail data 431 . Steps S 902 to S 904 are therefore executed repeatedly in the loop processing for the mail data 431 to process each of a plurality of pieces of the mail data 431 stored in the volatile memory part 430 .
[0147] The data search part 421 determines whether or not the piece of the mail data 431 to be processed has been staying for a fixed length of time or longer (Step S 902 ). Specifically, the following processing is executed.
[0148] The data search part 421 calculates a staying time of the mail data 431 by using the current time and time and date information that is included in the mail data 431 to be processed.
[0149] For example, the staying time can be calculated as a difference between the time at which the processing is started and the sending time and date of the mail. The time and date information on the mail data 431 is included in a key so that the difference between the current time and the time included in the key can be calculated.
[0150] The data search part 421 determines whether or not the calculated staying time is equal to or more than a fixed length of time. In the case where the calculated staying time is equal to or more than the fixed length of time, the data search part 421 determines that the mail data 431 to be processed has been staying for the fixed length of time or longer. The fixed length of time can be set to suit system requirements.
[0151] The fixed length of time is also referred to as first time range in the following description.
[0152] Step S 902 has now been described.
[0153] In a case of determining that the mail data to be processed has not stayed for the fixed length of time or longer, the data search part 421 proceeds to Step S 905 .
[0154] In a case of determining that the mail data to be processed has been staying for the fixed length of time or longer, the data search part 421 determines whether or not a data store log of the mail data 431 to be processed has been written onto the data store log data 441 (Step S 903 ).
[0155] For example, in the case where a unique ID included in the key of the mail data 431 is utilized as a part of information on a data store log, the data search part 421 can use the unique ID included in the key to search the data store log data 441 for a data store log of the mail data 431 to be processed.
[0156] In a case of determining that a data store log of the mail data 431 to be processed has been written onto the data store log data 441 , the data search part 421 proceeds to Step S 905 .
[0157] In a case of determining that a data store log of the mail data 431 to be processed has not been written onto the data store log data 441 , the data search part 421 stores information on the mail data 431 to be processed in the volatile memory part 430 as data to be added to the data store log data 441 (Step S 904 ).
[0158] For example, the data search part 421 records in the volatile memory part 430 the key of the mail data 431 to be added. In the case where there are a plurality of pieces of the mail data 431 to be added, the data search part 421 may generate a list of the keys of the pieces of the mail data 431 to be added, and store the list in the volatile memory part 430 .
[0159] The data search part 421 next determines whether or not every piece of the mail data 431 stored in the volatile memory part 430 has been processed (Step S 905 ).
[0160] In a case of determining that not every piece of the mail data 431 stored in the volatile memory part 430 has been processed, i.e., that there is at least a piece of the mail data 431 remain to be processed, the data search part 421 returns to Step S 902 to select a new piece of the mail data 431 and executes Steps S 902 to S 904 .
[0161] In a case where it is determined that every piece of the mail data 431 stored in the volatile memory part 430 has been processed, the log output part 422 of the data search processing part 420 adds, to the data store log data 441 of the non-volatile memory part 440 , based on the information on the mail data 431 that is recorded in the volatile memory part 430 , the data store log of the mail data 431 to be added (Step S 906 ), and ends the whole processing.
[0162] The log output part 422 in this embodiment writes a data store log that includes time and date and a unique ID in the data store log data 441 .
[0163] In this embodiment, writing processing is executed for all data store logs at once after the loop processing is ended, instead of executing writing processing for a data store log of a piece of the mail data 431 to be added each time a selected piece of the mail data 431 is processed by the loop processing. A delay in data store processing due to writing processing is prevented in this manner.
[0164] FIG. 10 is a sequence diagram for illustrating processing that is executed when a failure occurs on the data store server 108 in the first embodiment. FIG. 11 is an explanatory diagram for illustrating log data that is used by the collection/search server 109 to identify the extent of a failure in the first embodiment.
[0165] The failure monitoring part 510 of the collection/search server 109 sends a state checking request to the data store server 108 (Step S 1001 ). The failure monitoring part 510 may send a state checking request periodically or when an instruction from the operator is received.
[0166] Step S 1001 is processing for detecting a failure in the data store server 108 . In a case where a failure in the data store server 108 is detected, the collection/search server 109 checks the chance of a loss of the mail data 431 stored in the volatile memory part 430 of the data store server 108 .
[0167] The data store management part 410 of the data store server 108 receives the state checking request (Step S 1002 ), checks the running state and the like of the data store server 108 , and sends the result of the checking as state information to the collection/search server 109 (Step S 1003 ).
[0168] The state information can be any kind of information as long as whether or not there is a chance of loss of the mail data 431 can be determined. For example, in the case where the mail system includes a plurality of data store servers 108 , the state information can be configuration information on the plurality of data store servers 108 and the dead/alive information on each data store server 108 .
[0169] Next, the failure monitoring part 510 of the collection/search server 109 receives the state information and, based on the state information, determines whether or not there is a possibility of loss of the mail data 431 (Step S 1004 ). For example, in the case where two or more data store servers 108 are shut down, the collection/search server 109 determines that a loss of the mail data 431 is likely.
[0170] In a case where it is determined that a loss of the mail data 431 is unlikely, there is no need to identify the extent of a failure, and the collection/search server 109 accordingly ends the processing without executing the subsequent steps.
[0171] In a case where it is determined that there is a loss of the mail data 431 , the log collecting part 520 of the collection/search server 109 sends a log obtaining request to the incoming mail server 106 , the outgoing mail server 107 , and the data store server 108 (Step S 1005 ). In the case where the OS running on the incoming mail server 106 is a UNIX-based OS, for example, Step S 1005 is accomplished by using the scp command or the like.
[0172] The incoming mail server 106 , the outgoing mail server 107 , and the data store server 108 separately send log data to the collection/search server 109 (Steps S 1006 , S 1007 , and S 1008 ).
[0173] The log collecting part 520 of the collection/search server 109 receives the pieces of log data sent from the respective servers, and stores the received log data in the non-volatile memory part 550 (Step S 1009 ). The log data received from the incoming mail server 106 is stored as the receiving log data 551 , the log data received from the outgoing mail server 107 is stored as the sending log data 552 , and the log data received from the data store server 108 is stored as the data store log data 553 .
[0174] The failure extent searching part 530 of the collection/search server 109 uses the received log data to identify the extent of the failure (Step S 1010 ). A method of identifying the extent of a failure is described with reference to FIG. 11 .
[0175] As described with reference to FIG. 9 , only logs of pieces of the mail data 431 that have been staying in the mail system for a fixed length of time (the first time range) or longer are stored in the data store log data 441 in the mail data search processing. More specifically, only data store logs of pieces of the mail data 431 that precede the processing start time (the current time) by the first time range or more are stored.
[0176] Therefore, in the case where the processing of FIG. 9 and the processing of FIG. 10 are executed in parallel, the data store log data 553 is as illustrated in FIG. 11 . The number of logs stored in the data store log data 553 is also much smaller than the number of logs stored in the receiving log data 551 or the sending log data 552 .
[0177] The extent of a failure can be identified quickly in this embodiment based on the described features of the data store log data 553 .
[0178] The failure extent searching part 530 first extracts from the receiving log data 551 logs in a period between the current time and a time point that precedes the current time by the first time range. The failure extent searching part 530 also extracts from the sending log data 552 logs in the period between the current time and the time point that precedes the current time by the first time range.
[0179] The time point that precedes the current time by the first time range may be referred to as first time point in the following description.
[0180] In the example of FIG. 11 , logs in the hatched portion of the receiving log data 551 and logs in the hatched portion of the sending log data 552 are extracted.
[0181] The failure extent searching part 530 next extracts from the sending log data 552 logs in a period between the first time point and a time point that precedes the first time point by a length of time in which an extent of failure is to be identified. The failure extent searching part 530 also extracts from the data store log data 553 logs in the period between the first time point and the time point that precedes the first time point by the length of time in which an extent of failure is to be identified.
[0182] The length of time in which a extent of failure is to be identified may be referred to as second time range and the time point that precedes the first time point by the second time range may be referred to as second time point in the following description. The second time point (the length of time in which the extent of a failure is to be identified) can be set to suit system requirements.
[0183] In the example of FIG. 11 , logs in the blackened portion of the sending log data 552 and logs in the blackened portion of the data store log data 553 are extracted.
[0184] There are no duplicates between logs in the hatched portions and the logs in the blackened portions as illustrated in FIG. 11 . This is because logs of the mail data 431 in the range from the current time to the first time point are not output.
[0185] The processing of extracting the logs may be executed in a case where logs are stored in Step S 1009 .
[0186] The failure extent searching part 530 compares the receiving logs in the period between the current time and the first time point with the sending logs in the period between the current time and the first time point to search for receiving logs that are not included in the sending log data 552 . For example, the failure extent searching part 530 can compare a unique ID in a receiving log with a unique ID in a sending log.
[0187] The failure extent searching part 530 also compares the sending logs in the period between the first time point and the second time point with the data store logs in the period between the first time point and the second time point to search for data store logs that are not included in the sending logs. For example, the failure extent searching part 530 can compare a unique ID in a sending log with a unique ID in a data store log.
[0188] The extent of a failure such as the number of pieces of the mail data 431 lost and the number of people affected by the loss of mail data is identified through the processing described above. In other words, because a log found by the search includes the sender address and the subject of the mail as illustrated in FIG. 6A , FIG. 6B , and FIG. 6C , the failure extent searching part 530 can notify information about the extent of a failure based on information that is included in the found log.
[0189] Step S 1010 has now been described.
[0190] Next, the failure extent searching part 530 of the collection/search server 109 sends information about the identified extent of the failure as failure extent information to the incoming mail server 106 (Step S 1011 ). For example, the found logs themselves can be sent as the failure extent information.
[0191] The mail receiving part 211 of the incoming mail server 106 receives the failure extent information sent from the collection/search server 109 (Step S 1012 ), generates a delivery failure notification to be sent to the mobile terminal 101 , and sends the generated delivery failure notification to the mobile terminal 101 (Step S 1013 ). For example, a list that associates the address of a sender with the subject of mail can be sent as the delivery failure notification.
[0192] The mobile terminal 101 receives the delivery failure notification sent from the incoming mail server 106 (Step S 1014 ). This informs the sender of the mail who is the owner of the mobile terminal 101 that the mail sent by the sender has failed to reach the destination apparatus.
[0193] While the incoming mail server 106 deals with a failure by sending a delivery failure notification in the processing described above, this embodiment is not limited thereto.
[0194] For example, in the case where the body of lost mail has been output as a log, the failure extent searching part 530 may output in Step S 1011 the found log and information about processing for dealing with a failure, restore the mail (mail data) based on the output information about processing for dealing with a failure, and send the restored mail to the destination server 105 .
[0195] To accomplish the processing described above, the collection/search server 109 sends failure extent information that includes the restored mail to the outgoing mail server 107 , and the outgoing mail server 107 resends the lost mail to the destination server 105 .
[0196] Examples of the processing for dealing with a failure include “sending a delivery failure notification to the mobile terminal” and “restoring mail data and sending the mail data to the destination server”.
[0197] The collection/search server 109 in the processing described above automatically identifies the extent of a failure (Step S 1010 ) and sends failure extent information (Step S 1011 ). However, this embodiment is not limited thereto, and processing based on the operator's operation may be executed instead.
[0198] FIG. 12 is an explanatory diagram for illustrating an example of a terminal screen, which is used by the operator to operate the collection/search server 109 of the first embodiment.
[0199] A terminal screen 1201 is operated when Steps S 1010 and S 1011 of FIG. 10 are executed. The terminal screen 1201 is a screen that is displayed by a terminal program installed as standard in a common information processing apparatus.
[0200] The operator can obtain a differential between logs of different types by, for example, entering the DIFF command of the UNIX. The failure extent searching part 530 receives a given command to execute processing that resembles Step S 1010 , and displays the result of the processing on the terminal screen.
[0201] The operator can also send failure extent information to the incoming mail server 106 by operating the collection/search server 109 so that a log found through a search with the use of the DIFF command is input to the failure extent searching part 530 .
[0202] As described above, according to the first embodiment, only logs of pieces of mail that fulfill a given condition are written in the non-volatile memory part 440 on the data store server 108 . This makes the number of logs that are written smaller than in the related art, and a drop in the performance of data store such as in-memory KVS is accordingly prevented.
[0203] In addition, the failure extent searching part 530 can identify the extent of a failure by comparing pieces of receiving log data and pieces of sending log data that are within a given time range, and comparing pieces of sending log data and pieces of data store log data that are within another given time range.
[0204] Unlike the related art where the amount of receiving log data and sending log data to be compared is huge, this embodiment is capable of identifying the extent of a failure quickly by comparing pieces of data within a limited time range. Storing only logs of pieces of mail data that fulfill a given condition in the data store log also speeds up the comparison processing described above.
MODIFICATION EXAMPLE
[0205] While a piece of the mail data 431 that is to be added to the data store log data 441 is identified based on the length of time for which the mail has been staying in the mail system in the first embodiment, the first embodiment is not limited thereto. For instance, a piece of the mail data 431 that is to be added to the data store log data 441 may be identified based on the processing described below.
[0206] FIG. 13 is a flow chart for illustrating mail data search processing that is executed by the data search processing part 420 of the data store server 108 in a modification example of the first embodiment.
[0207] In Modification Example 1, the data search part 421 determines whether or not the destination domain of a piece of the mail data 431 to be processed is matched with a target domain (Step S 1302 ). The target domain is set in advance.
[0208] For example, in the case where a domain name included in the key of the mail data 431 is utilized as a part of information on a data store log, the data search part 421 determines whether or not the target domain is the destination domain of a piece of the mail data 431 to be processed based on the domain name included in the key.
[0209] Steps S 1301 , S 1303 , S 1304 , S 1305 , and S 1306 are the same as Steps S 901 , S 903 , S 904 , S 905 , and S 906 , respectively, and a description thereof is therefore omitted.
[0210] Fast failure extent identification focused on a particular domain is accomplished by executing the data search processing of FIG. 13 .
Second Embodiment
[0211] A mail system according to a second embodiment of this invention includes a plurality of carrier networks. In a case where a failure occurs in one of the plurality of carrier networks, the collection/search server 109 in another of the plurality of carrier networks identifies the extent of the failure.
[0212] The second embodiment is described below by focusing on differences from the first embodiment.
[0213] FIG. 14 is an explanatory diagram for illustrating an example of the configuration of a mail system according to the second embodiment.
[0214] The mail system of the second embodiment includes two carrier networks 103 , one of which is a carrier network A and the other of which is a carrier network B. The mail system of the second embodiment also includes a log management server 1400 . The log management server 1400 is coupled to the carrier network A 103 and the carrier network B 103 to manage logs for each carrier network 103 separately.
[0215] To each of the carrier network A 103 and the carrier network B 103 , the incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 are coupled.
[0216] The mobile terminal 101 of the second embodiment is coupled to the carrier network A 103 and the carrier network B 103 via the mobile network 102 .
[0217] The destination server 105 of the second embodiment is coupled to the carrier network A 103 and the carrier network B 103 via the internet 104 . The destination server 105 of the second embodiment sends/receives mail to/from the outgoing mail server 107 that is coupled to the carrier network A 103 , and sends/receives mail to/from the outgoing mail server 107 that is coupled to the carrier network B 103 .
[0218] The incoming mail server 106 , the outgoing mail server 107 , the data store server 108 , and the collection/search server 109 in this embodiment are the same as those in the first embodiment, and a description on the configurations of the respective servers is therefore omitted here.
[0219] FIG. 15 is a block diagram for illustrating an example of the configuration of the log management server 1400 in the second embodiment.
[0220] The log management server 1400 is implemented with the use of an information processing apparatus. The hardware configuration of the log management server 1400 includes a processor 1501 , a volatile memory 1502 , a non-volatile memory 1503 , and a network I/F 1504 , which are coupled to one another via an internal communication line such as a bus.
[0221] The processor 1501 executes a program stored in the volatile memory 1502 . By executing a program that is stored in the volatile memory 1502 with the use of the processor 1501 , the function of the log management server 1400 is implemented. In the following description, a program described as performing processing is actually being executed by the processor 1501 .
[0222] The volatile memory 1502 stores programs executed by the processor 1501 , and includes a storage area in which data necessary to execute the programs is temporarily stored. Specifically, the volatile memory 1502 stores programs that implement a failure monitoring part 1510 and a log collecting part 1520 , and includes a volatile memory part 1530 .
[0223] The failure monitoring part 1510 executes processing for monitoring each carrier network 103 for a failure.
[0224] The log collecting part 1520 executes processing for obtaining a log from the collection/search server 109 of each carrier network 103 and storing the obtained log in the non-volatile memory 1503 . The log collecting part 1520 in this embodiment stores, for each carrier network 103 separately, receiving log data 1541 , sending log data 1542 , and data store log data 1543 in a non-volatile memory part 1540 .
[0225] The volatile memory part 1530 stores data that is managed by the failure monitoring part 1510 and the log collecting part 1520 .
[0226] The non-volatile memory 1503 includes the non-volatile memory part 1540 in which data is stored permanently.
[0227] The non-volatile memory part 1540 stores data that is managed by the failure monitoring part 1510 and the log collecting part 1520 . The non-volatile memory part 1540 also stores, for each carrier network 103 separately, the receiving log data 1541 , the sending log data 1542 , and the data store log data 1543 .
[0228] The receiving log data 1541 , the sending log data 1542 , and the data store log data 1543 are the same as the receiving log data 551 , the sending log data 552 , and the data store log data 553 .
[0229] The network I/F 1504 is an interface for coupling to other apparatus via a network. The network I/F 1504 in this embodiment is coupled to the carrier network A 103 and the carrier network B 103 .
[0230] FIG. 16 is a sequence diagram for illustrating processing that is executed in the second embodiment when a failure occurs in one of the carrier networks.
[0231] In the following description, the carrier network in which a failure has occurred is the carrier network A 103 .
[0232] The log collecting part 1520 of the log management server 1400 sends a log obtaining request to the collection/search server 109 of each of the carrier network A 103 and the carrier network B 103 (Step S 1601 ). For example, the log management server 1400 sends a log obtaining request by broadcast. The log collecting part 1520 may send a log obtaining request periodically or may send a log obtaining request when an instruction from an operator is received.
[0233] The log collecting part 520 of the collection/search server 109 of the carrier network B 103 receives the log obtaining request and sends to the log management server 1400 the receiving log data 551 , the sending log data 552 , and the data store log data 553 , which are stored in the non-volatile memory part 550 (Step S 1602 ).
[0234] The log collecting part 520 may obtain the log data by sending a log obtaining request to the incoming mail server 106 , the outgoing mail server 107 , and the data store server 108 that are coupled to the carrier network B 103 .
[0235] The log collecting part 1520 of the log management server 1400 receives the log data and stores the received data in the non-volatile memory part 1540 as log data of the carrier network B (Step S 1603 ). For example, the log collecting part 1520 stores the log data in the non-volatile memory part 1540 in association with the identifier of the carrier network B.
[0236] The failure monitoring part 1510 of the log management server 1400 determines for each carrier network 103 whether or not a failure has occurred in the carrier network 103 , based on the carrier network's response to the log obtaining request (Step S 1604 ).
[0237] For example, in the case where log data is not sent from the collection/search server 109 within a fixed length of time after the sending of the log obtaining request, the failure monitoring part 1510 determines that a failure has occurred in the carrier network 103 to which this collection/search server 109 is coupled.
[0238] The failure monitoring part 1510 in this embodiment determines that a failure has occurred in the carrier network A 103 because the collection/search server 109 of the carrier network A 103 fails to send log data.
[0239] In a case where a failure is detected in one of the carrier networks 103 , the failure monitoring part 1510 of the log management server 1400 sends failure information to the collection/search server 109 of the other carrier network 103 (Step S 1605 ).
[0240] The failure information includes identification information on the carrier network 103 in which a failure has been detected and log data of the carrier network 103 . For example, the failure monitoring part 1510 uses identification information on the carrier network 103 in which a failure has been detected to obtain from the non-volatile memory part 1540 log data that is associated with this carrier network 103 .
[0241] The log collecting part 520 of the collection/search server 109 receives the failure information (Step S 1606 ), and stores the log data included in the failure information in the non-volatile memory part 550 in association with the identification information on the carrier network 103 (Step S 1607 ).
[0242] The failure extent searching part 530 of the collection/search server 109 uses the log data stored in the non-volatile memory part 550 to identify the extent of the failure (Step S 1608 ). Step S 1608 is the same as Step S 1010 , and a description thereof is therefore omitted.
[0243] The failure extent searching part 530 of the collection/search server 109 next sends information about the identified failure extent to the incoming mail server 106 as failure extent information (Step S 1609 ). Step S 1609 is the same as Step S 1011 , and a description thereof is therefore omitted.
[0244] The mail receiving part 211 of the incoming mail server 106 receives the failure extent information sent from the collection/search server 109 (Step S 1610 ), generates a delivery failure notification to be sent to the mobile terminal 101 , and sends the generated delivery failure notification to the mobile terminal 101 (Step S 1611 ). Steps S 1610 and S 1611 are the same as Steps S 1012 and S 1013 , respectively, and a description thereof is therefore omitted.
[0245] The mobile terminal 101 receives the delivery failure notification sent from the incoming mail server 106 (Step S 1612 ). This informs the sender of the mail who is the owner of the mobile terminal 101 that the mail sent by the sender has failed to reach the destination. Step S 1612 is the same as Step S 1014 .
[0246] While the incoming mail server 106 deals with a failure by sending a delivery failure notification in the processing described above, this embodiment is not limited thereto.
[0247] For example, in the case where the body of lost mail has been output as a log, the log collecting part 1520 may output in Step S 1609 the found log and information about processing for dealing with a failure, restore the mail (mail data) based on the output information about processing for dealing with a failure, and send the restored mail to the destination server 105 .
[0248] To accomplish the processing described above, the collection/search server 109 sends failure extent information that includes the restored mail to the outgoing mail server 107 , and the outgoing mail server 107 resends the lost mail to the destination server 105 .
[0249] Examples of the processing for dealing with a failure include “sending a delivery failure notification to the mobile terminal” and “restoring mail data and sending the mail data to the destination server”.
[0250] While the log management server 1400 sends a log obtaining request to the collection/search server 109 of each carrier network 103 in the processing described above, this embodiment is not limited thereto.
[0251] For example, the incoming mail server 106 , the outgoing mail server 107 , and the data store server 108 may each send logs to the log management server 1400 when outputting logs (Step S 709 , S 811 , or S 906 ). The log management server 1400 in this case sends a state checking request, instead of a log obtaining request, to the collection/search server 109 .
[0252] As described above, according to the second embodiment, the extent of a failure that has occurred throughout one of the carrier networks 103 can be identified by the collection/search server 109 of the other carrier network 103 .
[0253] Various types of software illustrated in the present embodiment can be stored in various electromagnetic, electronic, and optical recording media and can be downloaded to a computer via a communication network such as the Internet.
[0254] Further, in the present embodiment, although an example of using software-based control has been described, part of the control may be realized by hardware.
[0255] While the present invention has been described in detail with reference to the accompanying drawings, the present invention is not limited to the specific configuration, and various changes and equivalents can be made within the scope of the claims.
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A computer system for realizing increased speed of identifying extent of a failure in a messaging system, provided with: a first computer including a message receiving part, a first log output part, and a first memory part configured to store receiving log data; a second computer including a data store management part configured to manage a data store, a first search part configured to search a message that meets a given condition from among messages stored in the data store, a second log output part, and a second memory part configured to store data store log data; a third computer including a message sending part, a third log output part, and a third memory part configured to store sending log data; and a fourth computer including a monitoring part, a log collecting part, and a second search part configured to search for lost message.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a bar for supporting a movable web as the web is transported and redirected from a first direction of movement to a second direction of movement, and in particular, to a turning bar which generates an air cushion to support, stabilize and remove wrinkles from the web as it makes the turn.
2. Description of the Prior Art
A variety of systems and devices are known in the prior art for developing an air cushion to support a moving web as the web changes direction. The purpose of such air cushion is to support the web free of engagement with a solid member during web transport to prevent damage and wear to the web.
Examples of such prior art devices are disclosed in Johnson U.S. Pat. No. 3,567,093, issued Mar. 2, 1971, Johnson U.S. Pat. No. 3,498,515, issued Mar. 3, 1970, Hamlin et al. U.S. Pat. No. 3,679,116, issued July 25, 1972, Sander U.S. Pat. No. 4,043,495, issued Aug. 23, 1977, Reba U.S. Pat. No. 4,136,808, issued Jan. 30, 1979, and Daane U.S. Pat. No. 4,197,972, issued Apr. 15, 1980.
Many of the prior art turning bar devices employ a plurality of apertures or slits in pressurized turning bar housings through which pressurized air passes and provides a direct support for the web during transport. It will be appreciated that devices of this nature use inordinately large amounts of pressurized air to accomplish the purpose of web support and are consequently inefficient and expensive to operate. In addition, such devices, due to uneven air distribution found at the turning bar surface, can cause wrinkling and other deformations to occur in the web. Prior art devices are also often characterized by even greater inefficiencies when operating at high speeds.
In the above-noted U.S. Pat. No. 4,197,972, issued to Daane, a turning bar device is illustrated which utilizes the Coanda effect to provide an air cushion for a web. When utilizing the Coanda effect ambient air is entrained to provide a portion of the web cushion and thus operating efficiencies are attained. The present invention also relates to a turning bar arrangement employing the Coanda effect to provide an air cushion. The present invention, however, employs a specific arrangement for bringing the Coanda effect into play, an arrangement that is specifically adapted to ensure even air distribution to the Coanda nozzle forming a component of the turning bar. Even air distribution is important to maintain proper web stability and control as the web makes the turn about the bar. In the present invention web control can be readily accomplished without the necessity of employing air nozzles disposed along the edges of web travel as is the case in Daane to eliminate side drift or lateral tracking instability of the web as well as to ensure predetermined desired spacing of the web with respect to the turning bar.
Another feature of the present invention resides in the employment in the turning bar of means to crown the web as it makes the turn, thus removing wrinkles therefrom and contributing to web stabilization. The invention is particularly useful with wet coated webs wherein contact could disrupt or cause defects in the coating.
BRIEF SUMMARY OF THE INVENTION
Apparatus constructed according to the teachings of the present invention includes an elongated first plenum defining means having inlet and outlet openings therein, an elongated housing surrounding and spaced from the elongated first plenum defining means to define a second plenum therewith in fluid flow communication with the first plenum through the outlet means, and means defining a curved fluid flow attachment surface positioned immediately adjacent to a slit formed in the housing in communication with said second plenum. The dual plenum arrangement of the present invention is so constructed as to allow even distribution of air to the housing outlet slit thereby providing a precisely controlled air cushion for the web being turned about the apparatus. The air cushion is comprised of the pressurized air passing through the housing restricted outlet slit and ambient air entrained thereby. The air cushion attaches itself to the curved fluid flow attachment surface due to the Coanda effect. Means is preferably provided to vary slit width along the length thereof to provide more pressurized air at the center of the web than at the edges thereof, thus serving to crown the web.
DESCRIPTION OF DRAWINGS
FIG. 1 is a plan view of the preferred form of apparatus constructed in accordance with the teachings of the present invention;
FIG. 2 is a cross sectional view taken along line 2--2 in FIG. 1;
FIG. 3 is an enlarged detail view of the means defining a restricted opening in the apparatus housing and related structure as taken along line 3--3 in FIG. 1; and
FIG. 4 is a view similar to that of FIG. 2 but illustrating an alternative embodiment.
DETAILED DESCRIPTION
In FIGS. 1-3 apparatus constructed in accordance with the teachings of the present invention includes first plenum defining means 10 in the form of an elongated conduit formed of any suitable material such as aluminum. At one or both outer ends thereof means 10 is supported by a suitable housing (not shown). At at least one end thereof, and preferably at both ends thereof, the interior or plenum defined by means 10 is selectively placed in communication with any suitable source of pressurized air such as an air compressor (not shown). Pressurized air entering the first plenum defining means 10 will be caused to exit therefrom through a plurality of air distribution slots or apertures 12 formed along the length of means 10.
Surrounding elongated first plenum defining means 10 and spaced therefrom is a housing 14 which is also preferably in the general shape of a conduit formed of aluminum or other suitable material. Housing 14 and first plenum defining means 10 are commonly connected by end caps 15 and 17 and cooperate to form a generally cylinderically shaped second plenum 16 therebetween. Apertures 12 provide fluid flow communication between the first plenum and second plenum 16.
As may be seen most clearly with reference to FIG. 2, housing 14 forms a gap 20 near the upper end thereof substantially diametrically opposite to the locations of apertures 12 in the elongated first plenum defining means 10. Gap 20 extends along the full length of housing 14. A plate 22 is secured to housing 14 as by means of screws 23 or any other suitable expedient to generally cover the gap along its length. The free end of plate 22 projects over a first planar surface 26 formed on housing 14 as shown in detail in FIG. 3. The bottom of plate 22 forms a second planar surface 28 which is parallel to first planar surface 26 and defines an elongated slit therewith. Second planar surface 28 converges with a third planar surface 29 formed on housing 14 at a predetermined angle which may be in the order of 30 degrees for example.
It will be appreciated that pressurized air in second plenum 16 will exit from the slit defined by planar surface 26 and 28 as a thin high speed gaseous flow at an acute angle with respect to the direction of a web W as the web passes over the slit in a predetermined first direction of movement (generally horizontal direction in the drawing). After exiting from the slit the pressurized gas will attach itself to a generally curved fluid flow attachment surface defined in part by fourth and fifth planar surfaces 30 and 32 formed on housing 14. In a representative construction of the turning bar, surface 30 diverged from planar surfaces 26 and 28 an angle of 17 degrees and surface 32 by an angle of 40 degrees, although this may be varied as necessary. As shown in FIG. 2 planar surface 32 merges into and is contiguous with the outer curved surface 38 of curved deflection member 40 mounted in a recess 42 formed in housing 14. It will be appreciated that the pressurized gas passing through the slit and ambient air entrained thereby will attach to the generally curved surface as defined by surfaces 30, 32 and 38. The air cushion will direct the web from a predetermined first direction of movement shown at the upper left end of FIG. 2 to a second predetermined direction assumed by the web W at the location shown at the right side of FIG. 2 where the web exits from curved deflection member 40.
It should be noted that web W is brought into close proximity with the turning bar at a location downstream from the slit whereat the air cushion is moving substantially the same direction as the web. If web W were to approach the slit too closely it would be subjected to undesirable suction forces that would tend to pull the web downwardly. If desired, suitable adjustment mechanism (not shown) may be associated with the turning bar to enable an operator to "fine tune" positioning of the bar slit relative to the web to optimize results.
Lateral air loss from the cushion supporting web W is prevented by employing two sidewalls 46 and 48 along the edges of the generally curved fluid flow attachment surface. Additional control over the characteristics of the air cushion may be provided by employing a suitable means of varying the width of the slit along its length to establish a desired air flow profile. It has, for example, been found that by making the slit wider in the center than at the edges, more air cushioning in the middle of the web is obtained which creates cross machine spreading and improved guiding of the web. In essence, this provides for a crowning effect in the web whereby wrinkles will be removed. The turning bar may thus be used to accomplish the objectives of a far more expensive Mount Hope roll without contact with the web. Slit thickness variations may be accomplished through the use of any suitable expedient such as the employment of shims 50 or a screw adjustment mechanism of the type shown in my U.S. Pat. No. 4,186,860, issued Feb. 5, 1980.
As indicated above it is highly important that pressurized air be evenly distributed in the system at the point where it is introduced into the slit. The dual plenum arrangement of the present system as described above serves to accomplish this. It will be appreciated that air exiting from apertures 12 divides into two segments as shown by the arrows in FIG. 2 and flows within the second plenum 16 until the vicinity of the gap 20 is reached. Such flow path tends to dampen out and even any flow anomalies that may have been created along the length of the system prior to passage of the pressurized air through the slit.
FIG. 4 shows an alternative embodiment of the present invention. This embodiment differs from that shown in FIGS. 1-3 only by virtue of the fact that it employs a cambered curved deflection member 54. It has been found that such cambered configuration can be used to further improve web turning efficiency, i.e. the extent of arc over which the web floats without contact, by virtue of the fact that air flow will be modified at the point of camber to hold the web W against the deflection member over a longer length. This occurs because the Coanda effect causes the air cushion to bend inwardly at the location of camber.
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Apparatus for providing an air cushion to support web material during turning thereof and including means defining two plenums providing a flow path for pressurized gas prior to the gas exiting from a slit adjacent a generally curved fluid flow attachment surface. The dual plenum arrangement results in an even air distribution at the location of the slit thus contributing to web stability and control as the web floats on a cushion of air comprised of the pressurized air and ambient air along the generally curved fluid flow attachment surface due to the Coanda effect.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to tonneau covers for enclosing the cargo area of a vehicle, such as a pickup truck, and in particular to a tonneau cover having a pivot lever for pulling the cover tight and a magnetic attachment to hold the pivot lever in place. The pivot lever enables the cover to be mounted with a relatively low force which remains consistent over a wide range of ambient temperatures.
Numerous mechanisms have been used to attach flexible sheet tonneau covers to pickup trucks. The most commercially popular mechanisms are snap fasteners and a continuous, hook fastener that engages about a flange to mount the tonneau cover flexible sheet. While tonneau covers employing such fastening devices have obtained commercial success, attachment and removal of these tonneau covers can sometimes be difficult. With snap fasteners, it is necessary to properly align the male and female halves of a large number of snap fasteners to completely attach the cover sheet. Furthermore, during cold temperatures, it may be difficult to pull the flexible sheet taut while aligning the individual portions of the snap fasteners.
The continuous hook fastener overcomes the difficulty of aligning multiple snap fasteners. It can still be difficult to attach the cover sheet in extremely cold conditions. This is due to the increased stiffness of the sheet and hook fastener as a result of cold temperatures.
Accordingly, it is an object of the present invention to provide a fastening mechanism which is easy to use over a larger range of ambient temperatures.
It is a further object to provide a fastening mechanism that requires a relatively low force to be applied by the user to mount the cover sheet.
The present invention provides a tonneau cover attaching mechanism which uses a pivot lever along the side edges of the flexible cover sheet. The proximal, inner end of the pivot lever is positioned against an outwardly facing bearing surface of a rail mounted to the cargo box. With the proximal end of the pivot lever seated against the bearing surface, the pivot lever is rotated outward and downward, pulling the flexible cover taut. The rotation of the pivot lever can be accomplished with the application of a downward force by the palms of the user. The pivot lever provides a significant mechanical advantage such that a relatively low downward force is required to pull the flexible cover taut.
Once the pivot lever is rotated downwardly and outwardly, a magnet carried by the pivot lever engages a magnet attached to the rail to hold the pivot lever in its downwardly rotated locked position. The magnetic force needed to hold the pivot lever in its downward, locked, position is only the force necessary to resist the tension in the tonneau cover, which acts to rotate the pivot lever upward. The tension in the tonneau cover, while it may be relatively high, acts against the pivot lever with a relatively short moment arm. By spacing the magnet outward from the proximal end of the pivot lever, the magnetic force operates over a large moment arm, thereby reducing or minimizing the magnetic force required to securely hold the pivot lever, and thus the cover sheet, in place.
The pivot lever is preferably an elongated plastic strip sewn to the edge of the cover sheet. It carries a magnet strip while the rail attached to the top of a cargo box wall carries another magnet strip. The rail is formed with the outward facing bearing surface for engagement with the proximal, inner, end or edge of the plastic strip. The cover sheet is mounted to the rail by placing the plastic strip's inner edge against the rail bearing surface and then rotating the strip downward and outward by pushing downward on the cover sheet edge and strip with the palms of your hands. The mounting operation can begin at one corner of the cover sheet and progress along the cover sheet edge to another corner. Alternatively, the mounting operation can start in the middle of one side of the cover sheet and work lengthwise to each corner. While an elongated pivot lever strip is preferred, it may be possible to use several spaced pivot levers along the side edge of the cover sheet. Various embodiments of the invention are shown and described in the following detailed description.
Further objects, features and advantages of the invention will become apparent from a consideration of the following description and the appended claims when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pickup truck having a tonneau cover with a pivot lever and magnetic attachment according to the present invention installed thereon;
FIG. 2 is a sectional view as seen from substantially line 2--2 of FIG. 1 illustrating the frame rail of the tonneau cover;
FIG. 3 is a sectional view similar to FIG. 2 showing the tonneau cover rail with the pivot lever used to attach the flexible sheet cover member to the rail in a position ready to mount the cover sheet to the rail;
FIG. 4 is a sectional view similar to FIG. 3 showing the pivot lever in an intermediate position during rotation to the lock position;
FIG. 5 is a sectional view similar to FIGS. 3 and 4 showing the pivot lever in the lock position;
FIG. 6 is a sectional view of the pivot lever illustrating the forces acting on the lever when the cover sheet is attached to the rail;
FIG. 7 is a sectional view similar to FIG. 5 illustrating an alternative embodiment of the rail and pivot lever;
FIG. 8 is a sectional view of yet another embodiment of the pivot lever; and
FIG. 9 is a sectional view of the rail and pivot lever illustrating another embodiment of the rail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a pickup truck 10 is shown having a tonneau cover 12 which is attached to the cargo box 14 according to the present invention. The tonneau cover 12 includes a frame 16, only a portion of which is visible. The frame 16 is comprised of a number of frame rails 18 which are attached to one another to form a rectangular frame. One frame rail 18 is partially exposed. The rectangular frame is placed upon the top of the cargo box sidewalls 20 and 22 as well as the top of the cargo box front wall 24 and tailgate 26. The frame 16 is attached to the cargo box by a plurality of clamps 28, only one of which is shown.
The tonneau cover 12 further includes a flexible cover sheet 30 which is drawn tightly over the frame 16 and attached to the frame 16 via the pivot lever and magnetic attachment of the present invention. The cover sheet 30 has a central region 32 which is bounded by side edges 34. The side edges 34 are positioned above the upper ends of the cargo box sidewalls so that the cover sheet can extend over the cargo box of the pickup truck.
With reference to FIG. 2, frame rail 18 is shown in cross section. Frame rail 18 is an elongated member which extends substantially the length of the cargo box side wall with a generally uniform cross section. Such a rail can be economically manufactured as an aluminum extrusion. However, other materials and or manufacturing processes could be used to form the frame rail. The rail 18, as shown in FIG. 2, includes a pair of upwardly open hooks 36 along its inner, or cargo box edge. The hooks 36 are used to couple the rail to the clamps 28 to secure the rail to the cargo box. A bracket 37 of the clamp 28 is shown in FIG. 3. Various types of attachments including clamps, nuts and bolts, etc. can be used to secure the rail to the cargo box and form no part of the present invention. The rail 18 further includes a lower wall 19 which rests upon the cargo box. For protection of the surface finish of the cargo box, a foam tape 38 is typically applied to the surface of the wall 19.
At the upper end of the rail 18, there is an upper wall 40. An outer wall 41 extends downward and outward from upper wall 40 to the lower wall 19. The upper wall 40 extends outward, beyond the outer wall 41, forming a lip 42. The outer wall 41 is recessed beneath the lip 42, forming an undercut or bight 44. Downwardly and outwardly from the bight 44, the outer wall 41 forms a channel 46. The channel 46 receives a magnet strip 48. Magnet strip 48 is retained beneath an angled surface 50 and a flange 52. Flange 52 is bent upward to the position shown to retain the magnet strip 48 after the magnet strip has been placed in the channel 46.
The flexible cover sheet 30 is attached to the rails by the operation of a pivot lever 54 shown in FIGS. 3-6. In the preferred embodiment, the pivot lever 54 is a plastic extrusion that extends the length of the rail 18. However, if desired, multiple pivot levers 54 could be attached to the flexible cover sheet at spaced intervals along the length of the side edge. The pivot lever 54 is sewn to the lower surface of the cover sheet along the side edge 34 by one or more seams 56. At the outer edge, the flexible cover sheet may be wrapped around a stiffening rod 58.
Another magnet strip 60 is attached to the pivot lever for the purpose to be described below. The pivot lever has a proximal or inner end 62 which is adapted to be received into the bight 44 in the frame rail 18. The proximal end 62 is dish shaped, having a concave surface 53 so that the end 62 will fit into the bight 44 with the flat surface 55 of the pivot lever forming a continuation of the surface of the rail upper wall 40 (FIG. 5). The concave surface 53 engages the round surface 65 at the end of lip 42. This round surface forms a bearing surface that faces away from the cargo box.
In FIG. 3, the pivot lever 54 is shown in a position seated against the round bearing surface 65 of the lip 42. The pivot lever 54 is moved into a locked position by pushing downward on the pivot lever in the direction of the arrow F shown in FIG. 3. As this occurs, the lever rotates downward toward the magnet 48. Rotation continues as shown in FIG. 4 until the magnet 60 carried by the pivot lever engages the magnet 48 carried by the rail 18. In this position, the proximal end 62 of the pivot lever is seated into of the bight 44.
The force F acts over a large moment arm, the distance between the location of the force F and the concave surface 53 of the pivot lever which contacts the rail lip 42. Because of the mechanical advantage, the force F is relatively low compared to the tension developed in the cover sheet. As a result, a higher cover sheet tension can be generated compared to tonneau covers with other attachment mechanisms such as snaps or hook fasteners which do not have this mechanical advantage. Since the cover sheet tension is high, even with the normal variation in tension due to ambient temperature changes, the tension will always be high enough to avoid slack conditions in the cover sheet.
With reference to FIG. 6, the various forces are shown which act on the pivot lever 54 when the cover sheet is attached to the rail. The tension in the cover sheet 30 creates a force T. This is resisted by the reaction force R acting on the concave surface of the dish shape proximal end 62 of the pivot lever. The forces T and R are not directly aligned with each other, thereby creating a moment tending to rotate the pivot lever clockwise as viewed in FIG. 6. It is preferable to configure the pivot lever and rail 18 such that the moment arm between the tension force T and reaction force R is as short as possible to minimize the resulting moment.
The two magnets 48 and 60 create a magnet force M acting downward on the pivot lever as shown in FIG. 6. This force M acts over a large moment arm, the distance between the magnet 60 and the surface 53, to resist the moment created by the forces T and R. Since the magnet moment arm is large compared to the cover sheet tension moment arm, the magnitude of the force M required to hold the pivot lever down is much smaller than the tension force T.
Removal of the cover sheet is accomplished by pushing upward on the distal end 66 of the pivot lever. Preferably the distal end 66 extends outward beyond the magnet 60, forming a release tab for applying the upward release force. It is only the relatively small magnet force M that must be overcome to release the cover sheet. The variation in the force M resulting from changes in ambient temperature is negligible. As a result, the force required to remove the cover sheet 30 remains fairly consistent over a large variation in ambient temperatures.
The pivot levers will typically be provided on the two side edges of the cover sheet and the rear edge. At the front of the cargo box, the cover sheet will be fixed to the rail. When the cover sheet is removed from the cargo box, it is rolled in a small spiral and stored at the front of the cargo box. The pivot levers are used on the remaining three sides to pull the cover sheet tight.
An alternative embodiment is shown in FIG. 7. A pivot lever 54' is shown having a flat wall 70 ending with an angled surface 72 at its proximal end. A frame rail 18' has an upper wall 40' which is connected to the outer wall 41' forming an undercut 74. The undercut forms a flat bearing surface 76 which is inclined at an acute angle 78 to the surface of the upper wall 40. The surface 76 bears against the proximal end of the pivot lever 54' to resist the tension in the cover sheet 30. This embodiment creates a small moment arm between the tension in the cover sheet and the reaction force. Like the previous embodiment, the proximal end of the pivot lever 54' is seated beneath an undercut or a lip so that the proximal end of the pivot lever is not free to move upward away from the rail 18'.
Yet another embodiment of the present invention is shown in FIG. 8. There a pivot lever 54" is shown having a magnet strip 60. Unlike the previous embodiments, the extruded plastic forming the pivot lever 54" has a closed channel 80 in which the magnetic strip 60 is disposed. A thin wall 82 of the plastic covers the surface of the magnet and forms the engaging surface of the pivot lever. Such an enclosed channel for the magnet is similar to the covered magnet strips used to seal refrigerator doors. Preferably the pivot lever is made of a flexible PVC or other plastic resin to enable the pivot lever to rolled in a coil as the cover sheet 30 is rolled to a storage position near the front of the cargo box. With the protective layer of plastic covering the magnet strip 60, it may be possible to hold the pivot lever in its locked position by contact of the covered magnet strip with the surface of the pickup truck cargo box. This would eliminate the magnet strip attached to the rail and also reduce the size and weight of the rail. The plastic wall 82 covering the magnetic strip would avoid marring the finished surface of the cargo box.
As another alternative construction, the cargo box wall may be equipped with a plastic molded upper cover. It is possible to mold this cover with a bearing surface for the proximal end of the pivot lever 54". With the provision of a bearing surface in the upper end of the cargo box, it may be possible to provide a tonneau cover that no longer requires separate frame rails attached to the cargo box side walls. Instead, the pivot lever 54" can rotate about the bearing surface in the molded plastic cover and the magnet engage the metal cargo box surface adjacent to the molded plastic cover.
In another alternative embodiment, the magnet strip 48 can be deleted from the rail if the rail itself were made of a paramagnetic material. Such a case, is shown in FIG. 9 with the rail 18" where the magnet strip 60 of the pivot lever is attracted directly to the rail itself.
The tonneau cover of the present invention, having a pivot lever and a magnetic attachment to hold the pivot lever in place enables the tonneau cover sheet to be attached with attachment and removal forces that are consistent over a large range of ambient temperatures. The pivot lever is held in place by a magnetic force which is not susceptible to variations caused by ambient temperature. As a result, the release force necessary to remove the flexible cover sheet is fairly constant over a large range of temperatures. The pivot lever provides a mechanical advantage in pulling the cover tight with a relatively low force required by the user.
It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims.
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A tonneau cover for covering an area of a vehicle bounded by upright walls of the vehicle in which a flexible cover sheet is attached to a frame rail mounted to the vehicle by the use of a pivot lever. The pivot lever has an inner or proximal end which engages an outward facing bearing surface of the frame rail. Once engaged, the sever is rotated outward and downward to apply tension to the cover sheet. The pivot lever is held to the rail in the downward pivoted position by complementary magnets carried by the pivot lever and the frame rail. The magnetic force resists the rotational moment applied to the pivot lever by the tension in the cover sheet.
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FIELD OF THE INVENTION
[0001] This invention relates town alignment device. In particular, the invention relates to an alignment device for starter bars for masonry block walls.
BACKGROUND TO THE INVENTION
[0002] The use of masonry blocks walls in construction is very popular. In order to construct a masonry block wall that has the necessary structural strength, the masonry block wall must be tied to an associated foundation or footing. When the foundation or footing for a masonry block wall is being prepared, reinforcing bars are placed in the footing. These reinforcement bars (known as starter bars) protrude from the concrete footing and are required to engage the masonry block wall. However, the starter bars are often not placed in the correct location in relation to the cavity in the masonry blocks of the masonry block wall.
[0003] Misaligned starter bars are a huge problem for a block layer. The block layer is often unable to bend or adjust the incorrectly placed starter bars coming out from the concrete footing. Accordingly, the starter bars are not in their correct position and do not line up with the vertical reinforcing bars that are placed in the masonry block wall. The starter bars being out of position and not aligning with the vertical reinforcing bars in the masonry block wall during wall construction will result in the wall not meeting the structural capacity as detailed in the engineering specification for the wall. In a worst case scenario, the entire wall, including the footing, will need to be demolished and rebuilt at substantial cost.
[0004] The majority of reinforced masonry block walls require starter bars (and vertical reinforcing bars) to be generally used at 400 mm intervals along the wall. The problem of misaligned starter bars is therefore a considerable inconvenience to the block layer because of the large number of starter bars in each wall construction.
OBJECT OF THE INVENTION
[0005] It is an object of the invention to overcome or at least alleviate one or more of the above disadvantages and/or provide the consumer with a useful or commercial choice.
SUMMARY OF THE INVENTION
[0006] In one form, although not necessarily the only or broadest form, the invention resides in an alignment device able to align substantially vertical starter bars for a masonry block wall, the alignment device comprising:
[0007] a plurality of spacer arms spaced a predetermined distance from each other; and
[0008] a plurality of attachment members attached to respective spacer arms, the attachment members able to be operatively attached to the vertical starter bars.
[0009] Preferably there are at least three or more spacer arms. The spacer arms are normally equally spaced from each other.
[0010] The spacer arms may be interconnected by at least one connector rail. Typically, there are two connector rails.
[0011] The spacer arms may be removably attached to the at least one connector rail. Alternatively, the spacer arms may be integrally formed with the connector rail.
[0012] Typically, the spacer arms are relatively linear. However, it should be appreciated that the spacer arms may be non-linear.
[0013] Similarly, the at least one connector rail is relatively linear. However, it should be appreciated that the at least one connector rail could be non-linear.
[0014] The attachment members are preferably in the form of a clip. However, other forms of attachment members may be suitable, such as clasp, buckle, catch, clamp, clench, clinch, fastening, grapple, hook, pin or a snap.
[0015] The attachment members may be removably attached or fixed to respective spacer arms.
[0016] One or more supports may form part of the alignment device to ensure that the spacer arms are held at a desired position. Typically, there are a plurality of supports. More preferable there are at least three supports. The supports may be connected or tied to a spacer arm and/or a connector rail.
[0017] Each support may include a holder and at least one leg. The holder may operatively support the spacer arms. The holder may engage and/or position and/or align a spacer arm and/or a connecting rail. The holder may include holder members to engage and/or align a spacer arm or a connecting rail.
[0018] The leg may be removably attached to the holder. The leg may be movable and/or adjustable with respect to the holder. However, it should be appreciated that the leg and holder may be fixed with respect to each other. Accordingly, the leg and holder may be integrally formed.
[0019] In another form, the invention resides in a method of aligning substantially vertical starter bars for a masonry block wall; the method including the steps of:
[0020] locating a plurality of starter bars at a desired position, each starter bar having at least one attachment member; and
[0021] attaching the vertical starter bars to at least some of the attachment members to align the vertical starter bars.
[0022] The method may further include one or more of the steps of:
[0023] connecting the starter bars to a at least one connection rail;
[0024] 16 . operatively supporting the starter bars with a support.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] An embodiment, by way of example only, will be described with reference to the accompanying drawings, wherein:
[0026] FIG. 1 is a perspective view of an alignment device being used to support a series of starter bars according to an embodiment of the invention;
[0027] FIG. 2 is a side sectional view of an alignment device according to an embodiment of the invention;
[0028] FIG. 3 is a perspective view of an alignment device as shown in FIG. 1 according to an embodiment of the invention; and
[0029] FIG. 4 is a perspective view of an alignment device incorporating a different spacer arm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] FIGS. 1 and 2 show an alignment device 10 that is used to hold a series of starter bars 5 in a desired position in order to ensure the starter bars 5 are positioned correctly within a proposed masonry wall. The alignment device 10 includes a series of spacer arms 20 , an associated series of attachment members 30 , two connection rails 40 and a number of supports 50 .
[0031] The spacer arms 20 are used to space starter bars 5 at the correct distance from each other. The spacer arms 20 , shown in more detail in FIG. 3 , are made from injection moulded plastic. However, it should be appreciated that the spacer arms 20 may be made using other suitable materials. The spacer arms 20 are elongate and rectangular in transverse cross section. However, it should be appreciated that the spacer arms 20 may be of a variety of other transverse cross sections including round, elliptical, square or the like shape. A snap-in clasp 21 is located at each of the ends of each of the spacer arms 20 to connect the spacer arms 20 to respective connection rails 40 . The spacer arms 20 may be made of various lengths to suit masonry walls of different sizes.
[0032] The attachment members 30 are used to hold respective starter bars 5 . The attachment members 30 are removably attached to the spacer arms 20 . A person skilled in the art would appreciate that various known forms of removable attachment of the attachment members to the spacer arms may be used. For example, the attachment members may be threaded with a corresponding threaded hole provided in the spacer arm. Alternatively, the attachment members may be snap locked into corresponding holes provided in the spacer arm 20 . This enables attachment members 30 of different sizes to be attached to the spacer arms 20 as shown in FIG. 3 and FIG. 4 . However, it should be appreciated that the attachment members 30 may be integrally formed with the spacer arms 20 .
[0033] The position of the attachment members 30 may be varied according with structural requirements of a masonry wall. For example, the attachment members 30 shown in FIG. 3 are located centrally on the spacer arms 20 whilst the attachment members 30 , shown in FIG. 4 , is located toward one end of the spacer arm 20 . It should be appreciated that the number of attachment members 30 and the position of the attachment members 30 may be varied on the spacer arms 20 depending on requirements. For example, a spacer arm 20 may have two attachment members 30 , one attachment member 30 having a position as shown in FIG. 3 and one attachment member 30 as shown in FIG. 4 .
[0034] The attachment members 30 , shown in FIGS. 3 and 4 , are in the form of C-shaped clips. The clips are resilient so that a starter bar 5 can be held by the clip. The C-shaped clips may be of different sizes to cater for different sized starter bars 5 . It should be appreciated that other forms of attachment members 30 may be used instead of the C-shaped clips to hold the starter bars 5 .
[0035] The connection rails 40 are used to hold the spacer arms 20 . The connection rails 40 are in the form of a C-section 41 . Holes 42 are located through and spaced equally along the length of the C-section 41 . The holes 42 are used for location of respective snap-in clasps 21 of the spacer arms 20 . As an alternative, it should be appreciated that the spacer arms 20 and the connection rails 40 may be permanently fastened to each other. Both the connection rails 40 are of a continuous length. However, it should be appreciated that the connection rails 40 may be formed from sections which are fitted together to form the connection rail 40 . A person skilled in the art would readily appreciate how sections are connected together. Further, it should be appreciated that the connection rails may be shaped differently.
[0036] The supports 50 , shown in detail in FIG. 2 , are used to support the connection rails 40 and accordingly the spacer arms 20 . Each support 50 is formed from a holder 60 and a leg 70 . The holder 60 includes two holding members 61 which engage and support the connection rails 40 . The holder members 61 are adjustable to align the spacer arms 20 and connection rails 40 above a trench to represent the location of the wall to be built. It should be appreciated that the holder 60 may be modified to engage and support the spacer arms 20 .
[0037] The leg 70 is located at one end of the holder 60 and has a pointed end 71 for digging into the ground. The leg 70 is movable with respect to the holder 60 .
[0038] In order to correctly align a series of starter bars 5 , the first step is to locate each pointed end 71 of the leg 70 of the supports 50 within the ground and away from and adjacent to (but not within) a trench for forming a concrete footing. The holders 60 of the supports 50 are then moved with respect to the leg 70 to locate the holders 60 at a desired height and desired horizontal location representing the exact position of the block wall to be built. Next, the attachment members 30 are selected depending on the diameter of the starter bars 5 . The spacer arms 20 are also selected depending on requirements of the masonry wall such as positioning requirements of the starter bar 5 and the size of the blocks.
[0039] The attachment members 30 and the spacer arms 20 are joined together (if required). Subsequently, the spacer arms 20 are inserted into the holes of the connection rails 40 to form a “ladder” arrangement. The spacer arms 20 are held to the connection rails 40 using the snap-in clasps 21 .
[0040] Once the starter arms 20 and connection rails 40 are joined together, the connection rails 40 are placed within holders 60 of the supports 50 . The starter bars 5 are then attached to the attachment members 30 to hold the starter bars 5 in their desired location. When the starter bars 5 are set plumb, a base of the starter bar 5 can be tied off to a reinforcing cage in the footing. Accordingly, the footing can then be laid ensuring the starter bars 5 are in the correct location with respect to the masonry wall to be built.
[0041] There are considerable advantages in using the alignment device 10 to install the starter bars 5 in a precise location when forming the footing, when pouring the concrete for the footing and when building the masonry block wall on the top of the footing. The advantages include:
[0042] 1. Reducing the time taken to set out and accurately tie the starter bars 5 to the reinforcing cage in the footing trench and maintaining the starter bars 5 in vertical alignment.
[0043] 2. Allowing one person to easily tie the starter bars 5 in the correct location in the footing trench and thereby ensuring the starter bars 5 will be in the correct location in the masonry blocks when the blocks are laid.
[0044] 3. Providing the correct location for the starter bars 5 for both centrally located and non-centrally located reinforcing steel applications, being typical specifications for reinforced masonry block walls.
[0045] 4. Ensuring the starter bars 5 are rigidly and securely positioned by the combination of tying the starter bar 5 to the reinforcing cage in the trench and clipping the starter bar 5 to the alignment device 10 at about 500 mm above ground level. This two point connection provides the additional security that ensures the starter bar 5 does not move out of place even during the pouring of the concrete for the footing.
[0046] 5. Providing a simple and effective means of setting and maintaining the starter bars 5 in a vertical position to ensure they line up adjacent to the vertically placed reinforcing steel in the masonry block wall.
[0047] 6. Providing the longitudinal set out of the starter bars 5 at 400 mm centres for the length of the wall or at the centres specified in the engineering specification.
[0048] 7. Assisting in the containment of the entire reinforcing steel grid of the foundation.
[0049] In this specification, the terms “comprise”, “comprises”, comprising” or similar terms are intended to mean a non-exclusive inclusion, such that a system, method or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.
[0050] It should be appreciated that various other changes and modifications may be made to the invention described without departing from the spirit or scope of the invention. For example, the alignment device could be manufactured in one piece flat lengths of extruded plastic with the connection rails and spacers arms being integrally formed. The lengths have sufficient strength to adequately support the starter bars above ground level while being flexible enough to be rolled up for convenience between jobs. Accordingly, the starter bars in this instance will be tied to spacer arms using wire as the attachment members.
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The invention resides in an alignment device able to align substantially vertical starter bars for a masonry block wall, the alignment device comprising a plurality of spacer arms spaced a predetermined distance from each other and a plurality of attachment members attached to respective spacer arms, the attachment members able to be operatively attached to the vertical starter bars.
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CROSS-REFERENCE TO RELATED APPLICATION
This application corresponds to the disclosures of two Japanese applications viz No. 53-057593, filed May 17, 1978 and Oct. 13, 1978, the priority dates of which application applicant claims under the International Convention.
BACKGROUND OF THE INVENTION
The present invention relates to devices utilizable in different types of breathing systems, such as those for administering anesthetic gases, or for the administration of oxygen to patients.
In recent years a number of improvements have been evolved for use in the practice of inhalation anesthetic administration. These improvements include: the two tube circle circuit disclosed in U.S. Pat. No. 3,556,097; the unilimb device and the anesthesia breathing system disclosed in U.S. Pat. No. 4,007,737; the anesthetic system described in the article entitled "A Streamline Anesthetic System" J. A. Bain and W. E. Sporel, which appears in Volume 19, No. 4 at page 426 of the Canadian Anesthetic Society Journal (July 1972), and the tube device of which is disclosed in U.S. Pat. No. 3,856,051 granted Dec. 24, 1974; and the system described by Drs. S. Ramanathan, Chalon, and Turndorf in an article entitled "A Compact, Well-Humidified Breathing Circuit For the Circle System" which appeared in Volume 44, No. 3 commencing at page 238 of the March 1976 issue of Anesthesiology.
Among such and other well-known breathing systems, that most commonly used is probably the circle circuit, orginally introduced in 1926 and an improvement of which is disclosed in U.S. Pat. No. 3,556,097 mentioned above. The principal problem in utilizing a circle circuit of such design arises from the use of two flexible tubes. Such tubes can impede the surgeon who may be confronted with having to operate in the vicinity of the head and neck of the patient. In addition, the same sized flexible tubes used in a circuit system for adults, cannot be employed for infants. Instead a miniaturized pair of flexible tubes must be utilized for the latter. While the rebreathing system described by Drs. Bain and Sporel in the article, and his pipe disclosed in said U.S. Pat. No. 3,856,051, mentioned above, have certain advantages from the standpoint of ease in the application to the patient and handling, the particular circuit is not generally regarded as efficient with regard to fresh gas economics during spontaneous breathing. Nor would the fresh gas tube of the said patent support such breathing. This pipe is, therefore, limited in its usage to the Bain and Sporel rebreathing system which has not been generally accepted to replace the circle circuit system.
In an effort to overcome the physical problems presented by the use of two flexible tubes or hoses in the manner illustrated in U.S. Pat. No. 3,556,097, both the patentee of U.S. Pat. No. 4,007,737 and Drs. Ramanathan, Chalon, and Turndorf have illustrated and described unilimb devices utilizable in a circle circuit system.
Although the unilimb devices thus suggested by prior researchers in this field have offered advantages over the two tube or hose system previously used in a circle circuit system, there are certain critical aspects in such prior unilimb devices which can present problems in certain applications therefor and/or which may otherwise limit their use to special situations. For example, although the unilimb of U.S. Pat. No. 4,007,737 is designed to minimize dead air space in a circle circuit breathing system, it does so by providing two one way valves in the terminal connector adapted for attachment to the mouth piece or other inlet means to the patient's respiratory system. Since any malfunction of either one-way valve could have a most serious, if not fatal, consequence, it becomes highly desireable to eliminate such valves altogether in this location. Further, by providing spacers between the inner and outer tubes in order to maintain them in a concentric disposition, the unilimb of the last-mentioned patent can develop undesireable gas flow impediments when the tubes become twisted.
While the clinical report by Drs. Ramanathan et al. does illustrate the use of a unilimb flexible tube or hose system between the source of the gas and the patient, insufficient details of the patient end of the device are disclosed to enable one skilled in the art to determine its exact physical structure.
Prior art devices of these types, moreover, appear to have been designed and utilizable only for particular applications. Thus, for example, a unilimb device for a circle circuit has had no utility in the rebreathing system described by Drs. Bain and Sporel in the article heretofore referenced. conversely, no device specifically designed for use in a rebreathing system, has heretofore been employable in a circle circuit system.
Additionally, prior art devices have been structured for a particular application and with fixed physical characteristics e.g. to provide a predetermined volume of dead air space, thus limiting the use of the device to the specific application for which the device may have been designed. Hence, if, for example, it should become desireable in the circle circuit to provide more or less dead air space than a given unilimb device is designed to provide, it has been necessary heretofore to have a new unilimb device designed and fabricated for such other specific application.
It has also been the observation of the present inventor that such unilimb prior art devices as have heretofore been described in any of the references, such as those hereinabove mentioned, have not been found particularly practicable from the standpoint of being readily manufacturable at a reasonable cost. This would appear to be particularly the situation with respect to the device of U.S. Pat. No. 4,007,737 with its one-way valve system and spacers for maintaining concentric disposition of the inner tube with respect to the outer tube.
If the cost of manufacturing such devices should prove too great, there will be considerable reluctance on the part of hospitals and other potential users of the devices to purchase the same, and particularly to discard them where such discard might become necessary or desireable after use with a patient which may have some type of communicable disease. Prior unilimb devices moreover have not heretofore been constructed in such a manner as to be easily disassemblable for cleaning sterilization or other type of servicing.
Thus, the devices of the prior art have not proved to be satisfactory from the standpoints of their fabrication, their servicing, their disposability, their utility, nor their adaptability for use in different systems, or for different applications in the same system.
SUMMARY OF THE INVENTION
The present invention will be found to provide a unilimb device which may be easily and inexpensively fabricated for assembly or dissassembly, and hence, is readily servicable. It may be constructed for adaptation to universal applications, not only to satisfy different requirements for gas handling in the same system, but for use in both the circle circuit system and the rebreathing system.
The invention comprises a pair of flexible gas conducting tubes, one being of a smaller diameter than the other and serving to conduct the inspiratory gas from a source thereof inlet means for the patient's respiratory system. The larger flexible tube is disposed about the smaller tube and, through the space between the two tubes, may serve to conduct expiratory gas from such inlet means back to a carbon dioxide absorber, or for other disposition. The two tubes extend between a pair of more rigid plastic terminals. One of such terminals may be provided with outer and inner tubular extensions to which one of the pair of corresponding ends of the larger and smaller tubes maybe attached respectively, with the smaller tubular extension, placing the smaller tube in communication through an opening in the terminal with a hose from inspiratory gas source; and with the terminal providing a separate gas passage whereby the larger tubular member may be placed, through another opening in the terminal, in communication with a hose leading to the CO 2 absorber or other unit.
The other terminal may be short and tubular in configuration, having one end adapted for connection with the inlet means for the patient's respiratory system, and its other end adapted to receive the other ends of the two flexible tubes. The end of the larger tube may grippingly fit over or inside the other terminal end, and the end of the smaller tube may extend therein. An orificed transverse wall may be disposed between the two terminal ends and serve as a stop for the axial advance of the end of the smaller tube, thereby to prevent the inner tube from obstructing the flow of expiratory air back through the larger tube. Because of the proximity of the end of the smaller tube to the inlet means the amount of dead space in the vicinity of the inlet means to the patient's respiratory system, may be minimized. The open ends of both the larger and smaller flexible tubes are in direct communication with the nozzle leading to the inlet means to the patient's respiratory system, as well as with each other. Since the pressure of the gas arriving through the smaller tube will always be in excess of the pressure of the gas being carried away by the larger tube, and because the one-way valves are already provided by the anesthesia machine, no one-way valve has been found to be necessary at the outlet of the inner tube, or the entrance of the outer tube. Even when the patient exhales back through the nozzle, the expiratory gas will be carried away between the walls of the larger and smaller tubes.
While the device in a circle circuit system thus provides a minimum of dead space, a requirement particularly important in the administration of oxygen to infants, it is also part of the present invention to provide telescoping or adapter elements for either or both of the terminals whereby, paradoxically, dead space may be increased for situations where the level of the carbon dioxide in a patient may become abnormally low, as for example, where patients may be receiving prolonged artificial ventilation. by sliding out the telescoping tubular extensions, the circuit may readily be adapted to provide adequate dead space to enable the patient's carbon dioxide level to be regulated over a wide range, thereby facilitating the maintenance of normocapnia during anesthesia and mechanical ventilation, when appropriate.
It is also a feature of the present invention that the second terminal, which may normally be connected to the source of gas, and the carbon dioxide absorber, may be modified in a number of ways by the use of a plug and an adapter, to increase dead space in a circle circuit. Additionally, by connecting a bag or a respirator, or a one-way valve, to the opening in the terminal which would normally be in communication with a carbon dioxide absorber in a circle circuit system, the device may be adapted to a rebreathing or non-rebreathing circuit for use in transporting a patient away from an operating room during recovery or when adequate anesthetic machines are not readily available.
Because the components of the device of the present invention are relatively simple to construct and may be manufactured as separate items, they may be easily assembled into the complete unilimb device, and any one of the components may be quickly replaced should such replacement become necessary. Additionally, since the several components may be readily detached from the other components, each of the components may be easily cleaned and sterilized. Also, because the cost of fabricating the several components is not great, any or all of the components may be simply be disposed of after any use thereof, as for example, by a patient having a contagious disease or a communicable virus.
While it is contemplated that the inner tube shall be used as the inspiratory limb, and the outer tube as the expiratory limb in order to avoid obstruction due to water condensation of the exhaled gases which may occur after prolonged artificial ventilation, it would be possible to reverse the connections without hypercarbia and hypoxia presenting immediate hazards to the patient.
The device of the present invention may thus be adapted for use in any of the several presently used breathing systems in order to utilize the most desirable features of such circuit for any particular application. In other words, the same unilimb device may be utilized either in a circle circuit, or as a re-breathing circuit, or a non-rebreathing circuit, a pediatric circuit with a minimum dead space, or to provide greatly augmented dead space in any of such circuits to regulate arterial carbon dioxide. Moreover, the device has proven to be extremely reliable and affords safe institution of spontaneous, assisted or controlled ventilation. This results particularly from the elimination of valves in the terminal and the need for maintaining concentricity of the tubes by spacers or other means.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 illustrates, in perspective view, a typical conventional dual tube circle circuit;
FIG. 2 is a schematic view of the circle circuit of FIG. 1;
FIG. 3 is a longitudinal cross-section of the preferred embodiment of the device of the present invention;
FIG. 4(a) is a section on the line a--a of FIG. 3;
FIG. 4(b) is a section on the line b--b of FIG. 3;
FIG. 4(c) is a section on the line c--c of FIG. 3;
FIG. 4(d) is a section through the line d--d of FIG. 3;
FIG. 4(e) is a section on the line e--e of FIG. 3;
FIG. 4(f) is a section on the line f--f of FIG. 3;
FIG. 5 is a front view of the transverse wall element 29 shown in FIG. 3;
FIG. 6 is a schematic view of a circle circuit of FIG. 2 in which the device of FIG. 3 has been substituted for the two hose arrangement of FIGS. 1 and 2;
FIG. 7(a) is a longitudinal section of a modified form of the terminal element shown in the left-hand side of FIG. 3;
FIG. 7(b) is a front view of the modified transverse wall element 30 and surrounding elements shown in FIG. 7(a);
FIG. 8(a) is also a longitudinal section of the terminal element shown in the left-hand side of FIG. 3, but illustrating a modification in the end of the inner tube;
FIG. 8(b) is a longitudinal section of a still further modification of the end of the inner tube;
FIG. 9(a) is a longitudinal section of the terminal element shown on the left-hand side of FIG. 3, but illustrating the substitution for the transverse wall in FIG. 3 of a screen type wall, and a different disposition of the inner tube;
FIG. 10(a) is a longitudinal section of the terminal shown on the left-hand side of the FIG. 3, in a further modified form;
FIG. 10(b) is a view taken on the line aa of FIG. 10(a) looking in the direction of the arrows;
FIG. 11(a) is a longitudinal section of the terminal shown on the left-hand side of the FIG. 3 in a still further modified form;
FIG. 11(b) is a view taken on the line a--a of FIG. 11a looking in the direction of the arrows;
FIG. 12 is a longitudinal section of a modified form of the terminal shown on the right-hand side of FIG. 3;
FIG. 13 is a longitudinal section of the terminal shown on the right-hand side of FIG. 3, but with base connections thereto;
FIG. 14 is a longitudinal section similar to FIG. 3, but illustrating a modification of, and addition to, the terminal shown on the right-hand side of FIG. 3;
FIG. 15 is a schematic view of the circuit in which the embodiment of the invention illustrated in the FIG. 14 may be utilized;
FIG. 16 is a sectional-view of still further modification of, and addition to, the terminal illustrated on the right-hand side of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, a typical circle circuit includes a source of gas 1, conduit means 2 extending therefrom, and a carbon dioxide absorber 3 which receives exiratory gas through a conduit 4. Reprocessed gas moves out through the outlet 5 after having passed through the carbon dioxide absorbing granule 6. As the reprocessed gas moves out of the outlet 5, it joins fresh gas from the source 1 as the fresh gas is arriving through the conduit 7, and the merged gases then pass through the one-way inspiratory valve 13 and the flexible hose 9 into the common inlet-outlet pipe 11, as inspiratory gas to the inlet means (not shown) to the patient's respiratory system. The expiratory gases return through the inlet pipe 11, but then pass back through the return hose 10, one-way expiratory valve 14, past the reservoir bag 12 and into the carbon dioxide absorber 3 through the inlet for reprocessing. This system is shown schematically in FIG. 2.
The device of the present invention is intended to replace the two hoses 9 and 10, and the inlet-outlet pipe 11 of the circle circuit thus illustrated in FIGS. 1 and 2, and briefly described above. The inspiratory tube 21 is extended through the expiratory tube 22. The difference in the diameters of these two tubes is such that a sufficient volume of expiratory air may pass between the outer wall of the inner tube 22 and the inner wall of the outer tube 21. The latter desirably may be constructed of plastic, as a corrugated tube, while the inner tube 22 preferably is extruded of a vinyl type material. These two tubes are separately fabricated, so that when the device of the present invention is to best assembled, the smaller tube 22 is simply pushed in and through the outer tube 21 until the leading end of the tube 22 appears at the other end of the corrugated outer tube 21.
As may be seen in FIG. 3, two corresponding ends 22' and 21a of the inner tube 22 and outer tube 21 are disposed in and about a terminal element 23, respectively. This element 23 may be generally tubular in configuration, with a tapered nozzle end 23a for connection with the inlet means to the patient's respiratory system. The external diameter of the opposite cyclindrical end 23b of the terminal element 23 is such as to enable the uncorrugated end 21a of the tube 21 to be force fitted thereover. A transverse wall 29, preferably orificed in the manner shown in FIG. 5, with the orifices 29', may serve as a stop to prevent the end 22' of the tube 22 from extending into the opening in the nozzle end portion 23a of the terminal element 23 and thereby block the flow of expiratory air back into the expiratory air passage 21c, but permitting such end 22' to be disposed as close as possible to the opening in the nozzle and portion 23a.
The opposite ends 21b and 26 of the tubes 21 and 22 respectively, are connected to a second terminal element 24. This second terminal element 24, in the embodiment shown in FIG. 3, comprises a wall or housing 24a which defines three openings--24b, 27 and 28, and a cavity 24c, and includes a tubular extension portion 24d. The opening 24b may be coaxial with the opening 28. The end 21b of the tube 21 may be forced fitted over a sleeve 21", which itself is slipped over the tubular extension 24d, but only after the end 26 of the smaller inner tube 22 is first inserted through the opening 24b and passed through the cavity 24c and into a smaller receiving area 24e, into which the end 26 may be force fitted, thereby placing it in direct communication with the opening 28. After the end 26 of the inner tube 22 has thus been securely inserted in and gripped by the wall-defining the area 24e, and the outer tube end 21b has been attached over the tubular extension 24d in the manner heretofore described, the unilimb device of the present invention is ready for connection into a circle circuit system of the type shown in FIGS. 1 and 2, in the manner illustrated in FIG. 6. Thus, the opening 27 may be connected as at 14 in FIG. 2, and the opening 28 is connected to the inspiratory air line as at 13 in FIG. 2. The terminal element 23 then substitutes for the inlet-outlet 11 shown in FIGS. 1 and 2. Thereby, there are eliminated from the circuit the cumbersome double hose 9, 10, and Y-pipe connection shown at 11a in FIG. 1. The manner in which this substitution thus appears is illustrated in FIG. 6. While this device of the present invention in the embodiment illustrated in FIG. 3 provides a minimum of dead air space between the end 22' of inner tube 22 and the opening in the nozzle 23, which is connected to the inlet means (not shown) to the patient's respiratory system; should a small increase in such dead space be required or desireable in any situation, the same may be readily obtained by sliding the sleeve 21" axially to the left along the tubular extension 24d. Thereby, the corrugated outer tube 21 and terminal 23 are also displaced axially to the left relative to the inner tube 21, with the result that the end 22' becomes disposed toward the right further away from the opening in the nozzle end portion 23a of the terminal 23, to increase the dead space between said opening and end 22'.
It will be readily appreciated by those persons skilled in the art that the inspiratory air from the source 1, as supplemented by air from the carbon dioxide absorber 3, is brought to the inlet means (not shown) of the patient's respiratory system through the opening 28, the tube 22, and the terminal element 23. Expiratory air on the other hand, passes back from the patient into the terminal element 23, where it is diverted around the incoming inspiratory air at the end 22' of the inner tube 22, and into the passage of 21c between the outer corrugated tube 21 and the inner tube 22. This expiratory air is then brought back through the terminal element 24 via the passage defined by the tubular extension 24d, the cavity 24c, and the opening 27, from whence it is carried back pastthe reservoir bag 12, and into the carbon dioxide absorber 3 for reprocessing and ultimate return with fresh inspiratory gas.
It will be readily appreciated that in this particular embodiment shown in FIG. 3, there is provided in the terminal element 23, a minimum of dead space. While the device as illustrated in FIGS. 3-5 is to be preferred, at least for those applications where a minimum of dead space may be desired, other configurations of the terminal element and two tube ends may also be utilized.
In the embodiment of the terminal element illustrated in FIGS. 7(a) and 7(b), the orificed transverse wall 29 of the FIG. 3 embodiment is omitted, and a plurality of radially extending spacers 30 secured to the cylindrical wall portion 23 are provided to support the end 22' of the tube 22 in coaxial alignment with the terminal element 23, and to limit the distance that the tube end 22' may extend toward the nozzle opening.
In the further embodiment of the terminal element illustrated in FIGS. 8(a) and 8(b), the only modifications over that of FIG. 3 lies in providing the orifices 31 or serrations 31' in the end 22' of the inner tubular member 22.
In the still further embodiment of the invention illustrated in FIGS. 9(a) and 9(b), there is substituted for the transverse wall 29 of the FIG. 3 embodiment, a screen-like member 29' , and the inner inspiratory air tube is brought into the terminal element 23 along one side of the outer tubular member 21.
In the still further embodiment of the invention illustrated in FIGS. 10(a) and 10(b), there is substituted for the transverse wall 29 in the FIG. 3 embodiment, an orificed transverse annular wall 32' , having a coaxial tubular extension 32 which serves to receive and limit the axial incursion of the end 22' of the inner tube 122. Additionally, the inner wall 23b' is configured to provide a counter bore type recess 23b'' to receive the radiating flange 32' which constitutes a transverse wall referred to above. This flange or wall 32' is punctured with a ring of orifices 33 for passage of expiratory air back into the passage 21c defined by the inner wall of the outer tube 21 and the outer wall of the inner tube 22.
In the last alternate embodiment of the terminal element 23, illustrated in FIGS. 11(a) and 11(b), it will be seen that this is quite similar in configuration to the embodiment of FIGS. 10(a) and 10(b), the difference being that the axially extending orifices 33, shown in FIGS. 10(a) and 10(b) have been eliminated from the transverse wall-flange 32. In place of said axially extending orifices 33, a series of orifices 33' have been provided in the tubular extension 32, thereby to permit the expiratory gas to pass into the passage 21c.
FIG. 12 illustrates a possible different configuration for the right-hand terminal element shown in FIG. 3, and FIG. 13 illustrates the manner in which tubes 34 and 35 may be inserted into the openings 27 and 28 respectively, to place this element in communication with the carbon dioxide absorber 3 and the gas source 1 in a circuit such as illustrated in FIG. 6.
In the further embodiment of the invention illustrated in FIGS. 14 and 15, it will be noted that the basic device illustrated in FIG. 3 is employed, but it has been modified to the extent of having had its opening 27 closed by a plug 34', and instead of having the end of a connector tube 35 inserted into the opening 28, as illustrated in FIG. 13, an interfitting end 37 of an extension adapter 38 is pressed into the opening 28. This adapter, however, does not continue the separation of the inspiratory and expiratory air passages in the manner accomplished by the terminal element 24, as illustrated in FIGS. 3, 12 and 13. Instead, the extension adapter 38 defines a single cavity 39, into which there are three openings 40, 41, and 42. Opening 40 is placed in direct communication with the inner tube 22. The oppositely disposed opening 41 is placed in communication with the tube 35 from the source of gas 1 and reprocessed gas from the CO 2 absorber 3; while the third opening 42 is placed in communication through the elbow 43 and the hose 36 with the carbon dioxide absorber 3, in the manner shown in the schematic diagram of FIG. 15. This adaptation of the present invention, in effect, provides an extensive dead space for use in situations where it is desired to increase the level of carbon dioxide in the patient's respiratory system.
In the further adaptation illustrated in FIG. 16, the plug 34'' serves to close off the opening 28 and hence, the end of the inner tube 22. The circle circuit illustrated in FIG. 16, in this alternative embodiment, is connected by the adapter 38' to the opening 27' and the two hoses 35 and 36. By this adaptive embodiment, it may be seen that the circle circuit is provided with more extensive dead space by employing only the outer tube 21 not the inner tube 22.
From the foregoing it will be readily appreciated by those skilled in the art that the device of the present invention may not only be employed effectively in a circle circuit breathing system to provide a minimum of dead space but is may be readily adapted to provide greatly augmented dead space in such a system, and also may be adapted for use in various other presently known breathing systems. The device may be readily assembled from its basic components and, since it contains no moving valve parts, it is completely safe and reliable. Because of the simplicity of the structure of its components, it is easy to dissassemble for cleaning and sterilization. Moreover, since its components may be inexpensively manufactured, any of such components, or even the entire device may be disposed of after usage in certain situations, without great economic loss.
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This application discloses a unilimb device of universal application to different types of breathing systems. The device comprises two gas carrying tubes, one within the other, the corresponding ends of the tubes being within two common terminal elements. One of the terminal elements provides for two separate passages, each being connectable, one to a source of gas, and the other for disposition of the expiratory gases. The other terminal element includes a nozzle end for connection to the inlet for the patient's respiratory system, with the opposite end serving to receive the other ends of the two flexible tubes and to provide short passages to the nozzle to minimize dead air space. Provision may be made for telescoping each terminal element, and the inlet element may be provided with a member for extending or adapting it to different breathing systems.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of International Patent Application No. PCT/GB02/02271 filed May 15, 2002, designating the United States and claiming priority of British Patent Application No. 0112244.9 filed May 18, 2001, the disclosures of both foregoing applications being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a sub-aqua breathing system that allows a person operating underwater to breathe air from a compressed air tank supported on the water surface.
[0003] There are many occasions when it is desired to operate below the water surface, for example when freeing the propellers of water craft entangled with fishing nets, lines, or weed, etc. in rivers or streams; for the inspection of vessel hulls; for the rescue of people trapped below the water surface in swimming pools, or from cars or vessels sunk in rivers or docks; or for sporting purposes.
[0004] Normally sub-aqua or ‘SCUBA’ equipment can be used in such situations but it is heavy and cumbersome to operate and difficult to manoeuvre whilst wearing. ‘SCUBA’ equipment also takes some time to get ready for use and/or put on and this can be a serious problem in, for example, an emergency situation.
[0005] Recently there have been developments in which floating members, similar to large life buoys or rubber dinghies, are used to support a petrol engine or, batteries and an electric motor, which drive an air pump to feed a hose, possibly via an air receiver, with a mouthpiece regulator at the remote end of the hose. Such devices are cumbersome, heavy to transport, difficult to maintain and are expensive.
SUMMARY OF THE INVENTION
[0006] The present invention seeks to provide a sub-aqua breathing system that overcomes or substantially alleviates the drawbacks of the prior art described above and other known deficiencies of existing underwater breathing equipment.
[0007] According to the present invention, there is provided a sub-aqua breathing system comprising a housing containing buoyant material and a toroidal compressed air tank, said tank being connectable to an air line feeding a mouthpiece regulator.
[0008] Preferably, the buoyant material is disposed in regions around the periphery of the toroidal compressed air tank.
[0009] The housing conveniently includes a storage compartment for an air-line when not in use.
[0010] In a preferred embodiment, the system includes a base rotatably mounted to the housing to cover the storage compartment and having at least one opening therein for the passage of an air-line from the storage compartment through the base.
[0011] In an alternative embodiment, the sub-aqua breathing system including a base and a release mechanism for releasably mounting the base to the housing over the storage compartment.
[0012] Preferably, the release mechanism is a lever pivotally mounted to the housing, the lever and base including cooperating means that engage to retain the base on the housing.
[0013] The release mechanism advantageously includes spring means to bias the lever into a position in which the cooperating means are in engagement.
[0014] Preferably, the release mechanism includes a safety release pin that cooperates with the housing and the lever to prevent inadvertent operation of the release mechanism.
[0015] In a preferred embodiment, the sub-aqua breathing system includes at least one air line coiled within the storage compartment, the or each air line having one end connected, via an air flow control valve, to the toroidal compressed air tank.
[0016] Preferably, a removable cover is mounted on the housing to provide access to the interior thereof.
[0017] The housing may conveniently contain a mast with a diving pennant attached thereto, the mast being removable from the housing and mountable in a socket thereon.
[0018] In one embodiment, the buoyant material is formed from a number of circumferentially spaced floats the system including means for radially deploying the floats from the housing.
[0019] Preferably, the deployment means includes an air bag associated with each float and inflatable in response to operation of a manually operated valve to direct air from the compressed air tank to the air bags to radially deploy the air bags from the housing.
[0020] The floats are advantageously attached to spring means operable to retract the floats in response to operation of a second manually operated valve to expel the air from the air bags.
[0021] The housing preferably has a discus-like shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0023] [0023]FIG. 1 shows a top perspective view of a sub-aqua breathing system according to an embodiment of the invention;
[0024] [0024]FIG. 2 shows a top plan view of the system illustrated in FIG. 1;
[0025] [0025]FIG. 3 shows a front view of the system illustrated in FIG. 1;
[0026] [0026]FIG. 4 shows a bottom plan view of the system illustrated in FIG. 1;
[0027] [0027]FIG. 5 shows a cross sectional view along line X-X in FIG. 3;
[0028] [0028]FIG. 6 shows a top perspective view of the system illustrated in FIG. 1 but with the floats in their extended positions;
[0029] [0029]FIG. 7 shows a bottom perspective view of a second embodiment of a sub-aqua breathing system according to the present invention;
[0030] [0030]FIG. 8 shows an enlarged partial side sectional view of the release mechanism forming part of the system shown in FIG. 7; and
[0031] [0031]FIG. 9 shows a side view of the system shown in FIG. 7 with the safety pin removed and the base plate falling away from the housing to release one or more air-lines.
DETAILED DESCRIPTION OF THE INVENTION
[0032] With reference to the drawings, the equipment comprises a two-part, lightweight plastics, injection moulded generally circular housing 1 enclosing a toroidal compressed air tank 2 . The housing also contains regions of buoyant material 3 surrounding the tank 2 . The bottom part 4 of the housing has a central disc-like rotatable portion 5 with apertures 6 through one of which the air line 7 extends, the air line being coiled inside the housing 1 and fed out, or wound up inside the housing 1 , by rotation of the central rotating portion 5 in opposite directions respectively. The air line 7 may be 10 metres long, and can be extended by the addition of one or two additional 10 metre lengths. The present embodiment (see FIG. 5) is shown with only one air line 7 coiled up and extending from the housing 1 . However, it will be appreciated that the housing 1 may also contain multiple air lines 7 coiled up within it.
[0033] The top part 8 of the housing has a removable central portion 9 through which access to the interior of the housing 1 may be obtained and which contains the main compressed air control valve 15 and first stage regulator 15 a which reduces the pressure from the tank to an intermediate pressure which is supplied via the air line to a mouthpiece or second stage regulator (not shown) which reduces the intermediate pressure to ambient water pressure and which supplies air when the user inhales. The interior of the housing 1 may also be used to store a telescopic mast carrying the conventional ‘diver working below’ pennant (not shown). The mast can be removed from the interior of the housing 1 and engaged in a socket (not shown) in the top of the housing 1 or in the removable central portion 9 so that it extends vertically upwardly from the housing 1 . The central portion 9 also carries a light 9 a that may be controlled so that it illuminates or flashes when the assembly is in use. The light may also be used to summon assistance by flashing, in morse code, the universal SOS signal.
[0034] The top and bottom parts of the housing 8 , 4 are attached to each other and together form a sealed unitary component. Similarly, an “0” ring is disposed between the cover 9 and the housing 1 so that the cover 9 forms an airtight fit with the housing 1 when the cover 9 is in place. The cover 9 and housing 1 cooperate with each other with a bayonet type fitting. Nodules 9 b are formed on the upper surface of the cover 9 to enable the user to manipulate the cover 9 and attach it or remove it from the housing 1 . The air trapped inside the airtight housing 1 provides additional buoyancy to that provided by the buoyant material.
[0035] The buoyant material may be a single body within the housing outside the toroidal air tank 2 , or a number of separate floats 3 equally spaced about the periphery of the toroidal tank 2 and having their radially outer surface contiguous with and forming, or being attached to a separate section of the outer surface of the housing 1 . The separate floats 3 are mounted so that they move radially outwardly when a valve 10 a , controlled by a button 10 operable from outside the housing 1 , feeds air from the tank 2 to inflate air bags 11 mounted between the float 3 and the air tank 2 to provide additional buoyancy and support on the water surface especially in rough seas or bad weather, as shown in FIG. 6. The floats 3 are retractable by suitable springs (not shown) when a second button 12 is pressed to cause dumping of the air in the bags 11 via a second valve (not shown). In an alternative, simpler version of the system, the floats 3 may be fixed and immovable within the housing 1 .
[0036] The housing 1 has circumferentially spaced regions around its periphery that are cut away. Handles 13 extend across these regions e.g. between the extensible floats, to allow easy carrying of the assembly, and to provide support for the user when they surface.
[0037] The device can be supplied with suitable air line systems to support 2 or 3 users for specific purposes, such as for SCUBA training purposes to allow trainees to become accustomed to breathing underwater without suffering the encumbrance of the air supply tank, or for sub-surface rescue where one mouthpiece regulator may be replaced by a regulator connected to an “orinasal” (breathing mask) for use by the person being rescued. The air tank 2 may be filled with sufficient compressed air to provide air for a single diver for about 2 hours before recharging is required. However, it will be appreciated that when multiple or branched air lines 7 are used to support multiple users the air supply will be expended more quickly. A pressure gauge 14 is mounted on the housing 1 to provide a visible indication of the air pressure in the tank 2 .
[0038] An alternative embodiment of the device will now be described with reference to FIG. 7 to of the accompanying drawings. The assembly is the same as that described with reference to the first embodiment with the exception that the air line or lines 7 are deployed from the housing 1 in a different fashion. Instead of being rotatable, the portion 5 is releasable from the housing 1 and drops away from it in response to operation of a release mechanism 20 so that the coils of the air line are quickly and completely freed from the housing 1 . This version is more appropriate when the assembly is to be used as an emergency life saving aid as the air line 7 is released very quickly and does not need to be unwound from the housing 1 .
[0039] As can be seen from FIG. 7, the rotatable portion 5 is replaced with a releasable base plate 21 beneath which the air line or lines 7 are coiled within the housing 1 . The base plate 21 is loosely mounted to the housing beneath a lug 22 . Two further lugs 23 can also be seen in the Figures. However, the base plate 21 is cut away in the region of these lugs 23 so that the base plate 21 can drop away past them. The release mechanism 20 is located radially opposite the lug 22 . The three lugs 22 , 23 together form feet to support the housing 1 on a flat surface. The construction and operation of the release mechanism 20 will now be explained with particular reference to FIG. 8.
[0040] The release mechanism 20 comprises a lever 24 pivotally mounted on the housing 1 . The lever 24 has a button part 25 extends partially up the side of the housing 1 and a base plate retention part 26 extending beneath the housing 1 and terminating in a groove 27 . The base plate 21 is formed with a corresponding protruberance 28 which locates in the groove 27 to retain the base plate 21 mounted to the housing 1 . The lever 24 is biased into the rest position shown in Figure by a spring element 29 mounted on the housing 1 and which engages a rear surface of the button part 25 . A safety release pin 30 is also provided to prevent inadvertent operation of the release mechanism 20 . The pin 30 extends through an aperture 31 in the housing 1 and locates in an opening 32 in an upper region of the button part 25 thereby preventing movement of the lever 24 . The upper end of the pin 30 is formed with a loop 33 to which a length of cord (not shown) may be attached to tie the pin to another part of the housing 1 to prevent it from being lost when removed from the aperture 31 .
[0041] When the air line 7 is to be released, the user removes the pin 30 by pulling it from the aperture 31 in the direction indicated by arrow A in FIG. 9. Next, they depress the button part 25 sufficiently hard enough to overcome the bias provided by the spring element 29 . This causes the base plate retention part 26 to pivot so that the protruberance 28 is no longer seated in the groove 27 . The base plate 21 is now free to drop away from the housing 1 , as shown in FIG. 9, thereby releasing the air lines 7 from the storage compartment in the housing 1 .
[0042] A further cord (not shown) may be provided between the base plate 21 and the housing 1 to prevent loss of the base plate 21 when released from the housing 1 .
[0043] It will be appreciated from the foregoing that the sub-aqua breathing system of the present invention provides a highly portable, easy to use device. As it floats on the water surface, the diver is unencumbered by a compressed air tank on his back and so has considerably more freedom. The size and weight of the device is also much less than with conventional SCUBA gear.
[0044] While particular embodiments of the invention have been described above it will be clear that alternative forms of construction would occur to those skilled in the art, such alternatives are intended to be within the scope of the invention which is defined by the following claims.
[0045] The invention has been described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art, that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the appended claims, is intended to cover all such changes and modifications that fall within the true spirit of the invention.
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A sub-aqua breathing system which enables a person operating underwater to breathe air from a compressed air tank supported on the water surface. The system includes a housing containing both a buoyant material and a toroidal compressed air tank connected to an air line feeding a conventional mouthpiece regulator. The air line may be coiled and stored within, or on, the housing. Preferably the housing is of discus-like shape with the buoyant material in the form of floats normally nested within the housing, but deployable radially outward to increase stability when the assembly is floating on the water surface.
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Exemplary of the present lightweight compositions are fired ceramic foam matrices characterized by pores which are essentially spherical in shape, extremely narrow in size distribution, and substantially non-interconnected, which compositions contain anorthite as the crystalline phase present in the largest proportion and which are dimensionally stable at a maximum temperature in the range 2000° to 2550° F.
There are also provided foamed insulating firebrick of the silica-alumina type, containing either mullite or corundum as the crystalline phase present in the largest proportion, and which are dimensionally stable at a maximum temperature in the range 2300° to 3200° F.
Also provided are fired lightweight foamed clay articles useful as structural and semi-structural building materials.
BACKGROUND OF THE INVENTION
Lightweight ceramic compositions which are strong and durable are in great demand for refractory structural and semi-structural applications. Lightweight ceramics are desirable because of their dimensional stability, insulating properties, non-combustibility and inertness to corrosive and abrasive environments.
Ceramics are made in lightweight form by a variety of processes which commonly comprise one of the following steps as the means of inducing porosity:
1. THE "BURNOUT" METHOD: THE INCORPORATION OF COMBUSTIBLE OR VOLATILIZABLE PARTICLES IN A MIXTURE OF CERAMIC RAW MATERIALS PRIOR TO FIRING;
2. "FIREBLOATING" A CERAMIC MATERIAL TO RELEASE A GAS SUCH AS STEAM OR AN OXIDE OF CARBON OR SULFUR;
3. BONDING LIGHTWEIGHT INORGANIC PARTICLES WITH A RELATIVELY DENSE CEMENTITIOUS MATRIX, SUCH AS CLAY- OR SILICA-BONDED BUBBLE ALUMINA; OR
4. DISPERSING OR DISSOLVING CERAMIC RAW MATERIALS IN A LIQUID, FOAMING THE LIQUID, AND THEN DRYING AND FIRING THE FOAM. In this method a preformed froth may be mixed with the dispersion or solution: a compressed or condensed gas may be incorporated into the dispersion or solution and allowed to expand; or finally a gas may be generated in the liquid medium by a chemical reaction.
An example of a burnout process is the manufacture of insulating firebrick from a mixture of clay, sawdust, and gypsum. Firebloating processes are used to manufacture lightweight clay masonry or insulation units, foamed glass, expanded perlite, and expanded shale aggregate.
Low density ceramics available commercially have disadvantages such as high cost, poor mechanical strength or difficulty in controlling density. Also, certain standard commercial processes for making lightweight ceramics particularly by the burnout or firebloating methods can discharge major amounts of carbonaceous or sulfur-containing air pollutants.
THE PRIOR ART
Known lightweight clay articles prepared by foaming water dispersions of clays are described by H. D. Foster, "Manufacture of Lightweight Products", Bull. Am. Ceram. Soc., 19 (12) 468-73 (1940) and by C. M. Nicholson and G. A. Bole, "Cellulated Ceramics for the Structural Clay Products Industry" Jour. Am. Ceram. Soc., 36 (4) 127-36 (1953). Known dispersion-foaming processes for clays employ organic polymeric or surface active foam stabilizers, such as cellulose ethers or esters, glues, gums, hydrolyzed vegetable and animal proteins, amines containing large hydrocarbon radicals, soluble salts of sulfonated hydrocarbons, and the like. Such foams have the serious disadvantage of loss of induced porosity and progressive shrinkage during drying and/or firing, resulting in inability to control density under commercial manufacturing conditions, and often inability to achieve practical densities lower than 40 to 50 PCF (pounds/cubic foot).
U.S. Pat. No. 3,737,332 issued June 5, 1973 describes the use of fatty amines to stabilize dispersion-foamed clays and achieve densities in the range of 1 to 12 PCF. However, one observes that the foamed clays thereby produced have relatively low strengths after firing, and are susceptible to severe cracking unless they are carefully dried over periods of at least several hours before firing. In addition to the relatively high drying shrinkages, the volume firing shrinkage of such foamed clays normally ranges from 35 to 45%, thus making it extremely difficult to control and reproduce density under practical commercial manufacturing conditions.
The present invention relates to novel foamed ceramics of the silica, alumina, and silica-alumina types, in which porosity is induced by foaming an aqueous dispersion of ceramic materials.
It is an object of this invention to provide lightweight ceramic compositions which are dimensionally stable at 1600° F. and higher, and which have exceptional strength and durability at densities below about 105 pounds per cubic feet.
It is a further object of this invention to provide cellular clay materials which have a uniquely uniform pore structure in which most of the void volume is provided by pores having effective diameters outside the range between about 2 microns and about 100 microns.
It is a further object of this invention to provide foamed kaolin shapes which have high green strength and exhibit low drying shrinkage.
It is a further object of this invention to provide lightweight foamed clay shapes which can be placed in a kiln while still moist and subjected to rapid firing conditions without destructive cracking or deformation.
It is a further object of this invention to provide foamed lightweight insluating firebrick which have a predominantly anorthite mineralogy and meet A.S.T.M. classification C155-70 for Groups 16 through 23.
An important object of this invention is to provide foamed clay compositions which fire to lightweight ceramic matrices without the evolution of noxious volatiles.
It is a further object of this invention to provide processes and techniques for the production of the novel foamed ceramic compositions described herein.
It is a further object of this invention to provide lightweight ceramic shapes suitable for use as building brick or blocks and as non-combustible core material for insulated panels, or for other structural or semi-structural applications such as exterior facings, wall and ceiling tile, curtain wall panels, panellized brick, partition walls, and the like.
Other objects and advantages of this invention will be apparent from the following detailed description thereof.
SUMMARY OF THE INVENTION
The foregoing and other objects of this invention are accomplished by production of foamed clay compositions by blending of a type formulation comprising:
Approximate Range of Parts By Weight per HundredConstituent Parts of Dry Ingredients______________________________________Clay about 20 to about 95Hydraulic cement about 4 to about 35Inert particulate about 0.2 to about 30lamellar foamstabilizerWater about 21 to about 70Gas generating sufficient to provide aagent final density of about 10 to about 105 PCF.______________________________________
The order of addition of the ingredients may be varied, and the preferred order depends mainly on the specific equipment used for mixing and the particular gas generating agent used. After the gas generating agent and the hydraulic cement have been incorporated, the blending is performed as rapidly as possible and the resulting dispersion is removed from the blending zone before an appreciable proportion of the gas has been generated. The dispersion is then discharged into a mold, or onto a conveyor or other next point of application. The mixture is then allowed to foam and set. With suitably chosen formulations foaming is essentially completed within a few minutes. The foamed clay compositions so produced exhibit good early green strength, and can be sufficiently hard in about 15 minutes or less to permit demolding and other handling operations. The green foamed clay articles can then be fired either with or without a prior drying step, so as to develop full ceramic maturity and achieve high strengths.
Suitable clays include kaolinite, illite, and montmorillonite types; fireclays, brick clays, flint clays, shale clays, slip clays, ball clays, kaolins, bentonites, and others. It should be noted that a natural clay may adventitiously contain a non-colloidal particulate lamellar material as defined below. Such a lamellar material may occur as an impurity in the clay, such as talc, mica, or pyrophyllite; or else the lamellar material may consist of a non-colloidal clay fraction such as delaminated kaolinite platelets with diameters greater than about 1 to 2 microns and diameter-to-thickness ratios greater than about 5:1. A clay which fortuitously naturally contains the appropriate minor fraction of such a lamellar material is found to perform the function both of the clay component and the lamellar material. The use of such a clay without the deliberate addition of a separate lamellar foam stabilizer is understood to be within the scope of the present invention.
If the desired end product is an insulating refractory it is preferred that the clay component be of relatively high purity, e.g., low in iron oxide or other reducible oxides, and low in organic and in alkali content. Suitable domestic clays for this purpose are kaolins found in Alabama, Florida, Georgia and South Carolina.
It is preferred that the clay component be at least partially deflocculable, since deflocculation reduces the quantity of water necessary to obtain a fluid dispersion and hence minimizes subsequent drying and/or firing shrinkages.
Part of the clay may be advantageously precalcined or employed as pulverized grog in order to further minimize shrinkages.
The clay content of the present formulations ranges between about 20 and 95 parts; unless otherwise noted the term "parts" as used in this specification denotes "parts by weight per hundred parts of dry insoluble ingredients". The precise amount of clay depends on the specific application and desired properties. For example, higher levels of clay generally result in higher firing shrinkages, but usually have an advantage in higher strengths for a given density, and lower cost.
The formulations of this invention include between about 4 and 35 parts of a hydraulic cement. This term is meant to include materials containing aluminates or silicates of alkaline earth elements or mixtures thereof, which compounds are hydratable to cementitious phases. Thus, calcium aluminates, calcium silicates, portland cements, slag cements, barium aluminates and others are included. Certain commercially available low iron calcium aluminates and white portland cement are particularly preferred for refractory clay foams wherein a low iron content is advantageous.
The setting rate and the green strength of the clay foam compositions both increase as the hydraulic cement content of the formulation increases. The preferred range of hydraulic cement is between about 5 and 20 parts.
An important feature of the present invention is the incorporation of an inert non-colloidal particulate lamellar foam stabilizer.
The average diameter of the lamellar particles is generally less than about 1 millimeter and the ratio of the average particle diameter to its average thickness is greater than about 5:1. Such lamellar foam stabilizers have been described in my U.S. Pat. Nos. 3,565,647 issued Feb. 23, 1971 and 3,729,328 issued Apr. 24, 1973. Examples of such lamellar materials are platey talc, mica, graphite, pulverized exfoliated vermiculite, pyrophyllite, and metal flakes such as flakes of aluminum, bronze and the like. The various lamellar materials differ in foam stabilizing efficiency. Quantities used in the present formulations vary between about 0.2 and 30 parts, depending mainly on the specific lamellar material used and the desired pore size of the foam. Higher levels of the lamellar foam stabilizer generally yield smaller pores. The lamellar foam stabilizers preferred in the present invention are talc, pyrophyllite and graphite. The preferred ranges are talc 3 to 15 parts; pyrophyllite 8 to 25 parts; and graphite 5 to 30 parts.
The gas generating agent employed in the production of the clay foam compositions is selected from any of a variety of chemical foaming systems known and used in the prior art. Such chemical foaming systems include hydrogen peroxide catalyzed by manganese dioxide, copper oxide or catalase; the combination of a carbonate such as calcium or magnesium carbonate, with an acid or acid salt such as sulfuric acid or aluminum sulfate, which react to generate carbon dioxide; the combination of a metal nitrite such as calcium nitrite, with an ammonium salt such as ammonium sulfate, which react to liberate nitrogen gas; and the like. Particles of aluminum or of zinc metal will also react to liberate gas in alkaline aqueous media, such as in the presence of portland cement, or alkali or quaternary ammonium hydroxides or silicates.
The preferred gas generating agent for foams intended for refractory use is the combination of hydrogen peroxide and a transitional metal oxide catalyst such as manganese dioxide. For clay foam building products the preferred gas generating agents are catalyzed hydrogen peroxide, and an acid-carbonate combination.
The total quantity of water employed in a specific formulation depends on the quantity and type of clay present, the quantity of hydraulic cement present, the type and quantity of foam stabilizers and non-plastic ceramic materials, the particle size distributions of the clay materials, whether deflocculants are employed, and the types and amounts of any other additives. The quantity of water is selected in a given formulation so as to obtain pourable fluidity but should not be so great as to destabilize the foam prior to setting, retard setting excessively, or yield foams of too low green strength or excessive shrinkage. For practical purposes the total quantity of water will be in the range of about 21 to 70 parts by weight per 100 parts by weight of the dry ingredients. The lower water levels are used in formulations containing coarser clays, appreciable amounts of non-plastic materials, or highly deflocculated clays. The higher amounts of water are used in formulations containing finer clays, swelling-type clays such as montmorillonites, or undeflocculated clays.
Other ceramic materials which do not interfere with the foaming reaction, or adversely affect the physical characteristics of the foamed clays, may be included in the formulations at levels up to about 76 parts. Such other materials may be incorporated for example in order to achieve a desired chemical or mineralogical composition after firing. Examples of such materials are aluminas including alpha aluminas, tabular aluminas, hydrous aluminas and high-surface-area aluminas; silicas; zircon; zirconia; limestone; dolomite; talc; olivine; pyprophyllite; kyanite; mullite; raw and calcined bauxite; feldspar; syenite; wollastonite; grog; trap rock; fly ash; particulate glass; metakaolinites; zeolites; and the like.
Reinforcing fibers may be added to enhance green or fired strength. For example, wood, cellulose, glass, asbestos, aluminosilicate and other organic or inorganic fibers can be incorporated in the formulations.
Water-soluble or water dispersible resins or polymers may also be used, particularly to enhance green strength. These include urea-formoldehyde, polyvinyl alcohol, methycellulose, polyacrylamide, polyoxythylene glycol, polyvinyl acetate, polyvinylpyrrolidone, starch, gelatin, and the like. Such resins or polymers are generally used at levels less than about 5 parts, because of their relatively high costs.
Deflocculants, dispersants, water reducers, and surface active agents may also be used to advantage, according to methods known in the art. Examples of such materials are sodium and potassium silicates, polyphosphates, lignosulfonates, amine oxides, alkali salts of fatty acids, alkali carbonates, and the like.
Also advantageous for certain purposes is the inclusion of accelerators or retarders. Such materials are well-known for calcium aluminates and portland cements, and function well in the present system. Examples of suitable accelerators are lithium salts, calcium sulfate hemihydrate, portland cement, hydrate calcium aluminate, and sodium carbonate, for calcium aluminate cements; and calcium chloride, triethanolamine, and calcium aluminate, for portland cements. Suitable retarders include citrates, sugars, hydroxylic carboxylic acids, borates, and phosphates, for both calcium aluminate and portland cements.
The foamed ceramic compositions of the present invention are all of the silica-alumina type and have a composition such that after firing they will contain the empirical equivalent of between about 20 to 85%, by weight, of alumina, and 15 to 95%, by weight, of silica; the total content of alumina and silica being at least about 65%, by weight.
The foamed clay products of this invention are characterized by a controllable, remarkably uniform pore structure as contrasted to known cellular foamed clays. The pores are generally isometric in shape and usually highly non-interconnected, with the major portion (i.e., greater than 50%) of the pore volume being due to pores of diameters outside the range between about 2 and 100 microns. The term "isometric" as used herein to refer to the shape of the pores is intended to mean equidimensional, i.e., the pores assume shapes which, while not necessarily spherical, are such that all diameters passing through the center are roughly the same length. It is believed that the novel and unique pore structure of the present invention accounts for the characteristic superior strength-to-density ratios, high abrasion resistance, and remarkable resistance of the present foamed clays to loss of porosity on drying and firing.
Moreover, relatively minor changes in formulation permit the practitioner of this invention to vary average pore size and to vary pore connectivity for each selected density, as desired to enhance certain final properties. For example in refractory insulation applications, pore diameters in the range 100 to 1000 microns are preferred in order to achieve the desirable low thermal conductivities at elevated temperatures while still maintaining good mechanical properties; by contrast, in foamed structural clay products the preferred pore diameters are in the range of about 1000 to 3000 microns and low pore connectivity is preferred. In the present invention pore diameters are readily and reproducibly varied by the type and amount of lamellar foam stabilizer as has already been described. Low pore connectivity is achieved by using dry formulation components of smaller particle size, preferably finer than about 60 standard U.S. mesh, and also by using smaller quantities of lamellar foam stabilizers so as to create larger pore diameters, which promote low connectivity.
The foams of the present invention generally have linear drying shrinkages less than 2 to 3%, and very often less than 1%. Also, linear firing shrinkages are generally similar to the firing shrinkages of the corresponding unfoamed formulations, so that the foams of the invention may be fired to full ceramic maturity without any appreciable loss of induced porosity. Suitable embodiments of the present invention yield controllable fired densities down to about 10 PCF (pounds/ft. 3 ). In addition foamed insulating firebrick of the present invention exhibit long term dimensional stability as determined by A.S.T.M. Test C113-68.
The invention will now be described in greater detail in conjunction with the following specific examples thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples 1 to 6
A dry batch was prepared by thoroughly blending the dry ingredients in the proportions by weight given in Example 1 in Table I below using an 8-quart twin-shell Patterson-Kelly blender, and 3 kg of blender charge. The water mix was prepared by stirring the sodium silicate solution and then the hydrogen peroxide solution into the water in the proportions shown in Table I.
100 grams of the dry batch was thoroughly and uniformly blended into 38.3 grams of water mix, using a high shear laboratory stirrer. Total mixing time was 20 to 30 seconds. The dispersion, which had the flow characteristics of a deflocculated kaolin casting slip, was poured into an open mold 3 inches square, in area and 3 inches deep, The formulation foamed for about 8 minutes, and then hardened. About 11/2 to 2 hours after casting, the foamed clay was hard enough to handle without breakage. The foam was demolded, and allowed to dry in air overnight. Air dried density was 21 pounds per cubic foot (PCF) and linear drying shrinkage less than 1%.
The dried foam was then fired by heating in an electric muffle furnace to 2350° F. over 3.5 hours, soaking at 2350±° 25° F. for 1 hour, and then allowed to cool down over about 6 hours.
Fired density was 27 PCF and linear firing shrinkage 14%. The foam decreased in weight a total of 19% between drying and firing.
In another experiment, a sample of green foam prepared as in Example 1 was fired on the same schedule; the firing was begun 2.5 hours after casting without any prior drying of the foam. There was no apparent difference in fired properties from those of the pre-dried fired foam.
The fired clay foam satisfied the requirements for Group 23 insulating firebrick, A.S.T.M. Classification C155-70. The pores were substantially spherical in shape, only partially interconnected, and extremely narrow in size distribution. Average pore diameter was about 1.3 millimeters (1300 microns). X-ray diffraction analysis indicated mullite and cristobalite were the crystalline phases present in the largest proportions. Cold crushing strength was 380 pounds per square inch (PSI) by A.S.T.M. test C93-67, as compared to 145 PSI for a commercial Group 23 insulating firebrick having a density of 32 PCF.
The formulations of Examples 2 through 6 were blended, foamed, dried and fired similar to the procedure used for Example 1. In each case the fired clay foams were white or off-white in color, extremely uniform in appearance and narrow in pore size distribution. Compressive strengths were high for the densities obtained.
Examples 4, 5 and 6 illustrate the replacement of raw clay by calcined clay to reduce firing shrinkage. Low firing shrinkage allows the production of relatively large unit dimensions on fast firing cycles, without excessive warpage or cracking.
The gas generating agent in each of the Examples 1 to 6 is hydrogen peroxide catalyzed by manganese dioxide ore. The lamellar foam stabilizer is platey talc. If the lamellar foam stabilizer is omitted from any of the formulations, the gas evolved by the gas generating agent is not retained by the dispersion, but escapes and the foam collapses.
TABLE I__________________________________________________________________________ EXAMPLE Parts by Weight__________________________________________________________________________ 1 2 3 4 5 6Kaolin, CW-L 76.6 86.1 90.9 56.3 37.5 --Calcined Kaolin -35 M -- -- -- 18.8 37.5 73.9Calcium aluminate, CA-25 19.1 9.6 4.8 18.8 18.9 18.5Platey talc 3.8 3.8 3.8 5.6 5.6 7.4Manganese dioxide 0.5 0.5 0.5 0.5 0.5 0.23 Total dry batch: 100.0 100.0 100.0 100.0 100.0 100.0Sodium silicate, Type N -- -- 0.5 0.14 0.28 --35% Aqueous hydrogen peroxide 2.2 2.2 2.2 2.2 2.2 2.1Water 36.1 36.1 35.6 30.6 30.4 25.6 Total water mix: 38.3 38.3 38.3 32.9 32.8 27.7Green Foam Properties Air dry density, PCF 21 23 23 23 25 24 Drying shrinkage, linear % <1% <1% <1% <1% <1% <1% Handling time, hr. 2. 3. 5.5 3.5 8. 16.Fired Foam Properties Average pore diameter microns 1300 1300 1000 800 700 1500 Density, PCF 27 30 25 23 29 24 Color white white white light white white grey Firing shrinkage, linear % 14 15 9.0 2.3 5.5 2.8__________________________________________________________________________
Examples 7 to 12
The formulations listed in Table II below were blended, foamed, and fired, by the procedure detailed for Example 1. In each case the fired clay foams were uniform in appearance; pore size distributions were narrow and average pore sizes ranged from 900 to 5000 microns. The fired foams all exhibited excellent dimensional stability at 2300° F. or above, and were white or off-white in appearance.
Examples 8 and 10 illustrate the use of different calcium aluminates, and Example 9, portland cement as the hydraulic cement component of the formulation. In Example 11 the lamellar foam stabilizer is graphite, and in Example 12, aluminum flake.
TABLE II__________________________________________________________________________ EXAMPLE Parts by Weight__________________________________________________________________________ 7 8 9 10 11 12Kaolin, CW-L -- -- 18.8 18.8 18.8 19.8Calcined kaolin, -35 Mesh -- -- 56.3 56.3 56.3 59.6Calcined kaolin, 40×140 Mesh 51.2 51.2 -- -- -- --Calcium aluminate, CA-25 19.2 19.2 -- -- 18.8 19.8Calcium aluminate, Refcon -- -- -- 18.8 -- --Portland cement, white Type I -- -- 18.8 -- -- --Alumina, Alcoa AL-325 Mesh 25.6 -- -- -- -- --Alumina, Alcoa T61-48 Mesh -- 25.6 -- -- -- --Platey talc 3.8 3.8 5.6 5.6 -- --Graphite powder -- -- -- -- 5.6 --Aluminum flake -- -- -- -- -- 0.3Manganese dioxide 0.24 0.24 0.5 0.5 0.5 0.5 Total dry batch 100.0 100.0 100.0 100.0 100.0 100.0Sodium Silicate, Type N -- -- -- 0.14 0.14 0.15Borax -- -- 0.10 -- -- --35% Aqueous hydrogen peroxide 2.2 2.2 2.2 2.2 2.2 2.2Water 31.4 21.8 40.0 35.3 25.9 27.4 Total water mix: 33.6 24.0 42.3 37.6 28.2 29.8Fired Foam Properties Average pore diameter, microns 900 2000 1300 1500 5000 3000 Density, PCF 21 26 25 24 24 25 Firing shrinkage, linear % 4.2 1.5 4. 5. 1. 3.8__________________________________________________________________________
Examples 13 to 18
The formulations 13 to 18 as listed in Table III below were blended, foamed and fired according to the procedure of Example 1. Examples 5, 13, 14 and 15 illustrate the effect of varying the level of lamellar foam stabilizer, in this case platey talc. The fired foams exhibited average pore diameters which changed approximately in inverse proportion to the amount of lamellar foam stabilizer, while the resulting density did not change significantly. There was also no appreciable change in firing shrinkage.
When dispersions of clays are foamed according to methods of the prior art, it is observed that attempts to reduce pore size, for example, by increased additions of surface active agents, invariably yield increased firing shrinkages, often to the point where it is not practical to fire such foams commercially. By contrast, the present foamed clays fire with shrinkages on the same order as unfoamed clay bodies of otherwise the same formulation.
Examples 16, 17 and 18 illustrate that fired foam density is readily controlled in the present invention by changing the level of gas generating agent, in this case catalyzed hydrogen peroxide. Densities of 15 PCF and even lower are readily achieved without engendering excessive firing shrinkage. Dispersion-foamed clays lighter than about 25 PCF have hitherto been impractical because of loss of porosity on firing, or excessive shrinkage which makes density too difficult to control commercially.
TABLE III__________________________________________________________________________ EXAMPLE Parts by Weight__________________________________________________________________________ 13 14 15 16 17 18 5Kaolin, CW-L 36.2 38.3 39.0 37.5 37.5 36.2 37.5Calcined kaolin, -35 Mesh 36.2 38.3 39.0 37.5 37.5 36.2 37.5Calcium aluminate, CA-25 18.2 19.1 19.5 18.9 18.9 18.2 18.9Platey talc 9.1 3.8 2.0 5.6 5.6 9.1 5.6Manganese ore 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Total dry batch 100.0 100.0 100.0 100.0 100.0 100.0 100.0Sodium silicate, Type N 0.27 0.29 0.29 0.28 0.28 0.27 0.2835% Aqueous hydrogen peroxide 2.1 2.2 2.2 1.1 3.8 3.6 2.2Water 29.3 31.0 31.6 31.5 28.8 27.8 30.4 Total water mix: 31.7 33.5 34.1 32.9 32.9 31.7 32.8Fired Foam Properties Average pore diameter, microns 500 1500 3000 500 1200 800 700 Density, PCF 29 27 26 39 15 15 29 Firing shrinkage, linear % 4.2 5.0 5.5 5.5 4.0 6.0 5.5__________________________________________________________________________
Example 19______________________________________ Parts By Weight______________________________________Kaolin, Albion Cast 100 56.5Calcium aluminate, Refcon 13.0Calcium carbonate, -100 mesh 14.8Pyrophyllite, 200 mesh 15.7 Total dry batch 100.0Sodium silicate, type N 0.43Tetrasodium pyrophosphate 0.0435% Aqueous hydrogen peroxide 1.6Water 37.2 Total water mix 39.32.5% Aqueous MnSO.sub.4.sup.. H.sub.2 O 1.7______________________________________
The dry batch ingredients were blended in the proportions by weight for Example 19, and a water mix was made by dissolving the sodium silicate, tetrosodium pyrophosphate, and 35% hydrogen peroxide in the water. A 2.5% aqueous solution of manganese II sulfate monohydrate was prepared separately. 1572 grams of water mix was preheated to 40° C., and then rapidly blended with 4000 grams of the dry batch using a 20-quart Hobart mixer. After about 45 seconds of mixing time 68 grams of the foaming catalyst solution, 2.5% MnSO 4 .H 2 O, was blended in. The dispersion was then cast into an open rectangular mold.
After 20 minutes, the clay dispersion had foamed and set sufficiently hard to be demolded. The foam was then fired, without prior drying, at 2400° F. over a total heating schedule of 6 hours, including a 2 hour soak at 2400° F.
The fired foam was pale tan in appearance, and had an extremely uniform pore structure of average pore diamter 700 microns. Fired density was 28 PCF and linear firing shrinkage, 5.4%. X-ray diffraction analysis gave anorthite as the major mineralogical phase present. The empirical chemical composition was Al 2 O 3 38.2, SiO 2 44.9, TiO 2 1.3, CaO 14.5, MgO 0.2, Fe 2 O 3 0.7, (Na 2 O + K 2 O) 0.2, and MnO 0.02 weight percent. The fired foam satisfied the requirements for Group 23 insulating firebrick, A.S.T.M. Classification C155-70.
Examples 20 to 23
Foams formulated as given in Table IV below were made as follows. The dry batches were preblended, and the water-mix solutions were prepared separately. The dry batch was blended with the water mix in the given proportions using a high shear mixer, and a total blending time of 30 to 45 seconds. The 35% hydrogen peroxide was then immediately dispersed in the slurry over a period of about 15 seconds using high shear mixing. The mixture was then immediately cast into a mold, and allowed to foam and then set.
The foam formulation numbers 20 to 23 may be fired at temperatures ranging from 2400° to 2800° F., depending on the degree of ceramic maturity desired, and the refractoriness of the specific formulation. Example 23 which contains 67.4% alumina after firing yields the most refractory foam. The fired foams exhibit excellent dimensional stability at temperatures above 2500° F., and are suitable for use as insulating firebrick at service temperatures above 2500° F. They contain either mullite or corundum as the crystalline phase present in the greatest proportion. The foams are much lower in density than commercially available refractory insulation intended for use above 2500° F.
TABLE IV__________________________________________________________________________ EXAMPLE Parts By Weight__________________________________________________________________________ 20 21 22 23Kaolin casting clay 73.0 28.7 59.0 28.7Calcined kaolin, -35 Mesh -- 42.7 -- --Refcon calcium aluminate -- -- 13.6 --CA -25 calcium aluminate 13.4 14.2 0 14.2Kyanite, -48 Mesh -- -- 13.6 --Calcined bauxite, -48 Mesh -- -- -- 42.7Pyrophyllite, -200 Mesh 13.4 14.2 13.6 14.2Manganese dioxide ore, -325 Mesh 0.2 0.2 0.2 0.2 Total dry batch 100.0 100.0 100.0 100.0Type N sodium silicate 0.45 0.47 0.45 0.47Organophosphoric acid surfactant 0.0022 0.0022 0.0023 0.0024Water 33.2 33.4 33.8 33.0 Total water mix: 33.7 34.9 34.3 33.535% Hydrogen peroxide 1.5 1.6 1.5 1.6Typical Fired Foam Properties Average pore diameter, microns 1000 900 700 600 Density, PCF 33 28 32 27 Firing shrinkage, linear % 8.0 6.5 8.9 3.5Chemical Analysis, weight %Al.sub.2 O.sub.3 47.4 47.4 45.7 67.4SiO.sub.2 47.8 47.8 46.9 27.1TiO.sub.2 1.3 1.3 1.4 1.8CaO 2.7 2.7 5.0 2.7MgO 0.1 0.1 -- 0.1Fe.sub.2 O.sub.3 0.6 0.6 0.8 1.0Na.sub.2 O + K.sub.2 O 0.2 0.2 0.2 0.2MnO 0.1 0.1 0.1 0.1__________________________________________________________________________
Examples 24 to 27
Referring to Table V, in each of Examples 24 to 27 the clay slurries were prepared by blunging the clay and other insoluble solid ingredients in water containing the sodium silicate and sodium citrate, where used, until a uniform dispersion was obtained. Batch sizes corresponding to about 2.5 pounds of dry ingredients were used. In Examples 24 and 25, the clay was ground to minus 40 U.S. mesh size before blunging. The resulting slurries are stable and if desired may be stored under agitation for at least several days before foaming.
To prepare the clay foams, the calcium aluminate cement was rapidly and thoroughly dispersed into the slurry using a high shear mixer and mixing times of 15 to 20 seconds. In Example 26, the sodium hexafluosilicate (Na 2 SiF 6 ) was dry-blended with the calcium aluminate cement before dispersion into the clay slurry.
Immediately after the cement was dispersed, the hydrogen peroxide was dispersed into the mixture for about 15 seconds under high shear, and the slurry was then cast into open-top molds, allowed to foam and set, demolded, cut to size, and fired at 2000° to 2100° F.
The fired foams have a uniform, substantially non-interconnected pore structure, and excellent strength-to-density ratios. These foams make attractive, insulating, and fire-resistive structural-clay building units especially useful for veneer brick, partition wall brick, panellized brick, face-brick, and common brick applications.
In commercial production, batch sizes up to several hundred pounds may be foamed at one time; or else blending and foaming may be accomplished continuously using high-shear mixing equipment such as is described in U.S. Pat. No. 3,729,328.
TABLE V__________________________________________________________________________ EXAMPLES Parts By Weight__________________________________________________________________________ 24 25 26 27Shale-type brick clay 89.5 89.5 -- --Fine-grained brick clay -- -- 44.8 --Ball clay -- -- -- 56.9Silica flour, -120 Mesh -- -- -- 28.4Fly ash -- -- 44.7 --Platey talc 5.0 5.0 5.0 4.7Manganese dioxide ore, -325 Mesh 0.5 0.5 0.5 0.5Type N sodium silicate 0.75 0.75 -- 0.71Sodium citrate -- 0.025 -- --Water 30.0 27.5 55.0 37.9 Total clay slurry 125.8 123.4 150.0 129.1Lumnite calcium aluminate 5.0 5.0 5.0Refcon calcium aluminate -- -- -- 9.5Sodium hexafluosilicate -- -- 0.25 -- Total cement 5.0 5.0 5.25 9.535% hydrogen peroxide 0.75 0.75 0.75 0.75Typical firing temperature, °F. 2000 2000 2000 2100Fired Foam PropertiesAverage pore size, microns 700 700 500 150Density 68 66 55 66Color brick- brick- brick- cream red red red__________________________________________________________________________
Examples 28 to 32
Referring to Table VI, formulations 28 to 32 were blended and foamed by the procedure described for Example 1. The foams were fired at the temperatures shown in the Table.
Examples 28 and 29 illustrate the control of pore structure in the present invention by variation of the level of the lamellar foam stabilizer, in this case talc, without having large changes in density. These foams are intended for structural or semi-structural building units, and in this case the larger average pore sizes are preferred. Such larger average pore sizes tend to reduce the water absorption, and thus enhance the durability of the fired foams under cyclic freezing and thawing conditions.
Examples 30 to 32 illustrate the use of low-iron clays and other materials in order to achieve light- or white-firing foams for esthetic architectural applications.
TABLE VI__________________________________________________________________________ EXAMPLES Parts By Weight__________________________________________________________________________ 28 29 30 31 32Shale-type brick clay 83.8 89.5 -- -- --Georgia kaolin -- -- 39.8 59.6 59.6Silica flour, -120 Mesh -- -- 39.7 19.9 19.9Platey talc 10.5 5.0 10.0 10.0 --Pyrophyllite, -140 Mesh -- -- -- -- 10.0Manganese dioxide ore, -325 Mesh 0.5 0.5 0.5 0.5 0.5Lumnite calcium aluminate 5.2 5.0 10.0 10.0 --Refcon calcium aluminate -- -- -- -- 10.0 Total dry batch 100.0 100.0 100.0 100.0 100.0Type N sodium silicate 1.1 0.5 0.5 0.75 0.75Water 41.2 34.8 29.9 34.8 29.9 Total water mix: 42.3 35.3 30.4 35.6 30.735% Hydrogen peroxide 0.79 0.75 0.50 0.50 0.75Typical firing temperature, °F. 1950 2000 2250 2250 2100Fired Foam Properties Average pore size, microns 450 100 250 250 1100 Density PCF 59 63 50 54 43 Color brick- brick- tan tan white red red__________________________________________________________________________
Examples 33 and 34
Referring to Table VII, Example 33 illustrates the use of the combination of aluminum powder and sodium hydroxide as the gas generating agent of the present invention in a formulation for a high temperature insulation firebrick. Example 34 illustrates the combination of calcium carbonate and aluminum sulfate as the gas generating agent. These formulations were blended, foamed, and fired according to the method of Example 1, at 2400° and 2000° F., respectively.
______________________________________ Parts By Weight______________________________________ 33 34Georgia kaolin 18.9 --Calcined kaolin, -35 Mesh 56.5 --Fine-grained brick clay -- 88.2Platey talc 5.6 4.9Aluminum powder 0.2 --Precipitated calciumcarbonate -- 2.0CA-25 Calcium aluminate 18.8 --Lumnite Calcium aluminate -- 4.9 Total dry batch: 100.0 100.0Sodium hydroxide 0.5 --Aluminum sulfate -- 1.5Water 41.9 63.7 Total water mix: 42.4 65.2Firing temperature, °F. 2400 2000Fired Foam Properties Average pore size, microns 1500 1200 Density, PCF 32 72______________________________________
While the invention has been described above in conjunction with certain preferred embodiments thereof, it is to be understood that these are merely illustrative of others which will now readily occur to those skilled in the art and that the scope of the invention is limited only by the prior art and the appended claims.
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This invention provides cellular clay compositions which are dimensionally stable at 1000°F. and higher, and which have a controlled pore structure that enhances the strength, durability and insulating properties of the compositions.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 09/864,737, filed May 23, 2001, now U.S. Pat. No. 6,459,105, issued Oct. 1, 2002, which is a continuation of application Ser. No. 09/567,262, filed May 9, 2000, now U.S. Pat. 6,255,196, issued Jul. 3, 2001, which is a divisional of application Ser. No. 09/434,147, filed Nov. 4, 1999, now U.S. Pat. 6,196,096, issued Mar. 6, 2001, which is a continuation of application Ser. No. 09/270,539, filed Mar. 17, 1999, now U.S. Pat. 6,155,247, issued Dec. 5, 2000, which is a divisional of application Ser. No. 09/069,561, filed Apr. 29, 1998, now U.S. Pat. 6,119,675, issued Sep. 19, 2000, which is a divisional of application Ser. No. 08/747,299, filed Nov. 12, 1996, now U.S. Pat. 6,250,192, issued Jun. 26, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method and apparatus for sawing semiconductor substrates such as wafers and, more specifically, to a wafer saw and method of using the same employing multiple indexing techniques and multiple blades for more efficient sawing and for sawing multiple die sizes and shapes from a single semiconductor wafer.
2. State of the Art
An individual integrated circuit or chip is usually formed from a larger structure known as a semiconductor wafer, which is usually comprised primarily of silicon, although other materials such as gallium arsenide and indium phosphide are also sometimes used. Each semiconductor wafer has a plurality of integrated circuits arranged in rows and columns with the periphery of each integrated circuit being rectangular. Typically, the wafer is sawn or “diced” into rectangularly shaped discrete integrated circuits along two mutually perpendicular sets of parallel lines or streets lying between each of the rows and columns thereof. Hence, the separated or singulated integrated circuits are commonly referred to as dice.
One exemplary wafer saw includes a rotating dicing blade mounted to an aluminum hub and attached to a rotating spindle, the spindle being connected to a motor. Cutting action of the blade may be effected by diamond particles bonded thereto, or a traditional “toothed” type blade may be employed. Many rotating wafer saw blade structures are known in the art. The present invention is applicable to any saw blade construction, so further structures will not be described herein.
Because semiconductor wafers in the art usually contain a plurality of substantially identical integrated circuits arranged in rows and columns, two sets of mutually parallel streets extending perpendicular to each other over substantially the entire surface of the wafer are formed between each discrete integrated circuit and are sized to allow passage of a wafer saw blade between adjacent integrated circuits without affecting any of their internal circuitry. A typical wafer sawing operation includes attaching the semiconductor wafer to a wafer saw carrier, mechanically, adhesively or otherwise as known in the art, and mounting the wafer saw carrier on the table of the wafer saw. A blade of the wafer saw is passed through the surface of the semiconductor wafer, either by moving the blade relative to the wafer, the table of the saw and the wafer relative to a stationary blade, or a combination of both. To dice the wafer, the blade cuts precisely along each street, returning back over (but not in contact with) the wafer while the wafer is laterally indexed to the next cutting location. Once all cuts associated with mutually parallel streets having one orientation are complete, either the blade is rotated 90° relative to the wafer or the wafer is rotated 90°, and cuts are made through streets in a direction perpendicular to the initial direction of cut. Since each integrated circuit on a conventional wafer has the same size and rectangular configuration, each pass of the wafer saw blade is incrementally indexed one unit (a unit being equal to the distance from one street to the next) in a particular orientation of the wafer. As such, the wafer saw and the software controlling it are designed to provide uniform and precise indexing in fixed increments across the surface of a wafer.
It may, however, be desirable to design and fabricate a semiconductor wafer having various integrated circuits and other semiconductor devices thereon, each of which may be of a different size. For example, in radio-frequency ID (RFID) applications, a battery, chip and antenna could be incorporated into the same wafer such that all semiconductor devices of an RFID electronic device are fabricated from a single semiconductor wafer. Alternatively, memory dice of different capacities, for example, 4, 16 and 64 megabyte DRAMs, might be fabricated on a single wafer to maximize the use of silicon “real estate” and reduce thiefage or waste of material near the periphery of the almost-circular (but for the flat) wafer. Such semiconductor wafers, in order to be diced, however, would require modifications to and/or replacement of existing wafer saw hardware and software.
SUMMARY OF THE INVENTION
Accordingly, an apparatus and method for sawing semiconductor wafers, including wafers having a plurality of semiconductor devices of different sizes and/or shapes therein, is provided. In particular, the present invention provides a wafer saw and method of using the same capable of “multiple indexing” of a wafer saw blade or blades to provide the desired cutting capabilities. As used herein, the term “multiple indexing” contemplates and encompasses both the lateral indexing of a saw blade at multiples of a fixed interval and at varying intervals which may not comprise exact multiples of one another. Thus, for conventional wafer configurations containing a number of equally sized integrated circuits, the wafer saw and method herein can substantially simultaneously saw the wafers with multiple blades and therefore cut more quickly than single blade wafer saws known in the art. Moreover, for wafers having a plurality of differently-sized or shaped integrated circuits, the apparatus and method herein provides a multiple indexing capability to cut non-uniform dice from the same wafer.
In a preferred embodiment, a single-blade, multi-indexing saw is provided for cutting a wafer containing variously configured integrated circuits. By providing multiple-indexing capabilities, the wafer saw can sever the wafer into differently sized dice corresponding to the configuration of the integrated circuits contained thereon.
In another preferred embodiment, a wafer saw is provided having at least two wafer saw blades spaced a lateral distance from one another and having their centers of rotation in substantial parallel mutual alignment. The blades are preferably spaced apart a distance equal to the distance between adjacent streets on the wafer in question. With such a saw configuration, multiple parallel cuts through the wafer can be made substantially simultaneously, thus essentially increasing the speed of cutting a wafer by the number of blades utilized in tandem. Because of the small size of the individual integrated circuits and the correspondingly small distances between adjacent streets on the wafer, it may be desirable to space the blades of the wafer saw more than one street apart. For example, if the blades of a two-blade saw are spaced two streets apart, a first pass of the blades would cut the first and third laterally separated streets. A second pass of the blades through the wafer would cut through the second and fourth streets. The blades would then be indexed to cut through the fifth and seventh streets, then sixth and eighth, and so on.
In another preferred embodiment, at least one blade of a multi-blade saw is independently raisable relative to the other blade or blades when only a single cut is desired on a particular pass of the carriage. Such a saw configuration has special utility where the blades are spaced close enough to cut in parallel on either side of larger integrated circuits, but use single blade capability for dicing any smaller integrated circuits. For example, a first pass of the blades of a two blade saw could cut a first set of adjacent streets defining a column of larger integrated circuits of the wafer. One blade could then be independently raised or elevated to effect a subsequent pass of the remaining blade cutting along a street that may be too laterally close to an adjacent street to allow both blades to cut simultaneously, or that merely defines a single column of narrower dice. This feature would also permit parallel scribing of the surface of the wafer to mutually isolate conductors from, for example, tie bars or other common links required during fabrication, with subsequent passage by a single blade indexed to track between the scribe lines to completely sever or singulate the adjacent portions of the wafer.
In yet another preferred embodiment, at least one blade of a multi-blade saw is independently laterally translatable relative to the other blade or blades. Thus, in a two-blade saw, for example, the blades could be laterally adjusted between consecutive saw passes of the sawing operation to accommodate different widths between streets. It should be noted that this preferred embodiment could be combined with other embodiments herein to provide a wafer saw that has blades that are both laterally translatable and independently raisable, or one translatable and one raisable, as desired.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic side view of a first preferred embodiment of a wafer saw in accordance with the present invention;
FIG. 2 is a schematic front view of the wafer saw illustrated in FIG. 1 ;
FIG. 3 is a schematic front view of a second embodiment of a wafer saw in accordance with the present invention;
FIG. 4 is a schematic view of a first silicon semiconductor wafer having a conventional configuration to be diced with the wafer saw of the present invention;
FIG. 5 is a schematic view of a second silicon semiconductor wafer having variously sized semiconductor devices therein to be diced with the wafer saw of the present invention;
FIG. 6 is a schematic front view of a third embodiment of a wafer saw in accordance with the present invention;
FIG. 7 is a schematic view of a third silicon semiconductor wafer having variously sized semiconductor devices therein to be diced with the wafer saw of the present invention;
FIG. 8 is a top elevation of a portion of a semiconductor substrate bearing conductive traces connected by tie bars; and
FIG. 9 is a top elevation of a portion of a semiconductor substrate bearing three different types of components formed thereon.
DETAILED DESCRIPTION OF THE INVENTION
As illustrated in FIGS. 1 and 2 , an exemplary wafer saw 10 according to the invention is comprised of a base 12 to which extension arms 14 and 15 suspended by support 16 are attached. A wafer saw blade 18 is attached to a spindle or hub 20 which is rotatably attached to the extension arm 15 . The blade 18 may be secured to the hub 20 and extension arm 15 by a threaded nut 21 or other means of attachment known in the art. The wafer saw 10 also includes a translatable wafer table 22 movably attached in both X and Y directions (as indicated by arrows in FIGS. 1 and 2 ) to the base 12 . Alternatively, blade 18 may be translatable relative to the table 22 to achieve the same relative X-Y movement of the blade 18 to the table 22 . A silicon wafer 24 to be scribed or sawed may be securely mounted to the table 22 . As used herein, the term “saw” includes scribing of a wafer, the resulting scribe line 26 not completely extending through the wafer substrate. Further, the term “wafer” includes traditional full semiconductor wafers of silicon, gallium arsenide, or indium phosphide and other semiconductor materials, partial wafers, and equivalent structures known in the art wherein a semiconductor material table or substrate is present. For example, so-called silicon-on-insulator or “SOI” structures, wherein silicon is carried on a glass, ceramic or sapphire (“SOS”) base, or other such structures as known in the art, are encompassed by the term “wafer” as used herein. Likewise, “semiconductor substrate” may be used to identify wafers and other structures to be singulated into smaller elements.
The saw 10 is capable of lateral multi-indexing of the table 22 or blade 18 or, in other words, translatable from side-to-side in FIG. 2 and into and out of the plane of the page in FIG. 1 various non-uniform distances. As noted before, such non-uniform distances may be mere multiples of a unit distance, or may comprise unrelated varying distances, as desired. Accordingly, a wafer 24 having variously sized integrated circuits or other electronic devices, elements, or components therein may be sectioned or diced into its non-uniformly sized components by the multi-indexing wafer saw 10 . In addition, as previously alluded, the saw 10 may be used to create scribe lines or cuts that do not extend through the wafer 24 . The wafer 24 can then subsequently be diced by other methods known in the art or sawed completely through after the blade 18 has been lowered to traverse the wafer to its full depth or thickness.
Before proceeding further, it will be understood and appreciated that design and fabrication of a wafer saw according to the invention having the previously-referenced, multi-indexing capabilities, independent lateral blade translation and independent blade raising or elevation is within the ability of one of ordinary skill in the art and, that likewise, the control of such a device to effect the multiple-indexing (whether in units of fixed increments or otherwise), lateral blade translation and blade elevation may be effected by suitable programming of the software-controlled operating system, as known in the art. Accordingly, no further description of hardware components or of a control system to effectuate operation of the apparatus of the invention is necessary.
Referring now to FIG. 3 , another illustrated embodiment of a wafer saw 30 is shown having two laterally spaced blades 32 and 34 with their centers of rotation in substantial parallel alignment transverse to the planes of the blades. For a conventional, substantially circular silicon semiconductor wafer 40 (flat omitted), as illustrated in FIG. 4 , having a plurality of similarly configured integrated circuits 42 arranged in evenly spaced rows and columns, the blades can be spaced a distance D substantially equal to the distance between adjacent streets 44 defining the space between each integrated circuit 42 . In addition, if the streets 44 of wafer 40 are too closely spaced for side-by-side blades 32 and 34 to cut along adjacent streets, the blades 32 and 34 can be spaced a distance D substantially equal to the distance between two or more streets. For example, a first pass of the blades 32 and 34 could cut along streets 44 a and 44 c and a second pass along streets 44 b and 44 d . The blades could then be indexed to cut the next series of streets and the process repeated for streets 44 e , 44 f , 44 g , and 44 h . 1 f however, the integrated circuits of a wafer 52 have various sizes, such as integrated circuits 50 and 51 , as illustrated in FIG. 5 , at least one blade 34 is laterally translatable relative to the other blade 32 to cut along the streets, such as street 56 , separating the variously sized integrated circuits 50 , 51 . The blade 34 may be variously translatable by a stepper motor 36 having a lead screw 38 ( FIG. 3 ) or by other devices known in the art, such as high precision gearing in combination with an electric motor or hydraulics or other suitable mechanical drive and control assemblies. For a wafer 52 , the integrated circuits, such as integrated circuits 50 and 51 , may be diced by setting the blades 32 and 34 to simultaneously cut along streets 56 and 57 , indexing the blades, setting them to a wider lateral spread and cutting along streets 58 and 59 , indexing the blades while monitoring the same lateral spread or separation and cutting along streets 60 and 61 , and then narrowing the blade spacing and indexing the blades and cutting along streets 62 and 63 . The wafer 52 could then be rotated 90°, as illustrated by the arrow in FIG. 5 , and the blade separation and indexing process repeated for streets 64 and 65 , streets 66 and 67 , and streets 68 and 69 .
As illustrated in FIG. 6 , a wafer saw 70 according to the present invention is shown having two blades 72 and 74 , one of which is independently raisable (as indicated by an arrow) relative to the other. As used herein, the term “raisable” includes vertical translation either up or down. Such a configuration may be beneficial for situations where the distance between adjacent streets is less than the minimum lateral achievable distance between blades 72 and 74 , or only a single column of narrow dice is to be cut, such as at the edge of a wafer. Thus, when cutting a wafer 80 , as better illustrated in FIG. 7 , the two blades 72 and 74 can make a first pass along streets 82 and 83 . One blade 72 can then be raised, the wafer 80 indexed relative to the unraised blade 74 and a second pass performed along street 84 only. Blade 72 can then be lowered and the wafer 80 indexed for cutting along streets 85 and 86 . The process can be repeated for streets 87 (single-blade pass), 88 , and 89 (double-blade pass). The elevation mechanism 76 for blade 72 may comprise a stepper motor, a precision-geared hydraulic or electric mechanism, a pivotable arm which is electrically, hydraulically or pneumatically powered, or other means well known in the art.
Finally, it may be desirable to combine the lateral translation feature of the embodiment of the wafer saw 30 illustrated in FIG. 3 with the independent blade raising feature of the wafer saw 70 of FIG. 6 . Such a wafer saw could use a single blade to cut along streets that are too closely spaced for dual-blade cutting or in other suitable situations, and use both blades to cut along variously spaced streets where the lateral distance between adjacent streets is sufficient for both blades to be engaged.
It will be appreciated by those skilled in the art that the embodiments herein described while illustrating certain embodiments are not intended to so limit the invention or the scope of the appended claims. More specifically, this invention, while being described with reference to semiconductor wafers containing integrated circuits or other semiconductor devices, has equal utility to any type of substrate to be scribed or singulated. For example, fabrication of test inserts or chip carriers formed from a silicon (or other semiconductor) wafer and used to make temporary or permanent chip-to-wafer, chip-to-chip and chip-to-carrier interconnections and that are cut into individual or groups of inserts, as described in U.S. Pat. Nos. 5,326,428 and 4,937,653, may benefit from the multi-indexing method and apparatus described herein.
For example, illustrated in FIG. 8 , a semiconductor substrate 100 may have traces 102 formed thereon by electrodeposition techniques requiring connection of a plurality of traces 102 through a tie bar 104 . A two-blade saw in accordance with the present invention may be employed to simultaneously scribe substrate 100 along parallel lines 106 and 108 flanking a street 110 in order to sever tie bars 104 of adjacent substrate segments 112 from their associated traces 102 . Following such severance, the two columns of adjacent substrate segments 112 (corresponding to what would be termed “dice” if integrated circuits were formed thereon) are completely severed along street 110 after the two-blade saw is indexed for alignment of one blade therewith, and the other blade raised out of contact with substrate 100 . Subsequently, when either the saw or the substrate carrier is rotated 90°, singulation of the segments 112 is completed along mutually parallel streets 114 . Thus, substrate segments 112 for test or packaging purposes may be fabricated more efficiently in the same manner as dice and in the same sizes and shapes.
Further, and as previously noted, RFID modules may be more easily fabricated when all components of a module are formed on a single wafer and retrieved therefrom for placement on a carrier substrate providing mechanical support and electrical interconnection between components.
As shown in FIG. 9 , a portion of a substrate 200 is depicted with three adjacent columns of varying-width segments, the three widths of segments illustrating batteries 202 , chips 204 end antennas 206 of an RFID device. With all of the RFID components formed on a single substrate 200 , an RFID module may be assembled by a single pick-and-place apparatus at a single work station. Thus, complete modules may be assembled without transfer of partially-assembled modules from one station to the next to add components. Of course, this approach may be employed to any module assembly wherein all of the components are capable of being fabricated on a single semiconductor substrate. Fabrication of different components by semiconductor device fabrication techniques known in the art is within the ability of those of ordinary skill in the art and, therefore, no detailed explanation of the fabrication process leading to the presence of different components on a common wafer or other substrate is necessary. Masking of semiconductor device elements not involved in a particular process step is widely practiced and so similar isolation of entire components is also easily effected to protect the elements of a component until the next process step with which it is involved.
Further, the present invention has particular applicability to the fabrication of custom or nonstandard ICs or other components, wherein a capability for rapid and easy die size and shape adjustment on a wafer-by-wafer basis is highly beneficial and cost-effective. Those skilled in the art will also understand that various combinations of the preferred embodiments could be made without departing from the spirit of the invention. For example, it maybe desirable to have at least one blade of the independently laterally translatable blade configuration be independently raisable relative to the other blade or blades, or a single blade may be both translatable and raisable relative to one or more other blades and to the target wafer. In addition, while, for purposes of simplicity, some of the preferred embodiments of the wafer saw are illustrated as having two blades, those skilled in the art will appreciate that the scopes of the invention and appended claims are intended to cover wafer saws having more or less than two blades. Thus, while certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the invention disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims.
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A semiconductor wafer saw and method of using the same for dicing semiconductor wafers including a wafer saw including variable lateral indexing capabilities and multiple blades. The wafer saw, because of its variable indexing capabilities, can dice wafers having a plurality of differently sized semiconductor devices thereon into their respective discrete components. In addition, the wafer saw with its multiple blades, some of which may be independently laterally or vertically movable relative to other blades, can more efficiently dice silicon wafers into individual semiconductor devices.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/481,485, filed Oct. 8, 2003.
BACKGROUND OF INVENTION
The invention relates to an optical reflectance probe system for the illumination of a sample material and detection of reflected light.
Optical reflectance measurements are commonly used for the analysis of materials. In a typical optical reflectance system, light is shown upon the material to be analyzed. An optical detector/measurement instrument gathers some of the light reflected off of the material and measures the intensity of the light either at specific wavelengths or across a spectral range yielding a measurement of intensity versus wavelength.
Materials can be analyzed in this way for the presence of certain constituents, the amount of these constituents, and the uniformity of these constituents throughout the consignment of the material. Specific uses include measurement of blend uniformity in pharmaceutical products, water or other solvent content in pharmaceutical products, measurement of protein, carbohydrates and water in agricultural products, and the presence of foreign material in an otherwise homogeneous material such as flour. Other applications include paint matching, quality control for paper, textiles, packaging, food, pharmaceuticals and cosmetics.
Typically, an arrangement of a light source, lenses and mirrors are used to align and project the illumination from the light source through a viewport window onto the sample material. Then additional lenses and mirrors are used to capture the light reflected from the sample material and guide it to the optical detector/measurement instrument. Optical fibers are also commonly used to guide the illumination light to the sample and/or optical pickup fibers to capture and guide the reflected light from the sample material back to the optical detector/measurement instrument. Common light sources include incandescent and particularly tungsten-halogen lamps. Common optical detector/measurement instruments include photometers, monochronometers and optical spectrographs.
Optical reflectance measurement systems require calibration. Calibration includes the use of reflectance standards including white references, references with known spectral signatures, spectral line sources, transmissive filters, and shutters. Calibration generally takes place during manufacture of the optical detector/measurement instrument, and commonly again after the system components are integrated. Calibration of the system can change due to vibration, temperature change or other conditions, so it is common to recalibrate periodically to ensure the system is performing within a required accuracy. In certain applications, such as the production of pharmaceutical products, there are government regulations requiring periodic verification of performance, and again, requiring the use of these calibration standards.
Current optical reflectance measurement systems require that some or all of these standards be employed by an operator dismounting the probe and manually introducing these references for the system to sample. This can be a cumbersome and time consuming task, as the system may be mounted at a point generally inaccessible. The unit could easily be damaged during the removal, or during reinstallation, requiring the system to be repaired, recalibrated, or worse, go unnoticed where data generated by the system is relied upon to produce safe and effective product.
In process control or quality control applications, optical reflectance measurement systems are required to be adjacent to the sample material being measured. Where the sample material is contained in a chamber, such as a vacuum chamber, mixer, blender or environmental chamber, the optical reflectance probe must view the sample material through a viewport window. This window must withstand pressures, abrasion, chemical attack, and provide a seal between the probe and the chamber interior, while providing a clear optical path for the probe to view. Further, mounts for the optical reflectance measurement system must be provided to hold the probe in reference to the window to view the sample material within the chamber.
Current window and mount systems employ a flat viewport window and a series of mounting brackets. The viewport window reflects some of the illuminant light from the probe back into the probes collecting optics, thus distorting the reflectance measurement. Anti-reflection coatings on the window reduce but do not eliminate this back reflection. Further, these coatings cannot be applied to the inner surface of the window because some of the coating may abrade off, contaminating the material, and generally cannot withstand chemical attack and other environmental conditions. Other means to reduce effects caused by this back reflection require complicated optical schemes including collimation and focusing optics. The mounting brackets are generally custom for the particular chamber and optical reflectance probe being employed, and must be designed special for each application. Further, due to constraints placed by chamber geometry and the requirements of bracket position and orientation to the window, placement of the window at a desired viewing position may not be possible for certain applications.
SUMMARY OF INVENTION
The present invention provides a self-calibrating optical reflectance probe system having an illuminant light source to illuminate a sample material, optical pickup means to collect reflected light from the sample material, and an articulated white reference reflection standard for illuminant reference. The probe system preferably has multiple illuminant light sources for redundancy and multiple optical pickup fibers for diversity in reflected light detection for more accurate measurements. Additional optional But preferred elements for the probe system include an optical line source for wavelength calibration and verification, a spectral reference standard for dynamic range verification and/or wavelength calibration and verification, a transmissive filter for dynamic range measurement and a shutter for dark reference, a curved window to reduce reflected light from the window surface, and an uncomplicated mount preferably employing a single sanitary pipe fitting and clamp (both preferably common to industry), which serves as the viewport as well and the probe mount, eliminating the need for additional brackets to mount the optical reflectance probe assembly. An additional fixture employing an integral curved window can be welded onto a chamber containing the material to be detected, thus providing a seal between the chamber and the probe assembly and simultaneously providing the required mount for the probe assembly. These components can be used individually or severally to calibrate the optical reflectance probe system and verify proper and accurate operation without the removal of the system from its installation, and all by automation without the intervention of an operator. The components, including the reference standards, are preferably enclosed within the assembly so as to be sealed from contamination and protected from damage due to handling.
It is therefore an object of the invention to provide an optical reflectance probe system incorporating means that enables the system to self-calibrate and verify calibration without operator intervention.
It is another object of the invention to provide an optical reflectance probe system with a viewport window that reduces back reflection.
Yet another object of the invention is to provide an optical reflectance probe system with an uncomplicated mount using components common to industry, eliminating the need for custom mounting brackets.
Still another object of the invention is to provide an optical reflectance probe system having a viewport incorporated within a probe mount to eliminate the need for additional mounting brackets.
The above and other objects, features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
These and other objects and purposes of the invention will be best understood in view of the following detailed description of the invention taken in conjunction with the appended drawings, wherein:
FIG. 1 schematically shows a cross-sectional view of a self-calibrating optical reflectance probe system and mount with a reference standard positioned in a referencing position;
FIG. 2 is similar to FIG. 1 but shows the probe system and mount with the reference standard positioned out of an optical path of the probe system;
FIG. 3 schematically shows a cross-sectional view of the probe system and mount of FIG. 1 with the probe system and mount separated to depict individual components used for mounting; and
FIG. 4 shows an isolated end view of a transmissive filter and shutter components and a spectral line source of the probe system of FIG. 1 in relation to optical pickup fibers and an illuminant light source of the probe system.
DETAILED DESCRIPTION
Referring to FIG. 1 , a self-calibrating optical reflectance probe system in accordance with a preferred embodiment of the invention is shown as including a probe housing 1 that encases components of the probe system. Seals 25 and 26 prevent contaminants from entering the probe system. The probe housing 1 has a threaded exterior 15 , allowing a pipe fitting flange 14 to be adjusted along the length of the probe system to position the end of the probe system at a desired distance from a viewport window 11 . A locking ring is shown as preventing the pipe fitting flange 14 from moving in relation to the probe housing 1 . A gasket 16 and clamp 17 hold the probe system on a sanitary pipe fitting mount 12 . The sanitary pipe fitting 12 is mounted by a weld 27 in a hole cut in a chamber 13 where a material (not shown) is to be sampled. The sanitary pipe fitting mount 12 houses the viewport window 11 , which is sealed against egress of the sample material by a seal 24 . The seal 24 can be made of an inert material such as Teflon® so as to not contaminate any material in the chamber 13 . The viewport window 11 is preferably made of sapphire for abrasion resistance as well as chemical resistance, again so as not to contaminate the sample material in the chamber 13 . Within the probe system there are two sample illumination lamps 3 and four optical pickup fibers 4 (two of which can be seen in FIG. 1 ) uniformly dispersed for diversity in sensing the reflected light from the sample material. A white reference standard 7 is provided in the form of a disk of diffuse reflective material, such as Spectralon®. This white reference standard 7 is mounted on an articulating mount rotatable on a bearing 28 and driven by a linkage 6 and actuator 5 . In FIG. 1 , the white reference standard 7 is shown in the “white reference” position, i.e., in an optical path through the probe system. Further, a shutter/filter wheel 18 is shown attached to an optic mounting plate 22 . An electronic control module 9 controls all of activities of the lamps 3 and actuator 5 via communications from an optical detector/measurement instrument (not shown) of any suitable type. The back of the probe system can be mounted to either a breakout box for communication and powering the probe system as well as interconnecting to the optical pickup fibers 4 , or directly to the optical detector/measurement instrument. FIG. 1 shows a mounting end 2 of a breakout box or detector/measurement instrument attached with screws to the probe housing 1 , such that the sanitary pipe fitting mount 12 is the singular mount for the probe system, or optionally a combination of the probe system and optical detector/measurement instrument.
In FIG. 2 , the probe system is shown in a material sampling mode with the white reference standard 7 rotated into a position out of the optical path of the probe system, such that light generated by the sample illumination a lamp 3 is reflected back to the optical pickup filters 4 .
FIG. 3 shows the probe housing 1 , gasket 16 , clamp 17 , and sanitary pipe fitting mount 12 separated to more readily show how the probe system is mounted.
FIG. 4 depicts an end on view of the optic mounting plate 22 , showing a preferred arrangement for the sample illumination lamps 3 , optical pickup fibers 4 , and shutter/filter wheel 18 , the latter of which is mounted for rotation on bearings 19 and driven by an actuator (not shown). FIG. 4 further depicts individual shutters 20 , open apertures 30 , and individual transmissive filters 21 . Also, the mounting position for a spectral line source 29 is shown.
Operation of the probe system will be described in reference to the Figures. During operation, only one of the illumination lamps 3 need be powered (the other being provided for redundancy) to illuminate the white reference standard 7 ( FIG. 1 ), whose diffuse reflectance of the illuminant is partially captured by the optical pickup fibers 4 . The light captured by the optical pickup fibers 4 is processed and used as a high level (white) reference signal. The white reference standard 7 remains in this position, preventing light passing through the window 11 from reaching the pickup fibers 4 . The illumination lamp 3 is then turned off or the pickup fibers 4 are shuttered by rotating the shutter/filter wheel 18 to position the shutters 20 over the pickup fibers 4 . A dark signal captured by the pickup fibers 4 at this time is processed and used as a low level (dark) reference signal.
Further testing of the system can be administered by rotating the shutter/filter wheel 18 , positioning the transmissive filters 21 over the optical pickup fibers 4 , again with the white reference standard 7 deployed and the illumination lamp 3 powered. Depending on the filter chosen for the transmissive filters 21 , stray light can be measurement or spectral accuracy verified. If a time-integrating optical detector/measurement instrument (such as a photo detector array based spectrograph) is employed, system linearity can be measured by deploying the white reference standard 7 and the illumination lamp 3 powered and the shutter/filter wheel 18 positioning the open apertures 30 over the optical pickup fibers 4 , then sampling the captured light at varying integration times set in the optical detector/measurement instrument. Spectral resolution and accuracy can be measured by deploying the white reference standard 7 while the illumination lamp 3 is de-powered, the shutter/filter wheel 18 positions the open apertures 30 over the optical pickup fibers 4 , and the spectral line source 29 is powered. Light from the spectral line source 29 will reflect off the white reference standard 7 and a potion thereof is subsequently captured by the optical pickup fibers 4 . The light captured by the optical pickup fibers 4 can be processed yielding both spectral accuracy and spectral resolution.
During material sampling, the white reference standard 7 is retracted as shown in FIG. 2 , the illumination lamp 3 powered, and the shutter/filter wheel 18 positioned such that the open apertures 30 are over the optical pickup fibers 4 . Light from the illumination lamp 3 passes through a dust window 10 and again through the viewport window 11 onto the sample material within the chamber 13 . The dust window 10 and viewport window 11 have curvatures such that their inner and outer curvatures are spherical and their inner and outer centers of curvatures are substantially at the same locus point. Further, the center of curvatures of the dust and viewport windows 10 and 11 are positioned substantially at the level of the lamps 3 and on center with the probe system. This arrangement maintains minimal effect on the light passing through the windows 10 and 11 , while all light reflected from the lamp 3 by the surfaces of the windows 10 and 11 is to a great degree projected back to the lamps 3 and away from the optical pickup fibers 4 . This arrangement also provides greater structural strength for the viewport window 11 , allowing for higher loads or a thinner window 11 for an existing load specification. Additionally, the curved shape allows sample material to more easily fall away from the window 11 , and enables sample material to be blown clean from the window 11 with an air jet to a greater degree than a flat window would allow. Light passing through both windows 10 and 11 and reaching the sample material is reflected back through the windows 10 and 11 , where some of the reflected light is captured by the optical pickup fibers 4 . This light is then processed by the optical detector/measurement instrument and, with information gained from the white reference and dark reference signals, yields information about the sample material itself.
If in operation, the lamp 3 being used fails, the second lamp 3 can be powered and a new white reference signal generated using the process outlined above to again ready the system for material sampling. This switching of lamps 3 and all testing described above can be automated and performed without operator intervention. Documentation on test results required by regulatory agencies can also be automatically generated, again without operator intervention. In systems employing more than one probe system, each probe system can have the capability of determining itself unhealthy and report this to the system gathering data, which would then take appropriate action, such as calling service for the probe system that declared itself unhealthy and not using data gathered from the unhealthy probe system.
In a variation of this system, a second reference standard could be installed with a second actuator to employ a reference standard with a known spectral signature. In operation of this embodiment, the white reference standard 7 would be retracted, the second reference standard deployed, the illumination lamp 3 powered and the shutter/filter wheel 18 positioned such that the open apertures 30 are over the optical pickup fibers 4 . Light captured by the optical pickup fibers 4 is then analyzed for spectral signature, both wavelength accuracy and absorption level accuracy.
While the invention has been described in terms of specific embodiments, it is apparent that other forms could be adopted by one skilled in the art. For example, the probe system and its components could differ in appearance and construction from the embodiments shown in the Figures, and appropriate materials could be substituted for those noted. Accordingly, it should be understood that the invention is not limited to the specific embodiments illustrated in the Figures. It should also be understood that the phraseology and terminology employed above are for the purpose of disclosing the illustrated embodiments, and do not necessarily serve as limitations to the scope of the invention. Therefore, the scope of the invention is to be limited only by the following claims.
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A self-calibrating optical reflectance probe system having an illuminant light source to illuminate a sample material, optical pickup means to collect reflected light from the sample material, and an articulated white reference reflection standard for illuminant reference to provide a system capable of accurately measuring optical reflectance and automated verification of proper operation. The probe system preferably employs an uncomplicated mount using a single pipe fitting and clamp.
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BACKGROUND OF THE INVENTION
This invention is an improvement on the support fastener shown in U.S. Pat. No. 3,954,243 issued May 4, 1976. The background of this invention is substantially identical to the prior art mentioned in U.S. Pat. No. 3,954,243, except the support fastener shown and claimed in U.S. Pat. No. 3,954,243 is removeable by insertion of a thin, blade-like member under the head to permit resilient distortion of the retaining arm. There are situations, which have been found by the common assignee of that patent and this application, which require that the support fastener be permanently and nonremoveably installed in the panel.
SUMMARY OF THE INVENTION
The present invention relates to a one-piece thermoplastic device which has the unique ability of distributing high shear loads and tortional loads directly to the supporting panel structure.
Another object of the present invention is to provide an economical, one-piece, hand-insertable fastener which is simple in construction but which overcomes the deficiencies of the prior art by wide distribution of stress forces commonly incurred in the applications involved.
A further object of the present invention is to provide a fastener which is compatible for useage with thin panels which are backed by a foamed insulation material and which are capable of displacing the foamed material in such a fashion that the fastener will be permanently seated without the use of any secondary preparation by the operator.
Still another object of the present invention is to provide a prong configuration which is acceptable in a non-circular aperture in the panel, said aperture having a large upper portion interconnected by a communicating slot to thereby provide one or more shoulders adjacent the slot for distribution of shear loads through adequate shoulder means in the fastener per se as well as to accept a distortable retaining arm in the communicating slot which is distorted during insertion and snaps back substantially to its original configuration to catch not only the end of the slot but a side wall of the slot in non-removeable fashion. Other objects of the invention will become apparent to those skilled in the art when the specification is read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 5, 7 and 9 are side elevational views in partial section showing the various stages of installation of the preferred embodiment of the present invention;
FIG. 2 is an elevational view from the backside of the base showing the canted or laterally shiftable retaining arm;
FIG. 3 is a bottom end view taken along lines 3--3 of FIG. 2; and
FIGS. 4, 6, 8 and 10 are front elevational views in partial section taken along lines 4--4 in FIG. 1; lines 6--6 in FIG. 5; lines 8--8 in FIG. 7; and lines 10--10 in FIG. 9, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein similar parts are identified by similar numerals, the fastener 10 includes a head 12, a stud 14, and a support means 16 extending from the head 12 in a direction opposite to that of the stud 14.
The head 12 in this preferred embodiment is a generally flat planar member having a rear surface 20 which serves as a reference, for purposes best set forth hereinafter. It will be recognized that the rear surface 20 could include, although not shown, a thin sealing flange or a series of protuberances arranged in such a fashion as to also serve as a reference for contacting the support with which it is associated. The stud 14 includes a substantially rigid curved hook-like member 24 which is integrally connected to the head 12 and extends outwardly and is thence reversely bent toward the rear surface 20 with the free end of said hook-like stud extending beyond an edge margin of said base and terminating in space relation to said reference, for purposes best set forth hereinafter. The hook-like member, for economies in manufacture, generally is defined by a pair of ribs with the outer rib 26 defining a convex surface while the inner rib 28 defines a concave surface, with the ribs 26 and 28 being joined by a central web 27 and terminating in a rounded nose or free end 30. The hook-like member 24 has substantial width which is preferably less than the width of the head 12 and terminates adjacent the rear surface 20 in a solid section 32 forming a rigid shoulder means adjacent rear surface 20 capable of carrying substantial shear loads. Extending integrally from the outer rib 26 in a curved fashion toward the rear surface 20 is a resilient retaining arm 40 which is narrower than stud 24 and terminates in space relation to the back surface 20 with a cammed shoulder end 42.
In the present embodiment, the arm 40 initially is substantially parallel to the side edges of the hook-like member 24 and thence is curved or angularly disposed off to one side of its initial position, as designated by the portion 44. This canted portion 44 terminates in the cammed shoulder end 42 which adjacent one edge of the arm is relieved by a recess 46, for purposes best set forth hereinafter.
In the present embodiment the head 12 is provided on its front surface with a support means 16 in the form of a hook-like element for accepting a secondary element, such as a wire shelf, although many various forms of support means shown in the fastening art generally or as shown in U.S. Pat. No. 3,954,243, and not shown in this patent application, can be carried by head 12.
The fastener 10 described above is capable of being utilized with a thin support panel 60 having a non-circular aperture 62. The aperture 62 in the preferred embodiment has a large upper portion 64 and a lower communicating slot 66, with the margins of the aperture adjacent its juncture with the slot 66 forming at least one supporting shoulder means 68. The width of the upper portions 64 is substantially equal to the width of the hook-like portion 24 while the slot 66 is substantially equal in width to the resilient arm 40.
Referring now to FIGS. 1 and 4 through 10, the operation of the fastener is such that the rounded nose 30 is introduced in the upper portion 64 of aperture 62 by lateral telescoping through the panel 60 and then rocked or rotated with the trailing resilient arm 40 moving within the slot portion of aperture 62. As the fastener is rotated into the hole, the flexible arm 40 is deflected laterally when its canted portion 44 contacts the side margins of the slot 66, as viewed in the figures, until such time as its end 44 contacts the bottom of the slot 66 at which time the arm is also deflected toward the convex rib 26. The rotation of the fastener is continued until the rounded nose 30 contacts the rear of the panel 60 and the reference surface 20 contacts the front of the panel 60, at which time the canted portion 44 snaps laterally to the side with the edge of the slot 66 being captured in the cut-out 46 at the end of the arm 40. The flexible arm 40 must slide along the rear surface 20 in the direction of the arrow A and must bow in the direction of the arrow B, as best seen in FIG. 7, and must flex laterally in the direction of the arrow C, as seen in FIG. 2, as it contacts the vertical edge of the slot 66 until such time as the free end of the arm clears the rear panel 60 whence the canted portion 44 of the arm 40 will spring back in the direction opposite to the arrow C in FIG. 2.
When the head is finally seated on the panel, as seen in FIGS. 9 and 10, the rounded free end 30 of the hook-like member 24 is in contact with the rear or left side of panel 60, as seen in the drawing. The hook-like prong or stud 14 provides resistance to torsional loads induced by forces appled to support 16 by distributing the forces over a large area of the panel 60 while the solid section or shoulder portion 32, under the head, fills the upper portion 64 and rests on the shoulder 68, as best seen in FIG. 10, to provide high resistance to shear loads in a downward vertical direction, as seen in the drawings, as well as to forces applied in other directions in the plane of the panel 60. The flexible arm 40, with its canted portion 44 and its cut-out 46, engages the lower edge of the slot portion 66 with its cammed end 42 and is made non-removeable by engagement of the cut-out 46 with side edges of the slot portions 66. Since the backside of panel 60 is normally a blind application, no means of access generally being available, the notch 46 engaging the side edge of slot 60 makes this fastener a non-removeable fastener.
The preferred embodiment described hereinabove can be readily manufactured from available thermoplastic materials by injection molding techniques known in the art. The configuration of the prong is such as to provide rigid characteristics for resistance of tortional and shear loads while the same material, as an integral part of the entire fastener, when reduced in section will provide a resilience to the arm 40 so that its canted portion 44 can be laterally moved and will spring back to lock the fastener in mounted position. The supporting means generally designated 16 can be either resilient, when used in a hook-like configuration as illustrated in this embodiment, or rigid by introducing heavier sections well known in the art and not shown.
It will be appreciated by those skilled in the art that a cooperative configuration arrangement, namely the use of this stud configuration with a variety of head configurations, will provide economies in manufacture. A single stud and head mold cavity could be utilized with an infinite variety of support designs, thereby providing a customer with a single fastener that will accept various supports as demanded by the style of a particular refrigerator, freezer, etc. with which it is to be used.
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A one-piece plastic fastener for supporting secondary members relative to a thin panel in a shouldered, non-circular aperture. The fastener provides a wide distribution of stress loading by a large hook-like prong which is rotated into contact with the backside of the panel by telescoping it through the aperture until the head covers the aperture. A resilient non-loadbearing arm extends from the prong in a curved or angular relationship for engagement with two adjacent edges of the non-circular aperture to permanently prevent unintentional retrograde motion of the fastener. The fastener is non-removeable due to the locking of the notch in the arm with the side edge of the non-circular aperture.
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CROSS REFERENCE TO RELATED APPLICATION
This application is related to the commonly assigned copending United States application Ser. No. 06/327,559, filed Dec. 4, 1981, entitled "Inductive Projectile Sensor on a Gripper Shuttle Weaving Machine".
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved electronic control device on a gripper shuttle weaving machine or loom which is of the type comprising a lathe beam and thereto fixed teeth for guiding the stripper shuttle which inserts the weft thread or filling into the weaving shed, and a thread brake located at the picking side of the weaving machine.
Swiss Pat. No. 469,839 discloses a procedure for operating a gripper shuttle weaving machine, wherein a weft thread brake is released or disabled during the throw of the shuttle and enabled or actuated when the shuttle reaches the catch box. For this purpose, a shuttle sensor is provided in the catch box for actuating the thread brake through an electronic control and amplifier device and an electromagnet.
With this known procedure and arrangement, the thread brake cannot be actuated speedily enough when the shuttle is braked and slowed down in the catch box. As a consequence thereof, the weft or filling thread may overshoot in the weaving shed such that faulty selvedges or loose weft threads cannot be avoided with certainty.
SUMMARY OF THE INVENTION
Therefore, it is a primary object of the invention to provide a new and improved control device for an electronic gripper shuttle weaving machine which avoids the aforementioned deficiencies and shortcomings.
It is a more specific object of the invention to provide a control device which enables rapidly actuating the thread brake and thus avoids formation of faulty filling or weft insertions and defective selvedges.
These objects and others which will become more readily apparent as the description proceeds are implemented by the electronic control device of this invention which comprises a sensor arranged at least at one of the guide teeth for furnishing an electrical sensor signal indicative of the passage of the gripper shuttle; an evaluation circuit connected to the sensor; and an electromagnetic device operatively connected to the evaluation circuit for actuating the thread bake upon appearance of an electrical sensor signal.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a schematic representation of a preferred embodiment of the inventive electronic control device, and some therewith co-operating components of a gripper shuttle or projectile weaving machine;
FIG. 2 is a pulse diagram illustrating the operation of the control device represented in FIG. 1; and
FIGS. 3, 4 and 5 respectively illustrate the arrangement of an inductive projectile sensor attached to one of the guide teeth of the weaving machine, viewed from the front side of the machine, in end view and plan view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, there are shown the following components of the gripper shuttle weaving machine or loom: a supply spool 1, a yarn guide 2, a yarn brake 3 having a fixed jaw 4 and a movable jaw 5, part of the lathe beam 6 with guide teeth 7, a projectile or gripper shuttle 8 in a position just before the end of the lathe beam 6, and part of the main drive shaft 9. The electronic control device 10-14 comprises a conventional clock pulse generator 10, a projectile sensor, in brief referred to sometimes herein simply as sensor 11, an electronic evaluation circuit 12 having two inputs, an adjustable delay circuit 12E, and an actuation device comprising a magnet coil or solenoid 13 and an armature 14 which is mechanically connected to the movable jaw 5 of the yarn brake 3.
The first input 12a of the evaluation circuit 12 is connected to the clock pulse generator 10, whereas the second input 12b thereof is connected with the sensor 11 through the delay circuit 12E. The evaluation circuit 12 may comprise a bistable circuit having set and reset inputs, such as to be set by the output of the clock pulse generator 10 connected to the set input, and reset by the output of the delay circuit 12E connected to the reset input. The delay circuit 12E may comprise a monostable circuit or monoflop which shapes a signal from the sensor 11 into a rectangular pulse whose length can be adjusted.
The gripper shuttle weaving machine may be of conventional construction as shown, by way of example, in the above-mentioned Swiss Pat. No. 469,839.
FIG. 2 schematically illustrates some signals produced by the control device 10-14 with the operating weaving machine during the weft or filling insertion: the output signal or clock pulse 10A of the clock pulse generator 10, the output signal or sensor signal 11A of the sensor 11, and the output signal or braking signal 12A of the evaluation circuit 12.
The clock pulse generator 10 which is coupled to the main drive shaft 9 of the weaving machine furnishes a start or clock pulse 10A with every revolution of the main drive shaft 9. The clock or start pulse 10A interrupts the braking signal 12A at the instant A such as to release the up to this instant closed yarn brake 3. At the same time, the projectile 8 is shot off, and the weft thread guided by the guide teeth 7 is inserted into the weaving shed. When the projectile passes by the sensor 11, the latter produces a sensor signal 11A which causes the braking signal 12A to reverse and close or actuate the yarn brake 3 again at the instant B.
The clock or start pulse 10A corresponds to an angular position of the main drive shaft 9 of e.g. 100 degrees. A very accurate adjustment of this angle is possible by a clock pulse generator 10 which comprises an exactly graduated circular scale.
The adjustable delay circuit 12E makes it possible to delay the sensor signal 11A, and thus the instant B of the braking signal 12, by a time interval which is adjustable within certain limits as illustrated by the dashed line. Thus, the instant of actuation of the thread brake 3 may be accommodated to various operational conditions of the weaving machine, thus avoiding any mechanical adjustment or displacement of the sensor 11.
The time-delay circuit 12E may be lodged in a portable housing or case provided with a plug connection or connector. Thus, it is possible for an operator to adjust the instant B and to simultaneously watch the selvedge. Such a procedure is not possible with the presently known control devices.
Referring to FIGS. 3, 4 and 5, an inductive sensor 11S comprising an induction coil is fixed to the lathe beam 6 by means of a coil support 15 and screw 16 or equivalent structure.
The substantially rectangular shape of the inductive sensor 11S, FIG. 5, is accommodated to the cross-section of the guide tooth 7 and to the distance to the thereto adjacent guide teeth 7a,7b. Thus, the inductive sensor 11S can be set onto the guide tooth 7 from the top thereof without removing the same from the lathe beam 6.
In order to provide for a strong magnetic field a D.C.-current may be applied to the induction coil of the inductive sensor 11S. When the projectile 8 passes by, a D.C.-pulse occurs in the induction coil, the amplitude of which is substantially greater than that of the always present spurious or noise signals, so that there is ensured for positive actuation of the yarn brake 3. As shown in FIG. 1, the sensor 11S is connected, through a connection line K not depicted in the FIGS. 3, 4 and 5, to the delay circuit 12E. The connection line K is preferably fixed to or along the pivotal shaft of the lathe in order to minimize transfer of torque to the connection line K.
The width b of the inductive sensor 11S in the direction of the lathe beam 6, FIG. 5, is dimensioned such that the inductive sensor 11S can be placed between two guide teeth 7a,7b neighbouring the guide tooth 7.
The inventive control device is not limited to the use of inductive sensors: in place thereof there might be used an optoelectrical sensor based on the light reflection principle, and which transmits a light beam which is reflected from the passing projectile 8. However, an inductive sensor 11S of the above-described type is advantageous insofar as it is insensitive to dust and dirt.
The coil of the inductive sensor 11S depicted in FIGS. 3, 4 and 5 also may surround two of the guide teeth 7; however, the illustrated embodiment of the inductive sensor 11S which surrounds one guide tooth is the simplest embodiment.
The illustrated and above-described control device may be used on a one color as well as on a multicolor weaving machine. Since the last-mentioned types of machines comprise a multiplicity of yarn brakes, there must be provided a change-over switch between the evaluation circuit 12 and the various magnetic actuation devices, such as the device 13,14 in FIG. 1, which change-over switch is controlled by a color change mechanism.
The above-described control device has various advantages over the conventional yarn brake controls which are mechanically synchronized with the main drive shaft of the weaving machine. Some of such advantages will be mentioned in the following portion of the description.
The mechanically controlled yarn brake is actuated--independent of the speed of the projectile--in a definite instant or with a definite angular position of the main drive shaft, e.g. 260°. Now when the projectile is too fast, as in the case of a very thin weft thread, the braking action occurs too late and along a relatively short braking or stop distance, and thus is insufficient. However, with the yarn brake of the present invention which is controlled by the projectile flight, when the projectile is too fast and arrives too early at the sensor, the braking action automatically starts at an instant earlier than otherwise would occur with normal speed, and the stop distance is not reduced.
Moreover, the projectile-controlled braking procedure of the invention is independent of the rotational speed of the main drive shaft and the angular position thereof. Thus, when the weaving machine is manually driven for test purposes, the adjustment of the yarn brake can be monitored at any individual weft or filling. This is impossible with the mechanically controlled yarn brake since there the start of the braking occurs only when the mentioned angular position is reached, i.e. when the weft thread has already been inserted into the weaving shed.
While there is shown and described a present preferred embodiment of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. Accordingly,
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Electronic control device on a gripper shuttle or projectile weaving machine or loom containing a lathe beam and thereto fixed teeth for guiding the gripper shuttle or projectile which inserts the weft or filling thread into the weaving shed, and a thread brake located at the picking side of the loom. The electronic control device comprises a sensor arranged on the lathe beam at least at one of the guide teeth and which furnishes an electrical sensor signal when the projectile passes by, an evaluation circuit connected to the sensor, and an electromagnetic device operatively connected to the evaluation circuit such as to actuate the thread brake upon appearance of an electrical sensor signal.
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REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of application Ser. No. 09/609,870, filed Jul. 3, 2000.
FIELD OF THE INVENTION
[0002] This invention relates to novel clarified hydrocolloids which substantially retain the physical properties of unclarified colloids. The invention also pertains to a novel process for making the clarified hydrocolloids.
BACKGROUND OF INVENTION
[0003] Hydrocolloids made from naturally occurring gums are used extensively in the food, pharmaceutical and cosmetics industries. Sols of most such hydrocolloids are opaque or translucent. When such hydrocolloids are clarified, the cost is usually uneconomical or there is inevitably a loss in the physical properties of the hydrocolloids compared to the unclarified colloids. This can, for example, include substantial loss in viscosity. Examples of naturally occurring gums used in making hydrocolloid sols are konjac, guar, locust bean and xanthan.
[0004] Konjac Glucomannan:
[0005] Konjac glucomannan, the first word sometimes spelled “konjak”, is an acetylated glucomannan obtained from the tubers of the tropical plant, Amorphophallus konjac , commonly called “Devil's Tongue” because of its high content of oxalic acid. The konjac tuber is harvested following two or three year's growth, after which it has a diameter of 4-6″. Processing steps include slicing, placing the slices on racks, sun or open fire drying, pulverization, dry or wet milling to remove the oxalic acid and some of the starch content which adheres to the konjac sacs, followed by sifting or air classification. These oval sacs are about 2 mm long and are composed mostly of konjac glucomannan encased in a proteinaceous membrane. Starch granules adhere to the membrane and much of these can be removed by a 30% alcohol (aq) wash. Native konjac glucomannan has a wide variation of acetyl content since it is both a storage and a structural polysaccharide. The more acetylated forms of the konjac glucomannan are water-soluble and the more deacetylated forms are water-insoluble. This is a simplistic statement, however, since a whole spectrum exists with respect to degree of acetylation with some of the soluble species on the edge of insolubility and minor changes in environment, such as salt concentration, excessive heating, removal of protective hydrocolloids or other molecules, etc., can lead to insolubilization.
[0006] Crude konjac flour, the most common commercial form, is a well-known foodstuff in China and Japan and has recently gained FDA approval in the U.S. as a fat replacer in meat. This application is based on the fact that when konjac glucomannan is heated with alkali, about pH= 31 7.5-11, deacetylation occurs and the resulting gel product is water insoluble and thermostable. The deacetylated gel or paste, commonly called “konnyaku” can even be fried at temperatures around 400° F. without melting or decomposing. If the gel formed by deacetylation is frozen and thawed, a tough, coherent spongeous mass is formed. Deacetylated konjac-containing films, foams, beads, and other forms can be prepared.
[0007] Konjac reacts with borate ion at alkaline pH to form amorphous gels as well as reacting synergistically with xanthan to form elastic gels.
[0008] As expected, there are numerous impurities in the crude, unclarified konjac. These include insoluble starches, cellulose, and nitrogen-containing impurities including proteins, many of which are derived from the konjac sac membrane. While crude konjac flours have numerous applications, as foods, as a soluble fiber source, as a fat replacement in meats, etc., the clarified form is preferable and in some applications, essential, for such applications as clear dessert gels, as a viscosifier or thickening agent for clear fluids, as clear capsules, films that are free from particulates, clear cosmetics (lotions and possibly gels in combination with clarified xanthan or borate), etc.
[0009] Guar Gum (galactomannan):
[0010] Guar gum is a galactomannan polysaccharide obtained from the seed of the legume Cyanopsis tetragonolobus , an annual plant that grows mainly in arid and semiarid regions of India and Pakistan. Guar is grown principally as a food crop for animals and as an ingredient in human foods and pharmaceuticals. The guar galactomannan is the major component in the seed endosperm, while the germ portion is mainly protein. In its commercial form, guar gum contains a significant number of impurities, including husks and other cellular debris, with the guar galactomannan comprising only about one-third of the product.
[0011] The guar galactomannan is composed of a backbone of (1→4)-linked β-D-mannopyranosyl units with single α-D-galactopyranosyl units connected by (1→6) linkages, with the ratio of galactose to mannose being about 0.55. There are many galactomannans in nature, each varying in this ratio which determines physical and chemical characteristics. Guar galactomannan is soluble in water to form viscous solutions. The actual viscosity values depend upon both the molecular weight and the purity. Guar gum imparts viscosity even in high ionic strength environments. Like konjac and locust bean gum, guar reacts synergistically with xanthan to form very viscous sols and/or gels, depending on proportions and concentrations. It also reacts with alkaline borate to yield amorphous gels.
[0012] Guar has numerous applications, some of which have been supplanted by guar derivatives. These range from oil drilling products to textile printing and dyeing to foods, cosmetics and pharmaceuticals.
[0013] Locust Bean Gum (galactomannan):
[0014] Locust bean, carob, gum is a galactomannan polysaccharide obtained from the evergreen leguminous tree, Ceretonia siliqua L., which grows extensively in Spain is also cultivated in Italy, Cyprus and other Mediterranean countries. Locust bean gum is the refined endosperm of the seed and in its commercial forms locust bean gum contains a significant number of impurities, such as husk residue and cellular debris, depending on the grade.
[0015] Locust bean gum, like guar is a galactomannan having the same basic structure. However, there are considerably fewer galactose side-chains in the locust bean galactomannan. The galactose to mannose ratio is 0.25, compared with guar's 0.55. This lower degree of branching is responsible for differences in properties, especially solubility. While guar is mostly soluble in cold water, locust bean gum is not. Dispersions must be heated to about 85° C. to achieve full viscosity. Weak gels are formed when hot sols of locust bean gum are allowed to cool quiescently. Locust bean gum will gel in the presence of borate ion at alkaline pH. It will react synergistically with xanthan to form a gel and will impart elasticity to agar and κ-carrageenan. Locust bean gum is stable over a wide range of pH values, but is rapidly degraded by enzymes found in indigenous microbes.
[0016] While guar and guar derivatives have replaced locust bean gum in a number of applications because of cost-effectiveness considerations, locust bean gum is still used in dairy and frozen dessert applications, meat products, pet foods, and the textile industry.
[0017] Aloe Acemannan:
[0018] Aloe acemannan is a mannan first isolated from Aloe barbadensis (var. Miller) by McAnally at Carrington Laboratories and is pharmacologically active. In its commercial state, it contains fine water-insoluble particulates that impart turbidity to the sol. About 80% of the commercial product is a polysaccharide that is composed of a mannose backbone of from 5-50,000 linked units, with >75% being greater than 10,000. Commercial acemannan is partially water soluble and forms viscous sols. It, too, reacts synergistically with xanthan to form elastic gels and alkaline borate to form amorphous gels.
[0019] Xanthan Gum:
[0020] Xanthan gum is a so-called heteropolysaccharide obtained from the fermentation of Xanthamonas campestris . The polymer backbone is composed of (1→4)-linked β-D-glucopyranosyl units, the same as cellulose. Trisaccharide side chains are attached to alternate D-glucosyl units. These are composed of acetyl mannose, glucuronic acid, and mannose residues, with about half of the terminal mannose units containing pyruvate as a 4,6 cyclic acetal. Many commercial xanthan gum products form somewhat turbid sols, although most of the cellular debris is removed by centrifugation as a processing step. A few higher-value commercial products form an essentially clear sol as a result of an additional filtration step in the processing.
[0021] Xanthan gum imparts high viscosity to aqueous solutions at low concentrations. It is compatible with a wide pH range (1-13), being quite stable at ambient temperature for all values. Xanthan gum sols will also add viscosity to solutions having high salt content. Xanthan interacts synergistically with galactomannans, such as guar gum and locust bean gum, and konjac glucomannan to significantly increase viscosity and/or form gels. With these unique properties and its GRAS listing as a food additive, xanthan gum has a wide range of applications, from oil well drilling to salad dressings, cosmetics, and pharmaceuticals.
[0022] Clarified Hydrocolloid Composites:
[0023] Hydrocolloid composites with varying components in varying weight/weight rations can be prepared by combining their sols and then recovering the product by one of any number of available methods. Although co-processed hydrocolloids and dry physical mixtures of hydrocolloids powders exhibit essentially the same solution properties, dispersion and water absorption properties can be significantly different and vary according to the relative proportions.
[0024] Clarified Hydrocolloid/Borate Interaction Products:
[0025] At pH values between about 7.5 and 9.0, the borate ion will interact with polymers containing cis-1,2-diols to form more viscous, amorphous systems. These polymeric diols can be synthetic, semi-synthetic, or natural. Some of the more common polymers which undergo this reaction are the polyvinyl alcohols; galactomannans, such as guar gum and locust bean gum; and glucomannans, such as konjac and Aloe (ace) mannans. Depending on the concentration of the polymer, or polymers if two or more are used, the borate, and other additives, if any, the consistency can vary from somewhat viscous fluids to crisp amorphous solids. At selected concentrations of the individual components, the reaction products behave like “healable” solids that will flow at body temperatures. Other soluble and insoluble materials can be added to impart desired properties, such as increased fluid absorption, fluid donation, elasticity, etc.
RELEVANT PRIOR ART
[0026] Konjac Clarification:
[0027] Snow, W. C. and Renn, D. W. Clarified and cold-melt konjac glucomannan. Patent Nos. WO 09302571 (Feb. 18, 1993) and EP 646133A1 (Apr. 5, 1995).
[0028] (Use of considerable heating, a variety of salts and other reagents, along with filter aid to clarify konjac and reduce turbidity (20-100 NTUs), nitrogen and UV spectral absorbance)
[0029] Ohashi, S., Shelso, G. J., Moirano, A. L., and Drinkwater, W. L. Clarified konjac glucomannan. Patent Nos. WO 09303047 (Feb. 18, 1993) and EP 00646134A1 (Apr. 5, 1995).
[0030] (Use of considerable heat to dissolve and filter. Impurities precipitated using aluminum sulfate or other salts such as calcium and magnesium sulfate, filtering, then recovering using isopropyl alcohol. Reconstituted konjac has an aqueous sol turbidity potential of less that 20 turbidity units . . . )
[0031] Asahi Kasei Kogyo KK. Glucomannan eye drops. Japan Patent JP6345653 (Dec. 20, 1994).
[0032] (Konjac powder, PROPOL PA, was stirred in distilled water for dissolution then centrifuged at 2000 rpm for 10 minutes after which the supernatant had a “first grade white turbidity”. This was diluted with distilled water and heated to boiling.)
[0033] Maekaji, K. The Mechanism of Gelation of Konjac Mannan. Agr. Biol. Chem . 38 (2), 315-321 (1974).
[0034] (Insolubles were removed by filtration of a 0.5% sol after stirring the dispersion for two hours at room temperature, by filtration through a glass filter.)
[0035] Jacon, S. A., Rao, M. A., Cooley, H. J., and Walter, R. H. The isolation and characterization of a water extract of konjac flour gum. Carbohydrate Polymers 20, 35-41 (1993).
[0036] (A 0.6% sol of konjac flour in distilled water was agitated for 1.5 hours in a temperature regulated shaker held at approximately 70° C. Insolubles were removed by centrifugation and the supernatants coagulated in 3 volumes of 99% ethanol. Precipitate separated, washed with ethanol, then dried to constant weight at 105° C.)
[0037] Morita, S., Morita, H., Shibata, K., and Nakayama, H. Gel for zone electrophoresis. Jpn. Kokai Tokkyo JP 04,248,460 [92,248,460].
[0038] (Clarification of a 0.4% sol by centrifugation, determination of dry weight and using clarified konjac sol directly without drying).
[0039] Nippon Chemifar Co., Ltd.. Konjac glucomannan manufacture. Jpn. Kokai Tokkyo Koho JP 58,213,001 [83,213,001] (Dec. 10, 1983).
[0040] (Dissolving overnight at room temperature, centrifuging, coagulating supernatant in ethanol, redissolving, centrifuging, coagulating, and freeze-drying).
[0041] Ogasawara, S. Yamazaki., and Nunomura, W. Electrophoresis on konjac mannan gel. Seibutsu Butsuri Kagaku 31(3)155-8(1987).
[0042] (50% ethanol for a week, centrifuged, pellets in 80% ethanol for 3 days, centrifuged, washed, filtered. Never dissolved.)
[0043] Sugiyama, N. and Shimahara, H. Method of reducing serum cholesterol level with extract of konjac mannan. U.S. Pat. No. 3,856,945 (Dec. 24, 1974).
[0044] (Konjac purified by dissolving the konjac flour in water, filtering through 150 mesh nylon then a glass filter, dialyzing and freeze-drying. Product is cloudy when reconstituted. Not a commercially viable process.)
[0045] Sugiyama, N. and Shimahara, H. Konjac mannan. U.S. Pat. No. 3,926,322 (Dec. 23, 1975).
[0046] (Dissolving in water, removing insolubles by filtration or centrifugation, freeze drying)
[0047] Sugiyama, N. and Shimahara, H. Konjac mannan. U.S. Pat. No. 3,973,008 (Aug. 3, 1976).
[0048] (Dissolving in water, removing insolubles by filtration or centrifugation, dialyzing and freeze drying)
[0049] Izumi, T. et al., “Use of glucomannan for the separation of DNA fragments by capillary electrophoresis” Journal of Chromatography A , 652, 41-46 (1993).
[0050] (use of non-deacetylated konjac as medium for capillary electrophoresis).
[0051] Ogasawara, S. et al., “Electrophoresis on Konjac mannan gel” Seibutsu Butsuri Kagaku 31, 155-158 (1987).
[0052] (use of konjac gels for electrophoretic separations in non-denaturing buffer systems).
[0053] Morita, S. et al., “Gel media for zone electrophoresis of proteins or nucleic acids” Jpn. Kokai Tokkyo Koho JP 04,248,460 (Sep. 3, 1992) CA117: 248159 g (1992).
[0054] (gel matrix of agarose and konjac glucomannan used for nucleic acid and protein separations in non-denaturing buffers).
[0055] Clarified Partially Depolymerized Konjac:
[0056] Tomita, M., Ono, J., Fukuwatari, Y., Mizota, T., and Nanba, K. Water-soluble dietary fibers and method for preparation of same. U.S. Pat. No. 4,971,814 (Nov. 20, 1990).
[0057] (Konjac powder is partially hydrolyzed using cellulase from Aspergillus to yield dietary fibers with average M.W. of 2,000-15,000.)
[0058] Tomita, M., Shimamura, S., Fukuwatari, Y. and Nanba, K. Glucomannan hydrolysates for treatment of intestinal cancer. Japan Kokai Tokkyo Koho JP 05,246860 (Sep. 24, 1993). ( Chem. Abstr , 120, 14904, 1994).
[0059] (Konjac glucomannan was partially hydrolyzed using cellulase and products used as anticholesteremics and antitumor agents in the large intestine.)
[0060] Takahashi, R., Ksusakabe, I., Kusama, S., Sakurai, Y., Murakami, K., Maekawa, A., and Suzuki, T. Structures of Glucomanno-oligsaccharides from the Hydrolytic Products of Konjac Glucomannan Produced by a β-Mannanase from Streptomyces sp. Agric. Biol. Chem , 48 (12) 2943-2950 (1984).
[0061] (Konjac glucomannan hydrolyzed with a purified mannanase.)
[0062] Tiefenthaler, K. H. O. and Wyss, U. Water soluble guar product and method for making it, U.S. Pat. No. 4,320,226 (Mar. 16, 1982).
[0063] (Depolymerization of guar gum in the presence of alkali).
[0064] Guar Gum Clarification:
[0065] Naoki, M., Shiyoujo, S., and Taku, T. Purification of galactomannan.
[0066] Japan Patent JP63101402A (Sep. 17, 1984).
[0067] (Galactomannan is contacted with an alkali metal hydroxide (e.g., sodium hydroxide)in a medium comprising water or a mixture of water with a hydrophilic organic solvent The product is then neutralized with neutralizing agent (e.g., hydrochloric or sulfuric acid) to obtain the desired galactomannan.)
[0068] Mitsuo, M. Purification of Galactomannan. Japan Patent JP5239105 (Sep. 17, 1993).
[0069] (An aqueous solution of crude galactomannan is blended with a chelating agent, the blended solution is filtered, the filtrate is mixed with a precipitating agent for galactomannan to recover and purify galactomannan.)
[0070] Mitsuo, M. Purification of Galactomannan. Japan Patent JP5239106 (Sep. 17, 1993).
[0071] (An aqueous solution of crude galactomannan is blended with a monosaccharide, the blended solution is filtered, the filtrate is mixed with a precipitating agent for galactomannan to recover and purify galactomannan.)
[0072] Hirofumi, N., Hideki, Y., and Michiyoshi, A. Purification of galactomannan. Japan Patent JP63035606 (Feb. 16, 1988).
[0073] (The pH of an aqueous solution obtained by dissolving a galactomannan-containing product such as crushed guar beans, locust beans or tara beans in hot water at 70° C. or above is adjusted to 4.5-6.5 by adding an acid to the solution. A filter aid (e.g., Perlite) of a mean particle diameter of 15-20 microns is added to this aqueous solution. This solution is filtered to remove insoluble matter such as protein and cellulose, and a hydrophilic organic solvent such as methanol or isopropyl alcohol is added to the filtrate to precipitate gum. This gum is dehydrated by pressing, dried and ground.)
[0074] Noble, O., Turquois, T, and Taravel, F. R. Rheological Properties of Galactomannan-Based Gels. Part I—Guar and Hydroxypropylguar Gels in Alkaline Media. Carbohydrate Polymers 12, 203-217 (1990).
[0075] (Guar gum purified by dispersing in stirring water at 60° C. and stirring rapidly for 1 or 2 hours. Insoluble material was removed by centrifugation and supernatants precipitated by addition of 95% isopropyl alcohol. Precipitate washed with ethanol and vacuum dried.)
[0076] Locust Bean Gum Clarification:
[0077] Braun et al., Preparation of Vegetable Gum Solutions. U.S. Pat. No. 2,144,522 (Jan. 17, 1939).
[0078] (Decolorizing and clarifying locust bean gum by adding activated carbon and aluminum sulfate, filtering, and coagulating in isopropyl alcohol).
[0079] Foster, Treatment of Manno Galactan Gums. U.S. Pat. No. 3,346,556. (Oct. 10, 1967)
[0080] (Example 5 discloses a means for clarifying locust bean gum by adding diatomaceous earth and filtering).
[0081] Naoki, M., Shiyoujo, S., and Taku, T. Purification of galactomannan. Japan Pat. No. JP63101402A (Sep. 17, 1984).
[0082] (Galactomannan is contacted with an alkali metal hydroxide (e.g., sodium hydroxide) in a medium comprising water or a mixture of water with a hydrophilic organic solvent The product is then neutralized with neutralizing agent (e.g., hydrochloric or sulfuric acid) to obtain the desired galactomannan.
[0083] Mitsuo, M. Purification of Galactomannan. Japan Patent JP5239105 (Sep. 17, 1993).
[0084] (An aqueous solution of crude galactomannan is blended with a chelating agent, the blended solution is filtered, the filtrate is mixed with a precipitating agent for galactomannan to recover and purify galactomannan.)
[0085] Mitsuo, M. Purification of Galactomannan. Japan Patent JP5239106 (Sep. 17, 1993).
[0086] (An aqueous solution of crude galactomannan is blended with a monosaccharide, the blended solution is filtered, the filtrate is mixed with a precipitating agent for galactomannan to recover and purify galactomannan.)
[0087] Hirofumi, N., Hideki, Y., and Michiyoshi, A. Purification of galactomannan. Japan Patent JP63035606 (Feb. 16, 1988).
[0088] (The pH of an aqueous solution obtained by dissolving a galactomannan-containing product such as crushed guar beans, locust beans or tara beans in hot water at 70° C. or above is adjusted to 4.5-6.5 by adding an acid to the solution. A filter aid (e.g., pearlite) of a mean particle diameter of 15-20 microns is added to this aqueous solution. This solution is filtered to remove insoluble matter such as protein and cellulose, and a hydrophilic organic solvent such as methanol or isopropyl alcohol is added to the filtrate to precipitate gum. This gum is dehydrated by pressing, dried and ground.)
[0089] Morikawa, M. and Suzuki, S. Purification of locust bean gum. JP63105004 (May 10, 1988).
[0090] (Crude locust bean gum is dissolved in warm water and filtering, followed by recovering the locust bean gum and drying.)
[0091] Xanthan Gum Clarification:
[0092] Kang, K. S. and Petitt, D. J. “Xanthan, Gellan, Welan, and Rhamsan” in Industrial Gums, Polysaccharides and Their Derivatives, Third Edition. Whistler, R. L. and BeMiller, J. N., Editors. Academic Press, 1992, page 346.
[0093] (“A clear product can be produced by diluting the fermentation liquor and clarifying it by filtration.”)
[0094] Rinaudo, M., Milas, M., and Kohler, N. Enzymatic clarification process for improving the injectivity and filtrability of xanthan gums.
[0095] (Abstract: Enzymatic treatment, in aqueous dispersion, of a xanthan gum containing bacteria cell residues and microgels, as impurities, by means of a Basidomycete cellulase . . . , improved the infectivity and filtrability thereof.)
[0096] Murofushi, K., Nagura, S., Homma, T., and Armentrout, R. Process for preparation of a purified xanthan gum. European Patent Application No. 92311401.1 (Jun. 30, 1993).
[0097] (Heat treatment followed by alkaline protease and lysozyme, then recovering the xanthan from the broth. “A clear aqueous solution of the xanthan gum may be obtained without complex procedures”.)
[0098] Aloe Acemannan Clarification:
[0099] McAnnalley, B. H. Process for preparation of aloe products, products produced thereby and compositions thereof. U.S. Pat. No. 4,735,935 (Apr. 5, 1988).
[0100] (Patent covering isolation of acemannan)
[0101] McAnnalley, B. H. Process for preparation of aloe products, products produced thereby and compositions thereof. U.S. Pat. No. 4,917,890 (Apr. 5, 1988).
[0102] (Patent covering isolation of acemannan)
[0103] Vilkas, E. and Radjabi-Nassab, F. The glucomannan system from Aloe vahombe (liliaceae), III. Comparative studies on the glucomannan components isolated from the leaves. Biochemie 6, 1123-1127 (1986).
[0104] (Aqueous sol prepared and centrifuged. Supernatant coagulated in ethanol.)
[0105] Mandal, G. and Das, A. Structure of the glucomannan isolated from the leaves of Aloe barbadensis (MILLER) Carbohydrate Research 87, 249-256 (1980).
[0106] (Aqueous sol prepared and centrifuged.)
[0107] Hydrocolloid Co-processing:
[0108] Yoshida, H., Kamiya, S., Takano, Y., and Toba, S. Instant konjac mannan food. Jpn. Kokai Tokkyo Koho JP62 96,061 (May 2, 1987).( Chem. Abstracts 107, 133074 (1987).
[0109] (“A solution containing konjac mannan and xanthan gum (95-5:5-95) at acidic to neutral pH is dried to give an instant konjac mannan food with high water absorbency and reconstitution rate”—konjac was not deacetylated.)
[0110] Kira, M. Preparation of agar gel (tokoroten) containing glucomannan. JPN. Kokai Tokkyo Koho JP 05, 199,853 (Aug. 10, 1993). (CA 119:224827 1993).
[0111] (“Tokoroten with improved strength and elasticity and yet without the odor of agar is prepared by the addition of glucomannan and thickening agents into the weak alkali-treated agar. After the mixture is heated to dissolve, it can be deodorized and decolorized prior to gelling”.)
[0112] Tako, M. Synergistic Interaction between Xanthan and Konjac Glucomannan in Aqueous Media. Biosci. Biotech. Biochem . 56(8), 1188-1192 (1992).
[0113] (Synergistic gel formation described for native, de-pyruvated, and de-acetylated clarified xanthan and clarified konjac. For clarification of the xanthan, a 0.1% sol of commercial xanthan in distilled water was heated at 90° C. for 30 minutes, then cooled to room temperature and filtered through Celite 545. The filtrate was made to 0.1% with KCl, coagulated in 2 volumes of ethanol, the precipitate collected and dried in vacuo. The konjac flour was soaked in 50% ethanol for three days at room temperature. The suspension was filtered and the residue was dissolved by stirring with distilled water at 90° C. for 30 minutes. The sol was filtered through Celite 545 and the clear filtrate coagulated in 2 volumes of ethanol. The precipitate was collected and dried in vacuo.
[0114] Nippon Chemipharm. Manufacture of konnyaku glucomannan for electric migration gel materials. Jpn. Kokai Tokkyo Koho JP58, 213,001 (Dec. 10, 1983).
[0115] (Purification by forming a sol, centrifuging, and coagulating the supernatants in ethanol.)
[0116] Kawano, N. Instantly Soluble Glucomannan Composition, Its Use and Preparation. Japan Patent Disclosure No. H5-38263. (Feb. 19, 1993).
[0117] (Fluidized bed granulation and drying of mixed polysaccharides, including konjac.)
[0118] Fujihara, K. and Nakagawa, T. Method of producing readily soluble poly-saccharides. Japan Patent Disclosure No: 1982-[Showa]-28.203 (Feb. 15, 1982).
[0119] (Dissolving polysaccharides or mixtures and spray-drying. Only mixture given is locust bean gum/xanthan.)
[0120] Musson, G. D. and Prest, C. T. Thermo-irreversible edible gels of glucomannan and xanthan gums. U.S. Pat. No. 4,894,250 (Jan. 16, 1990).
[0121] (preparation of deacetylated konjac gels containing xanthan and, optionally, carrageenan, pectin, algin, agar, gellan, and/or guar)
[0122] Fukuda, T. Manufacture of dried konjac with mono- and/or oligosaccharides Japan Kokai Tokkyo Koho JP 04 08,257 (Jan. 13, 1992) CA 116:172746c (1992).
[0123] (Dry konjac is manufactured by mixing konjac with mono- and/or oligosaccharides and drying. Rehydration in water restores its original gel state)
[0124] Kawano, K. Instantly soluble glucomannan composition, its use and preparation Japanese Unexamined Patent Application Disclosure H5-38263 (Feb. 19, 1993) WPI Acc No: 93-096400/12.
[0125] (Non-deacetylated konjac is co-processed with a variety of hydrocolloids (carrageenan, xanthan, agar, alginates, pectin, starch CMC, polyacrylates, etc.) by mixing in the fluid state, then drying to give products that are readily dispersible and soluble in water)
[0126] Renn, D. W., Lauterbaugh, G. E., and Hemmingsen. P. Soluble dried cassia alloy gum composition and process for making same U.S. Pat. No. 4,952,686 (Aug. 28, 1990).
[0127] (The initial patent on the technique of co-processing insoluble or poorly soluble hydrocolloids with one or more other hydrocolloids to impart solubility or other important properties. Clarified Cassia galactomannan coprecipitated with various gums to improve solubility of the galactomannan. Composite of clarified Cassia gum and xanthan is highly water absorbent.)
[0128] Snow. W. C. and Renn, D. W. Glucomannan spongeous matrices. Patent Nos. WO 09402029A1 (Feb. 3, 1994) and EP 650348A1 (May 5, 1995).
[0129] (Konjac co-processed with agar or at least one other gelling polysaccharide to form a spongeous matrix)
[0130] Yoshida, H. et al. Instant Konjak mannan food Jpn. Kokai Tokkyo Koho JP 62 96,061 (May 2, 1987) CA 107: 133085f (1987).
[0131] (Solution of konjac mannan and xanthan at acidic to neutral pH was dried to give an instant konjac mannan product with high water-absorbency and reconstitution rate—konjac was not deacetylated)
[0132] Applegren, C. H. Process for preparing a product comprising guar-gum U.S. Pat. No. 4,754,027 (Jun. 28, 1988).
[0133] (Guar composites produced by granulating non-clarified guar with sols of non-gelling hydrocolloids.)
[0134] Toba, S., Yoshida, H., and Tokita, T. Konjac mannan-containing reversible gel. U.S. Pat. No. 4,676,976. (Jun. 30, 1987).
[0135] (Reversible konjac/xanthan gel formation with strongest gels at 4:1 ratio)
[0136] Ishikawa, H. et al. Preparation of freeze-resistant konjac. Japanese Patent Application No. 60-4019, Filed Jan. 16, 1985, Abstract published Dec. 12 1986.
[0137] (Co-processed, but not dried, deacetylated konjac and insoluble alginate)
[0138] Ueno, K. Preparation of konjak resistant to freezing. Jpn. Kokai Tokkyo Koho JP 05 00,055 (Jan. 8, 1993) CA118: 146606d (1993).
[0139] (“Konjak resistant to freezing is prepared by adding starch and natural gums, e.g., locust bean gum and tara gum.”)
[0140] Umehara, S. et al., A dry gel containing starch and konnyaku mannan as an instant konnyaku Jpn. Kokai Tokkyo Koho JP 62, 259,550 (Nov. 11, 1987) CA108: 149158p (1988).
[0141] (dried gel of deacetylated konjac and starch that hydrates to gel particles in boiling water.)
[0142] Vernon, A. J. et al., Thermo-irreversible gelling system and edible materials based thereon European Patent Application Publication No.: 0 050 006 (Jul. 10, 1981).
[0143] (konjac and carrageenan gelled using phosphate buffer and heat)
[0144] Suto, S. et al., Scanning electron microscopy of blend of konjac mannan and hydroxypropyl cellulose. Sen-I Gakkaishi 48(8) 437-440 (1992).
[0145] (gel prepared from blend of konjac and hydroxypropyl cellulose)
[0146] Ikeda, M. and Harada, S. “Low calorie processed food made with gel particles of glucomannan coagulum” U.S. Pat. No. 5,213,834 (May 25, 1993).
[0147] (encapsulated organic acids to neutralize alkaline gels of konjac and konjac gels made with the addition of other hydrocolloids, such as carrageenan, alginates, locust bean gum, agar, xanthan, etc.)
[0148] Kawano, N. Instantly soluble glucomannan composition, its use and preparation. Japanese Unexamined Patent Application Disclosure H5-38263 (Feb. 19, 1993) WPI Acc No: 93-096400/12.
[0149] (non-deacetylated konjac is coprocessed with a variety of hydrocolloids (carrageenan, xanthan, agar, alginates, pectin, starch CMC, polyacrylates, etc.) by mixing in the fluid state, then drying to give products that are readily dispersible and soluble in water)
[0150] Hydrocolloid Films, Foams, Gels, and Sponges:
[0151] D. A. Harper, J. H. Morgan, S. Nochumson, M. V. Ostrovsky, D. W. Renn, W. C. Snow. “Agarose compositions for nucleic acid sequencing” U.S. Pat. No. 5,455,344 (Oct. 3, 1995).
[0152] (Sequencing nucleic acids using a polysaccharide gel medium in the presence of denaturing agents—includes deacetylated konjac gels)
[0153] Snow. W. C. and Renn, D. W. Glucomannan spongeous matrices. Patent Nos. WO 09402029A1 (Feb. 3, 1994) and EP 650348A1 (May 3, 1995).
[0154] (Konjac co-processed with agar or at least one other gelling polysaccharide to form a spongeous matrix upon freezing and thawing)
[0155] Masao, K. Glucomannan/polyhydric alcohol composition and film prepared therefrom. European Patent Application Publication No. 0 273 069 (Jun. 7, 1988).
[0156] (Konjac glucomannan films and applications.)
[0157] Kakizaki, T. and Kdubodera, M. Edible glucomannan film for food packing. Jpn. Kokai Tokkyo Koho JP 62,126,950 (Jun. 9, 1987). (CA107, 613, (1987).
[0158] (“A composition containing glucomannan, optionally other natural polysaccharides, and one or more of polyhydric alcohols, sugar alcohols, monosaccharides, disaccharides, and oligosaccharides is kneaded, dissolved in water, and made into a film to produce an edible film for food packaging”).
[0159] Merritt II, F. M. Edible film and method. U.S. Pat. No. 5,962,053. (Oct. 5, 1999).
[0160] (Abstract: Described is an edible, water insoluble film which is a blend of polysaccharide and protein and, in particular, a ternary blend of konjac flour as a major constituent, agar and gelatin. Also described is a method of forming the film including a deacetylating step to insolubilze the konjac flour.)
[0161] Nussinovitch, A. Sponge comprising expansion product of hydrocolloid. WO 9417137 A (Aug. 4, 1994).
[0162] (“Sponge is formed by foaming one or more hydrocolloids selected from agar, carrageenan, gelatin, alginate, starch, pectin, gellan konjak, mannan or xanthan locust bean gum. The sponge containing a plasticiser (esp. glycerol, sorbitol or other polyol, a sugar or sugar substitute, bubbles of a gas other than air and opt. a flavoring agent or taste enhancer.”)
[0163] Tanabe, O et al., Fiber-rich foods made from Konjak flour. Jpn. Kokai Tokkyo Koho JP 01, 256,366 (Apr. 4, 1988) CA113: 57776p (1990).
[0164] (water-insoluble, gelled deacetylated konjac recovered by freeze thawing—not dried)
[0165] Sakamoto, J and Tanuma, H. Low-calorie food products containing konjac mannan and processes for preparing the same U.S. Pat. No. 5,116,631.
[0166] (non-deacetylated konjac as a foam stabilizer for egg white meringues).
[0167] Ford, D. M. and Cheney, P. A., “Air or oil emulsion food product having glucomannan as sole stabilizer-thickener” U.S. Pat. No. 4,582,714.
[0168] (non-deacetylated konjac as a aerated food stabilizer)
[0169] Nozaki, H. et al. Devil's tongue-containing whip cream. Japanese Patent Application No. 01-177050, Filed Jul. 11, 1989, Abstract published May 7, 1991.
[0170] (prepared alkaline deacetylated gel added to cream while whipping)
[0171] Sawaguchi, K. Meringue. Japanese Patent Application No. 57-126718, Filed Jul. 22, 1982, Abstract published May 12, 1984.
[0172] (use of non-deacetylated konjac to stabilize meringues)
[0173] Sugino, Y. Porous gel foods and their manufacture from glucomannan and whipped egg white. Jpn. Kokai Tokkyo Koho JP 04 11,85 (Jan. 16, 1992).
[0174] (egg white/konjac whipped together then set (deacetylated) with calcium hydroxide and heat)
[0175] Bakis, G. et al., “Production of polysaccharide foam comprises mechanically foaming aqueous solutions of soluble polysaccharide, e.g., alginate, hyaluronate, carrageenan, chitosan or starch”WO 9400512 (Jan. 6, 1994) WPI Acc No: 94-026166/03.
[0176] (mechanically foaming an aqueous solution of a polysaccharide and used as wound dressing etc.)
[0177] Borate Interaction Products:
[0178] Renn, D. W. Solid borate-diol interaction products for use in wounds. World Patent WO 09953968A1 (Oct. 28, 1999).
[0179] (Interaction of sodium tetraborate with PVA and polysaccharides, glucomanans and galactomannans, having a cis 1,2-diol configuration in their structure).
[0180] Hogi, T. and Kameda, N., Transparent konnyaku mannan gels for optical products. JP 05,194,603 (93, 194,603) Aug. 3, 1993.
[0181] (Konjac mannan and sodium tetraborate product for contact lenses and medical optical devices.)
[0182] Muller, E. G., Borated polysaccharide absorbents and absorbent products. U.S. Pat. No. 4, 624,868. Nov. 25, 1986.
[0183] (Guar gum as an exemplification of cis-1,2-diol polysaccharides is first hydrated then thickened by cross-linking with borax and finally dried to a powder to flake form, preferably by freeze drying. The resulting particles can absorb up to 100 times their weight or more of aqueous fluids such as urine. Absorbent articles, such as disposable diapers, bandages, and the like are formed with the borax-cross-linked guar gum as absorbent.)
[0184] Anderson, R. L. Flushable premoistened wiper. U.S. Pat. No. 4, 362, 781. Dec. 7, 1982.
[0185] Premoistened wiper comprising a nonwoven web impregnated with a modified guar gum (phosphated) (5-14% of fiber weight)and wet with an aqueous lotion containing borate ions. Lotion also contains an organic hydroxy or keto acid or salt thereof (such as potassium citrate) capable of complexing with borate ions.
[0186] Zimmerman, V et al. Thin sanitary products with a pre-fabricated absorbent body. International Application Publication No. WO 95/17147. Jun. 29, 1995.
[0187] (Fibers coated with particles of a galactomannan, or derivative thereof)
[0188] Rademacher, K. and Fritsce, U. (Sebapharma) Dressing system. WO 9203172. Feb. 20, 1992.
[0189] (The bandage, dressing or support matrix consists of a biocompatible, open-pored plastic foam with a hydrogel embedded in the pores. The hydrogel is formed from a borate-modified Guar gum . . . )
SUMMARY OF INVENTION
[0190] The invention is directed to a process of producing a clarified hydrocolloid which, when hydrated, forms a clear sol, the said process comprising: (a) soaking a hydrocolloid-containing material dispersed in water until the hydrocolloid is hydrated; (b) stirring the hydrated hydrocolloid until a homogenous particulate-containing sol is obtained; (c) removing the insoluble particulates to produce a clarified sol; (d) removing any remaining particulates in the clarified sol by filtration; and (e) recovering clarified hydrocolloid directly from the filtrate.
[0191] The insoluble particulates in step (c) can be removed by centrifugation or by coarse filtration.
[0192] The hydrocolloid can be selected from the group consisting of konjac glucomannan, guar gum, locust bean gum, aloe mannan, agar, agarose, algins, β-, κ-, λ-ι-carrageenans, chitosan, collagen, curdlan and other β-1,3-glucans, fig seed gum (galacturonan), gellan, hyaluronic acid, pectins, Rhizobium gum, Porphyridium cruentum polysaccharide, starches (amylose, amylopectin), acacia gum, gum arabic, chondroitin sulfates, dextrans, flaxseed gum, gum ghatti, inulin (fructan), karaya gum, larch arabinogalactan, levan (fructosan), cassia gum, tara gum, fenugreek gum, oat glucans, okra mucilage, psyllium seed gum, pullulan, quince seed gum, rhamsan, scleroglucan, succinoglucan, tamarind gum, gum tragacanth, wellan, and xanthan gum.
[0193] In cases where the hydrocolloid is insoluble at ambient temperature, the hydrated colloid can be heated to solubilize the hydrocolloid before proceeding with step (c).
[0194] When the hydrocolloid is konjac glucomannan, the hydrated konjac can be heated to a temperature of less than or equal to about 45° C.
[0195] In conducting step (b) the hydrated colloid can be shear-stirred until a homogenous sol is obtained. Furthermore, in conducting step (e), water-miscible alcohol can be added to the solution.
[0196] The hydrocolloid recovered from the filtrate in step (d) can be dried to form a solid. The hydrocolloid after drying can be ground to a consistency of about 100 mesh.
[0197] The viscosity of the clarified hydrocolloid sol obtained after the performance of step (e) can be within about 70 to 90 percent of the viscosity of the untreated hydrocolloid sol at equivalent hydrocolloid concentration.
[0198] The sol of one or more other hydrocolloids can be added before recovery to yield clarified hydrocolloid composites.
[0199] A second clear hydrocolloid sol can be added before step (e) is performed. Alternatively, a second unclarified hydrocolloid sol can be added before step (c). Furthermore, a dry first hydrocolloid and a second dry hydrocolloid can be mixed before performing step (a).
[0200] The invention is also directed to a process of producing a hydrocolloid which when hydrated forms a clear sol comprising soaking the hydrocolloid in water until the hydrocolloid is hydrated, shear-stirring the hydrated hydrocolloid until the homogenous particulate-containing sol is obtained, centrifuging the sol to remove any filter-blinding material, adding a filter aid to the centrifugate, filtering the centrifugate at a temperature less than about 45° C., recycling the filtrate until it is clear, recovering the clarified hydrocolloid by miscible alcohol coagulation, and maintaining re-solubility characteristics of the clarified hydrocolloid by washing with high titer alcohol.
[0201] The invention includes a process of producing a konjac glucomannan which, when hydrated, forms a clear konjac glucomannan sol which comprises dispersing a konjac containing flour in water, permitting the dispersed konjac-water mixture to stand at room temperature until the konjac is hydrated, subjecting the hydrated konjac mixture to a high shear stirring action to produce a smooth sol, centrifuging the smooth sol to remove insoluble particulates in the mixture, adding a filter aid to the filtrate and mixing the filter aid into the mixture, filtering the mixture at a temperature less than 45° C. to obtain a clear filtrate, treating the clear filtrate with isopropyl alcohol to coagulate the konjac glucomannan, collecting the konjac coagulated konjac, and drying the konjac.
[0202] The invention also incorporates a process of producing a guar gum which when hydrated forms a clear guar gum sol, which comprises dispersing a guar gum containing material in water by first wetting the material with isopropyl alcohol and then adding water to the mixture, heating the mixture with stirring until homogenous and hydration of the guar is complete, centrifuging the mixture, adding a filter aid to the mixture and mixing the filter aid thoroughly into the mixture, filtering the mixture, adding an isopropyl alcohol to the filtrate obtained from the filtration step, collecting coagulated guar gum, drying the guar gum and grinding the collected coagulated guar gum into a powder.
[0203] The invention is also directed to a process of producing a locust bean gum powder which when hydrated forms a clear locust bean gum sol comprising adding a locust bean gum containing material to water, heating the locust bean gum-water mixture to the boiling point, stirring the mixture until a homogenous mixture is obtained, centrifuging the mixture, adding a filter aid to the centrifugate, mixing the mixture until homogeneous, filtering the mixture to obtain a clear filtrate, adding isopropyl alcohol to the filtrate to coagulate the locust bean gum, collecting the coagulated locust bean gum, drying the coagulated locust bean gum and grinding to yield a powder.
[0204] The invention includes in a further embodiment a process of producing an aloe mannan which when hydrated forms a clear aloe sol comprising adding an aloe mannan containing material to water, permitting the aloe-water mixture to stand until the aloe mannan is hydrated, raising the temperature of the aloe-water mixture to the boiling point, mixing the mixture until a homogenous mixture is obtained, centrifuging the mixture to remove undesirable particulates, adding a filter aid to the centrifugate, filtering the mixture, coagulating the aloe mannan by adding a miscible alcohol to the mixture, collecting the coagulated aloe mannan, drying the coagulated aloe mannan and grinding it to obtain a powder.
[0205] The invention is also directed to a process of producing a xanthan gum which when hydrated forms a clear xanthan gum sol comprising dispersing a xanthan gum containing material in water, heating the xanthan-water mixture to the boiling point, mixing the mixture until homogeneity is obtained, centrifuging the mixture to remove undesirable particulates, adding a filter aid to the mixture, heating to boiling, filtering the mixture, coagulating the xanthan by adding a miscible alcohol to the filtrate, collecting the coagulated xanthan gum and drying the coagulated xanthan gum and grinding it to obtain a powder.
[0206] The invention in a further version includes a process of producing a hydrocolloid composite which when hydrated forms a clear hydrocolloid composite sol comprising dispersing a first clarified hydrocolloid and at least a second clarified hydrocolloid in water, adding sodium chloride to the sol, mixing the mixture to obtain a homogenous mixture, and coagulating the first hydrocolloid with the second hydrocolloid as a precipitate by adding a miscible alcohol, collecting the coagulated hydrocolloid composite, drying the composite and grinding it to form a powder.
[0207] The invention is also directed to a clarified hydrocolloid or a composition comprising clarified konjac and clarified guar gum which composition forms a clear sol when mixed with water, a composition comprising clarified konjac and clarified xanthan gum which composition forms a clear sol when mixed with water, a composition comprising clarified xanthan gum and clarified guar gum which composition forms a clear sol when mixed with water, a composition comprising clarified aloe mannan and clarified guar gum which composition forms a clear sol when mixed with water, a composition comprising clarified konjac and clarified agar which composition forms a clear sol when mixed with water, a composition comprising clarified aloe mannan and clarified konjac which composition forms a clear sol when mixed with water, a composition comprising clarified konjac and clarified carboxymethyl cellulose which composition forms a clear sol when mixed with water, or a composition comprising clarified guar gum and clarified carboxymethyl cellulose which composition forms a clear sol when mixed with water.
[0208] The invention is also directed to a process of forming low sol viscosity hydrocolloids by having the particulate hydrocolloids absorb hydrogen peroxide and then heating the hydrocolloids or permitting the hydrated colloids to remain at room temperature for an extended period.
[0209] The invention includes a process of producing a reduced viscosity konjac which comprises adding hydrogen peroxide to the konjac-containing solid, blending the mixture until a homogenous paste is obtained, heating the paste to about 65° C. for about five hours, cooling the mixture to about room temperature, adding a filter aid to the mixture, filtering the mixture to obtain a clear filtrate, adding isopropyl alcohol to the clear filtrate to precipitate konjac, and collecting the coagulated konjac, drying the coagulated konjac and grinding it to form a powder.
DRAWINGS
[0210] In drawings which illustrate specific embodiments of the invention, but which should not be construed as restricting the spirit or scope of the invention in any way:
[0211] [0211]FIG. 1 illustrates a schematic flow sheet of the hydrocolloid clarification process according to the invention.
[0212] [0212]FIG. 2 illustrates a schematic diagram of the practical applications that can be made of the clarified hydrocolloids according to the invention.
DETAILED DESCRIPTION OF INVENTION
[0213] Although there are a number of published procedures in patent and journal literature for clarifying hydrocolloids, such as glucomannans, galactomannans, and fermentation polysaccharides, particularly for structure determination and derivatization, no clarified products having significant sales seem to be available commercially. This fact tends to demonstrate that none of these methods are cost-effective or, in some cases, capable of scale-up, or in other cases, the clarified hydrocolloids suffer a loss in properties, when compared to the unclarified hydrocolloids. In the case of locust bean gum and konjac, clarified products are manufactured by, for example, FMC Corporation to be sold as blends. Significant viscosity reduction is evident with their commercial products, but not evident in products produced by this invention.
[0214] We have developed a simple but non-obvious process that results in dry hydrocolloid products that, when reconstituted, form clear viscous sols, free from essentially all particulates and retain desirable physical properties, unlike commercial products. The method according to the invention appears to surmount the difficulties with prior processes by minimizing heating and high-shear stirring in the dissolution step. This keeps the impurities in as large a particulate state as possible. The process follows with centrifuging to remove the filter-blinding materials, filtering the mixture at a temperature less than about 45° C., except when the polysaccharides are insoluble at this temperature, using an appropriate filter aid, recycling the filtrate until it is crystal clear, recovering the clarified hydrocolloid through isopropyl alcohol coagulation, and maintaining ready re-solubility in the clarified products with a final wash of high-titer alcohol. This procedure can be used to clarify virtually all hydrocolloids, including konjac, guar gum, locust bean gum, Aloe acemannan, and xanthan gum, to name a few.
[0215] The clarified hydrocolloids obtained by the method according to the invention can be recovered directly, such as by coagulation in isopropyl alcohol, or can be combined with one or more other hydrocolloid sols and then recovered. The process of the invention can impart unique properties to the composite clarified hydrocolloids that are different from the original clarified hydrocolloids. Such properties cannot be achieved by direct blends of the solid materials. In one embodiment of the invention, a simple yet unique way for preparing low-viscosity, clarified depolymerized konjac has also been discovered and developed.
[0216] The products and process of the invention differ from the prior art in a number of respects. There are in existence a number of patents and publications that disclose procedures for “clarifying” konjac and other hydrocolloids. The products derived from most of these procedures are either unsatisfactory or the method is laborious and not cost-effective. Using the method according to the invention for clarifying polysaccharides, it is likely that cost-effective products can be obtained. These clarified polysaccharides can either be blended with other ingredients, co-precipitated with other hydrocolloids, or co-dried with other materials, leading to a number of interesting and useful, commercially feasible, clarified polysaccharide-based products.
[0217] The key inventive and successful factors with this process, and what makes it unique and different from existing konjac clarification processes, and other hydrocolloid clarification procedures is a combination of the way the crude hydrocolloids are reconstituted to minimize the possibility for degradation or conversion to insoluble entities, maintaining the impurities in as large a particle size as possible, the centrifugation method used to remove the filter-blinding solids, the filtration, and the polysaccharide recovery. All these steps lead to retention or enhancement of viscosity and other desirable properties.
[0218] The use of hydrogen peroxide in a heterogeneous reaction, i.e., imbibing the peroxide into the dry konjac powder and allowing the reaction to take place until the mixture becomes fluid, also is unique.
Clarifying Other Natural Polysaccharides
[0219] In addition to the polysaccharides mentioned in this discussion, there is no reason to believe that the following natural polysaccharides cannot be clarified using appropriate temperature and time modifications of the basic method. A non-limiting list follows.
[0220] Gelling
[0221] Agar, agarose, algins, β-, κ-, ι-carrageenans, chitosan, collagen, curdlan and other β-1,3-glucans, fig seed gum (galacturonan), gellan, hyaluronic acid, pectins, Rhizobium gum and Porphyridium cruentum polysaccharide.
[0222] Non-gelling
[0223] Acacia gum, gum arabic, λ-carrageenan, chondroitin sulfates, dextrans, flaxseed gum, gum ghatti, inulin (fructan), karaya gum, larch arabinogalactan, levan (fructosan), cassia, tara, fenugreek and other galactomannans, oat glucans, okra mucilage, psyllium seed gum, pullulan, quince seed gum, rhamsan, scleroglucan, starches (amylose, amylopectin), succinoglucan, tamarind gum, gum tragacanth, wellan, and xanthan gum.
EXAMPLES
[0224] Although isopropyl alcohol (2-propanol) coagulation has been used as the recovery method in many of the examples given, it is conceivable that other methods, such as spray drying, freeze drying, etc., can be used as well, to recover the clarified polysaccharides and composites.
CLARIFICATION PROCEDURES
Clarified Koniac (High Viscosity)
Example 1
[0225] (Using NaCl (aq.) to dissolve the Konjac, Direct Filtration) (MBI Notebook DWR1, p. 38):
[0226] Using a 2-litre Pyrex measuring bowl, 10 grams of AMOPHOL LG konjac powder (Shimizu Chemical Corp., lot LHB27) was dispersed in 1 litre of de-ionized water (tap water may be satisfactory) containing 25 grams of dissolved NaCl using a hand-held Braun blender/homogenizer to assure complete dispersion and minimize clumping. The container was covered with plastic film and the contents heated to boiling in a microwave oven. Occasional hand-stirring with a spatula was needed initially to keep the swelling particles from settling. The hot mixture, containing both dissolved konjac and swollen particles as well as particulate impurities, was allowed to cool to near room temperature. A brief high shear blending with the Braun Blender was used to assist in the dissolution of the swollen particles. Fifty grams of Dicalite SpeedPlus filter aid was added, along with 500 ml of de-ionized water. The mixture was blended briefly (Braun Blender), then filtered through a cloth pad in a 2-litre pressure filtration device, recycling until crystal clear. The clear filtrate was collected ( − 1400 ml) and then coagulated in 3 litres of 85% isopropyl alcohol (IPA)(aq.). After ½ hour, the white, voluminous fibrous coag was collected on fine-mesh Nitex cloth, squeezed, pulled apart, washed in 500 ml 60% IPA for ½ hour using magnetic stirring, again collected on Nitex, squeezed, pulled apart, and washed, with magnetic stirring in 500 ml of 99% IPA. The washed, clarified konjac fibers were again collected on Nitex cloth, squeezed, then pulled apart and dried in a forced air oven at about 40° C. The dried, fluffy white product, 7.4 g or 74% yield, without moisture correction, was ground to −20 mesh. A clear 0.5% sol was formed when this material was dissolved in 0.5% NaCl(aq.) A 1% sol in de-ionized water exhibited a viscosity of 10,870 mPas at 25° C., using the #2 spindle and 0.3 rpm settings on the Brookfield DV-II+Viscometer. An equivalent concentration of the starting material (1.35% based on 74% yield) had a viscosity of 5,250 mPas at 22° C., #2 spindle, 0.3 rpm.
Example 2
[0227] (MBI Notebook DWR1, pp. 16, 26, 29, 32, 36, 37):
[0228] In a similar manner other konjac flour-based products from Shimizu Chemical Industries, AMOPHOL TS, PROPOL RS, and PROPOL RX-H were clarified. Yields obtained were 72.0%, 65.5%, and 58.2% respectively.
Example 3
[0229] (No Salt, no Centrifugation) (MBI Notebook DWR1, p.46):
[0230] Five grams of AMOPHOL TS (Lot TGJ22, Shimizu Chemical Corporation) was dispersed in 0.5 litres of de-ionized water using a spatula. The mixture was heated to boiling in a microwave oven. An additional 250 ml of de-ionized water was added and stirred in using an Arrow overhead stirrer. To this was added 25 grams of Dicalite Speed Plus filter aid and stirred until homogeneous. This was filtered at room temperature through a thick cloth pad in a 2-litre pressure filtration apparatus (PFA). Only 200 ml of clear filtrate was collected before a tough film blinded the filter. The filtrate was coagulated in 400 ml of 85% IPA, stirring with a spatula while pouring. After one-half hour, the coag was collected on Nitex cloth, squeezed, and washed by stirring with 200 ml of 60% IPA for 20 minutes, again collecting on Nitex cloth and squeezing. 200 ml of 99% IPA was used for the final wash. After collecting and squeezing, the coag was dried at about 38° C. in a one-pass hot air oven. After grinding to −20 mesh, 0.4 g (about 60% yield) of white powder was obtained.
[0231] In a like manner, 10 g of Konjac Flour M (Shimizu Chemical Corporation, Lot 981027) was clarified with 6.37 g (63.7% yield) being obtained. The viscosity of a 1% sol of the clarified material was 1,156 mPas compared with a 1% viscosity of 656 mPas for the Konjac Flour.
Example 4
[0232] (Water, Centrifugation, Filtration) (MBI Notebook DWR3, p10)
[0233] Filtration difficulties were encountered with direct filtration of the konjac sol because of the formation of a waxy flexible film on the surface of the filter aid. The procedure was modified to include a centrifugation step before filtration. Filtration of the combined centrifugates was rapid and able to be done at low pressure input.
[0234] To 1 litre of de-ionized water was added 6.7 g of Konjac Flour AP (Shimizu Chemical Corporation, Lot 990820) and dispersed using a wire whisk attachment on a Braun hand-held blender. After standing at room temperature for about one hour to hydrate, the high-shear blade attachment to the Braun blender was used to prepare a smooth sol. This sol was distributed into 4 screw-cap polypropy-lene centrifuge bottles and centrifuged at 11,000 rpm for 40 minutes, using a Sorvall RC2-B centrifuge. After the supernatants were removed by decantation and combined, 50 g of Dicalite Speed Plus filter aid was added and mixed in thoroughly. This was filtered through a felt pad in a 2-litre pressure filtration device. Filtration was rapid and accomplished at <20 psi. The filtrate (800 ml) was sparkling clear. To this was added 500 ml of 99% IPA and the stirred with a spatula to mix thoroughly. A mucoid coag formed which on standing became firm enough to handle. This was collected on Nitex cloth, squeezed, pulled apart and washed in 300 ml of 99% IPA and again collected on Nitex cloth, squeezed and dried at about 38° C. in a one-pass hot air oven. After grinding to −20 mesh, 2.38 g (about 35.5% yield) of white powder was obtained. A 1% sol in de-ionized water was clear and exhibited a viscosity of 8,125 mPas at 21.3° C., using the #2 spindle and 0.3 rpm settings on the Brookfield DV-II+Viscometer. Conductivity was 20 μS at 21.5° C. using an Oakton TDSTestr™ conductivity meter.
[0235] Two pilot plant scale-ups of this procedure yielded white powders having viscosities of 25,250 and 29,030 mPas respectively for 1% sols compared with 32,500 for a 1.35% sol of the Konjac Flour AP.
Clarified Partially De-polymerized Konjac (Low Viscosity)
Example 5
[0236] (MBI Notebook3, pp. 2,4.)
[0237] To 350 g of AMOPHOL TS (Shimizu Chemical Corporation, Lot THF 19) in a stainless steel 5-quart Kitchen Aid mixing bowl was added 1400 ml of 10% hydrogen peroxide and the mixture blended until it became a stiff homogeneous paste. The bowl was covered with Saran Wrap and placed in a 65° C. water bath for 5 hours, occasionally mixing with a spatula. During this time a nearly clear, slightly yellow, low-viscosity fluid was obtained. After allowing the reaction product to cool to room temperature, 25 g of Dicalite Speed Plus filter aid was added and mixed in with a broad spatula. This mixture was filtered through a 30 g pre-coat of the filter aid on a felt pad in a 2-litre pressure filtration device. The clear filtrate (ca. 1500 ml) was coagulated in 4.5 litres of rapidly stirring 99% IPA. The fine precipitate was collected on Nitex cloth, squeezed, washed for 20 minutes in 4 litres of stirred 99% IPA, collected on Nitex cloth, squeezed, and dried at about 38° C. in a one-pass hot air oven. 299.5 g (86.5%) of fine white granular powder was obtained. A clear 10% solution (w/w) of this material in de-ionized water was easily prepared. Properties of this 10% solution were as follows: viscosity=1.4 mPas, pH=2.98, turbidity=16.4 N.T.U.
Clarified Guar Gum
Example 6
[0238] (MBI Notebook DWR3, p.33)
[0239] Commercial grade guar gum, PROCOL F (Lot: A7265B),was obtained from Polypro International, Minneapolis, Minn. To 10 g was added 30 ml of 99% IPA and the mixture stirred with a spatula until homogeneous. While agitating with the wire whisk attachment to a Braun hand-held blender, one litre of de-ionized water was added rapidly and stirred until nearly homogeneous. After standing at room temperature for one hour to complete hydration, the mixture was heated to boiling using a microwave oven then homogenized using the blender attachment. The mixture was reheated to boiling and transferred to 2-250 ml polypropylene screw-cap centrifuge bottles and centrifuged for 30 minutes at 11,000 rpm, using a Sorvall RC2-B centrifuge. After the supernatants were removed by decantation and combined, 25 g of Dicalite Speed Plus filter aid was added and mixed in thoroughly. This was filtered through a 30 gram pre-coat of the Speed Plus on a felt pad in a 2-litre pressure filtration device. The filtrate (ca. 800 ml) was sparkling clear. This was coagulated in 800 ml of rapidly stirring 99% IPA. The coag was collected on Nitex cloth, squeezed, pulled apart and washed in 250 ml of 99% IPA and again collected on Nitex cloth, squeezed and dried at about 38° C. in a one-pass hot air oven. After grinding to −20 mesh, 4.65 g (46.5% yield) of white powder was obtained. The 1% sol viscosity of clarified guar was >2,000 mPas compared with 2,575 mPas for a 1% sol of the PROCOL F.
Clarified Locust Bean Gum
Example 7
[0240] (MBI Notebook DWR1, p.43)
[0241] Using a Braun hand-held mixer, 2 g of commercial locust bean gum (T.I.C. Gums, Por/A, FCC Powder, Lot: P00124) was suspended in 300 ml of de-ionized water containing 2 g of NaCl. This was covered with Saran Wrap and heated to boiling in a microwave oven. The mixture was re-blended, 10 g of Dicalite SpeedPlus filter aid was added and mixed in thoroughly. This was then filtered through a 10 g pre-coat of the filter aid on a felt pad in a 500 ml pressure filtration vessel, recycling until sparkling clear. The clarified locust bean gum was recovered by coagulating the filtrate (ca. 250 ml) in 500 ml of 85% IPA. The coag was collected on Nitex cloth, squeezed, and washed successively with 200 ml 60% IPA, and 200 ml of 99% IPA, each time stirring for ½ hour, then collecting the coag on Nitex cloth and squeezing. Drying was effected at about 38° C. in a one-pass hot air oven. After grinding to −20 mesh, 1.28 g (64% yield) of white powder was obtained. A 1% sol of the clarified locust bean gum was clear and colorless and exhibited a viscosity of 438 mPas compared with a 1% sol viscosity of 212 mPas for the starting material.
Clarified Aloe Acemannan
Example 8
[0242] (MBI Notebook DWR3, p.26):
[0243] To 5 g of Aloe glucomannan (Carrington Laboratories' acemannan 95008, Lot: 10608) was added sufficient 99% IPA to just wet the powder evenly when stirred with a spatula. Using the wire whisk attachment to the Braun hand-held mixer, 750 ml of de-ionized water was added. The dispersed suspension was allowed to stand until fully hydrated. The mixture was brought to a boil in a microwave oven and blended using the blender attachment to the Braun. This sol was distributed into 3-250 ml screw-cap polypropylene centrifuge bottles and centrifuged at 10,000 rpm for 30 minutes, using a Sorvall RC2-B centrifuge. After the supernatants were removed by decantation and combined, 25 g of Dicalite Speed Plus filter aid was added and mixed in thoroughly. This was filtered through a 30 g pre coat of the filter aid on a felt pad in a 2-litre pressure filtration device. The filtrate (650 ml) was clear but not sparkling. The clarified Aloe glucomannan was recovered by adding 650 ml of 99% IPA and mixing thoroughly. After standing at room temperature for an hour to harden, the coag was collected on Nitex cloth, squeezed, and washed using 300 ml 99% IPA stirring for ½ hour, then collecting the coag on Nitex cloth and squeezing. Drying was effected at about 38° C. in a one-pass hot air oven. After grinding to −20 mesh, 2.0 g (40% yield) of white powder was obtained. A 1% sol of the clarified Aloe glucomannan was clear and very viscous.
Clarified Xanthan Gum
[0244] Example 9
[0245] (MBI Notebook DWR2, p.7)
[0246] Ten grams of Keltrol T (Monsanto, Lot 8K0725K) was dispersed in one litre of deionized water using a Braun hand-held blender. Dissolution was completed by heating to boiling in a microwave oven. Twenty grams of Celite (3 micron) was added and dispersed uniformly. The mixture was brought to boiling and filtered through a 30 gram pre-coat in a pressure filtration device. About 920 ml of filtrate was collected. This was coagulated in 2 litres of 99% IPA after mixing in 20 ml of 10% NaCl. The coagulum was collected on Nitex cloth, squeezed, and placed in 500 ml of 85% IPA overnight. The coag was collected and dried at about 38° C. in a single-pass, forced air oven. The white product was ground to −20 mesh yielding 6.8 g (68%) of powder. The viscosity of a 1% sol was 3,000 mPas compared with a viscosity of 3,562 mPas for a 1% sol of the starting material.
CO-PRECIPITATION (HYDROCOLLOID COMPOSITES)
[0247] The following examples are only a small part of the infinite number of combinations possible. Concentrations can be altered as can the materials for co-processing. Additionally, other soluble and/or insoluble materials can be included.
Clarified Konjac/Carboxymethyl Cellulose (CMC) (3:1)
Example 10
[0248] (MBI Notebook DWR2, p.63)
[0249] One litre of 1% clarified konjac (Marine BioProducts, Lot 268) sol, 335 ml of 1% CMC (Hercules, Cellulose gum Type 7MF PH, Lot 66989) sol, and 14 ml of 10% NaCl (aq.) solution were combined, mixed thoroughly with a Braun hand-held blender, then coagulated in 2.5 litres of rapidly stirred 99% IPA. The white stringy coag was collected on a fine sieve, squeezed to remove fluid, pulled apart, then washed by stirring with one litre of 99% IPA for 15 minutes. The washed coag was collected on Nitex cloth, squeezed, then dried in a forced-air oven at about 38° C. After grinding to −20 mesh, 10.7 g (80.1% yield) of white product was obtained. This was more readily soluble in water than was the clarified konjac control and rapidly formed a clear sol, almost spontaneously.
Clarified Koniac/Hydroxyethyl Cellulose (HEC) (4:1)
Example 11
[0250] (MBI Notebook DWR1, p.59):
[0251] One percent sols of clarified konjac (Marine BioProducts, Lot 257) and HEC (Hercules, Natrosol, 250L NF, FP10, Lot 13879) were prepared. To 400 ml of the konjac sol was added 100 ml of the HEC sol, the two mixed together thoroughly using a Braun hand-held blender, heated to boiling, then coagulated in 1 litre of 85% IPA while stirring with a spatula. The coag was collected on a Nitex cloth, squeezed, then washed successively with 500 ml of 85% IPA for 20 minutes and 250 ml of 99% IPA for 10 minutes, each time stirring, then collecting on Nitex and squeezing to remove as much fluid as possible. Drying was done in a forced-air oven at about 38° C. After grinding to −20 mesh, 3.2 g (64% yield) of white product was obtained. This was more readily soluble in water than was the clarified konjac control and rapidly formed a clear sol.
Clarified Koniac/Hydroxypropylmethyl Cellulose (HPMC) (4:1)
Example 12
[0252] (MBI Notebook DWR1, p.59):
[0253] One percent sols of clarified konjac (Marine BioProducts, Lot 257) and HPMC (Hercules, Benecel, MP-824, FP10, Lot 13510) were prepared. To 240 ml of the konjac sol was added 60 ml of the HPMC sol, the two mixed together thoroughly using a Braun hand-held blender, heated to boiling, then coagulated in 500 ml of 85% IPA while stirring with a spatula. The coag was collected on a Nitex cloth, squeezed, then washed successively with 300 ml of 85% IPA for 20 minutes and 300 ml of 99% IPA for 10 minutes, each time stirring, then collecting on Nitex and squeezing to remove as much fluid as possible. Drying was done in a forced-air oven at about 38° C. After grinding to −20 mesh, 1.3 g (43.3% yield) of white product was obtained. (The low yield is due to the fact that HPMC is some-what soluble in the alcohol concentrations used.) The konjac/HPMC composite was more readily soluble in water than was the clarified konjac control and rapidly formed a clear sol.
Clarified Konjac/Clarified Locust Bean Gum (1:1)
Example 13
[0254] (MBI Notebook DWR2, p.50)
[0255] Twenty millilitres each of 1% clarified konjac sol (Marine BioProducts, Lot 268) and 1% clarified locust bean gum (Marine BioProducts, DWR3-43B) were prepared using de-ionized water. These were combined, mixed thoroughly, heated to boiling in a microwave oven, and coagulated in 100 ml of 85% IPA. The coag was collected on Nitex cloth, squeezed, pulled apart, and washed by stirring for ten minutes with 100 ml of 85% IPA. After collecting on Nitex cloth, squeezing, and pulling apart, the washed coag was dried in a one-pass hot air oven at about 38° C., then ground to −20 mesh (0.31 g, 77% yield)
Clarified Konjac/Clarified Guar (3:1)
Example 14
[0256] (MBI Notebook DWR3, p.19)
[0257] To 100 ml of clarified guar (Marine BioProducts, DWR2-21-1) sol was added 300ml of a 1% aqueous sol of clarified konjac TS (Marine BioProducts, Lot 268), the sols mixed well with a spatula and then coagulated in 800 ml of 99% IPA while stirring with a spatula. The fibrous white coag was collected on Nitex cloth and squeezed to remove adhering fluid. After washing in 500 ml of 99% IPA for 0.5 hours, the coag was collected, squeezed, then dried in a one-pass hot air oven at about 38° C. The coag was ground to −20 mesh, giving 3.55 g (88.8% yield) of white powder. When placed in water it hydrated rapidly and dissolved.
Clarified Koniac/Agar (1:1)
Example 15
[0258] (MBI Notebook DWR2, p.78)
[0259] One litre aqueous sols each of clarified konjac (Marine BioProducts, Lot 268) and agar (Marine BioProducts, Lot 276) were prepared. Both were heated to near boiling using a microwave oven, mixed thoroughly along with 30 ml of 10% NaCl (aq.). The composite was recovered by pouring into 5 litres of rapidly stirring 85% IPA. The white, fibrous coag was shredded using a Braun hand-held blender, then collected on Nitex cloth and squeezed to remove the adhering fluid. The coag was washed successively using 2 litres of 85% IPA then 1.5 litres of 99% IPA, each time stirring 20 minutes, collecting on Nitex and squeezing. Drying was done at about 38° C. in a one-pass forced air oven. After grinding to −20 mesh, 30.0 g (75% recovery) of white powder was obtained. A 1% gel prepared from this powder was elastic, nearly clear and colorless.
Clarified Konjac/Xanthan (1:1)
Example 16
[0260] (MBI Notebook DWR2, p.78)
[0261] One and a half litres each of 1% aqueous sols of clarified konjac (Marine BioProducts, Lot 268) and xanthan (Monsanto Keltrol T, Lot 8K0725K) were prepared. These sols were combined, along with 30 ml of 10% NaCl, mixed thoroughly using a Braun hand-held blender, then coagulated by pouring into 6 litres of rapidly stirring 85% IPA. The fibrous white coag was collected on a fine sieve, squeezed, and pulled apart. After washing by stirring for 20 minutes in 1 liter 85% IPA, the coag was again collected, squeezed to remove the adhering alcohol, pulled apart and dried on Nitex cloth in a one-pass 38° C. forced air oven. After grinding to −20 mesh, 28.3 g (94% yield) of off-white powder was obtained. This powder rapidly absorbed about 200× its weight of de-ionized water or about 50× its weight of 1% NaCl to form a particulate gel. When heated and cooled, a clear elastic gel was formed. Aqueous gels of 0.06% were prepared that had a Jello®-like consistency.
Clarified Guar/Xanthan (1:1)
Example 17
[0262] (MBI Notebook DWR4, p.7)
[0263] To a dry mixture of 2.5 g of clarified guar (MBI Lot DWR3-44-1) and 2.5 g of Keltrol T xanthan (Monsanto lot 8K0725K) was added about 10 ml of 99% isopropyl alcohol and the mixture was stirred to ensure complete wetting. While being stirred with an overhead stirrer, 500 ml of deionized water was added. After dispersion was complete, the mixture was heated to boiling in a microwave oven and 400 ml was coagulated in 1 litres of 99% IPA using a spatula to agitate the mixture. After standing for one hour at ambient temperature to harden the precipitate, the product was collected using a plastic sieve. After squeezing, the precipitate was transferred to 300 ml of 99% IPA and stirred for about 20 minutes. The precipitate was collected on a Nitex cloth, squeezed, and dried in a 38° C. single-pass, forced-air oven. After grinding to −20 mesh, 3.16 g of powder was obtained. When 50 ml of water was added to 250 mg of this sample, the water was rapidly absorbed to form a relatively clear, semi-coherent gel. When this was brought to boiling in a microwave oven, it dissolved rapidly to form a clear, viscous solution, which when cooled, formed a clear, elastic gel.
CLARIFIED HYDROCOLLOID KONJAC GELS, FILMS, FOAMS AND SPONGES
[0264] When konjac glucomannan is heated with alkali, about pH= − 7.5-11, deacetylation occurs and the resulting gel product is water insoluble and thermostable. If the gel formed by deacetylation is frozen and thawed, a tough, coherent spongeous mass is formed. Deacetylated konjac gels, films, foams, sponges, beads, and other forms can be prepared. Porosity of the sponges depends on the rate of freezing of the sols.
[0265] The deacetylated konjac films are boiling water insoluble and are formed from a clarified konjac sol by adding alkali before casting the film, then heating to ensure that deacetylation occurs. Films can be prepared from a konjac/xanthan sol that are clear and hot water (>85° C.) soluble. If films are prepared from a clarified konjac sol, without heating, they are cold water soluble.
Clarified Konjac Gels
Example 18
[0266] (MBI Notebook DWR3 p.65)
[0267] To 250 ml of a 1% clarified konjac sol (MBI Lot 268) was added 2.5 ml of 1% NaOH. This was blended quickly, yet thoroughly, using the wire whisk attachment of the Braun hand-held blender. This mixture was rapidly poured equally into three 100 ml beakers. These were covered with plastic wrap and placed in a 99° C. oven to deacetylate and form a gel. This gel was not completely clear like the starting konjac sol, but slightly hazy. Gels containing 0.5% and 0.25% clarified konjac were also prepared in this manner.
Clarified Konjac Films
[0268] Water Soluble Films
Example 19
[0269] (MBI Notebook DWR3, p.64)
[0270] To 300 ml of a 1% clarified konjac sol (MBI Lot 268) in deionized water was added 1.5 g of glycerol. After mixing well, the sol was brought to boiling in a microwave oven, let stand in a 99° C. oven for 15 minutes to deaerate and poured into three oblong plastic dishes (11 cm×18.5 cm). The sols were dried to films at about 38° C. in a one-pass forced air oven. These films were tough, flexible, and fully transparent. When wet with water, the film rapidly absorbed water and disintegrated, then gradually dissolved.
[0271] Hot Water Soluble Films
Example 20
[0272] (MBI Notebook DWR3, p.64)
[0273] To 300 ml of a hot (<80° C.) aqueous 0.5% sol of 1:1 clarified konjac/xanthan (see Example 16) was added 1.5 g of glycerol and the mixture stirred thoroughly. After reheating to boiling, the sol was placed in a 99° C. oven for 15 minutes to deaerate, then poured into three oblong plastic dishes (11 cm×18.5 cm). The sols were dried to films at about 38° C. in a one-pass forced air oven. These films were tough, flexible, and fully transparent. When wet with water, the film rapidly absorbed water and became quite tough and elastic, while remaining transparent.
[0274] Water Insoluble Films
Example 21
[0275] (MBI Notebook DWR3, p.64)
[0276] To 100 ml of a 1% clarified konjac sol (MBI Lot 268) in deionized water was added 0.5 g of glycerol, and 1.0 ml of 1 M NaOH. After mixing thoroughly with the wire whisk attachment of the Braun hand-held mixer, the mix was poured into an oblong plastic dish (11 cm×18.5 cm). The dish was covered and placed in a 99° C. oven to set. The cover was removed and the dish placed in a 38° C., one-pass, forced air oven to dry. The resulting film was not completely transparent, but slightly hazy. It was tough and flexible and rapidly imbibed water, maintaining its toughness and flexibility.
Clarified Konjac Foams
[0277] Water Insoluble Deacetylated
Example 22
[0278] (MBI Notebook DWR3 p.63)
[0279] In the stainless steel bowl of a Kitchen Aid mixer was placed 300 g of 1% clarified TS konjac (MBI, Lot 268), 40 g of a 3% aqueous sol of hydroxyethyl cellulose (Hercules Natrosol 250 m Pharm, Lot FP 10 13809) as a foaming agent, and 4 g of glycerol as a plasticizer. This was mixed using the standard paddle attachment. This was insufficient HEC to induce foaming so about 5 ml of a solution of hand-soap (unknown origin) shavings was added and after beating for about 10 minutes on high speed, a thick white foam resulted. Three ml of 1M NaOH was added and rapidly beat into the foam. The foam was portioned into a variety of covered plastic dishes, covered and placed into a 99° C. oven for about one hour to deacetylate and form a thermo-irreversible gel matrix. The syneresate was removed by decantation and three of the foams dried in a 38° C. one-pass forced-air oven. When a sample of the white foam was placed in deionized water, it hydrated rapidly.
[0280] Water Insoluble Deacetylated, Frozen and Thawed
Example 23
[0281] (MBI Notebook DWR3, p.63)
[0282] The remaining three foams from Example 22 were placed, covered tightly, in a −18° C. freezer overnight. The frozen foams were thawed in hot running water and the water expressed from the jelly fish-like, tough foamy masses using a thumb and forefinger. The resulting partially de-watered foams were covered with 99% IPA and let stand for about 1 hour. The fluid was expressed by squeezing and the procedure repeated. These were then blotted between paper towels and dried on a rack in the hood. The resulting white parchment-like sheets rapidly hydrated to form tough jelly fish-like masses.
Clarified Konjac/Xanthan Foams
Example 24
[0283] (MBI Notebook DWR3, p.72
[0284] Three hundred millilitres of a hot sol containing 3.0 g of 1:1 clarified konjac/xanthan and 1 g of glycerol was prepared in a 2-litre measuring bowl. This was placed in a boiling water bath and 2 ml of a solution of hand-soap shavings in deionized water was added. The mixture was then foamed using the wire whisk attachment on a Braun hand-held mixer. The foam was distributed into plastic dishes at room temperature. Setting was rapid. The foams were removed from the dishes and placed on a rack in a 38° C. one-pass forced air oven to dry. Rehydration in water was rapid and a voluminous, low strength, clearish foamy mass resulted. In 1% NaCl, rehydration was slower and resulted in a significantly lower volume, stronger, elastic hydrated foam.
Clarified Konjac Sponges
Example 25
[0285] (MBI Notebook DWR3, p.65)
[0286] The gels from Example 18 were placed in a −18° C. freezer overnight to freeze. They were then thawed using warm running tap water. The 1% gel/sponge had very small pores and was too firm to squeeze to fully convert to a sponge. The lower percentage gels, when frozen and thawed, gave jellyfish-like sponges. When soaked in 99% IPA, squeezed and dried, parchment like disks were obtained that imbibed water, but more slowly and to a lesser extent than the frozen, thawed, and dried foams.
Clarified Hydrocolloid/Borate Interaction Products
[0287] Preparation of these amorphous solids consists of forming a sol of the cis 1,2-diol, and thermostable additives, if any, by dispersing the components in cool water, heating the mixture to boiling, adding hot aqueous sodium tetraborate, and allowing to cool. Other components can be added at suitable temperatures. If film preparation is desired, the hot sol can be distributed on a surface to form a film and the film used as is or dried. For powders or granules, the solid diol can be triturated with a concentrated solution of sodium tetraborate with or without glycerol. For in situ-formed coatings, the sponge, cloth, gauze, or other material to be coated can either be dipped into the hot mix, removed and drained, and optionally dried. Alternatively, the coatings can be applied by successively dipping the material to be coated into the borate solution, draining, blotting, blowing, or squeezing to remove the excess, if desired; dipping next into a cis-1,2-diol polymer solution, with or without additives; and finally again into the borate solution. If desired, this series can be repeated.
[0288] Possible additives to the polymeric cis-1,2-diol reaction mixture used for any of the products are: other borate-reactive and/or non-reactive hydrocolloids; reactive or non-reactive low molecular weight substances; insoluble particulates, both swellable and non-swellable, including charcoal and encapsulated chemical and/or biological reagents, ion-exchange resins, etc.; therapeutics; enzymes, antibodies; antimicrobials; etc.
[0289] Gelling hydrocolloids, such as agar, gellan, carrageenan, and curdlan can be added to the clarified konjac, guar, locust bean gum, or aloe mannan sols before cross-linking with borate. At concentrations where the hydrocolloid would have formed a firm gel alone, combinations can yield products with unique properties.
[0290] The following two examples are not meant to be limiting, since many different combinations of cis 1,2-diol containing molecules will cross-link using borates and can be combined with each other and/or non-reactive molecules to give unique properties. In addition, glycerol and/or other compatible plasticizers can be added and clear, hydratable films prepared.
Clarified Konjac/Borate Interaction Products
[0291] “Gels”
Example 26
[0292] (MBI Notebook DWR3, p.73)
[0293] To three 50-ml samples of 1% clarified konjac (MBI, lot 268) in deionized water was added selected amounts of a 3.79% borax solution (=2.0% NaB 4 O 7 ). After mixing thoroughly with a spatula, they were covered with plastic wrap and heated to boiling in a microwave oven, stirred again, and allowed to cool to room temperature. The following observations were made:
ml borax Observations (all clear and colorless) 1 mucoid consistency and slimy feel (free konjac) 5 flexible and slightly moist 15 firmer and slightly fragile
[0294] Films
Example 27
[0295] (MBI Notebook DWR3, p.73)
[0296] Films were prepared from the gels in Example 26 by adding a small amount of glycerol, heating to boiling in a microwave oven, mixing thoroughly and pouring into 11 cm×18.5 cm Rubbermaid plastic dishes. The gels were dried to films using a 38° C. one-pass, forced-air oven. Clear flexible films resulted that rapidly hydrated in deionized water.
[0297] Foam
Example 28
[0298] (MBI Notebook DWR3, p.73)
[0299] To 50 ml of the 1% clarified konjac sol (see Example 26) was added 1 ml of a hand-soap shavings sol and the mixture whipped to a stiff foam using the wire whisk attachment of the Braun hand-held blender. Two millilitres of the 3.79% borax solution was added and whipped in. A very elastic foam resulted. This was placed on inverted plastic dishes and dried using a 38° C. one-pass, forced-air oven. A thin whitish dried foam resulted that hydrated rapidly in deionized water to a tough, elastic thin foam.
Clarified Guar/Borate Interaction Products
[0300] “Gels”
Example 29
[0301] (MBI Notebook DWR3, p.73)
[0302] To three 50-ml samples of 1% clarified guar (MBI, lot DWR3-33-1) in deionized water was added selected amounts of a 3.79% borax solution (=2.0% NaB 4 O 7 ). After mixing thoroughly with a spatula, they were covered with plastic wrap and heated to boiling in a microwave oven, stirred again, and allowed to cool to room temperature. The following observations were made:
ml borax Observations (all clear and colorless) 1 flexible and slightly fragile 5 flexible and fragile 15 firmer and fragile
[0303] Films
Example 30
[0304] (MBI Notebook DWR3, p.73)
[0305] Films were prepared from the gels in Example 29 by adding a small amount of glycerol, heating to boiling in a microwave oven, mixing thoroughly and pouring into 11 cm×18.5 cm Rubbermaid plastic dishes. The gels were dried to films using a 38° C. one-pass, forced-air oven. A clear flexible film resulted from the first gel that was lowest in borate. The other two formed more brittle films. All hydrated rapidly in deionized water, became putty-like, and gradually dissolved when excess water was present.
[0306] Foam
Example 31
[0307] (MBI Notebook DWR3, p.73)
[0308] To 50 ml of the 1% clarified guar sol (see Example 29) was added 1 ml of a hand-soap shavings sol and the mixture whipped to a stiff foam using the wire whisk attachment of the Braun hand-held blender. One millilitre of the 3.79% borax solution was added and whipped in. A very elastic foam resulted. This was placed on inverted plastic dishes and dried using a 38° C. one-pass, forced-air oven. Thin, whitish dried foams resulted that hydrated rapidly in deionized water to a tough, elastic thin foam that, over a period of time, continued swelling.
Clarified Guar/Xanthan Film
Example 32
[0309] (MBI Notebook DWR4, p. 7)
[0310] A clear, hot water soluble film was prepared using the 1:1 guar/xanthan composite sol described in Example 17. After adding 0.5 g of glycerin and 100 ml of deionized water, the remaining sol (100 ml) was heated to boiling in a microwave oven and distributed equally into each of two oblong Rubbermaid™ plastic storage dishes and dried in a single pass, forced-air oven. The clear, flexible films rapidly absorbed ambient temperature water and became weak and swollen. In hot water, they dissolved.
[0311] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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This invention relates to novel clarified hydrocolloids which substantially retain the physical properties of unclarified hydrocolloids. The invention also pertains to a novel process for making the clarified hydrocolloids. A process of producing a hydrocolloid which, when hydrated, forms a clear sol comprising: (a) soaking a hydrocolloid containing material dispersed in water until the hydrocolloid is hydrated; (b) stirring the hydrated hydrocolloid until a homogenous particulate containing sol is obtained; (c) removing insoluble particulates to produce a clarified sol; (d) removing remaining particulates in the clarified sol by filtration; and (e) recovering the clarified hydrocolloid from the filtrate.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/285,508, entitled “Network Marketing Compensation System,” filed Apr. 20, 2001, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention is in the field of business methods for compensating distributors in direct sales organizations and, more particularly, to business methods for compensating distributors in multi-level compensation plans.
[0004] 2. The Relevant Technology
[0005] In the industry of direct sales organizations, there are several different types of compensation plans. Some of the more popular compensation plans include direct sales, multi-level, and network compensation plans, each having their own advantages and disadvantages.
[0006] Direct sales plans promote direct one-on-one selling by limiting any personal sales organization to one or two pay levels. Each pay level is a level in which the distributor or seller is compensated for sales made directly by the distributor. Although direct sales compensation plans are useful for fostering good personal relationships between the distributor and the buyers, direct sales compensation plans are not very good for developing large sales organizations. In particular, direct sales compensation plans generally provide a disincentive for recruiting new distributors to the company inasmuch as any new distributors become direct competitors of the existing distributors. Further, distributors are generally not compensated for recruiting new distributors into the company.
[0007] Direct sales plans, thus, act to encourage the distributor to emphasize the product and the distributor's personal sales rather than to promote recruiting, training and managing a personal sales organization that includes other distributors. People who are more comfortable with selling a product rather than recruiting, managing and training other people often prefer direct sales plans. As a consequence of these factors, organizations that utilize direct sales plans tend to develop slowly.
[0008] Multi-level plans such as uni-level and matrix compensation plans reward distributors for developing a large personal sales organization (i.e. “distribution genealogy”), which includes a front line of personally sponsored distributors/representatives (i.e. “frontline distributors”) and one or more legs, where a leg includes a frontline distributor and a genealogy of additional downline distributors that descend from the frontline distributor. A leg is formed, for example, when the frontline distributor sponsors one or more downline distributors, who in turn each sponsor one or more downline distributors, etc. Accordingly, a distributor's distribution genealogy includes the distributor's frontline distributors and all downline distributors that descend from the frontline distributors.
[0009] Multi-level plans typically encourage the development of large distribution genealogies by paying commissions and bonuses on the purchases and sales made by certain downline distributors/representatives within the distributor's distribution genealogy. Multi-level plans are generally useful for encouraging a distributor to develop a deep genealogy or personal sales organization, thereby enabling a distributor to maximize its profits. This feature, generally thought to be an advantage of multi-level plans is also a disadvantage. The disadvantage arises because it is easier for the distributor to manage and train only a few frontline distributors, rather than to train many. Some multi-level plans even limit the number of personally sponsored distributors that can be placed within a distributor's front line. Accordingly, multi-level plans generally promote deep distribution genealogies. However, this is often done at the expense of developing wide distribution genealogies, which could otherwise accelerate the overall growth of the company.
[0010] Network compensation plans, such as the popular stairstep/breakaway plan, compensate a distributor based on some combination of personal sales volume and the total sales volume of the distributor's personal sales organization. In most network compensation plans, the distributor achieves rankings based on the performance and qualification of the distributor's sales organization. Accordingly, the company can modify the behavior of the distributor and the ultimate shape of the distributor's sales organization by modifying the requirements that are necessary to achieve a ranking.
[0011] In stairstep/breakaway compensation plans, the distributor is generally compensated for developing a deep distribution genealogy because the distributor receives compensation based at least in part on the total sales volume of the distributor's genealogy. However, when any leg of the distributor's distribution genealogy becomes independently qualified for a particular ranking then that leg will break away from the distributors network, thereby preventing the distributor from receiving further commissions based on that portion of the distributor's distribution genealogy. Accordingly, the distributor is thereby encouraged only to develop legs to the extent that they do not become independently qualified to break away from the distributor's organization. This is a significant problem with stairstep/breakaway plans. In particular, this discourages training and successful development of many downline members, which would otherwise benefit the overall growth and development of the company.
[0012] Accordingly, there currently exists a need in the art to develop a method for compensating distributors in a direct sales organization in which the distributors are encouraged to develop wide and deep distribution genealogy while at the same time promoting the individual success of each leg within the distributor's distribution genealogy.
SUMMARY AND OBJECTS OF THE INVENTION
[0013] The present invention provides a network marketing compensation system for compensating distributors in a distribution network. The network marketing compensation system of the present invention is divided into three general compensation phases.
[0014] In the first phase, a distributor receives a personal rebate based on the distributor's personal volume, i.e., the unit amount of product the distributor purchases or sells during a month, as defined below in greater detail. The distributor also receives a commission based on the distributor's team volume, i.e., the distributor's personal volume combined with the distributor's front line volume, as further defined below. In the second phase, and upon meeting designated requirements, the distributor receives an override bonus. There are nine override bonus levels that are based on percentages of the personal volume of product that is acquired or sold by members within the distributor's distribution genealogy. The third phase comprises additional benefits, which are available by satisfying additional requirements. One particular benefit in the third phase includes an additional distributorship, referred to herein as an “additional performance team” position, that the distributor can place on the front line of the distributor's genealogy to receive additional bonuses. For enabling a distributor to satisfy the requirements of the second and third phases of the compensation plan, the present invention allows horizontal compression of leg volume within the distributor's genealogy, as explained below in greater detail.
[0015] The present invention is an improved network marketing compensation system over the prior art. The network marketing compensation system of the present invention rewards wide and deep distribution genealogies on various levels, while overcoming many of the problems associated with compensation plans of the prior art.
[0016] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be readily learned by the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the description. These and other objects and features of the present invention will become more fully apparent from the following description, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0018] [0018]FIG. 1 illustrates one presently preferred table of Phase I requirements and benefits of the compensation system of the present invention that includes minimum personal volume (PV) requirements and rebates;
[0019] [0019]FIG. 2 illustrates an exemplary distributorship genealogy that includes a distributor and seven members;
[0020] [0020]FIG. 3 illustrates presently preferred Phase I requirements and benefits of the compensation system of the present invention that includes minimum team volume (TV) requirements and commissions;
[0021] [0021]FIG. 4 illustrates presently preferred Phase II requirements and benefits of the compensation system of the present invention;
[0022] [0022]FIG. 5 illustrates a sample distributorship genealogy that includes a distributor, eleven downline members, and three generations that are determined according to Phase II compression rules of the present invention;
[0023] [0023]FIG. 6 illustrates presently preferred Phase III requirements and benefits of the compensation system of the present invention;
[0024] [0024]FIG. 7 illustrates a diagram of a distributorship genealogy having seven legs and an additional performance team position (APT); and
[0025] [0025]FIG. 8 illustrates a diagram of the distributorship genealogy of FIG. 7 in which two of the seven legs have been placed under the APT and in which the distributor has occupied the APT.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The present invention relates to a network marketing compensation system for compensating a distributor within a distribution network. The network marketing compensation system of the present invention is generally described herein in terms of three compensation phases. Qualification for compensation within each of the three phases is based on the personal performance of an individual distributor and upon the results of the distributor's leadership and management in creating a distribution genealogy. The three general phases of the invention are discussed herein in reference to FIGS. 1 - 8 .
PHASE I COMPENSATION
[0027] Phase I of the compensation plan of the present invention comprises a personal rebate and a commission. The personal rebate is based on a percentage of a distributor's personal volume, hereinafter “PV,” which is defined herein as the total commissionable volume of product that a distributor purchases for personal consumption or resale combined with the commissionable volume of product purchased by retail customers on the distributor's account within a given volume month. PV is generally equivalent to money spent and may or may not be expressed in units of money. Although in this preferred embodiment, PV is referred to as a monthly quantity, one of skill in the art will readily appreciate that PV could be based on virtually any period of time. The term “product” should be broadly construed to include any good, service, or other benefit that can be marketed by a network marketing company and purchased or sold by a distributor of that company. The term “distributor” should be broadly construed to include any individual, group, corporation, party, or other entity that has contracted with the company to sell products of the company to others or purchase products for personal consumption. Such distributors will generally be independent contractors to the company.
[0028] In a preferred embodiment illustrated in FIG. 1, a table 100 illustrates the relationship between minimum PV 110 and a distributor's rebate 120 . Thus, a distributor qualifies for a rebate 120 in any month in which the distributor's PV reaches or exceeds designated PV requirements 110 . For example, if a distributor's PV is at least 100, then the distributor is qualified to receive a first-level rebate 130 comprising a monetary equivalent of 5% of the distributor's PV. If a distributor's PV is at least 350, then the distributor is qualified to receive a second-level rebate 140 comprising a monetary equivalent of 10% of the distributor's PV. If a distributor's PV is at least 700 then the distributor is qualified to receive a third-level rebate 150 comprising a monetary equivalent of 15% of the distributor's PV. If a distributor's PV is at least 1,000, then the distributor is qualified to receive a fourth-level rebate 160 comprising a monetary equivalent of 20% of the distributor's PV. If a distributor's PV is at least 5,000 then the distributor is qualified to receive a fifth-level rebate 170 comprising a monetary equivalent of 25% of the distributor's PV. It should be appreciated that although PV is expressed in terms of integer units, rebates are paid in units of money. For example, according to the preferred embodiment of FIG. 1, if a distributor has a PV of 2,000 then the distributor will receive a rebate comprising a monetary equivalent of 20% of 2,000, or $400.
[0029] These monthly rebates, as they have been described, are mutually exclusive. In other words, even if a distributor is qualified for every level of monthly rebates, the distributor will only receive a single monthly rebate, which will be the highest rebate that the distributor is qualified to receive. For example, if the distributor has a PV of 5,000, the distributor will only receive a monthly rebate comprising a monetary equivalent of 25% of the PV, which is $1,250. It should be appreciated that the distributor will not receive each of the other rebates that the distributor is qualified to receive. One of skill in the art will appreciate that the minimum PV qualification levels 110 may be set for a variety of different thresholds and that the rebate percentages 120 associated with a particular qualification level may also be set according to a variety of factors to suit the needs of the company implementing the compensation plan of the present invention.
[0030] As mentioned earlier, the distributor can also qualify for a Phase I commission in addition to a rebate. To determine the level of a commission the distributor is eligible to receive, if any, it is first necessary to determine the distributor's team volume (“TV”), which will be generally described in reference to FIGS. 2 and 3.
[0031] [0031]FIG. 2 shows a distributor genealogy 200 comprising six levels. Distributor 210 is located in the first level and the distributors positioned in levels 2 thru 6 comprise the descendants of distributor 210 . Downline distributors 212 and 214 are distributors that have been personally sponsored by the distributor 210 and are included in the front line 216 of distributor 210 . Thus, distributor 210 is said to be the “sponsor” of distributors 212 and 214 . Distributor 218 is a descendant of distributor 214 , distributor 220 is a descendant of distributor 218 , distributor 222 is a descendant of distributor 220 , and distributor 224 is a descendant of distributor 222 . The various distributors in a genealogy such as that illustrated in FIG. 2 are variously referred to herein as “distributors,” “members,” or “positions.”
[0032] The compensation system of the present invention bases a distributor's compensation on the performance of the distributor and the downline of that distributor. As used herein, the term “top-line distributor” refers to the distributor for which compensation is being calculated. In FIG. 2, the top-line distributor is distributor 210 . It will be appreciated however, that in practice, distributor 210 and its downline may be part of a much larger distributor network.
[0033] A top-line distributor's TV, which is used to compute the Phase I commission, comprises the sum of (1) the distributor's PV, and (2) the distributor's front line volume (“LV”). As used herein, the LV is defined to include the PV of every distributor that is personally sponsored by the top-line distributor, or in other words, those distributors found in the top-line distributor's first level. Additionally, when a personally sponsored distributor is unqualified, i.e., has a PV of less than 100, then the LV is also defined to include the PV of every distributor that falls downline from that unqualified front line distributor, down to and including the PV of the first qualified position that is encountered in that downline.
[0034] For example, the LV of distributor 210 of FIG. 2 comprises the sum of the PV of every member on the distributor's front line 216 , which includes the PV of distributor 212 and the PV of distributor 214 . Because distributor 214 is unqualified, having a PV of only 55, the LV of distributor 210 also includes the PV of every distributor that is downline from unqualified distributor 214 , down to and including the first qualified downline distributor that is encountered. In this example, distributor 218 is the first encountered downline distributor that is qualified, having a PV of 150. Accordingly, the LV of distributor 210 includes the PV of distributor 212 (PV=1,100), the PV of distributor 214 (PV=55), and the PV of distributor 218 (PV=150), for a total LV of 1,305.
[0035] The TV of distributor 210 is finally computed by summing the PV of distributor 210 (PV=180) with the LV of distributor 210 (LV=1,305) for a total TV of 1,485. Once the distributor's TV has been determined, it is possible to calculate the distributor's Phase I commission according to the teachings of the present invention. In one presently preferred embodiment, shown in FIG. 3, the Phase I commission is computed according to table 300 in which a distributor qualifies for a monthly commission when the distributor's TV reaches or exceeds designated minimum amounts.
[0036] According to this presently preferred embodiment, the distributor's Phase I commission comprises a percentage of the PVs that are included in the calculation of the distributor's LV. The percentage that is paid out to the top-line distributor for each team member's PV is a function of both the top-line distributor's TV and the total amount of rebates and commissions that have already been paid out to team members. Team members are front-line distributors that contribute PV to the calculation of the top-line distributor's LV. For example, with reference to FIG. 2, distributors 212 , 214 , and 218 are classified as team members because their PV was included in the calculation of the LV of distributor 210 . According to another embodiment, a distributor may also receive a commission on all distributors within the top-line distributor's first generation, as defined and described below.
[0037] As shown in FIG. 3, there are four different Phase I commission levels 310 , 320 , 330 , and 340 , each of which can be obtained by satisfying the minimum team volume requirements 350 and minimum PV requirements 360 . For example, if a distributor has a PV of at least 100 and a TV of at least 100 but less than 350, then the distributor is qualified to receive a first-level, Phase I commission 310 comprising a monetary equivalent of (5%-X%) the PV of each team member, wherein X% comprises the rebate percentage plus the commission percentages, if any, that have already been paid to qualified team members. For example, if a team member has a PV of 100, thereby qualifying for a 5% personal rebate according to table 100 of FIG. 1, then the Phase I commission payable to the top-line distributor will be a monetary equivalent of (5%-5%) of 100, or $0.00. However, according to this present example, since the team member has already received a personal rebate of 5%, then the distributor will qualify to receive a “courtesy bonus” comprising a monetary equivalent of 5% of the PV of that team member. Additional qualifications for entitlement to the courtesy bonus are set forth below.
[0038] If a distributor has a PV of at least 100 and a TV of at least 350 but less than 700, the distributor is qualified to receive a second-level, Phase I commission 320 comprising a monetary equivalent of (10%-X%) of the PV of each team member. Additionally, if a team member has already received a personal rebate of 10%, then the distributor qualifies for a monetary equivalent of 5% courtesy bonus of the PV of that team member.
[0039] If a distributor has a PV of at least 100 and a TV of at least 700 but less than 1,000, the distributor is qualified to receive a third-level, Phase I commission 330 comprising a monetary equivalent of (15%-X%) of the PV of each team member. Additionally, if a team member has already received a personal rebate of 15%, then the distributor qualifies for a courtesy bonus comprising a monetary equivalent of 5% of the PV of that team member.
[0040] Finally, if a distributor has a PV of at least 150 and a TV of at least 1,000 then the distributor is qualified to receive a fourth-level, Phase I commission 340 comprising a monetary equivalent of (20%-X%) of the PV of each team member. If a team member has already received a personal rebate of at least 20%, then the distributor qualifies for a courtesy bonus comprising a monetary equivalent of 5% of the PV of that team member.
[0041] In a presently preferred embodiment, a distributor only qualifies for the courtesy bonuses mentioned above when the distributor is being paid on front-line distributors. In other words, distributors are not eligible to receive the courtesy bonus based on the PV of distributors who are deeper in the genealogy than the front line.
[0042] It should also be pointed out that the Phase I commissions, as they have been described, are mutually exclusive. In other words, a TV of 1,000 would theoretically qualify a distributor for every level of Phase I commissions 310 , 320 , 330 , and 340 ; however, the distributor can only receive the commissions from a single qualification level, which will be the highest level of commissions that a distributor is qualified to receive.
[0043] To further illustrate how Phase I commissions are computed, the Phase I commissions for the top-line distributor 210 of FIG. 2 will now be computed. Initially, the TV for distributor 210 must be known in order to identify the level of commissions that the distributor 210 is qualified to receive. As noted previously, the TV of distributor 210 is 1,485. A TV of 1,485 is greater than 1,000, thereby qualifying distributor 210 for a fourth-level, Phase I commission 340 . Accordingly, the total Phase I commission for distributor 210 comprises a monetary equivalent of the sum of (20%-X%) of the PV of each team member and a courtesy bonus of 5% of the PV of each front line team member that has already received a personal rebate of at least 20%. Team members include distributor 212 , distributor 214 , and distributor 218 . To determine the personal rebate for each of the team members, reference is made to table 100 of FIG. 1. In particular, distributor 212 , having a PV of 1,100, qualifies for a 20% personal rebate; distributor 214 , having a PV of only 55, does not qualify for a personal rebate; and distributor 218 , having a PV of 150, qualifies for a 5% personal rebate.
[0044] Accordingly, the Phase I commission for distributor 210 , in monetary equivalence, comprises the sum of (20%-20%) of the PV of distributor 212 (PV=1,100), or $0.00; (20%-0%) of the PV of distributor 214 ( 55 ), or $11.00; (20%-5%) of the PV of distributor 218 (PV=150), or $22.50; and a 5% courtesy bonus of the PV of front line distributor 212 (PV=1,100), or $55.00; thereby resulting in a grand total Phase I commission of $85.50.
[0045] As noted above, a distributor may also receive a commission on the PV of every distributor that is included in the distributor's “first generation.” The distributor's first generation includes: (1) all distributors on the top-line distributor's first line and (2) when a first line distributor is not “team qualified,” e.g., does not have a TV of at least 1,000, every downline distributor below any front-line distributor that is not team qualified, down to and including the first team qualified distributor encountered in that downline. A generation is delimited only by team qualified distributors, such that a generation includes all distributors located between the top-line distributor down to and including the first team qualified distributors encountered in each downline of the top-line distributor.
[0046] For example, according to this embodiment, top-line distributor 210 of FIG. 2 has a first generation that includes every downline distributor down to and including the first team qualified distributor encountered in each downline. In the present embodiment, distributor 210 has two downlines. The first comprises distributor 212 which is team qualified with a PV and TV of 1,100. The second downline comprises distributors 214 , 218 , 220 , 222 , and 224 . To determine which of these distributors are included in the first generation, it is necessary to find the first team qualified distributor encountered in the downline.
[0047] Using the rules for computing TV discussed above, it is determined that distributor 214 has a TV that includes (1) the PV of distributor 214 (PV=55) and (2) the PV of every personally sponsored distributor of distributor 214 , which includes distributor 218 (PV=150), for a total TV of 205, and is therefore inadequate for team qualification. Next, distributor 218 is found to have a TV that includes (1) the PV of distributor 218 (PV=150) and (2) the PV of personally sponsored distributor 220 (PV=40). Because distributor 220 is not personally qualified, e.g., does not have a PV of at least 100, the TV of distributor 218 also includes (3) the PV of downline distributor 222 (PV=160), resulting in a total TV of 350 , which is inadequate for team qualification. Next, the TV of distributor 220 is computed, which includes (1) the PV of distributor 220 (PV=40) and (2) the PV of distributor 222 (PV=160), for a total TV of 200, which is inadequate for team qualification. Finally, the TV of distributor 222 is determined, which includes: (1) the PV of distributor 222 (PV=160) and (2) the PV of distributor 224 (PV=1,300), for a total TV of 1,460, which is adequate for team qualification. Hence, distributor 222 is the first team qualified distributor in the downline of first level distributor 214 . Accordingly, the first generation of distributor 210 includes distributors 212 , 214 , 218 , 220 , and 222 .
[0048] Phase I commissions will now be computed for top-line distributor 210 according to this embodiment in which commissions are paid to all distributors within the top-line distributor's first generation, as described above. According to this embodiment, distributor 210 will receive the commissions described above, totaling $85.50, plus additional commissions on the PV of distributors 220 and 222 because they are part of the first generation of distributor 210 , as described above.
[0049] To determine how much of a commission distributor 210 will receive on the PV of distributor 220 and 222 , it is necessary to determine the percentage of rebates and commissions paid out on the PV of distributors 220 and 222 . To do this, it must first be considered that distributor 218 has a PV of 150 and TV of 350, as noted above, and is therefore qualified to receive a second-level commission 320 comprising a monetary equivalent of (10%-X) of the PV of distributor 220 . Distributor 220 only has a PV of 40, and therefore is not qualified for a personal rebate, such that distributor 218 will receive a 10% payout on the PV of distributor 220 . The next upline distributor, distributor 214 has a PV of only 55, and is therefore not qualified to receive a commission on distributor 220 , Accordingly, the total percentage that is already paid out on the PV of distributor 220 is 10%. Therefore, distributor 210 will receive a commission comprising a monetary equivalent of (20%-10%) of the PV of distributor 220 (PV=40), which equals $4.00.
[0050] Next, it is necessary to determine the percentage of rebates and commissions that have already been paid out on the PV of distributor 222 . Distributor 222 has a PV of 160 and is therefore qualified for a personal rebate of 5%. Distributors 214 and 220 are not qualified to receive a commission on the PV of distributor 222 because they each have a PV of less than 100, as noted above. Distributor 218 , however, does qualify for a second-level rebate 320 , having a TV of at least 350 and a PV of at least 150, and is therefore qualified for a commission of 10% minus the 5% rebate already paid to distributor 222 . Accordingly, a total of 10% has been paid out on the PV of distributor 222 . Therefore, distributor 210 is qualified to receive a commission comprising a monetary equivalent of (20%-10%) of the PV of distributor 222 (PV=160), or $16.00. Accordingly, the total Phase I commissions payable to distributor 210 on all first generation members comprises $85.50+$4.00+$16.00=$105.50.
[0051] It will be appreciated by one of skill in the art that the minimum team volumes to qualify for the various levels of Phase I commissions may be set at a variety of levels according to the desires and economics of the company implementing the plan of the present invention. Additionally, the percentages of PV of the team members utilized in calculating the Phase I commissions may also be varied according to the needs of the company implementing this plan, although it is generally preferred that a greater percentage be paid out for team members having a lower PV than for team members with a higher PV. In this embodiment, it is preferred that the total payout of Phase I commissions and rebates based on the PV of a single position not exceed 20 percent (excluding courtesy bonuses). In other words, the present plan permits a number of upline distributors to receive a Phase I commission based on the PV of a single downline distributor. The combination of these Phase I commissions plus the rebate received by the downline distributor should preferably not exceed 20 percent, excluding courtesy bonuses.
[0052] One feature of the present invention that is an advantage over the prior art is that the distributor is not penalized for the individual successes of the downline distributors. More particularly, there is no breakaway when a frontline or downline distributor becomes so successful so as to independently qualify for personal rebates, commissions, or other bonuses as described herein. Rather, the distributor's distribution genealogy remains intact, such that the frontline and downline distributors remain within the distributor's distribution genealogy so as to enable the distributor to receive the rebates and commissions the distributor is entitled to.
PHASE II COMPENSATION
[0053] In accordance with the teachings of the present invention, Phase II compensation of the present invention generally includes an override commission that is paid to a distributor that satisfies a minimum TV requirement and a minimum leg requirement. According to one presently preferred embodiment of the invention, as illustrated in FIG. 4, there are nine override commission levels for which a distributor can qualify that are set forth in table 400 , namely, Manager 410 , Senior Manager 420 , Executive Manager 430 , Director 440 , Senior Director 450 , Executive Director 460 , Vice President 470 , Senior Vice President 480 , and Executive Vice President 490 . All of the override commission levels 410 - 490 are associated with corresponding requirements 492 and benefits 494 .
[0054] The PV requirement for Phase II override commissions requires that the distributor have PV of at least 150. It should be appreciated that this requirement may be set at a variety of levels, according to the desires of those implementing this invention. The TV requirement for the Phase II override commission requires that the distributor have a TV of at least 1,000. A distributor's TV is computed the same way for Phase II as it is for Phase 1 , as described above in reference to FIGS. 2 - 3 . It should be appreciated, however, that the TV requirement can vary in amount or be eliminated entirely. For example, in one embodiment, Manager 410 does not have a minimum TV requirement.
[0055] The leg requirement of the Phase II override commission is generally described in terms of a required minimum number of legs with a minimum total PV requirement for each such leg. A leg is generally defined as the top-line distributor's personally sponsored distributors, in combination with the descendants (or downline distributors) of that position. For example, in FIG. 2 distributor 210 has two legs, a first leg comprising member 212 and a second leg that comprises distributor 214 in combination with distributors 218 , 220 , 222 , and 224 . A leg may comprise any number of descendent positions or alternatively, a leg may be limited in terms of levels or generations from the top-line distributor. According to a presently preferred embodiment, a leg includes all existing distributor descendents within the downline of a personally sponsored distributor. “Phase II generations,” as that term is used herein, refers to a “team qualified generation” and is determined according to Phase II compression rules, which will be described below.
[0056] The leg requirements to qualify for the various Phase II override commissions of the present invention are quantified in FIG. 4. These requirements are defined in terms of Organization Volume, or OV, requirements. The Organization Volume comprises the total leg volume of a single leg or, in other words, the total PV produced in a single leg of the top-line distributors distribution genealogy, as defined above. OV is thus computed by adding together the PV of every member within a given leg. For example, in FIG. 2, a first leg comprising distributor 212 has an OV of 1,100, which is the PV of distributor 212 , the only distributor in the first leg. A second leg, comprising distributors 214 , 218 , 222 , and 224 , has an OV of 1,705, which is the sum total of the PV of every member in the second leg (e.g., 55+150+40+160+1,300).
[0057] As illustrated in FIG. 4, a top-line distributor having at least one leg with an OV of at least 1,000 qualifies for the Senior Manager override commission. A distributor having at least one leg with an OV of at least 1,000, and a second leg with an OV of at least 3,000 qualifies for the Executive Manager override commission. A distributor having at least one leg with an OV of at least 1,000, a second leg with an OV of at least 3,000, and a third leg with an OV of at least 5,000 qualifies for the Director override commission. A distributor having at least one leg with an OV of at least 2,000, one leg with an OV of at least 5,000, and a leg with an OV of at least 10,000 qualifies for the Senior Director override bonus. A distributor having at least one leg with an OV of at least 5,000, one leg with an OV of at least 10,000, and a leg with an OV of at least 15,000 qualifies for the Executive Director override commission.
[0058] A distributor having at least three legs, each with an OV of at least 15,000 qualifies for the Vice President override commission. In a presently preferred embodiment of the invention, a distributor can alternatively qualify for the Vice President override commission by having at least three legs, each with an OV of at least 10,000, and a personal organizational volume (“POV”) of at least 75,000, where the POV is computed by adding together the PV of every member of the distributor's distribution genealogy. Notably, in this preferred embodiment, POV includes the top-line distributor's own PV.
[0059] A distributor qualifies for the Senior Vice President override commission by having at least three legs, with each leg having an OV of at least 20,000, or alternatively by having at least three legs, with each leg having an OV of at least 15,000, and a POV of at least 100,000. Finally, a distributor qualifies for the Executive Vice President override commission by having at least three legs, with each leg having an OV of at least 30,000, or alternatively, by having at least three legs, with each leg having an OV of 20,000, and a POV of at least 200,000.
[0060] It will be appreciated that the magnitude of the OV and POV required to achieve the various levels of Phase II override commissions may be varied according to the needs of the company implementing this plan. Various qualification requirements may be imposed with greater benefits available as higher requirements are met. The specific numbers provided herein are merely exemplary and not intended to limit the scope of the present invention.
[0061] According to the preferred embodiment, the invention allows horizontal compression to be used to satisfy specific leg requirements. According to one embodiment of horizontal compression of the present invention, a distributor's largest leg is applied to the largest leg requirement, the distributors second largest leg is applied to the second largest requirement, and any remaining legs are horizontally compressed, or summed together, and applied to the last leg requirement. For example, if a distributor has (1) one leg comprising 16,000 OV, (2) one leg comprising 12,000 OV, and (3) four legs that each comprise 2,000 OV, the distributor qualifies for the leadership rank of Executive Director 460 , assuming the distributor also has a PV of at least 150 and a TV of at least 1,000. The distributor qualifies for the rank of Executive Director 460 because its 16,000 OV leg satisfies the 15,000 leg OV requirement, its 12,000 OV leg satisfies the 10,000 leg OV requirement, and its remaining four 2,000 OV legs are horizontally compressed to equate 8,000 OV, thereby satisfying the 5,000 leg OV requirement.
[0062] To compute Phase II override commissions, it is first necessary to determine the Phase II generations for the top-line distributor, which are determined by performing compression of the distributor's genealogy. Generations under Phase II compensation are determined by analyzing each distributor's TV and determining, as a function of that TV, whether a generation break occurs between the distributor and the distributor's front line. If the TV of a distributor is less than 1,000, the distributor is not team qualified and no generation break occurs between that distributor and its front line. If the TV of a distributor is greater than or equal to 1,000 and the distributor has a PV of at least 150, the distributor is said to be team qualified and there is a generation break between the distributor and its front line. The TV of a distributor is determined, as discussed above, by summing the distributor's PV and the distributor's LV.
[0063] This analysis is best explained by reference to the sample distributor network illustrated in FIG. 5. At the bottom of the distributor network 500 in FIG. 5 is distributor 568 . Because distributor 568 has sponsored no other distributors into the organization, it has no downline and therefore has no possibility of Phase II compression. Thus, the Phase II compression analysis begins with the lowest distributor to have a front line. In FIG. 5, this is distributor 566 .
[0064] The first step in the Phase II compression analysis with respect to distributor 566 is to determine the TV of distributor 566 to ascertain whether distributor 566 is team qualified. This is done by adding the PV of distributor 566 to the LV of distributor 566 . In this example, this calculation is simple because the LV of distributor 566 comprises the PV of only one distributor—distributor 568 , with a PV of 3,000; thus, there are no other distributors in that generation to consider when calculating the TV of distributor 566 . Hence, the TV of distributor 566 is the sum of the PV of distributor 566 (2,000) and the LV of distributor 566 (3,000), or 5,000.
[0065] Because 5,000 is above the threshold qualification level for team qualification (1,000) and because distributor 566 has 150 PV, distributor 566 is team qualified. Consequently, a generation break 570 occurs directly beneath distributor 566 , thereby placing distributor 566 in a different generation from its front line (distributor 568 ).
[0066] Moving up the distribution network, the Phase II compression analysis can now be performed for distributor 560 by calculating the TV of distributor 560 . The front line of distributor 560 includes only a single distributor, distributor 566 . Having previously performed the Phase II compression analysis for distributor 566 , it is known that a generation break 570 exists directly beneath distributor 566 ; hence, the only distributor in the generation that includes distributor 566 is distributor 566 itself. Adding the PV of distributor 566 (PV=2,000) and the PV of distributor 560 (PV=200) yields a TV for distributor 560 of 2,200, which is sufficient to render distributor 560 team qualified. Thus, a generation break 572 occurs beneath distributor 560 , separating it from its downline distributor 566 .
[0067] Continuing up the distributor network, the TV for distributor 550 may now be ascertained. This is done by first identifying the distributors in the front line of distributor 550 . These include distributor 560 , distributor 562 , and distributor 564 . The TV of distributor 550 is now determined by summing the PV of distributor 550 (PV=200) and the LV of distributor 550 , which comprises the sum of the PV of distributor 560 (PV=200), distributor 562 (PV=200), and distributor 564 (PV=200), for a total TV of 800. This is below the amount necessary to team qualify distributor 550 ; thus, no generation break occurs between distributor 550 and its front line (distributors 560 , 562 , and 564 ).
[0068] Proceeding up the left hand side of the distribution network chart of FIG. 5, the Phase II compression analysis is now done for distributor 520 . The front line of distributor 520 is identified, and includes distributor 550 , distributor 552 , and distributor 554 . Because each of the front line distributors 550 , 552 , and 554 have a PV greater than 100, they are each personally qualified and no compression is required to compute the LV of distributor 520 , which comprises the sum of the PV of distributor 550 (PV=200), distributor 552 (PV=200), and distributor 554 (PV=200), for a total LV of 600. Summing the PV of distributor 520 (PV=200) with the LV of distributor 520 (LV=600) yields a TV for distributor 520 of 800. This is insufficient to team qualify distributor 520 ; thus, no generation break occurs between distributor 520 and its front line (distributors 550 , 552 , and 554 ).
[0069] Continuing up the distribution network, it is now possible to compute the TV for distributor 510 . As shown, distributor 510 has a front line that includes distributor 520 (PV=200), distributor 530 (PV=5,000), and distributor 540 (PV=2,500), for a LV of (200+5,000+2,500=7,700). Summing the PV of distributor 510 (PV=180) with the LV of distributor 510 (LV=7,700) yields 7,880, well above the threshold to team qualify distributor 510 ; thus, a generation break 574 occurs between distributor 510 and its front line (distributors 520 , 530 and 540 ).
[0070] It should be noted that it is not necessary to conduct compression analysis for distributors 562 , 564 , 552 , 554 , 530 , or 540 , as none of these distributors has any downline. Consequently, like distributor 568 , they have no possibility of Phase II compression. The generation calculation may be calculated working up the distribution organization as detailed in this example, or alternatively, by working down the organization, as described above in reference to FIG. 2, wherein it was shown how a generation includes the PV of all distributors located between the top-line distributor down to and including the first team qualified distributors encountered in each downline of the top-line distributor.
[0071] Once the Phase II generations have been identified according to the compression described above, it is possible to compute the override commissions for each leadership rank according to table 400 of FIG. 4. As shown in FIG. 4, each of the leadership ranks qualify for a “Phase I 20%” bonus for generation 1 , which comprises all Phase I payments as previously described. Accordingly, the rank of Manager 400 is only qualified for Phase I rebates and commissions described above. A Senior Manager 420 qualifies for the override commission of a Manager 400 and an additional override commission comprising the monetary equivalent of 5% of the PV of every member in generation 2 . An Executive Manager 430 qualifies for the override commission of a Senior Manager 420 plus an override commission comprising the monetary equivalent of 5% of the PV of every member in generation 3 . A Director 440 qualifies for the override commission of an Executive Manger 430 plus an override commission comprising the monetary equivalent of 5% of the PV of every member in generation 4 . A Senior Director 450 qualifies for the override commission of a Director 440 plus an override commission comprising the monetary equivalent of 5% of the PV of every member in generation 5 . An Executive Director 460 qualifies for the override commission of a Senior Director 450 plus an override commission comprising the monetary equivalent of 5% of the PV of every member in generation 6 . A Vice President 470 qualifies for the override commission of an Executive Director 460 plus an override commission comprising the monetary equivalent of 3% of the PV of every member in generation 7 . A Senior Vice President 480 qualifies for the override commission of a Vice President 470 plus an override commission comprising the monetary equivalent of 3% of the PV of every member in generation 8 . Finally, an Executive Vice President 490 qualifies for the override commission of a Senior Vice President 480 plus an override commission comprising the monetary equivalent of 3% of the PV of every member in generation 9 .
[0072] Returning now to FIG. 5, the computation of the Phase II override commission for distributor 510 is explained. Initially, the leadership rank for which distributor 510 has qualified must be determined so that the corresponding benefits 494 distributor 510 is qualified to receive are known. As shown, top-line distributor 510 has three legs, one leg comprising only member 540 has an OV of 2,500, a second leg comprising only member 530 has an OV of 5,000, and a third leg comprising members 520 , 550 , 552 , 554 , 560 , 562 , 564 , 566 , and 568 has an OV of 6,400, which is the sum of the PV of every member of the leg. Accordingly, distributor 510 has three legs, having OVs of 2,500, 5,000, and 6,400, thereby qualifying for the Phase II rank and override bonus of Director 440 which requires that the distributor have a PV of 150, a TV of 1,000, one leg with an OV of at least 1,000, a second leg with an OV of at least 3,000, and a third leg with an OV of at least 5,000.
[0073] Now, using table 400 from FIG. 4, the distributor's Director bonus can be calculated, which is the monetary equivalent of the sum of 5% of the PV of all distributors in its second generation (distributor 566 ) and 5% of the PV of all distributors in its third generation (distributor 568 ), or (0.05×2,000)+(0.05×3,000) $250.00. Although distributor 510 as a Director is entitled to also receive a 5% bonus for the PV of any distributors in its fourth generation, in this example there are no fourth generation distributors.
[0074] According to this presently preferred embodiment of the Phase II compensation of the present invention, a Senior Director qualifies for an additional bonus of $200 for having a POV of at least 25,000. An Executive Director qualifies for an additional bonus of $300 for having a POV of at least 35,000. A Vice President qualifies for an additional bonus of $400 for having a POV of at least 50,000. A Senior Vice President qualifies for an additional bonus of $500 for having a POV of at least 90,000. An Executive Vice President qualifies for an additional bonus of $750 for having a POV of at least 110,000.
[0075] Although specific dollar amounts have been given regarding POV requirements and additional bonus amounts, it should be appreciated that different dollar amounts can be used. The additional bonus can also include other perks, such as airfare, vacation packages, dinner vouchers, entertainment vouchers, etc. This bonus may also be accrued for use at a later time for company-sponsored events or other purposes approved by the company.
[0076] According to another embodiment, the additional bonus comprises money that must be spent on a car purchase or a car lease payment. To ensure the additional bonus is used as required, the distributor may be required to submit documentation of a car purchase or lease.
[0077] According to yet another embodiment, distributors that qualify for a leadership rank may also receive shares in a global bonus pool. The global bonus pool comprises a percentage of the total PV of all distributors in the company's entire sales organization. In one presently preferred embodiment of the invention, the global bonus pool comprises a monetary equivalent of 2% of the PV of all distributors of the organization. Thus, a share in the global bonus pool entitles the owner of that share to a portion of the pool equal to the number of shares earned by the distributor divided by the total shares in the global bonus pool held by all distributors.
[0078] According to one implementation of the present embodiment, an Executive Director 460 is granted one share in the global bonus pool, a Vice President 470 is granted two shares in the global bonus pool, a Senior Vice President 480 is granted three shares in the global bonus pool, and an Executive Vice President 490 is granted one share in the global bonus pool. When paying bonuses out of the global bonus pool, one dollar is preferably paid out for each point of PV in the pool.
PHASE III COMPENSATION
[0079] The compensation plan of the present invention also preferably includes a component of what is referred to herein as Phase III compensation. In accordance with the teachings of the present invention, there are four general Phase III compensation levels, which are referred to herein as “clubs.” As illustrated in table 700 of FIG. 7, these Phase III clubs include the Royal Executive Club 710 , the Royal Sapphire Club 720 , the Royal Ruby Club 730 , and the Royal Diamond Club 740 . The compensation levels along with the corresponding requirements 750 and benefits 760 are also shown in table 700 of FIG. 7.
[0080] In a presently preferred embodiment of the invention, a distributor must satisfy one of two requirements to qualify for the Royal Executive Club 710 in conjunction with having 150 PV and 1000 TV. The first requirement is to have three legs, with each leg having an OV of at least 40,000. The second requirement is to have a POV of at least 250,000 and three legs each having an OV of at least 25,000. It should be appreciated, however, that other requirements can also be imposed, such as, for example, requiring compliance with either of the first two requirements for a period of three consecutive months.
[0081] A distributor that is qualified for the Royal Executive Club is entitled to four shares of the Global Bonus Pool. The distributor is also entitled to create one additional performance team (“APT”) position. An APT position is a position on the top-line distributor's front line that is occupied by the top-line distributor. In one embodiment, the APT position also includes an option for the distributor to transfer up to three existing legs beneath the newly created APT position. The APT position is particularly beneficial for a distributor that chooses to occupy the APT position by itself because the distributor can then receive double Phase II and Phase III override commissions on certain members of the distributor's genealogy that descend from the APT position. The benefits associated with an APT position and the methods for establishing an APT position will be more fully explained in reference to FIGS. 7 - 8 .
[0082] [0082]FIG. 7 illustrates a sample genealogy 800 A in which a distributor 810 has seven legs 820 , 830 , 840 , 850 , 860 , 870 , and 880 . In this example, the POV of distributor 810 is 257,000, which is calculated by summing the OVs of each of the legs of distributor 810 (50,000+160,000+25,000+10,000+3,000+5,000+4,000). Because the POV of distributor 810 exceeds 250,000 and three of those legs have an OV of at least 25,000, distributor 810 is qualified for the Royal Executive Club 710 , and hence is entitled to an APT position.
[0083] In FIG. 7, APT position 890 is drawn in broken lines, indicating that the position is available to be filled, along with these potential transfer leg positions 892 , 894 , and 896 . In this example, the distributor 810 fills the APT position 890 with itself, as shown in FIG. 8. Also shown in FIG. 8, the distributor 810 has transferred two existing legs 860 and 880 to occupy two of the transfer leg positions 892 and 894 . The total leg OV between legs 860 and 880 is 7,000 (e.g. 3,000+4,000). Distributor 810 may also build other positions on the front line of APT 890 by sponsoring additional distributors into the company.
[0084] According to the new genealogy 800 B illustrated in FIG. 8, the distributor 810 is now eligible to receive two sets of Phase II override commissions on legs 870 and 880 , one from the distributor's original position 892 and one from the APT position 890 . Accordingly, it is beneficial for the distributor 810 to fill the APT descendent leg positions 892 , 894 , and 896 with those existing legs that have the highest OV, thereby maximizing the OV on which distributor 810 will earn double bonus commissions.
[0085] According to one embodiment of the present invention, the distributor can only fill the APT transfer leg positions 892 , 894 , 896 with legs that have a combined leg OV of 10,000 or less. According to this embodiment, APT transfer leg position 896 cannot be filled with leg 870 because the result would be a total leg OV of 12,000 (i.e., 3,000+4,000+5,000). According to another embodiment, the distributor can transfer any number of legs under the APT position.
[0086] According to yet another embodiment of Phase III compensation, the distributor is only eligible for an APT position if the distributor can qualify for the APT position without considering the OV of the legs it transfers beneath the APT position 890 . In accordance with this alternative embodiment of the invention, distributor 810 in FIG. 7 cannot fill any of the APT transfer legs 892 , 894 , or 896 with any leg having an OV of $7,000 or more. Thus, for example, distributor 810 would be precluded from transferring leg 850 below the APT position 890 because that would reduce the distributor's POV (excluding the OV of the APT position) to only 247,000 (i.e., 50,000+160,000+25,000+3,000+5,000+4,000). With a POV of only 247,000, the distributor would fail to qualify for the Royal Executive Club and would not be entitled to the corresponding APT bonus position.
[0087] It should also be appreciated that there are various limits and requirements that can be placed on an APT position. The foregoing embodiments are only given as a matter of illustration and should not be construed as limiting the scope of the present invention, Once an APT position is established on a distributor's genealogy, it is possible for the occupant of the APT position to independently qualify for an APT position of its own by satisfying the designated requirements of a corresponding Phase III compensation level.
[0088] To qualify for the Royal Sapphire Club 720 a distributor must satisfy one of two requirements in conjunction with having 150 PV and 1,000 TV. The first requirement is to have at least three legs, with each leg having an OV of at least 50,000. The second, alternative, requirement is that the distributor must have a POV of at least 300,000 and at least three legs that each leg have an OV of at least 30,000. When a distributor qualifies for the Royal Sapphire Club 720 , the distributor is eligible to maintain its APT position, as described above, an override commission comprising the monetary equivalent of 1% of the PV of every member in generation 10 of the Phase II compression, and four shares in the global bonus pool.
[0089] To qualify for the Royal Ruby Club 730 , a distributor must have 150 PV, 1,000 TV, and one of either three legs, each having an OV of at least 100,000, or, alternatively, a POV of 500,000 and three legs, each of which has an OV of at least 50,000. When a distributor qualifies for the Royal Ruby Club 730 , the distributor is eligible to maintain its APT position, an override commission comprising the monetary equivalent of 1% of the PV of every member in generation 10 and generation 11 of the distributor's Phase II genealogy, and four shares in the global bonus pool.
[0090] To qualify for the Royal Diamond Club 740 , a distributor must have either three legs, with each leg having an OV of at least 250,000, or, alternatively, the distributor must have a POV of 1,000,000 and three legs, with each leg having an OV of at least 100,000. When a distributor qualifies for the Royal Diamond Club 740 , the distributor is eligible to maintain its APT position, an override bonus comprising the monetary equivalent of 1% of the PV of every member in the distributor's Phase II generations 10 , 11 , and 12 , and four shares in the global bonus pool.
[0091] In an alternative embodiment of Phase III compensation, the alternative requirements for club membership that require three legs each having a predetermined OV and a POV of a specified amount is modified. In this alternative embodiment, the POV requirements must be reached exclusive of the TV of the three legs used in meeting the other portion of the club qualification requirement. Thus, for example, to qualify for Royal Executive Club 710 , illustrated in FIG. 7, under the alternative requirements of three legs each having an OV of at least 25,000 and a POV of at least 250,000, this requirement would be interpreted as requiring that the POV component of the requirement be satisfied independently of the three legs used to satisfy the other component of the requirement.
[0092] According to another embodiment, the leg requirements for any of the aforementioned Phase III club levels can be satisfied by using horizontal compression, as described above in reference to FIG. 4. However, according to one presently preferred embodiment, if an APT position is required to be used during horizontal compression to qualify a distributor for a Phase III club level because the distributor would not otherwise qualify for a Phase III club level, then that distributor is not eligible to receive the benefit of the APT position for other than qualification to the corresponding club level. In particular, an APT position that is required to be used during horizontal compression to maintain a distributor's qualification for a particular club level is not eligible to receive any earnings.
[0093] Qualifying for any of the aforementioned Phase III compensation levels can also be contingent on a distributor satisfying the designated requirements over a period of time, such as three or six consecutive months. According to other embodiments, a distributor that qualifies for membership in a phase III leadership club will receive a one-year membership in the designated club. For example, if a distributor qualifies for the Royal Executive Club 710 by satisfying the corresponding requirements, then the distributor will be granted a one-year membership in the Royal Executive Club 710 , entitling the distributor to all of the benefits that are associated with the Royal Executive Club 710 for the one-year membership period.
[0094] According to another embodiment, however, a distributor is required to continue satisfying all of the requirements of a leadership club in order to receive all of the benefits of the club. For example, even with membership to the Royal Executive Club 710 , a distributor must satisfy the corresponding Royal Executive Club requirements 750 each month in order to receive and maintain an APT.
[0095] According to yet another embodiment, entitlement to the 1% override bonuses and shares in the Global Bonus Pool is contingent on satisfying corresponding club requirements on a discrete monthly basis (i.e., the corresponding club requirements must be met for the month in which the override bonus and Global Bonus Pool shares are earned), while entitlement to official recognition and APT positions is contingent on having satisfied their corresponding requirements over a period of three consecutive months.
[0096] Qualification to a designated Phase III compensation level can also be predicated upon a sliding scale. To illustrate this point, an example will be given in which a distributor receives a one-year membership for satisfying the requirements of a designated compensation level for three consecutive months, as required. According to this example, the distributor qualifies for club membership by satisfying the designated requirements from month one to month three, such that the membership will expire in month fifteen. However, if the distributor also satisfies the designated requirements in months four and five, then the effective starting date of the membership will slide to month five, such that the membership will not expire until month seventeen.
[0097] Although numerous examples have been given, in which great detail is provided, it should be appreciated that the examples, as they have been provided, should be construed as illustrative and not limiting of the invention. In particular, the present invention can be embodied in other specific forms without departing from its spirit or essential characteristics. For example, the names, requirements and benefits associated with each of the three phases of the network marketing compensation system can vary. In particular, it should be appreciated that each of the aforementioned Phase III compensation levels can also be configured to include special recognition and other perks.
[0098] It should also be appreciated that the present invention may be embodied in other forms without departing from its spirit or essential characteristics. As properly understood, the preceding description of specific embodiments is illustrative only and in no way restrictive. The scope of the invention is, therefore, indicated by the appended claims as follows.
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The sales compensation plan of the present invention is a stair-step compensation plan without a breakaway to promote depth as well as breadth within the distributor's distribution genealogy. The compensation plan also includes an advanced performance team position that enables qualifying distributors to position themselves within their own frontline of their distribution genealogy to receive additional compensation for their efforts. Yet another feature of the compensation plan is the unique concept of horizontal compression for enabling leg volume requirements to be satisfied by horizontally compressing the leg volume of a plurality of legs.
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CROSS REFERENCE
[0001] This application relates to applicants' co-pending application entitled “Computer Telephony Integration (CTI) Complete Healthcare Contact Center,” (Attorney Docket 02-BS060/BS02530) filed simultaneously herewith and of which the “Brief Summary of the Invention” and “Detailed Description of the Invention” sections are incorporated herein by this reference.
[0002] This application relates to applicants' co-pending application entitled “Computer Telephony Integration (CTI) Complete Hospitality Contact Center,” (Attorney Docket 02-BS063/BS02526) filed simultaneously herewith and of which the “Brief Summary of the Invention” and “Detailed Description of the Invention” sections are incorporated herein by this reference.
NOTICE OF COPYRIGHT PROTECTION
[0003] A portion of the disclosure of this patent document and its figures contain material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, but the copyright owner otherwise reserves all copyrights whatsoever.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention generally relates to computer networks and to telephony. More particularly, this invention is directed to methods and systems for more efficient and effective communication and processing of electronic data in a call management and contact center system.
[0006] 2. Description of the Related Art
[0007] Large businesses commonly service customers through call management and contact centers (herein after referred to as a “call center”). These call centers are staffed with support agents, interactive voice response recordings, and/or information systems to process customer inquiries across numerous communications devices and network infrastructures. Each week, hundreds, if not thousands or more, of incoming communications (including calls, emails, faxes, letters, and other communications) and associated data are received, accessed, and/or managed by the call center. The agent (or an automated call forwarding system) may forward/transfer the incoming communication and/or associated data to an extension of a designated party who can respond to the customer. The extension is typically associated with a physical location of a phone, such as a phone in the designated party's office or a particular location in a building. Oftentimes, the designated party is unavailable to receive the incoming communication and/or associated data because the designated party is away from the phone or because the phone cannot display or otherwise provide the associated data. For example, if the designated party is a doctor working in a large hospital, the doctor may be located at numerous locations throughout the day, such as in-service patient floors for rounds and/or emergencies, conference rooms for meetings, and clinic rooms for appointments/consultation. Thus, the doctor travels to multiple locations at different times throughout the day as inpatient service loads, meeting times, clinic schedule changes, and other changes make it difficult to have a predictable schedule and location. While most doctors carry paging devices, these paging devices tend to have limited service areas that restrict communications outside of a geographic area and limited functionality that restricts an incoming communication to a short text message such as a phone number. These paging devices also do not transmit communications and/or data back to the call center such as confirmations that the incoming communication was reviewed, location of the paging device (e.g., paging device of Dr. Roberts is located on 3 rd floor/ICU section of Hawthorn building), and so on. Still further, most business people today tend to carry multiple communications devices, such as a pager, personal digital assistant (PDA), and cell phone. However, the call center of a business does not leverage the multiple communications devices of a designated party because each of these communications devices is customized in terms of software, hardware, and network configuration. For example, the PDA and the cell phone have different software applications, data processing, storage, management, and communications systems.
[0008] As discussed above, one of the biggest bathers facing a call center is locating and accessing multiple communications devices utilized by the staff of the call center. In addition, the incoming communications and associated data of the call center must be in a format that can easily be exchanged or otherwise shared with each communications device. For example, if the agent wants to share contact information (e.g., name, phone numbers, addresses, etc.) with a cell phone and a pager of a designated party, then the agent typically must enter this information twice—once on a platform communicating with the cell phone and once on a platform communicating with the pager. Another barrier is providing the incoming communication and/or associated data in a standardized or otherwise compatible data format, depending on functionality limitations of the communications device, so that each communications device has efficient and effective access to the information. For example, conventional wireless phones have limited functionality compared with personal computers (PC). Typically, wireless telephones provide limited contact information, such as a telephone listing by name rather than full address books and/or calendars. Additionally, conventional wireless telephones are unable to run application/software packages and may have limited capabilities for transmitting, receiving, and displaying video data.
[0009] To further complicate operations of the call center, most large businesses must work with several vendors who each provide only a portion of the required call management and contact center system. Further, these large businesses often do not have the technical staff to design, select, and integrate network(s), hardware and equipment, software, and/or develop customized applications. Even after a large business customer has purchased the required components, they have difficulty integrating these components into existing infrastructures, and most often, end up with several call centers that do not provide access to information and/or to staff across the entire enterprise. As a result, large businesses limp along with many different, non-integrated communications networks and call center systems.
[0010] Accordingly, large businesses need integrated call management and contact center systems and methods that can provide immediate access to resources (e.g., staff and data), improve operator productivity, increase customer satisfaction, and control costs. The integrated call management and contact center systems and methods must support various communications infrastructures to capitalize on emerging communications devices such as, for example, interactive pagers, on-site pagers, wireless phones, personal computers, etc. Consequently, the integrated call management and contact center systems and methods should enable sharing, transferring, and/or accessing staff and data over various communications devices while also complying with information system requirements of the business, such as security and fail-safe requirements.
BRIEF SUMMARY OF THE INVENTION
[0011] The aforementioned problems and others are solved by a dynamic computer telephony integration (CTI) complete customer contact center (hereinafter referred to as the “dynamic contact center”). The dynamic contact center comprises systems and methods that leverage the assets of a business' communications systems including internal telecommunications networks, information systems, data networks, and applications, of public telecommunications networks (e.g., public switched telephone network (PSTN) or mobile telecommunications switching office (MTSO)), of public data networks (e.g., Internet), and/or of various communications devices of a designated party affiliated with the business in order to facilitate improved access, sharing, notification, and/or management of incoming calls and associated data of the business' call center. Some advantages of the dynamic contact center include faster access to staff and data, ability to communicate incoming calls and data to staff over a variety of communications devices, less operator/agent intervention, and increased emergency recovery capabilities.
[0012] An embodiment of this invention describes a computer telephony integration (CTI) system having a private branch exchange (PBX) or other similar system for connecting a plurality of agent stations with at least one telephone line. Typically, the agent station includes a personal computer and/or a telephone that the agent uses to answer, respond to, and/or transfer incoming communications (including associated data) to a call center. The system includes detection means for detecting the incoming communication, an input/output processor to input and to output data associated with the incoming communication, a communications interface for communicating the incoming communication and/or associated data with a communications device associated with a designated party (i.e., staff) of the call center, a memory device for storing the data, a processor communicating with the memory device, and a call center application for managing a communications profile. The processor selects data stored in the memory device based upon the communications profile, and typically includes information about (1) customer data associated with the incoming communication, (2) data associated with the designated party, (3) data associated with at least one of services, products, and business operations affiliated with the call center, (4) data associated with network configuration, (5) data associated with a configuration profile of the communications device, and (6) data associated with communications systems of the call center. Further, the communications interface may include means for providing messaging delivery means for delivering and confirming receipt/review of the incoming communication (including associated data). In various embodiments, the communications device may be a transmitter, a telephone, an intercom communications device, a personal computer, a wireless communications device, an on-site pager, a mobile phone, a wireless phone, a WAP phone, an IP phone, a satellite phone, a computer, a modem, a pager, a digital music device, a digital recording device, a personal digital assistant, an interactive television, a digital signal processor, a Global Positioning System device, and other similar communications devices.
[0013] In another embodiment, the system further includes status means for communicating a status of the communications device associated with the designated party of the call center to the call center application. Typically, the status provides information about availability and/or location of the designated party, availability and/or location of the communications device, messaging delivery capabilities of the communications device, and/or messaging delivery confirmation to the communications device. Further, the system may include status processing means that use the status to provide routing instructions to the communications interface for connecting the incoming call and/or associated data with the communications device.
[0014] Another embodiment describes a method for communicating an incoming communication to a private branch exchange (PBX) or other similar system that connects a plurality of agent stations with at least one telephone line, associating a communications profile with the incoming communication, accessing a communications network of the call center to determine a status, and based upon the status, communicating the incoming communication and/or data to the communications device.
[0015] Still, a further embodiment describes a network of interconnected communications devices associated with a call center, a rule-based application dataserver for managing the exchange of an incoming communication and/or associated data between an agent station of the call center and a communications device of a designated party affiliated with the call center, and an application program installed in the agent station. According to this embodiment, the application program allows an agent to manage a communications profile associated with (1) customer data associated with the incoming communication, (2) data associated with a designated party, (3) data associated with at least one of services, products, and business operations affiliated with a call center, (4) data associated with network configuration, (5) data associated with a configuration profile of a communications device associated with a designated party of the call center, and (6) data associated with communications systems of the call center.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] The above and other embodiments, objects, uses, advantages, and novel features of this invention are more clearly understood by reference to the following description taken in connection with the accompanying figures, wherein:
[0017] FIG. 1 is a block diagram showing of an exemplary Dynamic Contact Center (DCC) application operating in an agent station according to an embodiment of this invention;
[0018] FIG. 2 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party over a telephone and/or an intercom workstation according to an embodiment of this invention;
[0019] FIG. 3 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party over a personal computer and/or an intercom workstation according to another embodiment of this invention;
[0020] FIG. 4 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes several customer communications devices for transceiving an incoming communication according to another embodiment of this invention;
[0021] FIG. 5 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes a plurality of intercom workstations for determining a status and communicating with a plurality of designated parties according to another embodiment of this invention;
[0022] FIG. 6 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes an internal business customer utilizing an intercom workstation for determining a status and communicating an internal communication with a designated party according to another embodiment of this invention;
[0023] FIG. 7 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party having an on-site paging device according to another embodiment of this invention;
[0024] FIG. 8 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party through an internal communications interface or a data network gateway to a wireless communications device according to another embodiment of this invention;
[0025] FIG. 9 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party through an internal communications interface or a telecommunications network to a wireless communications device according to another embodiment of this invention;
[0026] FIG. 10 is a schematic showing an exemplary operating environment for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party through an internal communications interface or a telecommunications network to alternate wireless communications device according to another embodiment of this invention;
[0027] FIG. 11 is a schematic showing another exemplary operating environment with telecommunications and data networks for a dynamic contact center system that includes means for determining a status of a designated party and communicating with the designated party through an internal communications interface or a telecommunications network to another alternate wireless communications device according to an embodiment of this invention; and
[0028] FIG. 12 is a schematic of an exemplary operating environment of a dynamic contact center system communicating with other systems over a telecommunications and/or data network.
DETAILED DESCRIPTION OF THE INVENTION
[0029] This invention now will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. 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 of ordinary skill in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).
[0030] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
[0031] The aforementioned problems and others are solved by a dynamic computer telephony integration (CTI) complete customer contact center (“dynamic contact center”). The dynamic contact center comprises systems and methods that leverage the assets of a business' communications systems including internal telecommunications networks, information systems, data networks, and applications, of public telecommunications networks (e.g., public switched telephone network (PSTN) or mobile telecommunications switching office (MTSO)), of public data networks (e.g., Internet), and/or of various communications devices of a designated party affiliated with the business in order to facilitate improved access, sharing, notification, and/or management of incoming communications and associated data of the business' call center. As is apparent to one of ordinary skill in the art, the subject-specific group of the business may be tailored to any industry that seeks to leverage the assets of a dynamic contact center. Some advantages of the dynamic contact center include faster access to staff and data (remote and on-site), ability to communicate incoming calls and data to staff over a variety of communications devices, less operator/agent intervention, and increased emergency recovery capabilities. As used herein, the term “data” includes electronic information, such as information and/or files stored in a database, electronic messages such as email, notifications, replies, and/or other means of communicating electronic information between or among the business' communications system (including the agent station), the public telecommunications networks, the public data networks, and/or of various communications devices of a designated party.
[0032] Referring now to the figures, FIG. 1 is a block diagram showing a Dynamic Contact Center (DCC) Application 110 residing in an agent station 100 . The DCC Application 110 operates within a system memory device. The DCC Application 110 , for example, is shown residing in a memory subsystem 12 . The DCC Application 110 , however, could also reside in flash memory 14 and/or in a peripheral storage device, such as storage device 40 associated with a DCC dataserver 42 . The agent station 100 also has one or more central processors 20 executing an operating system. The operating system, as is well known, has a set of instructions that control the internal functions of the agent station 100 . A system bus 22 communicates signals, such as data signals, control signals, and address signals, between the central processors 20 and a system controller 24 (typically called a “Northbridge”). The system controller 24 provides a bridging function between the one or more central processors 20 , a graphics subsystem 26 , the memory subsystem 12 , and a PCI (Peripheral Controller Interface) bus 28 . The PCI bus 28 is controlled by a Peripheral Bus Controller 30 . The Peripheral Bus Controller 30 (typically called a “Southbridge”) is an integrated circuit that serves as an input/output hub for various peripheral ports. These peripheral ports could include, for example, a keyboard port 32 , a mouse port 34 , a serial port 36 and/or a parallel port 38 . Additionally, these peripheral ports would allow the agent station to communicate with a variety of communications devices through ports 54 (such as SCSI or Ethernet), Wireless Transceiver 52 (using the IEEE Wireless standard 802.11 and Infrared), and Wired Comm Device Port 50 (such as modem V90+ and compact flash slots). The Peripheral Bus Controller 30 could also include an audio subsystem 35 . Additionally, the agent station may include a network server 44 operating with a network browser 46 . The DCC dataserver 42 , the network server 44 , and the network browser 46 may be stand alone or integrated components. Still further, the agent station 100 may include a power source 60 , such as a rechargeable battery to provide power and allow the agent station 100 to be portable. The power source 60 may additionally or alternatively include an alternating current (AC) power source or power converter.
[0033] The processor 20 is typically a microprocessor. Advanced Micro Devices, Inc., for example, manufactures a full line of microprocessors, such as the ATHLON™ (ATHLON™ is a trademark of Advanced Micro Devices, Inc., One AMD Place, P.O. Box 3453, Sunnyvale, Calif. 94088-3453, 408.732.2400, 800.538.8450, www.amd.com). Sun Microsystems also designs and manufactures microprocessors (Sun Microsystems, Inc., 901 San Antonio Road, Palo Alto Calif. 94303, www.sun.com). The Intel Corporation manufactures microprocessors (Intel Corporation, 2200 Mission College Blvd., Santa Clara, Calif. 95052-8119, 408.765.8080, www.intel.com). Other manufacturers also offer microprocessors. Such other manufacturers include Motorola, Inc. (1303 East Algonquin Road, P.O. Box A3309 Schaumburg, Ill. 60196, www.Motorola.com), International Business Machines Corp. (New Orchard Road, Armonk, N.Y. 10504, (914) 499-1900, www.ibm.com), and Transmeta Corp. (3940 Freedom Circle, Santa Clara, Calif. 95054, www.transmeta.com).
[0034] The preferred operating system is a LINUX® or a RED HAT® LINUX-based system (LINUX® is a registered trademark of Linus Torvalds and RED HAT® is a registered trademark of Red Hat, Inc., Research Triangle Park, N.C., 1-888-733-4281, www.redhat.com). Other operating systems, however, may be suitable. Such other operating systems would include a UNIX®-based system (UNIX® is a registered trademark of The Open Group, 44 Montgomery Street, Suite 960, San Francisco, Calif. 94104, 415.374.8280, www.opengroup.org). and Mac® OS (Mac® is a registered trademark of Apple Computer, Inc., 1 Infinite Loop, Cupertino, Calif. 95014, 408.996.1010, www.apple.com). Another operating system would include DOS-based systems. WINDOWS® and WINDOWS NT® are common examples of DOS-based systems (WINDOWS® and WINDOWS NT® are registered trademarks of Microsoft Corporation, One Microsoft Way, Redmond Wash. 98052-6399, 425.882.8080, www.Microsoft.com).
[0035] The system memory device (shown as memory subsystem 12 , flash memory 14 , or peripheral storage device 40 ) may also contain one or more application programs. For example, an application program may cooperate with the operating system and with a video display unit (via the serial port 36 and/or the parallel port 38 ) to provide a Graphical User Interface (GUI) display for the DCC Application 110 (e.g., GUI displays for a staff directory, a work profile of a designated party, a messaging screen for inputting a message and/or associated data, and a communications profile associated with the work profile, status, and/or business requirements). The GUI typically includes a combination of signals communicated along the keyboard port 32 and the mouse port 34 . The GUI provides a convenient visual and/or audible interface with the user of the agent station 100 . As is apparent to those of ordinary skill in the art, the selection and arrangement of the DCC Application 110 may be programmed over a variety of alternate mediums, such as, for example, a voice-activated menu prompt.
[0036] Typically, the DCC Application 110 is running on the workstation 100 when the incoming communication is detected at the PBX (or other similar system) by an automated call management and/or call routing system. The incoming communication is associated with initial customer data that triggers the DCC DataServer 42 to provide a communications profile of associated data along with the incoming communication to the workstation 100 (similar to decoding an ICLID signal for telecommunication special service features offered by telecommunication service providers). The DCC Application 110 allows an agent (or other staff or customers) of a call center to manage services provided by the dynamic contact center, such as: (1) accessing a staff directory including work profiles that provide up-to-date detailed information about a designated party, such as looking up the name of the designated party, a status of the designated party, and other information of the designated party (e.g., job title, job description, business department, business address, office hours, business associates such as secretaries, communications devices including personally owned/operated and employer affiliated, and routing addresses of the communications devices such as radio frequency identifiers, service node addresses, IP addresses, email addresses, and/or other electronic address information); (2) messaging options, such as taking, saving (e.g., email, voicemail, journal, etc.), retrieving, distributing (e.g., routing to one or more designated parties, delivery options including dates, times, priorities, etc.), and modifying a message; (3) issuing a query to determine the status of the designated party; (4) customizing the communications profile associated with DCC DataServer 42 including an access agent, a messaging agent, and a business requirements agent; (5) customizing presentation, features, and/or management of the incoming communication and/or associated data; and (6) controlling communications outside of the business' communications system, such as communications with a telecommunications network and/or a data network. For example, the agent (or the automatic call distributor using response rules received from an interactive response system) may interact with the Access Agent to control up-to-date staff directories, search for the designated party, use the work profile and/or the communications profile to launch a query to determine the status, receive the status, and communicate the status to a Messaging Agent to manage communications with the designated party.
[0037] In an embodiment, the DCC DataServer 42 has the ability to communicate with various networks, including internal and external telecommunications and/or data networks using appropriate protocols, such as standard transmission control protocol and Internet protocol (TCP/IP). The communications profiles stored by the DCC DataServer 42 provide increased security by allowing the business to internally control electronic data, utilize existing databases to add, delete, or otherwise change electronic data, and control how the business' communications system interacts with non-proprietary networks and communications devices, such as controlling routing instructions. Thus, DCC DataServer 42 functions as a computer server, database, and processor and is dedicated to managing DCC activity over the business' proprietary and non-proprietary networks.
[0038] The DCC Application 110 also allows the agent (or another authorized staff member) to control access, sharing, notification, routing, security, management, and/or additional processing of incoming communications and associated data. For example, DCC Application 110 allows the agent to control how the associated data is processed into the communications system of the business including (i) sending the data to a local storage device (such as local file server 216 shown in FIG. 1 ), or alternatively, to a remote storage device (such as a file server associated a the telecommunications service provider), (ii) archiving the data, (iii) encrypting the data, (iv) copying the data, and (v) associating the data with the communications profile. The DCC Application 110 may be downloaded from telecommunications network 204 , data network 230 , or provided on a storage media (e.g., diskette, CD-ROM, or installed by the computer system manufacturer) to install on the agent workstation 100 to enable, disable, and further control a variety of DCC Services. Still further, the DCC Application 110 allows the agent (or other staff) to customize presentation features, such as splitting a workstation screen into two viewing areas and presenting a video display of the incoming communication in one portion and presenting information associated with the Access Agent (e.g., staff directory) in the second portion.
[0039] FIG. 2 is a schematic showing an exemplary operating environment for a dynamic contact center (DCC) 200 . The DCC 200 includes a mobile telephone 202 , a telecommunications network 204 , a switch 206 , a private branch exchange (PBX) 208 , at least one telephone/voice workstation 210 , at least one modem 212 , at least one agent workstation 100 , a dynamic contact center application 110 , a wide area network 214 , at least one file server 216 , a firewall 218 , a local area network 220 , a remote PBX 228 , a data network 230 , a remote personal computer 235 , a communications interface 240 , a transceiver 245 , a business facility 250 , an intercom workstation 260 , a designated party 262 , an affiliated telephone 264 , and a personal identification transmitter 266 . The intercom workstation 260 is similar to traditional intercom systems; however, intercom workstation 260 may further include an audio subsystem (not shown) for broadcasting and receiving audio messages, a video subsystem (not shown), typically a liquid crystal display (LCD), for displaying images, a keyboard and/or mouse for inputting and/or otherwise selecting commands and/or data, and an internal transceiver (not shown) for receiving signals from personal identification transmitter 266 and for sending signals to either the transceiver 245 or to the communications interface 240 so that the designated party 262 can be located within the business facility 250 .
[0040] Typically, a customer uses mobile phone 202 to place a call routed through telecommunication network 204 and switch 206 to the PBX 208 (to the called telephone number of the call center). Alternatively, the customer may use the personal computer 235 to gain access to the DCC 200 through data network 230 . If so, firewall 218 screens and routes the incoming communication over the WAN 214 . The incoming communication (e.g., incoming call) is usually detected by an automated answering system (or similar system for communications initiated by personal computer 235 ) that provides intelligent routing of the call. For example, the customer may hear a prerecorded message prompting the customer to make an initial routing selection, such as, for example “Press 1 to place an order,” “Press 2 to speak with a customer service representative,” “Press 3 for directions,” “If you know the extension of the party (i.e., the designated party), please press * and the party's four digit extension,” and so on. Thus, the incoming communication may be initially routed to an appropriate agent (including agents connected with remote PBX 228 ) or to the extension of the designated party 262 (as described later, this extension may also be associated with a status of the designated party and the incoming communication may be further routed based on the status to the communications device). If the incoming communication is routed to the agent, then the call may be sent to the telephone/voice workstation 210 and/or through modem 212 to agent workstation 100 . Further, the incoming communication and initial routing instructions provide information about the call to the telephone/voice workstation 210 and/or the agent workstation 100 . For example, if the calling telephone number of the customer is decoded and/or if the customer provides an account number in response to an inquiry from the automated answering system (or if the account number is associated with other information like the ICLID signal of the calling number), then when the agent workstation 100 receives the incoming communication, the DCC Application 110 may automatically associate, retrieve, and pull up associated customer information (typically stored on file server 216 ). After the agent answers the incoming call, the agent may gather additional information from the customer, associate other customer data, identify the designated party 262 who can further handle the customer's needs, determine a status of the designated party 262 , and based upon an available status, transfer the incoming communication and associated data to an appropriate communications device, such as the workstation intercom 260 or the work telephone 264 . If the status is unavailable, then the agent may alternatively route the incoming communication and/or associated data to a messaging system, such as voicemail or pager number messaging.
[0041] The agent and/or the automated answering system determines the status of the designated party 262 by associating availability data of the designated party 262 , location data of the designated party 262 , availability data of the communications device, location data of the communications device, messaging delivery capability data of the communications device, and/or messaging delivery confirmation data with the communications device. Typically, the designated party 262 programs in protocols or rules related to his/her availability, location, and communications device. For example, the designated party 262 may input his/her work schedule including meetings, breaks, office hours and so on. Similarly, the designated party 262 may input specific times of unavailability (e.g., do not disturb), such as, for example, when a surgeon is operating on a patient during a scheduled surgery. The location data of the designated party 262 and/or the communications device may also be used to determine a status of the designated party 262 . In an embodiment, the designated party 262 wears a radio frequency (RF) transmitter 264 (or other means for identifying a location, such as, for example, a GPS transceiver or alternate location means) that transmits co-ordinates to nearby intercom workstation 260 in communication with transceiver 245 or that transmits co-ordinates directly to transceiver 245 . The DCC Application 110 maps the co-ordinates to associate a location with the business facility 250 (e.g., 3 rd floor Hawthorn Building, hallway section 4B). The location data may be further associated with the availability data of the designated party 262 to determine the status, such as whether the designated party 262 is available to receive the incoming communication. For example, if the designated party is located in a restroom, then the status of the designated party 262 is unavailable.
[0042] The availability data of the communications device may also be used to determine the status. For example, if the telephone 264 is off-hook, then the telephone 264 may be unavailable to receive the incoming communication and/or associated data. The telephone 264 may represent the extension of designated party 262 or, alternatively, telephone 264 may be associated with the designated party 262 through the communications profile and/or through determining the location of the designated party 262 and nearby facility communications devices (e.g., designated party is on 3 rd floor Hawthorn building, section 4B and proximate communications devices to area 4B include the intercom 260 in section 4B and the telephone 264 in section 4C). In addition, the location of the communications device may be used to determine the status. For example, telephone 264 may be located in a conference room with an ongoing meeting, and therefore, the telephone 264 would be unavailable. Still further, the messaging delivery capability of the communications device may be used to determine the status. For example, if the intercom workstation 260 has the means to display video images and text files, then the intercom workstation 260 would be available to receive associated video and files with the incoming communication. Finally, messaging delivery confirmation capabilities of the communications device may be used to determine the status. For example, if the telephone 260 is capable of providing a dual tone multi frequency signal, then the telephone 260 would be available to transmit a confirmation signal from the designated party 262 indicating that the incoming communications and/or associated data (including messages) has been delivered and received by the designated party.
[0043] The incoming communication and/or associated data may include voice, video, text, and/or other electronic data that is routed over the wide area network 214 through the communications interface 240 (or alternate communications means as shown in FIGS. 8-11 ) to the available communications device (e.g., the intercom workstation 260 and/or telephone 264 ). The communications interface 240 not only communicates the incoming communication and/or associated data, but also formats and/or otherwise configures the incoming communication and/or associated data (including messages transcribed by an agent from the customer) for the communications device. For example, the data stored on file server 216 may need to be converted from a data format compatible with the agent station 100 (and/or for storage on the file server 216 ) to another data format compatible with the communications device. The data formats may include printed text formats, a voice data formats, a video data formats, a dual tone multi-frequency data formats, and a digital data format (e.g., ASCII). In addition, the communications interface 240 may further include message delivery means that provide confirmation, such as a symbol or short message, that the communications device of the designated party 262 has received the incoming communication and/or associated data. Thus, the communications interface 240 advises an agent when there is a problem or error communicating the incoming communication (including associated data) with the communications device. If there is a problem or error, then the agent may select an alternate communications device (if the status is available) to communicate the incoming communication.
[0044] FIG. 3 illustrates a dynamic contact center (DCC) 300 similar to the DCC 200 disclosed in FIG. 2 . FIG. 3 further includes an affiliated computer workstation 302 coupled with the proprietary network of the communications system through communications interface 240 . According to this embodiment, the agent (or a router of the automated answering system) receives the incoming communication and any associated data at his/her workstation 100 , interacts with the customer, determines the status of the designated party 262 , associates the status with the communications profile to select the nearby affiliated computer workstation 302 , and provides the incoming communication and/or associated data to the workstation 302 for the designated party 262 to access. As discussed above, the communications interface 240 ensures that the incoming communication and/or associated data are formatted and/or otherwise configured for the workstation 302 . Further, the incoming communication and/or associated data routed to workstation 302 may be encrypted or otherwise secured so that only the designated party 262 has access. For example, workstation 302 may include a biometrics sensor 304 , such as, for example, a fingerprint ID device. The biometrics sensor 304 may provide security features that prevent unauthorized parties from exploiting the incoming communication and/or associated data. The biometrics sensor 304 could also comprise retina recognition device and software, DNA/RNA recognition device and software, facial recognition device and software, speech recognition device and software, and/or scent recognition device and software.
[0045] FIG. 4 illustrates a dynamic contact center (DCC) 400 similar to the DCC 300 disclosed in FIG. 3 . FIG. 4 further includes a POTS phone 402 and a personal digital assistant 404 to illustrate that the customer may use other wired and wireless communications devices to gain access to the PBX 208 through telecommunications network 204 .
[0046] FIG. 5 illustrates a dynamic contact center (DCC) 500 similar to the DCC 300 disclosed in FIG. 3 . However, FIG. 5 further includes a plurality of intercom workstations 260 and a plurality of designated parties 262 . According to this embodiment, the agent (or a router of the automated answering system) receives the incoming communication and any associated data at his/her workstation 100 , interacts with the customer to identify multiple designated parties 262 , determines the status of each of the designated parties 262 , associates each status with one or more communications profiles to select a nearby intercom workstation 260 for each designated party 262 , and provides the incoming communication and/or associated data to each intercom workstation 260 for each designated party 262 to access. The intercom workstations 260 are connected and associated so that the incoming communication and responses to the incoming communication are shared with the group of designated parties 262 . Accordingly, this conference feature determines the status of each designated party 262 in a group and simultaneously provides the incoming communications and responses from each available communications device to the group. While not shown, each designated party 262 of the group could be accessed through alternate available communications devices (such as telephone 260 shown in FIG. 2 , personal computer 302 shown in FIG. 3 , pager 810 , personal digital assistant (PDA) 812 , interactive pager 814 , and mobile phone 816 shown in FIG. 8 , MP3 1002 , digital signal processor 1004 , modem 1006 , and GPS 1008 shown in FIG. 10 , and interactive television 1108 shown in FIG. 11 ). As discussed above, the communications interface ensures that the incoming communication and/or associated data are formatted and/or otherwise configured for each communications device.
[0047] FIG. 6 illustrates a dynamic contact center 600 similar to the DCC 500 of FIG. 5 . However, according to the embodiment in FIG. 6 , a staff member 602 initiates the incoming communication to the call center through intercom workstation 260 . The agent (or automated answering system) receives the incoming communication and any associated data at his/her workstation 100 , interacts with the staff member 602 to identify designated party 262 , determines the status of the designated party 262 , associates the status with the communications profile to select a nearby intercom workstation 260 , and provides the incoming communication and/or associated data to the intercom workstation 260 for communications with the designated party 262 . This embodiment illustrates the advantage of being able to internally use the DCC 600 for staff to more easily locate and communicate with highly mobile on-site staff (e.g., network administrators, doctors, car salesman, etc.).
[0048] FIG. 7 illustrates a dynamic contact center (DCC) 700 similar to the DCC 500 disclosed in FIG. 5 . However, FIG. 7 includes interactive, on-site messaging pagers 702 assigned to each designated party (not shown). According to this embodiment, the agent receives the incoming communication and any associated data at his/her workstation 100 , interacts with the customer, determines the status of each designated party, associates the status with the communications profile to select the pager 702 , and provides the incoming communication and/or associated data to the pager 702 for each designated party 262 to access. Since the interactive pagers 702 allow the designated party to respond to the incoming communication and/or data, this response can be shared with the other pagers 702 in the group.
[0049] FIG. 8 illustrates a dynamic contact center (DCC) 800 similar to the DCC 200 disclosed in FIG. 2 . However, DCC 800 further includes a gateway 802 , a pager 810 , a PDA 812 , an on-site, interactive pager 814 , and a mobile phone 816 . According to this embodiment, the agent receives the incoming communication and any associated data at his/her workstation 100 , interacts with the customer to identify the designated party 262 , determines the status of the designated party 262 , associates the status with the communications profile to select one or more of the communications devices (including the intercom workstation 260 , the pager 810 , the PDA 812 , the on-site, interactive pager 814 , and the mobile phone 816 ) to communicate with, and provides the incoming communication and/or associated data to selected communications devices. As discussed above, the communications interface 240 ensures that the incoming communication, associated data, and/or responses are formatted and/or otherwise configured for each of the selected communications devices. Alternatively, the incoming communication and/or associated data may be routed through firewall 218 to the data network 230 and the gateway 802 to each of the selected communications devices. An advantage of using the gateway 802 is that the gateway 802 may be provided by a manufacturer of the selected communications device for specialized formatting and/or other configuration of the incoming communication and/or associated data for presentation by the selected communications device, such as formatting a picture for display by the liquid crystal display (LCD) screen of the PDA 812 . Still further, as shown in FIG. 9 , the incoming communication, associated data, and/or responses of a dynamic contact center 900 are routed through the telecommunications network 204 (including the public switched telephone network (PSTN) and mobile switched telephone network (MTSO)). An advantage of using the telecommunications network 204 is to leverage the assets of other affiliated data, up-to-date formatting and configuration programs (including sharing the costs of these systems with other customers of the telecommunications network), and increased range of accessing off-site staff (e.g., when a staff member is not located at the business facility 250 , the transmitter 266 and/or alternate communications devices, such as the mobile phone 818 , could provide the means to determine the location, and consequently the status, of the designated party).
[0050] FIG. 10 illustrates a dynamic contact center (DCC) 1000 similar to the DCC 200 disclosed in FIG. 2 . However, DCC 1000 further includes a MP3 1002 , a digital signal processor 1004 , a modem 1006 , and a global positioning system (GPS) 1008 . According to this embodiment, the agent receives the incoming communication and any associated data at his/her workstation 100 , interacts with the customer to identify the designated party 262 , determines the status of the designated party 262 , associates the status with the communications profile to select one or more of the communications devices (including the intercom workstation 260 , the MP3 1002 , the digital signal processor 1004 , the modem 1006 , and the GPS 1008 ) to communicate with, and provides the incoming communication and/or associated data to selected communications devices. As discussed above, the communications interface 240 and/or the telecommunications network 204 ensures that the incoming communication, associated data, and/or responses are formatted and/or otherwise configured for each of the selected communications devices. Alternatively, the incoming communication, associated data, and/or responses of a dynamic contact center 1000 may be routed through firewall 218 to the data network 230 and a gateway (not shown) to each of the selected communications devices. Still further, according to the embodiment depicted in FIG. 11 , a dynamic contact center 1100 includes an interactive television 1108 for communicating the incoming communication, associated data, and/or responses.
[0051] Regardless of the communications device used to communicate the incoming communication, associated data, and/or responses, this information may need to be formatted accordingly for the receiving communications device (including audio, text (e.g., ASCII), video, other digital formats, and combination thereof). Accordingly, the DCC DataServer 42 (via the communications profile) has the intelligence to associate the presentation capabilities of each of the receiving communications devices described in FIGS. 2-11 and to communicate the incoming communication (and associated data and response) to a communications interface (such as communications interface 240 or the gateway 802 ) for appropriate formatting. For example, if the alternate communications device uses the Wireless Application Protocol (WAP) technique, then the incoming communication and/or associated data are formatted using the Wireless Mark-up Language (WML). The Wireless Mark-up Language (WML) and the WAP technique are known and will not be further described. This is a description of a solution for a specific wireless protocol, such as WAP. This solution may be clearly extended to other wireless protocol, such as i-mode, VoiceXML (Voice eXtensible Markup Language), Dual Tone Multi-Frequency (DTMF), and other signaling means.
[0052] Referring now to FIG. 12 , a dynamic contact center (DCC) 1205 leverages the assets of a telecommunications network provided by PSTN 1225 and a wide area network 1230 to interconnect with remote business affiliated sites 1210 , a remote authorized user 1215 (e.g., a staff member working remotely from home), and a customer and/or other third party 1220 . Similar to the embodiments described above, the means of coupling the DCC 1205 , the affiliated business sites 1210 , the remote authorized user 1215 , the customer/third party, the PSTN 1225 and the WAN 1230 include a variety of means, including optical transmission of electronic data, wireless transmission of electronic data, and/or fixed-wire transmission of electronic data (e.g., via a local loop of a telecommunications network to communicate electronic data). Fiber optic technologies, spectrum multiplexing (such as Dense Wave Division Multiplexing), Ethernet and Gigabit Ethernet services, and Digital Subscriber Lines (DSL) are just some examples of the coupling means. For example, the DCC 1200 may utilize SmartRing, AVVID & Frame Relay, and SS7 VC interconnections. Accordingly, the telecommunications network 204 may include Advanced Intelligent Network (AIN) componentry that may be programmed to control features of the DCC 1200 , such as locating a designated party off-site and adding the off-site designated party to a group conference of the incoming communication, associated data, and/or responses (e.g., a mobile phone of the designated party could be located using fingerprinting or other techniques in the art, this location could be associated with a status, and the agent could process the incoming communication according to the status). The signaling between the DCC 1205 , the affiliated business sites 1210 , the remote authorized user 1215 , the customer/third party, the PSTN 1225 including AIN componentry, and the WAN 1230 are well understood in by those of ordinary skill the art and will not be further described. Further, those of ordinary skill in the art will be able to apply the principles of this invention to their own communications systems including their network configurations which may differ substantially from the leveraging the telecommunications network (shown as reference numeral 1225 in FIG. 12 , and alternatively, as reference numeral 204 in FIGS. 2-11 ), the WAN (shown as reference numeral 1230 in FIG. 12 , and alternatively, as reference numeral 214 in FIGS. 2-11 ), and the data network (shown as reference numeral 230 in FIGS. 2-11 ).
[0053] While several exemplary implementations of embodiments of this invention are described herein, various modifications and alternate embodiments will occur to those of ordinary skill in the art. For example, the DCC 200 may include wired, optical, and/or wireless components and/or other components (not shown). The DCC 200 may use any means of coupling each of the electronic components for communicating the incoming communication and/or associated data, but the coupling means is preferably high-capacity, high-bandwidth optical transport services, Gigabit Ethernet services, and/or the like. As those of ordinary skill in the art of computer telephony integration understand, the electronic components could also be coupled using other appropriate means, such as, for example a Synchronous Optical Network (SONET) structure with redundant, multiple rings. Copper conductors may also be used. Accordingly, this invention is intended to include those other variations, modifications, and alternate embodiments that adhere to the spirit and scope of this invention.
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Methods, systems, and products route communications according to schedules. When an incoming communication is detected, a schedule is retrieved that is associated with a recipient's address. A time associated with the communication is compared to entries in the schedule. If a match is determined, then an alternate destination may be chosen.
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FIELD OF INVENTION
The present invention relates to floor coating compositions. More particularly it is directed to floor polish compositions which exhibit exceptional resistance to stripping by germicides.
BACKGROUND OF THE INVENTION
Floor finishes for commercial operations are often formulated to achieve a compromise of what tend to be mutually exclusive properties: high gloss, ease of repairability, slip resistance, scuff resistance, and detergent resistance. Floor finishes designed for use in healthcare facilities, however, have an additional requirement of increasing importance, resistance of the finish to germicides. This additional requirement arises out of concerns about controlling the spread of infectious diseases. Thus, it has become common practice in such facilities to mop floors with germicides to eliminate a potential source of infection. These germicides usually contain either a phenolic derivative or quaternary ammonium salt as the biocidal agent. See for example U.S. Pat. No. 3,836,669.
When used at the proper dilution, the germicides are typically not harmful to floor finishes. However, in an effort to obtain an extra margin of safety, janitorial service staff commonly use germicides at concentrations higher than their label instructions recommend. This practice leads to the finish actually being stripped from the floor. There exists, therefore, a significant need to develop a floor finish which not only meets the stringent performance requirements of a floor polish but also exhibits excellent resistance to stripping by germicides.
According to the present invention, there is provided a floor finish composition formulated to have improved resistance to germicides without compromising floor polish performance requirements. The composition comprises a preservative, a wetting agent, a defoamer, a C 1 -C 4 alkyl carbitol, a plasticizer, a freeze-thaw stabilizer, a low acid styrenated acrylic resin copolymer, a rosin ester resin, a wax, and water. High quality polish performance is achieved particularly where the ratio of rosin ester resin to wax is greater than 1.
Additional objects, features, and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of the preferred embodiments exemplifying the best mode of carrying out the invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention there is provided an improved floor finish composition which exhibits exceptional resistance to removal by germicide concentrates. The composition comprises a preservative, a wetting agent, a defoamer, a C 1 -C 4 alkyl carbitol, a plasticizer, a freeze-thaw stabilizer, a rosin ester resin, a wax, an acrylic polymer, and water.
Testing of the present formulation has revealed that the stoichiometry/chemical nature of the wax, rosin ester resin and acrylic polymer ingredients, particularly the nature of the acrylic polymer component and the ratio of the rosin ester and wax components, should be held within predefined specifications to assure consistent high quality performance.
Acrylic polymers finding use in accordance with this invention are styrenated acrylic copolymers having an average molecular weight of about 5×10 5 to 1×10 6 , most preferably about 8×10 5 , and most preferably having a glass transition temperature of 50° C. Preferred acrylic copolymers for use in this invention are low acid (less than 8% acrylic acid) copolymers of hydrophobic monomers including styrene and 2-ethylhexyacrylate and hydrophilic monomers such as butyl, ethyl, and methyl acrylate (and methacrylate) and acrylic acid. One preferred acrylic polymer generally meeting those criteria is sold by Rohm & Haas under the tradename Rhoplex® NTS 2923. Most preferably the styrenated acrylic resin forms about 13 to 17 weight percent of the present finish compositions. The wax component of the present finish compositions are preferably nonionic emulsions of polyethylene, most preferably having a molecular weight of about 5500 to about 7500. The rosin ester resin ingredient is a common alkali soluble resin detailed for use in high gloss floor finishes. In the present compositions it is preferred that the weight ratio of rosin ester resin to wax is greater than 1, more preferably about 1.5 to about 4, most preferably about 2 to about 3.
The floor finish compositions in accordance with the present invention typically includes about 1.5×10 -4 to about 0.15 weight percent preservative, about 0.001 to about 10 weight percent wetting agent, about 0.01 to about 10 weight percent defoamer, about 0.1 to about 15 weight percent C 1 -C 4 alkyl carbitol, about 0.2 to about 30 weight percent plasticizer, about 0.1 to about 10 weight percent freeze-thaw stabilizer, about 8 to about 24 weight percent styrenated acrylic resin, about 0.025 to about 5 weight percent rosin ester resin, about 0.04 to about 6 weight percent wax, and water. Good finish characteristics are optimized where the weight ratios of the rosin ester resin to the wax is greater than 1.
The floor finish composition in accordance with the present invention is applied to surfaces in the same manner as present commercially available floor finish compositions. Acceptable surfaces for application include porous or non-porous surfaces commonly found in flooring, including vinyl, vinyl/asbestos, vinyl composition effective or filled vinyl, linoleum; resilient flooring composites; terrazzo; and marble.
The wax component of the present floor finish composition is effective to produce a coefficient of friction suitable for providing slip resistance for both high speed and conventional floor maintenance systems. Preferred waxes for use in accordance with this invention include polyethylenes, typically in non-ionic emulsion form, having a molecular weight of about 4,000 to about 10,000, more preferably about 5500 to about 7500. One preferred wax emulsion finding application in the present finish composition is ESI-CRYL 252 sold by Emulsion Systems, Inc., Valley Stream, N.Y. The floor finish compositions in accordance with the present invention include from about 0.04 to about 6 weight percent and preferably from about 0.04 to about 1.6 weight percent wax.
The rosin ester resin utilized in the germicidal resistant floor finish compositions of the present invention has a molecular weight of about 450 to about 500. One preferred rosin ester ingredient for this invention is that sold as a 25% solids solution by Emulsion Systems, Inc. Valley Stream, N.Y., under the tradename ESI-CRYL 802. Typically the present floor finish compositions include from about 0.025 to about 5 weight percent and preferably from about 1.5 to about 2.75 weight percent rosin ester.
In the present finish compositions the weight ratio of rosin ester to wax is most preferably greater than 1 for optimizing finish performance. Further, the weight ratio of the styrenated acrylic resin to the combined weight of wax and resin ester is about 3:1 to about 7:1, most preferably about 5:1.
The solvents utilized in accordance with the present invention are water miscible glycol ethers used alone or in combination. Preferably, the solvent component of the present is a mixture of diethylene glycol monobutyl ether and diethylene glycol monomethyl ether. Generally about 0.2 to about 30 weight percent, and more typically from about 2 to about 10 weight percent solvent is included. Preferably, the compositions of the present invention include about 0.1 to about 15, more preferably about 1 to about 5 weight percent diethylene glycol monobutyl ether and about 0.1 to about 15, more preferably about 1 to about 5, weight percent diethylene glycol monomethyl ether.
Plasticizers are used in the present compositions to obtain a coherent floor finish film. Examples of suitable plasticizers for use in accordance with the present invention include 2,2,4-trimethylpentane-1,3 diol monoisobutyrate, 2,2,4-trimethylpentane-1,3 diol di-isobutyrate, tributoxy ethyl phosphate, and dibutyl phthalate, used alone or in combination. Preferably, the plasticizer component of the present invention is 2,2,4-trimethylpentane-1,3 diol monoisobutyrate such as Texanol ester/alcohol available from Eastman Chemical Products, and tributoxy ethyl phosphate available as product KP-140 from FMC Corporation. Typically the plasticizer component of the present floor finish composition is utilized at a level of about 0.2 to about 30 weight percent and more typically about 0.2 to about 6 weight percent of the finish composition. Preferably the present composition includes about 0.1 to about 15, more preferably about 0.1 to about 3, weight percent 2,2,4-trimethylpentane-1,3 diol monoisobutyrate and about 0.1 to about 15, more preferably about 0.1 to about 3, weight percent tributoxy ethyl phosphate.
The preservative component of the present invention serves to prevent growth of bacteria and fungus in the finish composition on prolonged storage. Any commercially available preservative is suitable for use in accordance with the present invention. One preferred preservative is a mixture of 5-chloro 2-methyl 4-isothiazolin 3-1 (CAS number 26172-554), 2-methyl 4-isothiazolin 3-1 (CAS number 2682-20-4), magnesium chloride, magnesium nitrate, and water, sold by Rohm & Haas under the tradename Kathon® GC/ICP. Typically, compositions in accordance with the present invention include about 1.5×10 -4 to about 0.15 weight percent and preferably about 1.5×10 -4 to about 0.03 weight percent preservative.
Wetting agents suitable for use with the present invention can be selected from a wide variety of commercially available anionic and non-ionic surfactants. Anionic perfluoralkyl sulfonate salts are preferred. One such wetting agent is a mixture of 2-butoxyethanol, water, and ammonium perchloroalkalisulfonate sold by the Industrial Chemical Products Division of 3M Corporation under the brand name FC-120 Fluorad. The composition in accordance with the present invention typically includes about 0.001 to about 10 weight percent and preferably from about 0.001 to about 2 weight percent wetting agent.
Suitable defoaming agents for use in preparing the present finish compositions can, like many of the other floor finish ingredients used in the present invention, be selected from a wide variety of art-recognized commercially available products. One preferred class of defoamers are the well known organosilicone emulsions, for example, polydimethylsiloxane emulsion including, for example, the SAG 1010 Silicone Antifoam Emulsion available from Union Carbide Corporation. The defoamer is used at a level of about 0.01 to about 10 weight percent and preferably about 0.01 to about 2 weight percent of the finish composition.
A freeze-thaw stabilizer is utilized in formulating the preferred floor finish composition of this invention to protect the composition from freeze/thaw cycles which can occur during shipment and storage. Preferably the freeze-thaw stabilizer component of the present compositions is ethylene glycol used at a level of about 0.1 to about 10 weight percent, and preferably from about 0.1 to about 2 weight percent of the finish compositions.
The present floor finish compositions also include from about 10 to about 75 weight percent water to control the solids and viscosity of the composition.
The stoichiometry and components of the present floor finish compositions are summarized in Table I. Compositions formulated outside these specifications will not retain one or more of the properties which are characteristic of quality floor finish. Based on currently available test results the most important parameters for consistent finish quality are the composition and stoichiometry of the acrylic polymer, the rosin ester and the wax.
TABLE I______________________________________ Weight % Of Component FormulationIngredient Components Most FullFunction Component Preferred Range______________________________________Preservative Kathon GC/ICP 0.01-2 0.01-10 (1.5%)Wetting agent FC-120 (20%) 0.001-2 0.001-10Defoamer SAG 1010 0.01-2 0.01-10Solvent Butyl carbitol 1-5 0.1-15Solvent Methyl carbinol 1-5 0.1-15Plasticizer Texanol ester/alcohol 0.1-3 0.1-15Plasticizer KP-140 0.1-3 0-15Freeze stabilizer Ethylene glycol 0.1-2 0.1-10Polymer Rhoplex NTS-2923 35-40 25-60 (40%)Rosin ester resin Esicryl 802 (25%) 6-11 0.1-20Wax Esicryl 252 (40%) 0.1-4 0.1-15Diluent Water 20-60 10-75______________________________________
EXAMPLE I
A floor finish composition was formulated in accordance with the following specifications using standard floor finish formulation techniques.
______________________________________FLOOR FINISH FORMULATIONComponent Weight Percentage______________________________________Kathon CG/ICP 0.04(1.5% biocide)FC-120 Fluorad (20%) 0.014SAG 1010 Silicone Antifoam 0.03Butyl carbitol 3.51Methyl carbitol 3.06Texanol ester/alcohol 1.13KP-140 1.23Ethylene glycol 0.5Rhoplex NTS-2923 (40%) 37.96ESI-CRYL 802 8.47(25% solids)ESI-CRYL 252 2.03(40% solids)Water 42.03______________________________________
The germicidal resistance of the floor finish was determined as follows: 6 mL of a sealer was spread onto a 12×12 inch vinyl tile with a cotton gauze and allowed to dry. Next, using the same technique, a second coat of sealer was applied to the tile. After drying the sealer, one coat of the above floor finish formulation was applied over the sealer on the tile. A total of two coats of sealer and three coats of finish were applied to the vinyl tile. The dried finish composition exhibited the following characteristics: high gloss, scuff resistance, easy repairability, slip resistance, and detergent resistance according to the standards set forth by ASTM procedures. The test tiles were then placed in a Gardner scrubber and abraded for 100 cycles in the presence of several germicides used at 8 times their recommended dilution. The germicides utilized included acidic, neutral, and basic pH quaternary salt and phenolic formulations. No tile damage was noted in any case. Tiles similarly coated with conventional acrylic polymer finishes showed damage from finish stripping during abrasion in the presence of the germicides.
EXAMPLE II
Germicide strip resistant floor polish compositions A-E are formulated as indicated:
______________________________________Component A B C D E______________________________________preservative 0.5 0.01 1 0.08 1.0wetting agent 0.1 0.01 5 0.005 0.2defoamer 0.4 0.08 5 0.015 0.3solvent 10 2 10 4.9 7plasticizer 2 .2 4 2.45 2freeze-thaw 1.65 6.7 .9 1 0.1stabilizerpolymer 40 55 30 34 37rosin ester 2.75 6 2.6 3.55 5wax 1.6 5 1.5 2.0 0.5diluent 41 25 40 52.01 46.9______________________________________
Although the invention has been described with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of the invention as described and defined in the following claims.
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Floor polish compositions having good resistance to germicide solutions are described. They comprise styrenated acrylic resins in combination with a rosin ester resin, a wax and other floor finish functional ingredients. Optimum floor polish performance characteristics are obtained when the weight ratio of the rosin ester and wax is greater than one and when the weight ratio of the styrenated acrylic resin to the total weight of the rosin ester resin and wax components is between about 3:1 and about 7:1.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/269,293 filed on 5 May 2014 which is a continuation of U.S. patent application Ser. No. 12/302,404 (now, U.S. Pat. No. 8,761,378) which was filed on 25 Nov. 2008 under 35 U.S.C. 371 as the national stage of International Patent Application Number PCT/DK2006/000301 filed on 30 May 2006, where all of said applications are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The inventions relates to the field of telecommunication. More particular the invention concerns with a dynamic call connection distributor.
BACKGROUND OF THE INVENTION
[0003] Modern call centers and telemarketing centers provide services for automatically controlling the dialing of numbers, and finding an available agent at the call center.
[0004] Outbound calls from a call center are usually made by a power dialer or a predictive dialer, and when a connection to a customer is established the call is distributed to an available agent via an ACD (ACD: automatic call distribution).
[0005] Furthermore, modern systems provide the possibility for a call agent to be able to work from home as effectively as from an office. These solutions provide so-called “remote agent stations”, where a central system, e.g. a switch with ACD-like features, is located at a central call center is able to distribute calls to remote agents as well as to local agents at more or less the same terms. Thus, the central system can maintain a status of the remote agent, e.g. availability, present status, duration of present call, etc.
[0006] U.S. Pat. No. 5,778,060 describes a central system based on a conventional ACD switch (ACD: Automatic Call Distribution), which is connected to remote agents and local agents, who continuously transmit their status to the ACD switch via the fixed network of the ACD. Thereby it is possible for the ACD switch to distribute calls to remote agents at the same terms as to the local agents.
[0007] A problem related to the prior art systems of the above-mentioned type is however that the systems lack dynamics. Moreover, a problem relating to the prior art is that the systems require expensive equipment situated at the premises of the call agent in order to allow operation of the system and that operation and maintenance of the local switch is extremely expensive.
SUMMARY OF THE INVENTION
[0008] The invention relates to a dynamic call connection distributor comprising
an agent pool, comprising information of call agents, said agent pool is at least partly configurable by a plurality of individual call agents, a recipient dialer, comprising circuitry for dialing at least one number of predefined potential recipients for establishment of a recipient connection, an agent dialer comprising circuitry for establishing an agent connection from said dynamic connection distributor to a call agent, a call linker, comprising circuitry for linking said agent connection with said recipient call.
[0012] According to an embodiment of the invention, the dynamic connection distributor is easily configurable since no predefined connections exist in the agent pool whatsoever. The connections may thus be established exclusively on the basis of agent-defined endpoints, which are registered in the agent pool from a remote distance and hereby configures the agent pool.
[0013] Thus, the invention overcomes the problem relating to prior art systems where the connection between the call agents and the ACD necessarily relies on dedicated, predefined connections and endpoints, e.g. a predefined local telephone number or a VPN (VPN: Virtual private network) tunnel, to the central system or ACD switch.
[0014] Furthermore, the invention relates to a dynamic call connection distributor comprising—an agent pool, comprising information of call agents, said agent pool is at least partly configurable by a plurality of individual call agents,
a recipient dialer, comprising circuitry for dialing at least one number of predefined potential recipients for establishment of a recipient connection, an agent dialer comprising circuitry for establishing an agent connection from said dynamic connection distributor to a call agent, a call linker, comprising circuitry for establishing an agent call through said agent connection to an available call agent and linking said agent call with said recipient call,
[0018] In an embodiment of the invention, said agent pool is at least partly defined and maintained by distributed call agents by means of web interface.
[0019] According to a preferred embodiment of the invention, the agent pool is basically maintained dynamically by the call agents themselves, thereby allowing basically any physical distribution in contrary to prior art systems requiring the call agents to operate at fixed and centrally defined endpoints.
[0020] In an embodiment of the invention, said call linker establishes a call between a call agent and a recipient by connection of at least two outbound calls.
[0021] According to a further preferred embodiment of the invention, a call is established by connection of outbound calls from the call connection distributor to call agents and outbound calls from the call connection distributor to recipients, thereby allowing the system to be coupled and applied as an independent add-on to any local switch or telephone system.
[0022] In an embodiment of the invention, said agent pool comprises information of currently available call agents.
[0023] In an embodiment of the invention, said dynamic connection distributor further comprises a potential recipient database, comprising information of potential recipients to be dialed by said recipient dialer.
[0024] In an embodiment of the invention, said call linker comprises circuitry for linking a call, answered by a recipient with a connection established to an available call agent.
[0025] In an embodiment of the invention, said dynamic connection distributor comprises circuitry for establishing an agent connection from said dynamic connection distributor to a call agent on the basis of an agent-defined endpoint.
[0026] An agent-defined endpoint may e.g. comprise telephone number, IP addresses, VoIP numbers, etc.)
[0027] In an embodiment of the invention, said agent connection is maintained during an agent session and terminated when the session is ended.
[0028] In an embodiment of the invention, said agent session is initiated on the basis of a session start-up.
[0029] In an embodiment of the invention, said session start-up involves transmission of an agent-defined endpoint (ADE) from a distributed call agent to said agent pool.
[0030] In an embodiment of the invention, said session start-up involves transmission via PDCN (PDCN: Public Data Communication Network) of an agent-defined endpoint from a distributed call agent to said agent pool.
[0031] In an embodiment of the invention, said session start-up involves receipt of an agent-defined endpoint transmitted from a remote call agent.
[0032] In an embodiment of the invention, said session start-up involves receipt of an agent-defined endpoint transmitted from a remote call agent via PSTN (PSTN: Public Switched Telecommunication Network).
[0033] In an embodiment of the invention, said potential recipient database comprises information of the potential recipient endpoints.
[0034] Potential recipient endpoints may e.g. comprise telephone number, IP addresses, VoIP numbers, etc.
[0035] In an embodiment of the invention, said potential recipient database comprises additional information of the potential recipients.
[0036] Furthermore, the invention relates to a dynamic call connection distributor, wherein said system further comprises
potential recipients defined by said dynamic connection distributor in said potential recipient database, a number of call agents possessing the possibility to register an agent-defined endpoint in an agent pool located in said dynamic connection distributor, whereupon said dynamic connection distributor establishes a connection to said agent-defined endpoint.
[0039] In an embodiment of the invention, said registering of said agent-defined endpoint in said agent pool comprises transmission of agent-defined endpoint information from said call agent to said agent pool through an initiating connection.
[0040] The initiating connections may also be regarded as the connections necessary to establish and maintain call sessions with respect to control of calls to the call agent and from the dynamic connection distributor and with respect to logging of sessions, transfer or orders, transfer of order information, monitoring of agent performance, transfer of statistics, transfer of recipient relevant data, etc.
[0041] Furthermore, the invention relates to a method of establishing a connection between a call agent and potential recipients in a system comprising,
a dynamic connection distributor, potential recipients defined by said dynamic connection distributor in a potential recipient database, a number of call agents to be dynamically connected to said potential recipients via said dynamic connection distributor,
[0045] said method comprising the steps of
[0046] transmitting agent-defined endpoints to said dynamic connection distributor,
[0047] establishing an agent connection from said dynamic connection distributor to said agent-defined endpoint,
[0048] establishing an agent call via said agent connection between a recipient extracted from a potential recipient database.
[0049] Furthermore, the invention relates to a method of establishing a connection between a call agent and potential recipients in a system comprising,—a dynamic connection distributor,
potential recipients defined by said dynamic connection distributor in a potential recipient database, a number of call agents to be dynamically connected to said potential recipients via said dynamic connection distributor,
[0052] said method comprising the steps of
[0053] transmitting agent-defined endpoint to said dynamic connection distributor,
[0054] establishing an agent connection from said dynamic connection distributor to said agent-defined endpoint,
[0055] establishing an agent call, via said agent connection between a recipient extracted from a potential recipient database.
[0056] In an embodiment of the invention, said agent-defined endpoint is transmitted to said dynamic connection distributor by at least two call agents.
[0057] In an embodiment of the invention, said agent-defined endpoint is transmitted to said dynamic connection distributor by at least two distributed call agents by means of a web-based interface.
[0058] It is a very advantageous feature of the invention that the call agents may be distributed. The distribution of call agents means that call agents may in principle be physically located anywhere while utilizing the system. In accordance with the invention, a call agent will just have to register in the agent pool and preferably via a web interface, and hereby specify an endpoint, e.g. a telephone number, after which the session of receiving agent calls may begin. Thus, the call agents fully define the agent-defined endpoints in the agent pool of the dynamic connection distributor without any correlation between the physical location of the call agent and the place where the endpoint, e.g. telephone number is registered. Evidently of course the system may further apply supplemental fault detection and correction algorithms in order to detect agent invoked mistakes with respect to designation of endpoints.
[0059] Thus, the system according to the above embodiment of the invention intrinsically benefits from flexibility throughout all principle components of the system. Thus, the invention facilitates that such systems may centrally be applied as plug-and-play solutions without interfering with the setup of a company's existing switches, PBX, CTI etc.
[0060] Moreover, the invention facilitates that a call agent may be connected to a potential recipient via an outbound call from the central dynamic connection distributor without requirement of complex hardware setup procedures and configuration.
[0061] Moreover, the agent connection may be controlled decentralized by means of a simple standard web interface and a standard PSTN or PDCN connection.
[0062] According to the present invention, a call agent may for example register in the agent pool with the private telephone number of his brother while visiting his brother, and then use his brothers' telephone for receiving agent calls from the dynamic connection distributor. Another example is that a call agent may work while shuttling to and from work by registering in the agent pool of the dynamic connection distributor via a web interface of his Personal Digital Assistant (PDA) or laptop, and register the agent-defined endpoint to be his mobile phone. This way the call agent will be able to receive agent calls from the dynamic connection distributor on his mobile phone while shuttling to and from work.
[0063] In an embodiment of the invention, said web-based interface is established at a unit comprising computing facilities for use by a call agent.
[0064] In an embodiment of the invention, said web-based interface is presented to a user via a non-dedicated personal computer (PC).
[0065] According to the invention, the web-based interface is to be presented for the user on a regular Personal Computer which may e.g. be a computer comprising a central processing unit, a computer running a Linux or Windows operative system, an Apple Macintosh, etc. It is a very advantageous feature of an embodiment of the invention that the PC presenting the web interface is used for transmitting agent-defined endpoints.
[0066] In an embodiment of the invention, said transmitted agent-defined endpoint is transmitted to said dynamic connection distributor as a code referring to at least one audio communication address predefined in an agent pool of said dynamic connection distributor.
[0067] The audio communication address may e.g. comprise a telephone number, an IP address, predefined in an agent pool of said dynamic connection distributor. When coding the agent-defined endpoint, it is possible at the same time to establish an authentication and/or authorization of the call agent which may be defined in the DCD. The code may thus e.g. pinpoint one or one of several telephone numbers by which the call agent may be reached for establishment of an agent connection (AC).
[0068] In an embodiment of the invention, said transmitted agent-defined endpoint is transmitted to said dynamic connection distributor as an audio communication address by means of which said dynamic connection distributor establishes an agent connection.
[0069] When the agent-defined endpoint is transmitted as such to the dynamic connection distributor it is possible for e.g. a call agent to be reached at any possible and suitable audio communication address selected by the call agent.
[0070] In an embodiment of the invention, said transmitted agent-defined endpoint is transmitted to said dynamic connection distributor as an audio communication address and an associated security code on the basis of which said dynamic connection distributor establishes an agent connection.
[0071] When combining an audio communication address with a security code it is possible to allow the call agent to define his own endpoint as long as he is recognized by the DCD. In this way a call agent may be incorporated in the system at e.g. any telephone number he or she desires, thereby obtaining a significant degree of freedom. The system may thus establish agent connections to various agent-defined endpoints under continuous control by the call agent. Typically and preferably an agent-defined endpoint is maintained throughout a session.
[0072] In an embodiment of the invention, the dynamic connection distributor maintains call activity accounts related to the individual call agents.
[0073] The call activity accounts related to the individual call agents may e.g. comprise information related to a number of calls between the specified agent and recipients, duration of these calls, success criteria measuring related to these calls, customer satisfaction evaluation of these calls, etc.
[0074] In an embodiment of the invention, said transmission of agent-defined endpoints is initiated by the call agent.
[0075] In an embodiment of the invention, the steps of establishing a recipient call, linking said agent call with said recipient call is repeated with at least two different potential recipients during a session.
[0076] In an embodiment of the invention, said agent connection may comprise dialing a telephone number over PSTN.
[0077] In an embodiment of the invention, said agent connection may comprise establishing a connection to a specific destination over PDCN, e.g. IP address.
[0078] In an embodiment of the invention, said agent connection is established automatically on the basis of agent-defined endpoints.
[0079] In an embodiment of the invention, said agent-defined endpoint comprises information of which telephone number to dial.
[0080] In an embodiment of the invention, said ADE comprises information of which address to contact over PDCN, e.g. IP address.
[0081] In an embodiment of the invention, said agent-defined endpoints are transmitted via a web interface over PDCN.
[0082] In an embodiment of the invention, said agent-defined endpoints are transmitted via PSTN.
[0083] In an embodiment of the invention, said recipient call is established by dialing a telephone number via a PSTN.
[0084] In an embodiment of the invention, said recipient call is established by dialing a telephone number via PDCN.
[0085] In an embodiment of the invention, said recipient call is established by means of a recipient dialer.
[0086] In an embodiment of the invention, said method is initiated by an initiating connection and whereby said initiating connection involves that a call agent transmits said agent-defined endpoint to the dynamic connection distributor.
[0087] In an embodiment of the invention, said method is initiated by an initiating connection and whereby said initiating connection involves that a call agent transmits said agent-defined endpoint to the dynamic connection distributor and whereby said initiating connection initializes a session.
[0088] In an embodiment of the invention, said initiating connection is established by means of a telephonic call over PSTN.
[0089] In an embodiment of the invention, said initiating connection is established over PDCN e.g. via a web interface.
[0090] In an embodiment of the invention, said call agent is situated externally with respect to said dynamic connection distributor.
[0091] In an embodiment of the invention, said session is continued by establishment of further connections between a call agent and further recipients until a call agent actively communicates to the dynamic connection distributor that a call session is to be ended.
[0092] Furthermore, the invention relates to use of agent-defined endpoints to automatically establish a call between a potential recipient and a call agent by means of a central dynamic connection distributor.
[0093] Furthermore, the invention relates to use of agent-defined endpoints, wherein said agent-defined endpoint is transmitted by means of a web interface.
[0094] Furthermore, the invention relates to a dynamic connection distributor comprising a web-based interface wherein said dynamic connection distributor is at least partly configured and maintained by distributed call agents via said web-based interface.
[0095] In an embodiment of the invention, said dynamic connection distributor comprises a call linker for connecting an agent connection with a recipient connection.
[0096] Furthermore, the invention relates to a call linker comprising call connection circuitry for connection of at least two outbound calls from said call dialer into a call connection between at least one call agent and at least one potential recipient.
[0097] According to a further preferred embodiment of the invention, a call is established by connection of outbound calls from the dynamic connection distributor to call agents and outbound calls from the call connection distributor to recipients, thereby allowing the system to be coupled and applied as an independent add-on to any local switch or telephone system.
[0098] Furthermore, the invention relates to a call linker comprising call connection circuitry for connection of at least two outbound calls from said call dialer into a call connection between at least one call agent and at least one potential recipient.
THE DRAWINGS
[0099] The invention will now be described with reference to the drawings of which
[0100] FIG. 1 illustrates an embodiment of the present invention,
[0101] FIG. 2 illustrates a basic non-limiting flowchart of an embodiment of the present invention,
[0102] FIG. 2 a illustrates a detailed view of the dynamic connection distributor pursuant to the flowchart in FIG. 2 ,
[0103] FIG. 3 illustrates a basic non-limiting flowchart of an embodiment of the present invention,
[0104] FIG. 3 a illustrates a detailed view of the dynamic connection distributor pursuant to the flowchart in FIG. 3 ,
[0105] FIG. 4 illustrates a timeline indicating a session,
[0106] FIG. 5 illustrates a timeline indicating a session in a more detailed way,
[0107] FIG. 6 illustrates a further embodiment of the present invention,
[0108] FIG. 7 illustrates an example of an agent web-based interface,
[0109] FIG. 8 illustrates an example of another agent web-based interface (WI) and FIG. 9 illustrates an example of an administrator web-based interface (WI).
DETAILED DESCRIPTION
[0110] FIG. 1 illustrates an embodiment of the present invention wherein the system comprises a dynamic connection distributor DCD, one or several potential recipients PR 1 , PR 2 , . . . , PRm, a recipient connection RC, a PSTN (PSTN: Public Switched Telecommunication Network) and/or a PDCN (PDCN: Public Data Communication Network). The dynamic connection distributor DCD may comprise a call linker CL, an agent pool AP, a potential recipient database PRDB, recipient information RI, an agent dialer AD and a recipient dialer RD. Furthermore, the system may comprise one or several call agents CA 1 , CA 2 , . . . , Cn, one or several agent connections AC, and one or several agent-defined endpoints ADE.
[0111] According to the present invention a public data communication network (PDCN) may e.g. refer to the internet, the World Wide Web or other public data networks.
[0112] A call agent CA 1 , CA 2 , . . . , CAn registers in the agent pool AP in said dynamic connection distributor DCD. This may be done in several ways according to the below descriptions of FIGS. 2 , 3 and 4 .
[0113] The agent dialer AD establishes an agent connection AC to said agent-defined endpoint ADE on the basis of said endpoint received from said call agents CA 1 , CA 2 , . . . , CAn by means of an initiating connection IC. The initiating connection IC may, according to the invention, be established by means of a telephonic call over PSTN, by mail or preferably over PDCN via a web interface. In other words, an initiating connection IC related to a specific agent connection may typically be at least partly maintained while the agent connection is established. When e.g. applying a web-based interface as initiating connection IC the initiating connection would typically be active longer than the established agent connection. Thus, an initiating connection would typically designate both the initiating connection as well as the part of the connection which is no longer directly relevant for establishment of the connection but rather relevant for maintaining the agent connection.
[0114] Thus, the illustrated initiating connections IC may also be regarded as the connections necessary to establish and maintain call sessions with respect to control of calls to the call agent and from the dynamic connection distributor DCD and with respect to logging of sessions, transfer or orders, transfer of order information, monitoring of agent performance, transfer of statistics, transfer of recipient relevant data, etc.
[0115] The technical meaning of the above-mentioned sessions is explained below.
[0116] It is moreover noted that this initiating connection, when also designating the maintaining connection, may be continuous or comprise a series of discrete communication data.
[0117] The initiating connection IC is typically established by a call agent CA to identify him to the connection distributor DCD and to submit an agent-defined endpoint ADE to the agent pool AP of the dynamic connection distributor DCD. The agent connection AC is established according to the agent-defined endpoint ADE registered by the agent in the agent pool.
[0118] If a call agent CA 1 , CA 2 . . . , CAn defines that he wants to be connected via a telephone on the PSTN by means of the agent-defined endpoint ADE and registers this endpoint in the agent pool AP, the agent connection AC may be established by means of a call through the PSTN.
[0119] If, alternatively, a call agent CA 1 , CA 2 . . . , CAn defines that he wants to be connected via a PDCN device according to the agent-defined endpoint ADE and registers this endpoint in the agent pool AP, the agent connection AC may be established by establishment of IP-telephonic call, e.g. over VoIP, any hybrids thereof, or any suitable voice transferring communication means over PDCN.
[0120] If a call agent CA 1 , CA 2 . . . , CAn defines that he wants to be connected via a telephone via a wireless network by means of the agent-defined endpoint ADE and registers this endpoint in the agent pool AP, the agent connection AC may be established by means of a telephonic call via a wireless network, such as e.g. GSM or UMTS.
[0121] The recipient dialer RD comprised by the dynamic connection distributor DCD retrieves recipient information RI from said potential recipient database PRDB 5 which comprises e.g. information related to name and further contact information of potential recipients PR 1 , PR 2 , . . . , PRm. The recipient dialer RD then establishes the recipient connection RC to the relevant potential recipient PR 1 , PR 2 , . . . , PRm on the basis of contact information comprised in the recipient information RI.
[0122] This procedure may be done several ways dependent of the telecommunication equipment of the respective potential recipient PR 1 , PR 2 , . . . , PRm. If a potential recipient PR 1 , PR 2 , . . . , PRm can be reached via a telephone on the PSTN, the recipient connection may be established by means of a call through the PSTN, if a potential recipient can be reached via PDCN, the recipient connection RC will constitute a PDCN connection and a following establishment of IP-telephonic call, e.g. over VoIP, any hybrids thereof, or any suitable voice transferring communication means over PDCN. Likewise, if a potential recipient may be reached by a mobile phone the recipient connection is established by means of a telephonic call via a wireless network, e.g. GSM or GPRS.
[0123] Currently, it is preferred that the connection to the recipients is established via PSTN as PSTN at the time being is still the most widespread system covering as many potential recipients as possible.
[0124] FIG. 2 illustrates a non-limiting flowchart of an embodiment of the present invention. Thus, the steps in the flowchart may occur in a different order than visualized in the flowchart. This flowchart shows an embodiment of the invention where the DCD establishes an agent call on the basis of an endpoint registered by a call agent. The description of the flowchart moreover refers to relevant components of FIG. 1 In step 21 , a call agent AC registers in the agent pool AP to authenticate whereupon the agent pool AP may optionally perform a check of the current authorization permissions of the current call agent CA. Afterwards in step 22 the call agent CA registers an agent-defined endpoint ADE in the agent pool AP. The steps 21 and 22 may be performed by means of an initiating connection IC. In step 23 , the agent dialer AD of the dynamic connection distributor DCD establishes an agent connection AC to a call agent AC on the basis of the received agent-defined endpoint ADE. In step 24 , the dynamic connection distributor establishes an agent call through agent connection. The steps 23 and 24 may also be regarded as one step, namely that the agent dialer comprised by the dynamic connection distributor DCD dials a telephone number according to the agent-defined endpoint ADE to establish a call from the dynamic connection distributor DCD to a call agent CA. In step 25 a session is initiated. A session may be a series of calls to be established from the dynamic connection distributor DCD to at least one potential recipient PR. In other words, one agent call may be connected sequentially to several recipient calls. In step 26 , the recipient dialer RD establishes a recipient connection RC to a recipient on the basis of contact information received from the potential recipient database PRDB. The recipient connection RC may in one embodiment of the invention be established by means of a telephonic call from the recipient dialer of the dynamic connection distributor DCD to a potential recipient PR. Step 27 is indicating that the call linker CL comprised in the dynamic connection distributor is performing a coupling of the outbound recipient connection RC and the outbound agent connection AC with regard to audio. This coupling may in one embodiment of the invention be performed after a potential recipient has answered the call made over the recipient connection RC. In this way, a so-called predictive dialer may be utilized by the dynamic connection distributor DCD to increase activity and utilization of call agents CA.
[0125] A predictive dialer exhibits predictive behavior when it has more call attempts (attempts to establish a recipient connection RC) outstanding than it has call agents CA that are already available to handle calls. The predictive dialing happens when the predictive dialer dials ahead of the agents becoming available or when the predictive dialer matches a forecast number of available agents with a forecast number of available called parties or potential recipients that has picked up the phone. The matching and dialing ahead perspectives provide the large increases in dial rates and call agent productivity.
[0126] If a system e.g. has 100 agents working on it, the dialer will dial a number of calls, sometimes crudely based on a phone line to agent ratio of 1.5:1 or 2:1. This means that for each available agent, the system will dial the phone numbers of two potential customers. As these calls are made to the telephone network, the dialer will monitor each call and determine what the outcome of the call was. From 150 calls made, the system will immediately strip out any unproductive outcomes, such as busy calls (these are usually queued for automatic redial), no answers and invalid numbers. Some predictive dialers incorporate “answering machine detection”, which tries to determine if a live person or answering machine picked up the phone. This might cause delays before initiation of a conversation. If not enough calls are made ahead, then agents will sit idle, whereas if there are too many calls made and there are not enough agents to handle them, the call is typically dropped. The trick for predictive dialer manufacturers is to build their systems smart enough and large enough to be able to quickly respond by increasing or decreasing the dialing ratio used in order to cause more or less calls to be made. The advanced predictive dialer determines and uses many operating characteristics which are learned during the calling campaign. It uses these statistics continually to make sophisticated predictions so as to minimize agent idle time while controlling occurrences of nuisance calls, which are answered calls without the immediate benefit of available agents. An advanced predictive dialer can readily maintain the ratio of nuisance calls to answered calls at less than a fraction of one percent while still dialing ahead. However, this level of performance may require a sufficiently large critical mass of agents. A good predictive dialer should not always exhibit predictive behavior. That typically is when there are too few agents. In that case, each time the dialer contemplates a new call attempt the probability of no agent being available is too high unless there are more idle agents than call attempts—i.e. dials—outstanding.
[0127] According to the present invention the use of a predictive dialer according to the above description is only one possibility out og many, in that any type of dialer may be used by the dynamic connection distributor DCD.
[0128] Alternatively, the coupling may be performed before a potential recipient answers the call established through the recipient connection RC to avoid that a call agent CA is not ready when the potential recipient answers the call and the dynamic connection distributor couples the potential recipient PR and the call agent CA.
[0129] In step 28 , a conversation may start between the potential recipient PR and a call agent CA. Information relating to the conversation(s) such as information related to number of calls between the specified agent and recipients, duration of these calls, success criteria measuring related to these calls, logging and updating of recipient feed-back, customer satisfaction evaluation of calls, etc., may be communicated to the dynamic connection distributor DCD actively or passively. An active retrieving of this information may be obtained by a survey system monitoring the activity of the call agent. A passive retrieval of information may e.g. rely on information reported and communicated from the call agent e.g. on runtime basis via the initiating connection IC as a part of the maintenance of the agent call.
[0130] In step 29 , the conversation ends and a new conversation may be established within the same session by returning to step 26 or the session may terminate in step 30 .
[0131] Thus, a session may comprise establishment of several recipient connections RC and may typically comprise only one agent connection AC.
[0132] FIG. 2 a illustrates a further principle view of a dynamic connection distributor DCD according to an embodiment of the invention with reference to FIG. 2 . The figure illustrates that a call agent CA registers an agent-defined endpoint ADE in the agent pool AP of the dynamic connection distributor DCD. The agent pool may comprise any number of agent-defined endpoints dependent of the current registered and active call agents CA. The agent pool may in one embodiment of the invention further comprise authentication information of the call agent, e.g. name and may further comprise the submission of a user name and a password to authenticate a call agent CA. Hereafter the agent dialer AD comprised in the dynamic connection distributor DCD may establish an agent connection AC to the agent via an endpoint defined by agent ADE. The agent dialer may establish a connection through a PSTN. If 5 alternatively, the agent dialer AD may establish a connection to the call agent CA via the agent-defined endpoint AD via a PDCN e.g. by establishment of IP-telephonic call, e.g. over VoIP, any hybrids thereof, or any suitable voice transferring communication means over PDCN.
[0133] FIG. 3 illustrates a basic non-limiting flowchart of a further embodiment of the present invention. This flowchart illustrates a further embodiment where the call agent establishes an agent-defined endpoint on the basis of a number of endpoints registered by the call agent at the dynamic connection distributor.
[0134] In step 31 , a call agent pre-registers a number of different selectable endpoints which he intends to use as endpoint during call sessions. The number of selectable endpoints may in principle be very large, but it should however preferably be kept at a level where such a pre-registration does not result in further unnecessary time-consuming sign-up procedures. The pre-registration of step 31 may in principle be performed at any time and not necessarily in relation to a start-up of a session.
[0135] In other words, step 31 is basically optional when at least one endpoint has been pre-registered and availing the dynamic connection distributor DCD to establish a session between the call agent in question and a recipient.
[0136] In step 32 , the call agent may now initiate a session e.g. by means of a web-registration to the dynamic connection distributor DCD.
[0137] In step 33 , the call agent may be authenticated and choose one of the pre-registered endpoints.
[0138] The steps 31 - 32 may be performed during an initiating connection IC although e.g. step 31 may just be performed once and thereafter become optional. In step 34 and 35 , an agent dialer AD of the dynamic connection distributor DCD establishes an agent connection AC to a call agent AC on the basis of the determined agent-defined endpoint ADE. As previously mentioned, steps 34 and 35 may also be regarded as an action performed in one step, namely that the agent dialer comprised by the dynamic connection distributor DCD dials a telephone number according to the agent-defined endpoint ADE to establish a call from the dynamic connection distributor DCD to a call agent CA.
[0139] In step 36 a session is initiated. A session may be a series of calls to be established from the dynamic connection distributor DCD to at least one potential recipient PR. In other words, one agent call may be connected sequentially to several recipient calls. In step 37 , the recipient dialer RD establishes a recipient connection RC to a recipient on the basis of contact information received from the potential recipient database PRDB. The recipient connection RC may in one embodiment of the invention be established by means of a telephonic call from the recipient dialer of the dynamic connection distributor DCD to a potential recipient PR. Step 38 designates that the call linker CL of the dynamic connection distributor is performing a coupling of the outbound recipient connection RC and the outbound agent connection AC with regard to audio. This coupling may in one embodiment of the invention be performed after a potential recipient has answered the call made over the recipient connection RC. In this way, a so-called predictive dialer may be utilized by the dynamic connection distributor DCD to increase activity and utilization of call agents CA.
[0140] Alternatively the coupling may be performed before a potential recipient answers the call established through the recipient connection RC to avoid that a call agent CA is not ready when the potential recipient answers the call and the dynamic connection distributor couples the potential recipient PR and the call agent CA.
[0141] In step 39 , a conversation may start between the potential recipient PR and a call agent CA. Information relating to the conversation(s) such as information related to number of calls between the specified agent and recipients, duration of these calls, success criteria measuring related to these calls, logging and updating of recipient feed-back, customer satisfaction evaluation of calls, etc., may be communicated to the dynamic connection distributor DCD actively or passively. An active retrieving of this information may be obtained by a survey system monitoring the activity of the call agent. A passive retrieval of information may e.g. rely on information reported and communicated from the call agent e.g. on runtime basis via the initiating connection IC as a part of the maintenance of the agent call.
[0142] In step 40 , the conversation ends. Now a new conversation may be initiated in step 37 or the session may terminate in step 41 . Thus, a session may comprise establishment of several recipient connections RC and may typically comprise only one agent connection AC.
[0143] FIG. 3 a illustrates a further principle view of a dynamic connection distributor DCD according to an embodiment of the invention with reference to FIG. 2 . The figure illustrates that a call agent B registers an agent-defined endpoint ADE in agent pool AP of the dynamic connection distributor DCD by selecting one of the pre-registered endpoints, here EP 2 b.
[0144] One advantage of the present embodiment of the invention is that the sign-up procedure may be performed relatively fast as the call agent only needs to pinpoint the endpoint to be used by an agent and endpoint representing code AERC, e.g. “1” designating the call agents telephone number at home, “2” designation the call agents mobile telephone number, “3” designation an IP telephone number or ID, etc.
[0145] It should be noted that the above embodiment of the invention in principle maintains all benefits with respect to dynamics of the embodiment of FIG. 2 and FIG. 2 a in the sense that no connections between the call agents are wired or fixed although some endpoints has been pre-registered. In others words, the system as such maintains full flexibility with respect to configuration of switches, etc. due to the fact that all such switching is basically performed externally in the PSTN or PCDN.
[0146] The agent pool may in one embodiment of the invention further comprise authentication information of the call agent, e.g. name, and may further comprise the submission of a user name and a password to authenticate a call agent CA.
[0147] It should also be noted that the agent pool AP may in principle have any size suitable for the ongoing setup of call connections as the effective switching is performed externally.
[0148] FIG. 4 illustrates a timeline constituting an example of a session SES according to an embodiment of the invention. A session SES comprises a number of calls C 1 , C 2 , C 3 , C 4 , . . . , Cn established by the dynamic connection distributor DCD between a call agent CA and several potential recipients PR. Thus, a session SES may typically comprise one agent connection AC and several recipient connections RC.
[0149] FIG. 5 illustrates a more detailed timeline constituting an example of a session SES according to an embodiment of the invention. A session starts (1), when the dynamic connection distributor DCD establishes an agent connection AC on the basis of an agent-defined endpoint ADE (A). Subsequently, the agent dialer AD in the dynamic connection distributor DCD establishes an agent connection AC, (B). A recipient dialer RD in the dynamic connection distributor DCD establishes a new recipient connection RC (C). Hereafter the outbound agent connection AC and the outbound recipient connection RC of the dynamic connection distributor are coupled by means of a call linker CL (D). A conversation may start (E) and is subsequently ended (F).
[0150] The steps C, D 5 E and F may be repeated several times during a session. A session may end by means of a connection from the dynamic connection distributor DCD both to a potential recipient and to the call agent CA.
[0151] FIG. 6 illustrates a further embodiment of the present invention. This figure comprises the same elements as in FIG. 1 , and in addition the figure comprises an endpoint robot ER that receives the agent-defined endpoints and processes these to the agent pool. The endpoint robot ER may e.g. comprise a computer facility enabling the flexibility of the invention to be implemented e.g. in connection with a conventional non-flexible system such as an ACD (ACD: automatic call distributor). According to a preferred embodiment of the invention, the dynamic connection distributor DCD is established without applying conventional non-flexible systems such as the above mentioned.
[0152] FIG. 7 illustrates an example of a web-based interface WI according to an embodiment of the present invention. The figure illustrates an agent interface at the time where an agent registers the current endpoint to where the dynamic connection distributor DCD must establish a connection. In the upper left corner of the figure is visualized a box where a call agent CA may enter a telephone number. In an alternately embodiment of the invention, an IP (IP: Internet protocol) address or another contact code may be entered.
[0153] FIG. 8 illustrates an example of a web-based interface WI according to an embodiment of the present invention. The figure illustrates an agent interface at the time of the dynamic connection distributor DCD having established a connection to a recipient information RI received from the potential recipient database PRDB is presented to the agent to give him or her the best provisions to make a success.
[0154] FIG. 9 illustrates an example of a web-based interface WI according to an embodiment of the present invention. The figure illustrates an administrator interface at the time when an administrator is registering a call agent CA in the agent pool AP op the dynamic connection distributor DCD. The figure is illustrating that a call agent CA is registered with three different associated telephone numbers. It is now possible for a call agent CA to choose from one of these three telephone numbers and thereby make the agent dialer AD in the dynamic connection distributor DCD establish a connection to the selected telephone number.
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A dynamic call connection distributor and a related method, the distributor including an agent pool, having information of call agents, the agent pool is at least partly configurable by a plurality of individual call agents, a recipient dialer, including circuitry for dialing at least one number of predefined potential recipients for establishment of a recipient connection, an agent dialer including circuitry for establishing an agent connection from the dynamic connection distributor to a call agent, and a call linker, having circuitry for linking the agent connection with the recipient call.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The primary field of the invention relates to devices for illumination of limited areas to assist security personnel in performing assigned tasks in hidden or covert situations. Specifically, the flashlight provides enough light in areas of close proximity for the user to perform necessary tasks such as map reading, walking or equipment operation or maintenance while minimizing the possibility of the user being located by hostile observers with their unaided vision or with image intensifiers. In some situations the flashlight may be used as a specialized signaling device.
2. Related Art
Security officers and others are frequently required to conduct surveillance tracking and other operations within eyesight of persons they wish to observe. The task has always been dangerous because, if hostile persons, such as criminals, see the using officer, they may attack him. Presently, it is even more risky because the criminals have access to image intensifiers capable of magnifying very small amounts of light and displaying it on a screen. A variety of these intensifiers are available. Thus previously used covert lighting devices are now unacceptable because they can reveal the officer's location even when the lighting device is set to very low intensities. Other occurrences and features of traditional lighting devices which can reveal the officer's location include the time it takes to adjust the lighting intensity level, the decay time of energy radiation after the power is disconnected, accidental dropping of the lighting device when in the switched-on state and specular reflections of light from nearby surfaces.
A portable lighting device, disclosed in U.S. Pat. No. 4,517,628, granted to applicant, provided means for changing the color of the illumination from incandescent white light to filtered red light for use in blackout conditions; however, that concept is now inadequate as a covert signal light because the radiant energy decay time span is excessive. This device is vulnerable to detection even after it is off because the incandescent filament continues to emit reddish light until substantial cooling has taken place.
U.S. Pat. No. 4,677,533, issued to applicant, et al, discloses a lighting device intended for color discrimination having a combination of colored electronic lamps alone or in combination with an incandescent lamp and with separate electrically variable controls for the adjustment of brilliance of the illumination spectra. With this device specular reflections from illuminated objects or the careless and accidental misaiming of the light may subject the user to a higher probability of detection by hostile observers than is now acceptable for covert operations.
The rheostats taught in U.S. Pat. No. 4,677,533 produce a continuous and slow change in color which is inferior for signaling applications. The rheostat/switch designs are also faulted in an effective covert light which must ideally turn "OFF" instantaneously. This cannot be achieved if the power is turned "OFF" by an intensity control device such as a rheostat which slowly decreases the current and intensity before the actual "OFF" position is reached. The unfiltered incandescent lamp used in some embodiments prevents instantaneous darkening of the device even when the power is instantaneously turned off. Finally, the coordinated rheostat/switch prevents the device from instantaneously being switched from "OFF" to usable lighting intensity.
Other improvements in lighting devices are disclosed in U.S. Pat. Nos. 4,947,291 and 4,963,798, both issued to applicant. Among the featured improvements of the disclosures are components and circuits for the reduction of radiant energy in the infrared wavelengths, for the synthesis of specific radiation spectral patterns, and for dimming the radiated light and for monitoring battery power.
SUMMARY OF THE INVENTION
A preferred embodiment of the invention is realized in a portable flashlight but the broader application of its principles and features may be realized in various fixed lighting apparatus such as may be permanently mounted in vehicle cockpits and applications supplied with line power in lieu of portable batteries. The several featured improvements of the invention provide limited illumination for a using person who must see to covertly perform assigned tasks without divulging his presence, his location, or the performed task to other persons.
The invention provides one or more light sources in a hooded housing that shapes a beam of emitted radiation so that the direction of the emitted light beam is restricted to illuminate essentially only that surface to be seen by the user. In a preferred embodiment local gravity forces are used, firstly, to inhibit the application of power to the light source lamps by operation of the user's on-off switch to prevent radiation from the lamps of light energy into the volume of space centered along the horizontal planes where other persons or instruments could possibly detect the light and its user; and secondly, to enable the application of power to the light source lamps when the flashlight beam is pointed downward at small angles about the local vertical so as to illuminate only a small local surface area to be seen by the user in the performance of his assigned task.
In preferred embodiments having multiple light sources of different colors assembled in a projecting array, a portion of the light sources that are polarity sensitive, for example light emitting diodes (LEDs) can be assembled in reverse polarity relative to other polarity sensitive light sources of a different color so that a simple reversal of battery polarity in the assembly changes the color of the projected light. Similarly battery polarity reversal on an array containing an incandescent light source not affected by polarity together with polarity sensitive light sources will produce changes in the color of the projected light. The selection of the color of light emitted by a particular choice of polarity is made based upon the needs of the operator of the light, the type of surveillance equipment being used to locate him and the ambient conditions. For example, a bluish light may be desirable to avoid detection by red sensitive detectors while a whitish light would be superior for reading maps. The change from a first desirable color to a second desirable color can be made quickly through the use of a polarity reversing switch or by reversing the batteries. The first and second colors are predetermined by the type and placement of the lamps and they are accurately reproduced each time the operator selects a particular polarity.
As a combination, the invention provides additional polarizer filtering for the dual purposes of dimming adjustment of the projected lighting intensity and for the disproportionate reduction of reflection of light and energy from certain specular surfaces such as plastic overlays upon maps and charts, windshields, polished metals, pieces of glass, etc., or even the housing of the flashlight, itself. In an advanced embodiment of the invention the user's electrical (on-off) power switch is interlocked with the polarizer filter to preclude any "turn-on flare" and misdirection of high intensity light and energy upon initial ignition of the light source or sources. This interlocking of the on-off switch and the polarizer requires the user to gradually reduce the degree of cross polarization to increase the output lighting intensity from a dark or low level to that higher level of intensity which is just sufficient for the user's need in performing his task.
The preferred embodiment of the advanced combination, constituting a user's flashlight for covert applications, requires lamps for light sources that have characteristics of rapid decay time in the emission of light and energy. In other words the visible afterglow, which continues after the power is discontinued but which is detectable either by eye or sensing instrument, is to be reduced to a minimum. In the embodiment having directional control features, as provided, for example, by the gravity switch described above, rapid decay time has increased significance due to the possible reliance of the user upon the automatic turn-off feature of the flashlight when its light projecting axis enters the forbidden spatial zone. For example, if the flashlight were accidentally dropped its probable physical rotation may place the projected beam of residual light and invisible energies into the approximate horizontal plane where detection by the enemy and unintended persons is possible unless rapid time decay is provided. A light shielding hood increases the covert nature of the device because it obscures the lighted face of the device and delays detection until the full intensity of the projected beam is directed into the horizontal plane. This hood induced delay is necessary to permit the gravity switch to de-energize the lamps and for the lamps to decay.
Effective light sources for assembly in this invention, having rapid decay time on removal of power include luminescent lamps of the gaseous discharge, fluorescent, phosphorescent, and electroluminescent types and the family of solid state light emitting diodes. The decay time is also shortened by using a multiplicity of lamps in place of a single bright or hot lamp. The effective decay time for incandescent lamps may be reduced by optical attenuating filtering of the red spectra of the projected beam. In instances where multicolor viewing is a necessity the filtering could be designed to absorb large portions of the red spectrum but still transmit selected wavelengths within the red portion of the spectrum. The transmitted red energy would be helpful in identifying the color of red objects. Since the bulk of red energy would be absorbed by the filter, the decay time would be shortened and since selected energy in the red portion of the spectrum is transmitted, the color of red objects would be identifiable. Combinations of different types and colors of lighting sources may be assembled in removable and interchangeable modular packages.
In another embodiment, the gravity switch is used to activate a tactile or audible warning signal to alert the operator when light energy is being projected into a forbidden direction or spatial zone such as the horizontal plane.
An object of this invention is to provide a lighting device for persons engaged in covert activities in the performance of assigned tasks with the lighting device having features that prevent the beam of emitted light from being inadvertently directed into the space along the horizontal plane that may contain hostile observers having either natural or enhanced vision.
Another objective is to provide a lighting device for support of users while walking or performing other tasks which is effective in maintaining the covertness of its user should the device be accidentally dropped whereby its emitted light beam may rotate in space.
Another objective of the invention is to provide a covert lighting device that provides adjustable controls with recordable settings for its lighting intensity and/or color prior to specific instances of use for projecting exactly the required illumination in the minimum turn-on time span, and positive control and features for extinguishing the emitted light substantially instantaneously.
Another object of the invention is to provide improved security through polarity sensitive light sources in a circuit that effects a step change in color of the projected light upon reversal of the electrical polarity in the assembled device.
Another object of the invention is to reduce the amount of external radiation of light emitted to create the illumination needed by the user in adequately performing various assigned tasks.
It is another object of this invention to create a lighting device which has its emitted spectral energy filtered to create a balance between the objectives of rapid decay time and multicolor viewing.
Another object of this invention is a lighting device that is normally operable by the user only when its light beam is directed downward at small angles about the vertical direction sufficient only to illuminate small local areas thereby concealing the location of the user to hostile observers.
It is another objective of this invention to use gravitational forces to operate a switch to prevent the radiant energy emitted from the lighting device from being projected towards hostile observers. It is a further objective to use a light shielding hood extending from the exit aperture of its device to prevent the lighted exit aperture from being observed during the time span that is required for the gravity switch to operate and lamps to extinguish.
Another objective of this invention is to provide a lighting device that can be operated so that emitted light and radiant energy which may strike specular surfaces will be attenuated and reflections to the eye of the user and to the sensing elements of image intensifiers of hostile observers may be reduced.
Another objective of this invention is to provide controls, responsive to the user, whereby polarized light projected from the device can be adjusted to minimize specular reflections from nearby illuminated objects and surfaces.
Another objective of the invention is to provide a special signaling mode through emergency controls, responsive to the user, for pulsed light transmissions of rapid rise and decay times in directions chosen by the user for clearly defined signaling with lower probability of detection through image intensifiers located out of the chosen directional path.
A still further objective of the invention is to provide a tactile or audible warning to the user when holding the activated lighting device in a prohibited orientation.
Other objects, features, and advantages of the invention may become apparent from the description in connection with the accompanying drawings of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described with reference to accompanying drawings, in which:
FIG. 1 is a side elevation view of a tubular portable flashlight in accordance with the invention showing the operator's manual controls in the light-off and minimum intensity positions.
FIG. 2 is a side elevation view of the portable flashlight showing the bezel removed and the operator's controls in the automatic gravity activating mode with the polarizer dimmer adjusted for full lighting intensity.
FIG. 3 is a longitudinal cross-sectional view of the portable flashlight showing the removable cartridge and major internal subassemblies.
FIG. 4 is a plan view of a fully assembled lighting cartridge with batteries and an interchangeable light source array.
FIG. 5 is a cutaway illustration of the operator's controls showing the manual override switch in the automatic gravity activating position.
FIG. 6 is a cut away illustration of the operator's controls showing the manual override switch in the full "on" position overriding the gravity activating mode.
FIG. 7 is a partial cut away view of the flashlight with the cartridge inserted in the tubular housing, and showing a battery in reversed polarity assembly for a change of color of projected light, and the insertion of a tactile warning generator.
FIG. 8 is a partial cross-sectioned view illustrating the relationship of multiple light sources with polarizing and filtering optics with the tubular housing and bezel.
FIG. 9 is an end elevation view of a typical lighting array showing an incandescent lamp with multiple colored LED light sources.
FIG. 10 is a cutaway view of an insertable tactile warning module.
FIG. 11 is an end elevation view of the insertable tactile module.
FIG. 12 illustrates, in two dimensions, automatic gravity control of the projected illumination from the flashlight, limited to small angles about the vertical direction.
FIG. 13 is an end view of a typical gravity switch illustrating electrical circuit connecting surfaces.
FIG. 14 is an end view into the gravity switch retaining cup.
FIG. 15 is an enlarged schematic view showing the gravity mode of flashlight control in operating status.
FIG. 16 is an enlarged schematic view showing the gravity mode of flashlight control in the off status.
FIG. 17 is a basic electrical circuit for multiple light emitting sources.
FIG. 18 is a battery polarity sensitive electrical circuit for switching intensity and/or color and intensity of the projected light.
FIG. 19 is an alternative battery polarity sensitive electrical circuit for switching intensity and/or color and intensity of the projected light.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1-3 there is illustrated a preferred embodiment of the invention in a portable flashlight 20 contained in a tubular case 21, having at one end a removable hood or bezel 22 for securing a lamp module 23 and optics 24 and for shielding and restricting the projected light into a beam of illumination. The removable hood 22 is attached to the case 21 by matched machined threads 28 seen in FIGS. 2 and 3. At the opposite end of the case 21 a removable cartridge subassembly 25 is illustrated as inserted within the casing 21 and as being manually rotatable by the operator through angles limited by the cartridge lock pin 26 contained within the slot 27 in the case 21. The relative rotational position of the cartridge assembly 25 with respect to the case 21 is identified by graduated indicators 80 on the case 21 adjacent to the slot 27 and adjustable lock pin 26. The indicators of the coarse scale 81 allow adjustments of lighting intensity by the user's touch.
In normal covert usage of the flashlight 20, the insertable cartridge 25, illustrated in FIG. 4 and seen in FIG. 3, is rotated by the operator's control cap 29 to obtain the normal light-off condition when case markers 30 and cartridge marker 31 are aligned as illustrated in FIG. 1. Rotation of the cartridge subassembly 25 through the range of the slot 27 effects a continuous adjustment, as hereafter described, of the intensity of the projected light from minimum intensity upon departing from marker 30, 31 alignment to the highest intensity at the extreme position of the lock pin 26 within the slot 27. Thus rotation of the cartridge 25 achieves a dimming function for the flashlight 20 providing assurance that at normal turn-on of the light excessive light intensity (which might alert observers hostile to the user) is avoided. After turn-on the user rotates the cartridge 25 bringing the intensity upon the illuminated surface up to a satisfactory level.
Polarizing the light emitted from the flashlight substantially improves its covert characteristics. In a normal flashlight, the light emitted could divulge its user's location by reflecting off nearby specular surfaces. By placing a single polarizing filter on the preferred embodiment, we emit a polarized light. Depending upon the plane of polarization, the light is not reflected as efficiently from specular surfaces as nonpolarized light and because of this, the polarized light design is less likely to divulge its operator's presence. The efficiency of the specular reflection depends upon the degree of polarization of the emitted light and the polarizing characteristics of the specular surface. By placing a second polarizing filter in the flashlight and rotating this filter with respect to the first filter, we can control the intensity of the light emitted from the flashlight. Furthermore, we simultaneously dim the specular reflections. This specular dimming is disproportionally greater than the dimming of the light's intensity because the intensity of the reflected light is reduced by both the reduction in the light's intensity and the increase in polarization of the emitted light. Thus the percentage of dimming for the reflections is greater than that of the emitted light because a larger percentage of the emitted light is cross polarized with the specular surface at low intensities. This specular dimming becomes more effective at the low light levels which are the intensities needed for night vision. Since the polarizing filters are less effective in polarizing the light at longer wavelengths, the covert nature of the lighting device is further improved if the percentage of energy radiated in the red wavelengths is minimized.
Operation of the flashlight 20 by the user, in the normal sense, requires downward projection of light to illuminate surfaces existing in the bounds of a small zone 32 surrounding the vertical direction within an acute included angle, as illustrated in FIG. 12. In normal operation of the flashlight 20, the projection of light is extinguished automatically by a gravity switch 33, FIGS. 3-4 and 15-17. The gravity switch 33 interrupts the circuit from the batteries 35 if and when the flashlight 20 is aimed, either intentionally or accidentally, into the forbidden zone 34, FIG. 12, where hostile observers may be located. However, for an emergency signalling mode of operation, the user may aim the flashlight 20 into a selected horizontal direction with the intensity control of the lock pin 26 set by touch at a coarse scale marker 81, then operate the override switch 51 to the "on" position 53, FIG. 6, for bypassing the automatic gravity controlled mode.
The hood 22 can be designed to form an opaque hood surrounding and extending beyond the light emitting aperture at the front of the flashlight. This hood when used in concert with the gravity switch creates a flashlight which remains covert even under extreme conditions. FIG. 12 shows the flashlight at the angular orientation at which the gravity switch just turns "off." A hostile observer in the horizontal plane would theoretically not see the projected beam or the lighted face of the flashlight. However, in a real situation such as when its operator stumbles, the flashlight may be moving. Time would be required for the gravity switch to de-energize the lamps and time would be required for the lamps to decay to the visual "off" condition. If the hood in FIG. 12 were longer, it would provide that needed time and the covert flashlight would be visually extinguished by the time it rotated into a position which would compromise its location. To accommodate different types of light source modules 23 interchangeable hoods 22 are provided to confine the projected light within a beamwidth of less than seventy degrees.
Thus with the gravity switch shut-off operating angle set at less than forty five degrees from the downward vertical and with a half beamwidth design of the projected light less than thirty five degrees any upward pitch of the flashlight 20 will automatically extinguish the lamp or lamps 62-64, having fast decay characteristics, in less than eighty degrees from the downward vertical and before energy is radiated along horizontal directions. For an established gravity switch shut-off operating angle, alternate light source modules 23 having the shortest decay time can accommodate hoods 22 yielding the larger projected light beamwidth while source modules 23 of long decay time characteristics require hoods 22 yielding smaller projected light beamwidths to preclude radiation of energy along horizontal directions.
The dimming slot 27 of the case 21 is provided with a gravity switch disabling cam 36. Rotation of the cartridge 25, by the control cap 29, to place the cartridge lock pin 26 upon the disabling cam 36 region of the dimming slot 27 requires the user to push the control cap 29 deeper within the flashlight case 21.
The insertable and rotatable cartridge 25, seen within the case 21 in FIG. 3, is illustrated separately in FIG. 4. In addition to the control cap 29, the cartridge 25 is formed by an electrically conducting cage 37 consisting of a wraparound conducting strut 38 and a short conducting strut 39 arranged at right angles thereto for an open sided cage into which removable batteries 35 may be inserted and removed as operations and servicing requires. Interchangeable lamp modules 23 are assembled to the end of the cartridge cage 37 opposite to the control cap 29. At the end of the cage 37 nearest the control cap 29, a gravity switch retaining cup 40 is enclosed within the conducting struts 38, 39 of the cage 37. A battery spring 41 provides an electrical circuit between the batteries 35 and a contact plate 42 of the lamp module 23. When the lock pin 26 of the control cap 29 is placed by the user in the disabling cam 36 of the case 21, FIG. 1, the compression spring 41 situated between the battery 35 and light module 23 is compressed. In its compressed state, spring 41 exerts a counter force through battery 35, gravity switch 33, cap screws 47 and control cap 29. This force secures the flashlight 20 in a disabled gravity operating mode by retaining the lock pin 26 within the cam 36.
A typical gravity activating electrical switch 33, illustrated in FIGS. 3, 4, 13, 15, and 16 has an electrically conducting case 43, a post terminal 44, and a terminal feed through insulator 45. The post terminal 44 projects coaxially into the concavously arched inner region formed in the opposing end wall of the cylindrical conducting case 43. The case 43 contains a small volume of a conducting liquid, or other equivalent vehicle, for bridging the gap between the post terminal 44 and the conducting case 43 to close the electrical circuit at a defined downward pitch angle of the flashlight 20, symmetrically for all angles in azimuth or roll of the flashlight about its longitudinal axis, and for opening the electrical circuit at substantially the same defined downward pitch angle when the longitudinal axis of the flashlight 20 is elevated toward the horizontal direction, thus defining an acceptable spatial zone for covert operation of the flashlight 20. In the cartridge subassembly 25, the gravity switch case 43 contacts a terminal of a battery 35. The gravity switch post 44 projects into and through a passageway 46 in the retaining cup 40, which is an insulator, to make contact (for automatic gravity control of the flashlight 20) with the electrically conducting wraparound strut 38 to complete an electrical circuit to the lamp module 23. The gravity switch 33 is captured within the retaining cup 40 by a ring 69 tightly fitted within the cup 40 and loosely fitted about the gravity switch case 43, FIGS. 3 and 4.
The control cap 29 is mechanically tied to the gravity switch retaining cup 40 by at least three cap screws 47, FIGS. 14-16, which also serve as push rods against the flat surface 48 of the gravity switch case 43. Compression spring 41 maintains a force tending to separate the control cap 29 from the gravity switch retaining cup 40 a small distance 50 determined by the length of the three cap screws 47. When the control cap 29 is rotated and pushed inward in the flashlight case 21 to rest the lock pin 26 in the gravity mode "off" cam 36 the three cap screws 47 make contact with the flat surface 48 of the gravity switch 33 to effect a compression of the battery spring 41. Thus the batteries 35 and the gravity switch 33 move in unison toward the lamp module 23 within the cartridge cage 37 a short distance sufficient for the gravity switch post terminal 44 to break its contact with the wraparound strut 38, thereby opening the electrical circuit from the batteries 35 to the lamp module 23 to turn the flashlight 20 off when the user's selector control 51 is set for automatic gravity controlled operation.
The flashlight selector control 51 provides to the user an override function whereby light may be projected at any aiming angle of the flashlight 20 irrespective of the status of the gravity switch 33. It is expected that use of the override function may be operationally restricted to emergency and special field situations such as for signaling friendly forces, or when the user is located within shielding obstructions to hostile viewers. The gravity operating position 52 of the selector control 51 is shown in FIG. 5. A rotatable shaft 54 extends from the selector control 51 through the control cap 29 and retaining spring 49 into the closed end of the gravity switch retaining cup 40. Spring 49 is secured upon the shaft 54 by a contact pin 55 which passes diametrically through the shaft 54 at the surface of the gravity switch cup 40. FIG. 6 shows the selector control 51 and shaft 54 rotated to the override position 53, typically ninety degrees, to bring the contact pin 55 upon the wraparound strut 38 of the flashlight electrical circuit. Positioned inside the gravity switch cup 40, FIGS. 14-16, the override electrical circuit is completed by the override conducting spring 56 which, in both gravity and override modes of operation, bridges from the flat surface 48 of the gravity switch case 43 to the override shaft 54.
Secured in fixed relation to the flashlight case 21, by a locator pin 57 which fits in a matched notch 58 in the bezel threads 28 of the case 21, is the projecting optics 24, FIGS. 3 and 8. The projecting optical subassembly 24 includes the outer lens 59 and an optical polarizer 60 which are cemented into a unit having an O-ring 61 about their circumference to prevent entry of foreign substances within the flashlight case 21, FIG. 8.
A variety of interchangeable lamp modules 23 are considered within the scope of the invention, however, a preferred module 23, FIGS. 8 and 9, contains an array of multiple light sources including an incandescent lamp 62 and multiple light emitting diode (LED) lamps 63 which radiate energy at one or more colors of the visible spectra. An optical filter 64, typically in the blue spectra, absorbs the red and infrared energies of the incandescent radiation. The lamp module 23 is capped by a second polarizer 65. Rotation of the cartridge subassembly 25 with its lamp module 23 and module polarizer 65, fixed thereto and rotating therewith, relative to the flashlight case 21 and fixed polarizer 60 from a condition of cross polarization to parallel polarization increases the intensity of the projected light from its lowest intensity to the highest intensity.
The electrical circuit through the lamp module 23, FIG. is contained in the battery spring 41, the contact plate 42, the lamp circuit (filament, or junction, etc.) and the array manifold 66, which connects to conducting struts 38, 39 of the cartridge cage.
For insertion in or removal of the cartridge subassembly from the flashlight case 21, the spring loaded lock pin 26 is pushed radially inward within the circumference of the control cap 29. The control cap 29 is also provided with an O-ring 67 to prevent entry of foreign substances within the flashlight 20.
Typical electrical schematics for secure flashlights 20 are illustrated in FIGS. 17-19. A basic electrical schematic is illustrated in FIG. 17 showing a battery 35 powered flashlight 20 having at least one lamp but preferably an array of multiple lamps including for example an incandescent lamp 62 and a multiplicity of light emitting diodes (LEDs) 63 which may be selected to provide light in more than one color of the visible spectra. The LEDs 63 are arranged typically in parallel with the incandescent filament 62. The electrical circuit flows from the batteries 35 to the lamps 62, 63 through a circuit of the gravity activated switch 33 in series with a manual inhibiting circuit 68 which is mechanically implemented by the contact between the gravity switch post terminal 44 and the conducting wraparound strut 38 of the cartridge cage 37. The inhibiting circuit 68 is opened by the user when the cartridge lock pin 26 is placed in the gravity-off cam 36 of the flashlight case 21. The user's override switch 51 shunts the series circuit of the gravity switch 33 and the contact between the post terminal 44 and the conducting strut 38 to provide, when selected by the user, constant power to the lamp module 23 (62-63). Mechanically the override switch 51 is embodied in the override spring 56, the rotatable shaft 54, the contact pin 55, and the conducting strut 38.
The user of the flashlight 20 could inadvertently subject himself to detection should he unintentionally place the selector control 51 in the override position 53, thinking he had rotated the control cap 29 to activate the automatic gravity control mode. In advanced models of the flashlight 20 a tactile warning to the user can be provided. To provide vibration for stimulation of the user's sense of touch a tactile warning subsystem may be permanently incorporated or provided as desired by an insertable tactile module 73 designed to fit within the cage 37 of the cartridge 25 subassembly, as shown, for example in FIG. 7. The tactile module 73, FIGS. 10 and 11, contains a secondary automatic gravity actuated switch 74 and an electrical vibrator 75 which may be of the electronic, unbalanced rotating mass, or equivalent types. The insertable tactile module 73 has an insulating casing 76, an end-to-end bypass electrical conductor 77 for supply of electrical power both to the tactile module 73 and the illumination subsystem 23 by contact with the battery 35 and spring terminal 41 of the illumination subsystem 23. For its own electrical power supply a return conductor 78 extends from the tactile gravity switch 74 through the casing 76 to make contact with a conducting strut 38 of the cartridge cage 37 for return to the battery 35. Slotted keyways 79 extend longitudinally in the tactile casing 76 at matched locations for receiving therein the wraparound 38 and short 39 struts of the cartridge cage 37 to maintain electrical circuit continuity for the illumination subassembly 23 and the tactile module 73. In operation of the flashlight 20, the user may place the selector control 51 in the override position 53, FIG. 6, to effect electrical bypass of the illumination gravity switch 33 to activate the illumination subassembly 23 continuously regardless of physical orientation, and likewise to supply power continuously to the tactile module 73. If the flashlight 20 is pointed vertically downward the tactile gravity switch 74 interrupts the circuit to the tactile vibrator 75, however, if the flashlight 20 is aimed to project light upward or horizontally, FIG. 12, the tactile vibrator 75 is activated to warn the user. The tactile warning module 73 is ineffective if the user's selector control 51 is in the gravity position 52, FIG. 5, for automatic gravity control of the illumination subassembly 23.
For covert operations requiring a source of light, among the objectives is a requirement for the shortest possible rise and decay times for projection of visible light and any infrared energy upon application and removal of electrical power, respectively. The objective is achieved by this invention in the combination of a thermally insulated and opaque flashlight case 21 and bezel 22, the red and infrared attenuating filter 64 for the incandescent lamp 62, the LED lamps 63 at selected colors, and the bezel and lamp module polarizers 60 and 64 for intensity adjustment. The provision for interchangeable lamp modules 23 allows substitution of alternate lamp sources of solid state electroluminescent and gaseous discharge types for the incandescent and/or LED lamps for unique applications.
Referring to FIGS. 3, 4 and 7 it is seen that the batteries 35 may be assembled in the cartridge 25 in either polarity. In field operations the user of the flashlight 20 may dramatically alter the characteristics of the projected light in intensity and/or color by reversing the polarity of the batteries 35 in the electrical circuit.
In the basic circuit of FIG. 17, with battery 35 polarity as illustrated, the incandescent lamp 62 and all of the LEDs 63 are functional to provide full intensity and a specific spectrum of visible colors of light. Upon reversal of battery 35 polarity only the incandescent remains functional to provide a lower intensity and also an altered spectrum of colors of the projected light. If the incandescent lamp has a blue or red absorbing filter and the LEDs are red, the operator has the choice of a blue projected beam--superior for covert noncolor viewing--or a whitish beam--superior for multicolor covert viewing. The alternate embodiment illustrated by the circuit of FIG. 18 has a lamp module 23 containing an incandescent lamp 62 in combination with a first array 70 of LEDs for emitting a color spectra "A" of light and with a second array 71 of LEDs, connected for reversed battery 35 polarity, for emitting a color spectra "B" of light. In the circuit of FIG. 18 a reversal of battery 35 polarity, assuming the "A" array of LEDs 70 to possess comparable light intensity of the "B" array of LEDs 71, will yield projected light from the flashlight 20 substantially the same in intensity levels but dramatically different in color characteristics. In the alternate embodiment illustrated by FIG. 19 the lamp module 23 has an added diode 72 in series with the incandescent filament 62 making the series combination polarity sensitive, shunted by the parallel LED arrays 70, 71. Reversal of battery 35 polarity in FIG. 19, yields the "B" array 71 of LEDs operative for a major change of both the intensity and color of the projected light. The reversal of battery 35 polarity may be effected by inverted direction of assembly in the cartridge 25 or by a polarity reversing switch 82 as typically illustrated in FIG. 19.
This invention may be embodied in other specific forms without deviating from its concepts and essential characteristics. The preferred embodiment disclosed above is therefore to be considered in all respects as illustrative and not limiting of the scope of the invention indicated by the appended claims.
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A flashlight for security personnel has a gravity actuated switch for application of electrical power to multiple lamps to enable the projection of light in downward directions to illuminate multicolored working surfaces and to inhibit the projection of light in horizontal and other directions where hostile persons may be watching. The projected light intensity is variable by polarizing optical means and is coordinated with the gravity switch and the user's control so that the initial intensity at turn-on of the flashlight occurs at the lowest projected intensity. The lamp array, contained in a removable cartridge, has multiple light emitters selected for color characteristics, for a fast time decay response on turn-off, and for reduced red and infrared energy emissions. Reversal of battery polarity effects dramatic changes in color or intensity of the projected light. A manual control overrides the automatic gravity switch for projection of light in unrestricted directions while a tactile generator warns the user that light is projected in a high risk direction. Modular contruction of the removable cartridge permits selection of optional lighting arrays and accessories.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to locking means and in particular to locking means utilizing a line or cable.
2. Description of the Prior Art
My prior art U.S. Pat. No. 3,770,307 discloses a cable lock and seal device for a flexible cable and an enclsoure fixed secured to one end of the cable and with a passageway to receive the end of the cable therethrough and having a wedge element and disc-shaped jam element for locking the cable so that it can move freely in one direction but it is restricted from moving in the other direction.
SUMMARY OF THE INVENTION
The present invention relates to a locking means which is positive and which is used to represent what is commonly known as the "bolt" in conventional locks wherein in order to gain access into the locked parcel the bolt would have to be destroyed and also a lock is to be created that could not be "picked". The preset invention comprisies a locking shell through which a cable can be inserted and which has an internal tapered surface which goes from a round to triangular shape and which carries therein a cluster of balls mounted in a retainer which is spring tensioned in a first direction within the shell retainer. A cable can be inserted into the shell retainer so as to separate the balls and depress the spring thus allowing the balls to ride up the conical and triangular surface and separate allowing the cable to pass between the cluster of balls and out the other end of the shell retainer. When tension is applied to the cable to move it in the opposite direction out of the shell retainer, such tension causes the balls to move in the same direction as the tension on the cable, thus, forcing extreme pressure on the cable due to the conical and triangular shape of the internal surface of the shell retainer, thus, clamping and preventing the cable from being moved in the second direction relative to the shell. A second piece of the locking member comprises a body of material which is permanently crimped to the cable such that the locking case and the fixed member form a secure locking means.
The locking case can also be integrally formed with the fixed member such that the cable can be doubled back through the locking case.
Further objects, features and advantages of the invention will be readily apparent from the following description of certain preferred embodiments thereof taken in conjunction with the accompanying drawings although variations and modifications may be effected without departing from the spirit and scope of the novel concepts of the disclosure and in which
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a locking device of the invention mounted on a pair of doors;
FIG. 2 is a side elevational view of the invention;
FIG. 3 is a sectional view taken on line 4--4 in FIG. 2;
FIG. 4 is a sectional view taken on line 4--4 in FIG. 2;
FIG. 5 is a sectional view taken on line 5--5 in FIG. 4;
FIG. 6 illustrates a modification of the invention wherein the locking case and fixed member are integrally formed;
FIG. 7 is an end view taken from FIG. 2 of the fixed device;
FIG. 8 is an end view of a modified fixed member, and
FIG. 9 is an end view of a further modified fixed member.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the rear end of a truck 10 which has doors 11 and 12 which are secured by the locking device 13 of the invention. As shown in FIG. 2, the door 11 has an L-shaped member 14 attached thereto by screws or bolts 16 and 17 and the door 12 has an L-shaped member 15 attached thereto by bolts or nuts 19 and 21. The outer extending legs 22 and 23 are formed with openings through which the locking cable 27 of the invention extends. One end of the cable 27 is permanently attached to the fixed retaining means 24 and the free end of the cable is passed through the openings in portions 14 and 15 and the locking case 26 is passed over the end 25 of the cable 27 until it is against the portion 23. Since the locking case 26 can be freely moved in one direction relative to the cable which is to the left relative to FIG. 2 and which cannot be moved to the right relative to FIG. 2 due to its locking action a seal with a high degree of integrity is provided.
As shown in FIGS. 7, 8 and 9, the fixed member 24 is formed by crimping a block of aluminum having a central opening to the cable 27. The present member 24 comprises a substantial improvement over prior art members which are crimped onto a cable because with prior art devices the crimping is accomplished with crimping jaws that are circular or nearly circular in which case there is no real distortion of the cables original shape and the cable remains round. I have discovered that by using crimping shapes such as triangular, rectangular or square that substantially improved bonding between the cable 27 and the members 24 is accomplished. FIG. 7, for example, illustrates a fixed member 24 crimped in a triangular shape so that the central opening crimps the cable 27 into a triangular shape thus distorting the round shape of the cable causing each strand of the cable to have to find its own way out of the crimped object instead of following the path of the strand preceeding it. I have found that where a round crimp such as used in the prior art is utilized, that the path of each strand follows a definite spiral wherein it is stripped from the holding member whereas the path of each strand with a triangular, rectangular or square crimp such as illustrated in FIGS. 7, 8 and 9, respectively, are indefinite and do not follow any general pattern.
I have also discovered that starting with a round block of material with a central round opening which is crimped into a triangular shape such as shown in FIG. 7 that the center opening of the member 24 will be even more triangular than the external surface of the member 24.
I have also discovered that the bulky mass of the member 24 when made of aluminum, for example, is unaffected by the application of a burning flare or a propane torch due to the bulky cross-sectional area whereas with prior art seals having less bulk seals have been destroyed.
The generally flat-shape of the form shown in FIG. 8 utilizing a rectangular crimp provides two flat surfaces 61 and 64 upon which the seal number and other necessary or desirable imprinting can be placed.
The locking shell of the invention 26 is illustrated in sectional view in FIGS. 3 and 4 includes a generally cylindrical shell member 26 formed with a central opening 31 at a first end which opens into a larger opening 33 which extends to the end 29. The opening 31 at the end 28 of the shell is large enough to allow the end 25 of the cable to pass therethrough and a retainer member 44 formed with a central opening 46 is secured in the body member 26 adjacent the end 29 as shown. The internal space of the locking shell is formed with a cylindrical opening 33 and a tapered opening 32. The cylindrical opening 33 is adjacent the end 29 and the end retainer 44 and joins to a conical portion at a point 36 which passes into the tapered opening 32 to the end 34. As shown in FIG. 5, the conical tapered opening extends from point 36 and generally by transition goes into a triangular shaped opening before point 34.
A cluster of balls 38, 39 and 40 are held by a ball retainer 37 which has a central opening through which the balls extend and through which the cable 27 can extend. The retainer 37 is also formed with openings such that the balls 39 can engage the inner surface of the locking shell as shown in FIGS. 3, 4 and 5.
A coil spring 41 has a first end 43 which bears against the end plate 44 and a second end 42 which bears against the ball retainer 37 so as to bias it to the left relative to FIGS. 3 and 4.
The diameter of the cylindrical portion 33 of the internal opening of the locking shell is chosen such that when the cable 27 is inserted through the locking shell the balls will allow relatively free passage of the cable to the right as shown in FIG. 4. The tapered portion between points 36 and 34 of the internal opening 32 is such that upon the application of tension to the cable 27 to move the cable to the left relative to the shell 26 the balls 38, 39 and 40 will be cammed by the surface between the points 34 and 36 toward the center line of the cable 27 thus locking the cable so that it cannot be withdrawn by moving it to the left relative to FIG. 4.
In operation, the end 25 of the cable 27 is inserted through the opening 31 until it bears against the balls, 38, 39 and 40 and is further inserted into the locking shell and pushes the balls and the ball retainer 37 to the right relative to FIG. 3, thus, allowing the balls 38, 39 and 40 to move away from the cable until when the ball reach the point 36 illustrated in FIG. 4, the cable 27 can freely pass through the space between the balls and out the opening 46 of the retaining wall 44. As long as the cable is moved to the right relative to FIG. 4, the balls 38, 39 and 40 and the retainer 37 will remain in the position illustrated in FIG. 4, but any attempt to move the cable 27 to the left relative to FIG. 4 will immediately cause the balls 38, 39 and 40 to move on the internal conical and triangular shape surface between points 36 and 34 thus moving the balls together and applying pressure on the cable 27 so as to lock it for movement to the left relative to FIG. 4.
The shell 26 can be formed by deep drawing a sheet of flat stock or could be produced on a screw machine or a lathe from bar stock. It could also be cast or injection molded. The locking shell 26 and the fixed member 24 could be made of brass, aluminum, copper or steel. Cindered or powdered metal or nylon, delron or other plastics could also be used.
This lock can be applied in many applications wherever cinching, locking, suspending, connecting or taking up of a slack line is required.
Although three balls are illustrated in particular locking shells, it is to be realized that any number of balls such as 2, 3 or more could be used. The diameter of the balls would be chosen so as to be compatible with the size of the cable.
In one particular example utilizing cable having a 3/16 inch diameter, 1/4 inch balls were used. I have found that three balls provides the best necking down of the cable effect.
In a particular model constructed I have found that a resistance for approximately 5 pounds pressure is required to insert the cable into the locking shell and this resistance is the result of the compression of the spring 41 coupled with the friction of the balls 38, 39 and 40 and the ball retainer 37 as well as the friction between the balls and the inside wall of the shell 26.
By pushing on the cable 27, the balls are forced to roll upwardly relative to FIG. 3 toward the larger end of the cone and outwardly from the axis of the cone until the cluster of balls is spread far enough to allow the cable to pass through the cluster. Further pushing of the cable 27 allows it to move out the shell retainer 26 until the fixed member 27 and the shell member 26 are both touching the hasp members 14 and 15 thus leaving no exposed cable and locking procedure has been completed.
I have discovered that when an attempt is made to remove the cable by pulling and twisting to the left relative to FIGS. 2 and 4 that by reshaping the internal surface 32 so that it goes from a cone at point 36 to a triangular shape at point 34 prevents the balls from rolling around the inner surface of the triangular shaped portion toward the end 34 which substantially prevents the cable from being twisted from the lock. This triangular portion adjacent the end 34 can be seen in the sectional view 5 wherein the conical portion 36 gradually goes into a triangular shape portion at 34.
A modification of the invention is illustrated in FIG. 6 wherein the retainer and shell member are integrally formed in a single unit 47. A portion 49 is generally square-shaped in cross-section as illustrated in FIG. 9 and is crimped to the cable 27. An enlarged portion 48 is generally triangular shaped and is formed with a conical and triangular shaped opening and is fairly similar to the shell member 26 illustrated in FIG. 2 with the exception that it has been permanently bonded to the member 49 or may be integrally formed with the member 49. A flat portion 51 allows the seal identification to be attached and in use the free end of the cable is passed through the locking means which might be a hasp and then into the end 51 of the portion 48 and out the end 52. The balls within the shell member 48 prevent the cable 27 from being drawn upward relative to FIG. 6 but it can be freely drawn downwardly until the desired length of the cable 27 extends between the surfaces 49 and 51.
It is seen that this invention provides new and novel locking means and although it has been described with respect to preferred embodiments it is not to be so limited as changes and modifications may be made which are within the full intended scope of the invention as defined by the appended claims.
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A locking means for providing a seal comprising a locking shell formed with a central passageway which is internally tapered with an opening that changes from conical to triangular in shape and which carries spring loaded ball bearings and a retainer such that a cable can be inserted through the central opening in a first direction, thus, depressing the spring and allowing the balls to relieve pressure on the cable in said first direction but which provides substantial and locking pressure on the cable when the cable is placed under tension in the opposite direction. The cable may also be attached to a second fixed member such that a seal may be made by placing the locking case and the fixed member on the same cable.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a heat exchanger which constitutes a vehicle air conditioner. The present invention is based on Japanese Patent Application Nos. 11-201014, 11-219346, 11-220549, 11-220550, 11-220551, and 11-113111, the contents of which applications are incorporated herein by reference.
[0003] 2. Description of the Prior Art
[0004] One example of the structure of a heat exchanger which is used as an evaporator in a vehicle air conditioner is shown in FIG. 25. This heat exchanger is known as a drawn cup type heat exchanger, which has becoming. common recently and is configured so that a plate-shaped cooling medium flow portion 3 obtained by piling up substantially rectangular flat plates 1 and 2 which are subjected to drawing and cooling fins 4 bent into a wave shape are alternately laminated.
[0005] The flat plates 1 and 2 are brazed at the outer peripheral portions and the central portions in the cooling medium flow portion 3 . As the result a U-shaped cooling medium flow path R which travels between a cooling medium inlet 5 provided at the upper portion and the lower portion and leads to a cooling medium outlet provided at the upper portion and is aligned parallel the cooling medium inlet 5 , is formed within the cooling medium flow portion 3 .
[0006] In this heat exchanger a cooling medium is distributed to each cooling flow portion 3 at the cooling medium inlet 5 , and is vaporized in the process of passing through the cooling medium flow path R, and is then collected again at the cooling medium outlet 6 . After that the collected cooling medium is discharged from the heat exchanger.
[0007] Incidentally, the following problems have been pointed for the above-mentioned structured heat exchanger.
[0008] (1) In a heat exchanger used as an evaporator, the dryness of the flowing cooling medium is not constant, but it gradually increases in the process of vaporization. Thus, for a flow path cross-sectional area along the direction of the cooling medium flow, the specific volume of the cooling medium is increased and the flow path resistance is increased as the cooling medium moves downstream of the flow path. Therefore, high heat conductivity cannot always be obtained in the entire heat exchanger under the present circumstances. Also pressure losses cannot always be controlled to small levels.
[0009] (2) The cooling medium inlet 5 forms a continuous space by laminating the cooling flow portion 3 as shown in FIG. 26. Thus, the cooling medium flowing into the heat exchanger is distributed to each cooling medium flow portion 3 in the process of flowing within this continuous space in the directions of the arrows in FIG. 26. However, in a conventional heat exchanger the cooling medium collectively flows into the cooling flow portion 3 positioned downstream in the direction of the flow of the cooling medium and the distribution of the cooling medium into each cooling medium flow portion 3 is not uniformly carried out. As a result, cooling medium is apt to stagnate, and in the cooling flow portion 3 positioned upstream side in the direction of the flow of the cooling medium, heat exchange is not sufficiently performed.
[0010] (3) The cooling medium flowing into the heat exchanger is distributed into each cooling medium flow portion 3 from a space formed by lamination of the cooling flow portions 3 . However, since in the conventional heat exchanger the start portion of the cooling flow path leading to the space is narrower than the space, the cooling flow path R is rapidly reduced at this portion and pressure loss occurs. Also in the continuous space formed at the cooling medium outlet 6 the same phenomenon is occurs. That is, since the space formed at the cooling medium outlet 6 is wider than the end portion of the cooling flow path R, the cooling flow path R is rapidly enlarged at this portion and pressure loss occurs.
[0011] (4) The cooling medium flow portion 3 is formed by laminating two flat plates 1 and 2 which were subjected to drawing and brazing after providing the cooling medium portion R inside the plates. However, if the plates 1 and 2 are shifted, the disadvantage that airtightness of the cooling flow path R is not ensured or sufficient pressure resistance cannot be obtained or the like occurs. Thus, to prevent the shift of the flat plates 1 and 2 , one of the flat plates is provided with a claw. And when the one flat plate is laminated with the other flat plate, this claw is closed to fix both flat plates. However, this shift prevention countermeasure has the problems that a step of closing the claw is needed thereby increasing the assembly time and excess material for the claw is needed whereby the production costs are increased when it is assumed mass production is used.
[0012] The present invention was made in consideration of the above-mentioned circumstances. It is an object of the present invention to reduce the pressure loss which acts on a cooling medium flow path in accordance with the change of dryness of the cooling medium thereby to enhance the heat exchange performance in a drawn cup type heat exchanger.
[0013] It is another object of the present invention to uniformly distribute a cooling medium to a cooling medium flow path and at the same time reduce the pressure loss in the cooling medium flow path thereby to enhance the heat exchange performance.
[0014] It is still another object of the present invention to review a shift prevention structure provided in two flat plates constituting a cooling medium flow portion thereby to reduce the assembly time and the production costs.
SUMMARY OF THE INVENTION
[0015] The present invention relates to a heat exchanger in which a plate-shaped cooling medium flow portion provides an internal cooling medium flow path by laminating two flat plates subjected to drawing and a cooling fin are alternately laminated, a cooling medium inlet for allowing a cooling medium to flow into the cooling medium flow path and a cooling medium outlet for allowing a cooling medium which has passed through the cooling medium flow path to flow out are formed in the two flat plates, and the cooling medium flowing from the cooling medium inlet to the cooling medium flow portion is passed through the cooling medium flow path and is then allowed to flow out of the cooling medium outlet.
[0016] Particularly, the heat exchanger of the present invention is characterized in that a bulged portion protruding on the cooling medium flow path side is formed in the cooling medium flow portion by denting at least any one of the two flat plates from the outside, and a plurality of elliptical or oval cylindrical portions whose major diameter is oriented in the flow direction of the cooling medium are provided between two flat plates by butting the top portion of the bulged portion to the opposite flat plate, and the arrangement number of the plurality of cylindrical portions is gradually decreased as the cooling medium flows toward the downstream side in the flow direction of the cooling medium.
[0017] Further, another heat exchanger of the present invention is characterized in that a bulged portion protruding on the cooling medium flow path side is formed in the cooling medium flow portion by denting at least any one of the two flat plates from the outside, a plurality of elliptical or oval cylindrical portions whose major diameter is oriented in the flow direction of the cooling medium are provided between two flat plates by butting the top portion of the bulged portion to the opposite flat plate, and this plurality of cylindrical portions is formed of shapes gradually decreasing in size as the cooling medium flows toward the downstream side in the flow direction of the cooling medium.
[0018] In this case, it is preferable that the cylindrical portions diagonally adjacent to each other with respect to the flow direction of the cooling medium are arranged so that the cylindrical portions partially overlapp along the flow direction.
[0019] Further, another heat exchanger of the present invention is characterized in that the cooling flow path is formed in a U-shape and runs in one direction from a cooling medium inlet and returns to pass through a cooling medium outlet, and that the cross-section of the cooling medium flow path corresponding to the return path is formed so as to be larger than the cross-section of the cooling medium flow path corresponding to the forward path.
[0020] Further, another heat exchanger of the present invention is characterized in that the cooling medium outlet is formed so as to be larger than the cooling medium inlet. In this case a plurality of the cooling outlets are provided and the total opening area of each cooling medium outlet may be larger than the opening area of the cooling medium inlet.
[0021] Further, the present invention also relates to a heat exchanger in which a plate-shaped cooling medium flow portion provides an internal cooling medium flow path by laminating two flat plates subjected to drawing and a cooling fin are alternately laminated, an opening portion for allowing a cooling medium to flow into the cooling medium flow path is formed in two flat plates respectively, and a continuous space is formed in laminated adjacent cooling medium flow portion by butting adjacent opening portions so that the cooling medium flowing within this space is allowed to flow from the opening portion to the cooling medium flow path to thereby be distributed into each cooling medium flow portion.
[0022] Particularly, the heat exchanger of the present invention is characterized in that a restricting portion for restricting the flow of the cooling medium to guide a part of the cooling medium into the opening portion is provided in this space. In this case for example a protrusion which protrudes toward the upstream side in a flow direction of the cooling medium is formed as the restricting portion. Further, it is preferable that the restricting portion is provided integrally with any one of the two flat plates. Further, it is also preferable that the restricting portion is formed by being subjected to barring around the opening portion.
[0023] Further, another heat exchanger of the present invention is characterized in that a flow path cross-section of the cooling medium flow path communicating with the space on the inlet side (inlet side space) of the cooling medium is gradually reduced as the cooling flows toward the downstream side in the flow direction of the cooling medium.
[0024] Further, another heat exchanger of the present invention is characterized in that a flow path cross-section of the cooling medium flow path communicating with the space on the outlet side (outlet side space) of the cooling medium is gradually magnified as the cooling medium flows toward the downstream side in the flow direction of the cooling medium.
[0025] Further, the present invention is characterized in that in a heat exchanger wherein a cooling medium allowed to flow into a cooling medium inlet through the above-mentioned space on the inlet side and distributed to each cooling medium flow portion is passed through a cooling flow path and is allowed to flow out of a cooling medium outlet thereby to be discharged through the above-mentioned space on the outlet side, a baffle plate having an opening for allowing the cooling medium to pass and guiding the cooling medium, which cannot be passed through this opening portion, to the cooling medium flow path is respectively provided in the cooling medium inlet of each cooling medium flow portion and opening portions provided in the adjacent baffle plates are arranged so as not to overlap in the flow direction of the cooling medium. Alternatively, a baffle plate positioned on further downstream in the flow direction of the cooling medium may have the opening formed in a smaller size.
[0026] Further, another heat exchanger of the present invention is characterized in that as a register portion for registering the above-mentioned two flat plates, a protrusion portion formed in any one of the two flat plates and a concave portion formed in the other of the two flat plates so that the concave portion is fitted to the protrusion portion in a state of lamination of the two flat plates, are provided. In this case it is preferable that the register portions are provided at least two or more positions. Further, the protrusion portion and the concave portion are more preferably formed by concave and convex portions formed in the two flat plates when they are subjected to drawing. Alternatively, as the register portion a protrusion portion formed in any one of the two flat plates and a hole formed in the other of the two flat plates so that the concave portion is fitted to the protrusion portion in a state of lamination of the two flat plates, can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] [0027]FIG. 1 is a perspective view showing the first example of a heat exchanger according to the present invention;
[0028] [0028]FIG. 2 is an exploded perspective view showing a cooling medium flow path which constitutes the heat exchanger of FIG. 1;
[0029] [0029]FIG. 3 is a cross-sectional view taken along the line III-III in FIG. 1;
[0030] [0030]FIG. 4 is a cross-sectional view showing the space on the inlet side and a cooling medium flow path connected to the space in the first example of the heat exchanger according to the present invention;
[0031] [0031]FIG. 5 a cross-sectional view showing the space on the outlet side and a cooling medium flow path connected to the space in the first example of the heat exchanger according to the present invention;
[0032] [0032]FIG. 6 an exploded view for explaining a shape of the cooling medium flow path in the first example of the heat exchanger according to the present invention;
[0033] [0033]FIG. 7 is a view showing the second example of a heat exchanger according to the present invention, specifically an exploded view for explaining the shape of the cooling medium flow path thereof;
[0034] [0034]FIG. 8 is a perspective view showing the third example of the heat exchanger according to the present invention;
[0035] [0035]FIG. 9 is an exploded perspective view showing the cooling medium flow path which constitutes the heat exchanger of FIG. 8;
[0036] [0036]FIG. 10 is an exploded view for explaining the shape of the cooling medium flow path in the third example of the heat exchanger according to the present invention;
[0037] [0037]FIG. 11 is a perspective view showing the fourth example of a heat exchanger according to the present invention;
[0038] [0038]FIG. 12 is an exploded perspective view showing a cooling medium flow path which constitutes the heat exchanger of FIG. 11;
[0039] [0039]FIG. 13 is a cross-sectional view showing the space on the inlet side and a cooling medium flow path connected to the space in the fourth example of the heat exchanger according to the present invention;
[0040] [0040]FIG. 14 is a cross-sectional view showing the space on the inlet side and a cooling medium flow path connected to the space in the fifth example of the heat exchanger according to the present invention;
[0041] [0041]FIG. 15 is a cross-sectional view showing the space on the inlet side and a cooling medium flow path connected to the space, that is a modified example of the fifth example the heat exchanger according to the present invention;
[0042] [0042]FIG. 16 is a cross-sectional view showing the space on the inlet side and a cooling medium flow path connected to the space, that is a modified example of the fifth example the heat exchanger according to the present invention;
[0043] [0043]FIG. 17 is a perspective view showing the sixth example of a heat exchanger according to the present invention;
[0044] [0044]FIG. 18 is an exploded perspective view showing the cooling medium flow path which constitutes the heat exchanger of FIG. 17;
[0045] [0045]FIG. 19 is a cross-sectional view showing space on the inlet side and a cooling medium flow path connected to the space in the sixth example of the heat exchanger according to the present invention;
[0046] [0046]FIG. 20 is a bulged view of the respective baffle plates showing a modified example of the sixth example of the heat exchanger according to the present invention;
[0047] [0047]FIG. 21 is a cross-sectional view showing space on the inlet side and a cooling medium flow path connected to the space, that is a modified example of the sixth example of the heat exchanger according to the present invention;
[0048] [0048]FIG. 22 is a perspective view showing the seventh example of a heat exchanger according to the present invention;
[0049] [0049]FIG. 23 is an exploded perspective view showing a cooling medium flow path which constitutes the heat exchanger of FIG. 22;
[0050] [0050]FIG. 24A is a state explanatory view showing the operation of registering two flat plates at a registering portion in a seventh example of a heat exchanger according to the present invention;
[0051] [0051]FIG. 24B is a state explanatory view showing the operation of registering two flat plates at a registering portion in a seventh example of a heat exchanger according to the present invention;
[0052] [0052]FIG. 25 is a perspective view showing one example of a conventional evaporator; and
[0053] [0053]FIG. 26 is a cross-sectional view showing space on the inlet side and a cooling medium flow path connected to the space in the conventional evaporator.
DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
[0054] The first example of a heat exchanger according to the present invention will be described with reference to FIGS. 1 to 6 .
[0055] The heat exchanger shown in FIG. 1 is configured so that a plate-shaped cooling medium flow portion 11 and a wave-shaped cooling fin 12 are alternately laminated.
[0056] The cooling medium flow portion 11 is formed by laminating substantially rectangular flat panels 13 and 14 which have been subjected to drawing as shown in FIG. 2 and brazing their outer peripheral portions and their central portions. The upper portion of the cooling medium flow portion 11 is provided with a cooling medium inlet 15 and a cooling medium outlet 16 in parallel. As the result of brazing the outer peripheral portions and the central portions of the flat plates 13 and 14 , a U-shaped type cooling medium flow path R which runs downward from a cooling medium inlet 15 and returns back at the lower end portion to pass through a cooling medium outlet 16 is formed within the cooling medium flow portion 11 .
[0057] In the cooling medium flow portion 11 is formed a plurality of dimples 17 by denting the flat plates 13 and 14 which form the cooling medium flow path R from the outside, and these dimples 17 form a plurality of bulged portions (protrusions) 18 in the cooling medium flow path R. Each of these bulged portions 18 has an elliptic shape which defines the flow direction of the cooling medium as the major diameter when viewed in a plane view as shown in FIG. 3. By brazing opposed top portions 18 a of the bulged portions 18 an elliptic cross-sectioned cylindrical portion 19 is formed between the flat plates 13 and 14 . The shape of the cylindrical portion 19 is not limited to an ellipse but it may be an oval.
[0058] The cooling medium inlet 15 is composed of opening portions 13 a and 14 a formed in the flat plates 13 and 14 , respectively. The cooling medium inlets 15 provided in each cooling medium flow portion 11 are butted to each other without sandwiching the cooling fin 12 as shown in FIG. 4 so that continuous space Sin on the inlet side is formed. The cooling medium inlet 15 is composed of opening portions 13 a and 14 a formed in the flat plates 13 and 14 , respectively. Also, the cooling medium inlet 16 is composed of opening portions 13 b and 14 b formed in the flat plates 13 and 14 , respectively. The cooling medium inlets 16 provided in each cooling medium flow portion 11 are butted to each other without sandwiching the cooling fin 12 as shown in FIG. 5 so that continuous space Sout on the outlet side is formed.
[0059] In the above-mentioned structured heat exchanger the cooling medium is distributed into each of the cooling medium flow portions 11 in the process of running through the space Sin on the inlet side in the direction of the arrow in the FIG. 4, and the distributed cooling medium is vaporized in the process of passing through the cooling medium flow path R, and the cooling is collected again in the space Sout on the outlet side thereby to flow out. While the cooling medium is flows through the cooling medium flow path R the cooling medium collides as a result against the cylindrical portion 19 provided in the cooling medium flow path R, whereby turbulence occurs in the flow of the cooling medium and the thermal conductivity is enhanced by the turbulence effect.
[0060] Further, in the case of the heat exchanger of the present example, the bulged portions 18 are provided in such a manner that they gradually become fewer as the cooling medium flows downstream in the flow direction of the cooling medium in the cooling medium flow path R, as shown in FIG. 6. Accordingly, the cylindrical portions 19 are provided in such a manner that they gradually become fewer (the number of the cylindrical portions 19 is gradually reduced) as the cooling medium flows downstream. Thus, the cross-sectional area of the cooling medium flow path R is increased as the cooling medium flows downstream.
[0061] In a heat exchanger used as an evaporator the dryness of a cooling medium is gradually increased (the gas phase is further increases in proportion to the liquid phase) as the cooling medium flows downstream in the cooling medium flow path R. Accordingly, the specific volume of the cooling medium and the flow path resistance are gradually increase as the cooling medium flows downstream. On the other hand, in the present example by gradually decreasing the number of cylindrical portions 19 thereby to gradually increase the cross-sectional area of the cooling medium flow path R in accordance with the increase in the specific volume of the cooling medium along the flow direction, the flow path resistance of the cooling medium is decreased as the cooling medium flows downstream. As the result, the thermal conductivities are kept at higher values over the entire area of the cooling medium flow path R and pressure losses are kept at lower values. Therefore, the heat exchangeability when used as an evaporator of a heat exchanger is enhanced.
EXAMPLE 2
[0062] The second example of a heat exchanger according to the present invention will be described with reference to FIG. 7. In the following each example, the same reference numerals are used for the components already described in the above-described first example and the descriptions thereof are omitted.
[0063] In this heat exchanger the bulged portions 18 are formed in such a manner that they gradually become smaller as the cooling medium flows downstream in the flow direction of the cooling medium as shown in FIG. 7. Accordingly, the cylindrical portions 19 are also formed in such a manner that they gradually become smaller as the cooling medium flows downstream. Thus, the cross-sectional area of the cooling medium flow path R is increased as the cooling medium flows downstream.
[0064] Further, in this example the bulged portions, which are diagonally adjacent to each other with respect to the flow direction of the cooling medium are arranged in zigzag pattern so that they partly overlap along the flow direction of the cooling medium. Accordingly, the respective cylindrical portions 19 are arranged zigzag.
[0065] In this heat exchanger, by forming the cylindrical portions 19 which become gradually smaller thereby to gradually increase the cross-sectional area of the cooling medium flow path R in accordance with increase in the specific volume of the cooling medium which flows upstream to downstream, the flow path resistance of the cooling medium is decreased as the cooling medium flows downstream. As the result, the thermal conductivities are kept at higher values over the entire area of the cooling medium flow path R and pressure losses are kept at lower values. Therefore, the heat exchangeability when used as an evaporator of a heat exchanger is enhanced.
[0066] Further, in the cylindrical portions 19 , which are diagonally adjacent to each other with respect to the flow direction of the cooling medium, the front end portion of a cylindrical portion 19 which is positioned downstream of the rear end portion of an upstream cylindrical portion, becomes the upstream side of the flow direction. Accordingly, the local thermal conductivity, which tends to be reduced at the rear end portion of a cylindrical portion 19 which is positioned upstream is compensated by the cylindrical portion 19 which is positioned downstream. As the result, the thermal conductivity of the entire cooling medium flow portion 11 is enhanced.
[0067] Additionally, the cylindrical portions 19 are regularly arranged along the flow direction of the cooling medium, and an extent of a joint portion which is positioned at the top portions 18 a can be generally ensured. Thus, in any cross-section of the cooling flow portion 11 in the flow direction of the cooling medium, two flat plates 13 and 14 are joined to each other by adhesion of the bulged portions 18 whereby the joint strength of the cooling medium flow portion can be enhanced. Therefore, even if the flat plates 13 and 14 are thin, a sufficient pressure resistance is imparted to the cooling flow portion 11 .
EXAMPLE 3
[0068] The third example of a heat exchanger according to the present invention will be described with reference to FIGS. 8 to 10 . In the heat exchanger of the present example, by forming brazed portions positioned at the central portions of the flat plates 13 and 14 in positions biased to the forward path side as shown in FIGS. 8 to 10 , the flow path cross-section of the cooling flow path R corresponding to the backward path can be made larger than the flow path cross-section of the cooling flow path R corresponding to the forward path.
[0069] In this heat exchanger, by making the flow path cross-section of the cooling flow path Rr corresponding to the backward (return) path larger than the flow path cross-section of the cooling flow path Rf corresponding to the forward path in accordance with the increase in the specific volume of the cooling medium which flows from the upstream toward the downstream, the flow path resistance of the cooling medium is decreased and the thermal conductivities are kept at higher values over the entire area of the cooling medium flow path R and also pressure losses are kept at lower values. Therefore, the heat exchangeability when used as an evaporator of a heat exchanger is enhanced.
[0070] Incidentally, in the present example the sizes of the flow path cross-sections of the cooling flow paths R were differentiated between the forward path and the backward path by biasing the positions of brazed portions positioned at the central portions of the flat plates 13 and 14 . However, a difference may be imparted to the flow path cross-sections between the forward path and the backward path by changing the size of the dimple.
EXAMPLE 4
[0071] The fourth example of a heat exchanger according to the present invention will be described with reference to FIGS. 11 to 13 . In the heat exchanger of the present example, the cooling medium outlet 16 is formed with a larger size than the cooling medium inlet 15 as shown in FIGS. 11 to 13 .
[0072] In this heat exchanger, by forming the cooling medium outlet 16 in a larger size than the cooling medium inlet 15 in accordance with an increase in the specific volume of the cooling medium which flows from the upstream toward the downstream, flow path resistance of the cooling medium in the vicinity of the cooling medium outlet 16 is decreased. Thus, thermal conductivities are kept at higher values over the entire area of the cooling medium flow path R and also pressure losses are kept at lower values. Therefore, the heat exchangeability when used as an evaporator of a heat exchanger is enhanced.
[0073] Incidentally, in the present example a heat exchanger in which one space Sin on the inlet side and one space Sout on the outlet side are provided was described. However, by providing one space Sin on the inlet side and two spaces Sout on the outlet side the total opening areas of the two cooling medium outlets 16 may become larger than the opening area of the cooling medium inlet 15 .
EXAMPLE 5
[0074] The fifth example of a heat exchanger according to the present invention will be described with reference to FIGS. 14 to 16 . In the heat exchanger of the present example, protrusions (restricting portions) 20 which restrict the flow of a flowing cooling medium and lead a part of the cooling medium to a cooling medium inlet 15 composed of openings 13 a and 14 a are provided in an inlet side space Sin formed on the cooling medium inlet 15 side, as shown in FIG. 14. The protrusion 20 is integrally provided with the flat plate 13 by carrying out barring around the opening 13 a and protrudes on the upstream side of the flow direction of the cooling medium so that it is fitted to the opening 14 a of the adjacent cooling medium flow portion 11 .
[0075] When the protrusion 20 which restricts the flow of the cooling medium is formed in the inlet side space Sin, a flow of a part of the cooling medium which flows in the inlet side space Sin is restricted so that it is obstructed with the protrusion 20 , and the cooling medium is introduced from the cooling medium inlet 15 to the cooling medium flow path R. Thus, relatively much cooling medium is distributed to the cooling medium flow portion 11 positioned on the upstream side of the cooling medium flow portion 11 where a cooling medium was apt to remain. As the result, a uniform heat exchange can be carried out in all of the plurality of cooling flow portions and the heat exchangeability of the heat exchanger is enhanced.
[0076] Further, since the protrusion 20 can be easily formed by barring the periphery of the opening portion 13 a during drawing of the flat plate 13 , there are almost no increases in the production processes or cost which for formation of the protrusion 20 .
[0077] The degree of restriction of the cooling by the protrusion 20 can be appropriately set by varying the size of the protrusion 20 and adjusting the orientation of the protrusion 20 during drawing of the flat plate 13 , whereby the cooling medium can be distributed uniformly.
[0078] Incidentally, in the present example the protrusion 20 was provided on the flat plate 13 . However, it can be provided on the flat plate 14 . Alternatively, the protrusion 20 may be formed with another member and brazed at the same time when the flat plates 13 and 14 are brazed.
[0079] Alternatively, for example, as shown in FIGS. 15 and 16, the cooling medium flow path R communicating with the space Sin on the inlet may be deformed so that the flow path cross-section of it is gradually reduced toward the downstream side of the flow direction of the cooling medium at an inlet portion where the cooling medium flows from the space Sin on the inlet side to the cooling medium flow path R (corresponding to portion A in FIGS. 15 and 16). In this case, although the outlet portion is not shown, the region where the cooling medium flows from the cooling medium flow path R to the space Sout on the outlet, is also deformed so as to gradually increase as the cooling medium flows downstream in the flow direction. These deformations are made when the flat plates 13 and 14 are subjected to drawing.
[0080] By gradually reducing the flow path cross-section of the cooling medium flow path R communicating with the space Sin on the inlet side as the cooling medium flows downstream in the flow direction of the cooling medium, the rapid reduction of the cooling medium flow path R is decreased, whereby the pressure loss of the cooling medium which flows from the space Sin on the inlet side to the cooling medium flow path R is decreased. Similarly, by gradually magnifying the flow path cross-section of the cooling medium flow path R communicating with the space Sout on the outlet side as the cooling medium flows downstream in the flow direction of the cooling medium, the rapid increase of the cooling medium flow path R is decreased whereby the pressure loss of the cooling medium which flows from the cooling medium flow path R to the space Sout on the outlet side is decreased. As the results, the pressure losses at the inlet and outlet of the cooling medium flow path R are decreased and the heat exchangeability of the heat exchanger is enhanced.
[0081] In this example as shown in FIG. 15 a shape of the wall surface of the cooling medium flow path R is curved. However, the wall surface shape of that portion is not limited to a curved shape. For example, as shown in FIG. 16 the shape of the wall surface of the cooling medium flow path R may be wedge-shaped.
EXAMPLE 6
[0082] The sixth example of a heat exchanger according to the present invention will be described with reference to FIGS. 17 to 21 . In the heat exchanger of the present example as shown in FIGS. 17 and 18 the opening portion 13 a of a flat plate 13 which forms a cooling medium inlet 15 is formed in such a manner that it is smaller than the opening portion 14 a of a flat plate 14 which also forms a cooling medium inlet 15 and the center of the opening portion 13 a is shifted from the center of the opening portion 14 a . Additionally, as shown in FIG. 19 the opening portions 14 a in the respective cooling medium flow portions 11 are arranged at the same positions. On the other hand, the openings 13 a in the respective cooling medium flow portions 11 are arranged at different positions. That is, the portion where the opening portion 13 a is formed acts as a baffle plate 21 which hinders the flow of the cooling medium into the opening portion 14 a in laminated cooling flow portions 11 . Further, the opening portions 13 a formed in adjacent baffle plates 21 are arranged in such a manner that they are not overlapped in the flow direction of the cooling medium.
[0083] In this heat exchanger a cooling medium flowing in the space Sin on the outlet side is passed through the opening portion 13 a formed in each baffle plate 21 to flow downstream. On the other hand, a cooling medium which dose not pass through the opening portion 13 a is guided by the baffle plate 21 to flow into the cooling medium flow path R. Further, since opening portions 13 a formed in adjacent baffle plates 21 are arranged in such a manner that they do not overlap in the flow direction of the cooling medium, when for example a part of a cooling medium passing through the opening portion 13 a of an upstream baffle plate 21 a passes through the opening portion 13 a of the adjacent downstream baffle plate 21 b , it is hindered from flowing by the baffle plate 21 b and cannot pass through the opening portion 13 a whereby this part of the cooling medium is guided by the baffle plate 21 b and flows into the cooling medium flow path R.
[0084] As described above, by arranging the opening portions 13 a provided in the adjacent baffle plates so that they do not overlap, relatively much cooling medium is distributed to the cooling medium flow portion 11 positioned on the upstream side of the cooling medium flow portion 11 where the cooling medium was apt to remain. As the result, uniform heat exchange can be carried out by every one of the plurality of cooling flow portions, and the heat exchangeability of the heat exchanger is enhanced.
[0085] Incidentally, the number of opening portions 13 a formed on the baffle plate 21 is not limited. For example, as shown in FIG. 20 a plurality of opening portions 13 a having different sizes may be provided in the baffle plate 21 .
[0086] Additionally, for example as shown in FIG. 21 the opening portion 13 a of a baffle plate 22 positioned downstream in the flow direction of the cooling medium may be made smaller than that upstream. In this case, when, for example, a part of a cooling medium passing through the opening portion 13 a of the upstream baffle plate 22 a passes through the opening portion 13 a of the adjacent downstream baffle plate 22 b , it is hindered from flowing by the baffle plate 22 b and cannot pass through the opening portion 13 a , whereby this part of the cooling medium is guided by the baffle plate 22 b and flows into the cooling medium flow path R. Therefore, even when the opening portion 13 a of a downstream baffle plate 22 in the flow direction of the cooling medium is made smaller than that on the upstream side, relatively much cooling medium is distributed to the cooling medium flow portion 11 positioned upstream of the cooling medium flow portion 11 where a cooling medium was apt to remain. As the result, uniform heat exchange can be carried out in every one of the plurality of cooling flow portions and the heat exchangeability of the heat exchanger is enhanced.
EXAMPLE 7
[0087] The sixth example of a heat exchanger according to the present invention will be described with reference to FIGS. 22 to 24 A, 24 B.
[0088] A cooling medium flow portion is formed by laminating substantially rectangular flat plates 13 and 14 to braze them. The actual production of the heat exchanger is not performed by laminating a plurality of brazed cooling medium flow portions and again brazing them to join them, but by arranging brazing material-clad flat plates 13 and 14 , and a cooling fin 12 in this order to laminate them, assembling them and other parts and placing the assembly in a heating oven (not shown) to heat and braze the respective portions.
[0089] In this case the important point is registering the flat plates 13 and 14 . However, in the heat exchanger of the present example a plurality of spaced positions of outer peripheral portions to be brazed in flat plates 13 and 14 are provided with register (positioning) portions 23 as shown in FIGS. 22 and 23. The register portion 23 is composed of a protrusion portion 24 formed in the flat plate 14 and a concave portion 25 formed in the flat plate 13 to be fitted to the protrusion portion 24 in a state where the flat plates 13 and 14 are laminated as shown in FIGS. 24A and 24B. Both protrusion portion 24 and concave portion 25 are formed when the flat plates 13 and 14 are subjected to drawing.
[0090] In this heat exchanger, by laminating the flat plates 13 and 14 thereby to fit the protrusion portion 24 to the concave portion 25 the registering of both the flat plates 13 and 14 can be performed. That is, when this register portions 23 are used, the conventional step of closing a claw is omitted and the material which is required for forming the claw is not needed. As a result, a reduction of assembly time and production costs can be made.
[0091] Further, since a plurality of register portions 23 is provided at the outer peripheral portions of the flat plates 13 and 14 to be brazed, the accuracy of registering is enhanced and production errors in the heat exchanger are kept at a lower level.
[0092] Additionally, since the protrusion portion 24 and the concave portion 25 are formed by drawing the flat plates 13 and 14 , no excess material is needed and no excess steps for working them needed. Therefore, even if the register portions 23 are provided no excess production cost is required.
[0093] Incidentally, in the present example the protrusion portion 24 and the concave portion 25 are respectively formed in the flat plates 14 and 13 . However, the protrusion portion 24 and the concave portion 25 can be respectively formed in the flat plates 13 and 14 . Alternatively, both protrusion portion 24 and concave portion 25 may be formed in the flat plate 13 or the flat plate 14 so that the flat plates 13 and 14 are laminated to fit to each other.
[0094] Further, in the present example the register portion 23 was formed by combining the protrusion portion 24 with the concave portion 25 . Of course, the same effects can also be obtained by use of for example a hole instead of the concave portion 25 . In this case if this hole is formed in the step of removing the flat plate 14 from a mold, no excess production cost is required.
[0095] Incidentally, in Examples 3 to 7 the respective bulged portions 18 diagonally adjacent to each other with respect to the flow direction of the cooling medium are arranged in a zigzag pattern as in Example 2 so that parts of the bulged portions overlap along the flow direction of the cooling medium and the respective cylindrical portions 19 are arranged accordingly.
[0096] Therefore, in Examples 3 to 7, in the cylindrical portions 19 which are diagonally adjacent to each other with respect to the flow direction of the cooling medium, the front end portion of a cylindrical portion 19 which is downstream of the rear end portion of an upstream cylindrical portion, becomes the upstream side of the flow direction. Accordingly, the local thermal conductivity which tends to be reduced at the rear end portion of the cylindrical portion 19 which is positioned upstream is compensated by the cylindrical portion 19 which is positioned downstream. As a result, the thermal conductivity of the entire cooling medium flow portion 11 is enhanced.
[0097] Additionally, the cylindrical portions 19 are regularly arranged along the flow direction of the cooling medium, and the joint portion of the top portions 18 a can be widely ensured. Thus, the joint strength of the cooling medium flow portion can be enhanced. Therefore, even if the flat plates 13 and 14 are thin, sufficient pressure resistance is imparted to the cooling flow portion 11 .
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The present invention relates to a heat exchanger in which a plate-shaped cooling medium flow portion ( 11 ) provides an internal cooling medium flow path inside by laminating two flat plates ( 13, 14 ) subjected to drawing and a cooling fin are alternately laminated, a cooling medium inlet ( 15 ) for allowing a cooling medium to flow into the cooling medium flow path and a cooling medium outlet ( 16 ) for allowing the cooling medium passing through the cooling medium flow path to flow out are formed in said two flat plates, and the cooling medium flowing from the cooling medium inlet to the cooling medium flow path is passed through said cooling medium flow path and is then allowed to flow out of the cooling medium outlet. According to the present invention, a bulged portion ( 18 ) protruding on the cooling medium flow path side is formed in the cooling medium flow portion by denting at least any one of these two flat plates from the outside, and a plurality of elliptical or oval cylindrical portions whose major diameter is oriented in the flow direction of the cooling medium are provided between these two flat plates by butting the top portion of this bulged portion to the opposite flat plate. Additionally, the number of the cylindrical portions is gradually decreased as the cooling medium flows downstream in the flow direction of the cooling medium.
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TECHNICAL FIELD
[0001] The present invention relates to a method for manufacturing a SiC single crystal by a solution method.
BACKGROUND ART
[0002] Methods for manufacturing SiC single crystals by solution methods, which are typically top seeded solution growth (TSSG) methods, maintain a temperature gradient in which the temperature falls from the lower section to the upper section in a Si solution in a graphite crucible, from the interior toward the solution surface. The C that has dissolved from the graphite crucible into the Si solution at the high temperature section at the bottom, primarily rides the convection current of the solution and rises, reaching the low temperature section near the solution surface and becoming supersaturated. By holding a SiC seed crystal at the tip of a support rod (graphite) and contacting the solution with the bottom side of the seed crystal as a crystal growth plane, a SiC single crystal grows from the supersaturated solution, on the crystal growth plane of the seed crystal.
[0003] For production of a SiC single crystal as a practical material, it is necessary to increase the growth rate to improve production efficiency. Increasing the growth rate requires a higher degree of supersaturation D of the solute, but if the degree of supersaturation D exceeds a certain fixed value Dc the growth boundary becomes “a roughened surface” and it becomes impossible to maintain flat growth for continuous uniform single crystal growth.
[0004] PTL 1, in particular, discloses that for growth of a single crystal semiconductor by a Czochralski crystal growth process, it is necessary to delay the growth rate to the target diameter via the diameter-enlarging process by tapered growth from the seed crystal.
[0005] Also, PTLs 2 and 3 disclose that periodically varying the lifting speed when a Si single crystal is grown from a Si molten liquid increases the production efficiency (PTL 1) or results in a uniform oxygen concentration in the plane (PTL 2), causing growth of a Si single crystal.
[0006] However, these all involve growth from a Si “molten liquid”, and merely utilize the fact that the molten liquid surface temperature is the melting point and that a Si single crystal grows by simply raising it to that height or greater, whereas they cannot be applied to methods in which a SiC single crystal grows by “supersaturation” of C from a Si—C “solution”.
[0007] Consequently, it has been desired to develop a method of growing a SiC single crystal by a solution method, in which it is possible to maintain flat growth that allows continuous uniform single crystal growth, while also improving the growth rate necessary for realizing high productivity.
CITATION LIST
Patent Literature
[0000]
[PTL 1] Japanese Unexamined Patent Publication No. 2003-512282
[PTL 2] Japanese Unexamined Patent Publication HEI No. 6-271388
[PTL 3] Japanese Unexamined Patent Publication HEI No. 6-316483
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0011] It is an object of the present invention to provide a method for manufacturing a SiC single crystal wherein, for growth of a SiC single crystal by a solution method, it is possible to maintain flat growth that allows continuous uniform single crystal growth, while also achieving an improvement in growth rate necessary for realizing high productivity.
Means for Solving the Problems
[0012] In order to achieve the object stated above, the present invention provides a method for manufacturing a SiC single crystal in which a SiC single crystal is grown from a Si solution of C in a crucible, employing alternate repetition between a high supersaturation growth period in which growth is allowed to progress while keeping the degree of supersaturation of C in the Si solution at the growth boundary between the growing SiC single crystal and the Si solution higher than a maximum critical value at which flat growth can be maintained, and a low supersaturation growth period in which growth is allowed to progress while keeping the degree of supersaturation lower than the critical value. A solution having a Si molten liquid as the solvent and C as the solute is referred to as a Si solution of C. The Si solution may contain Cr, Ni or the like in addition to C as the solute.
Effect of the Invention
[0013] In the present invention, a high growth rate is obtained in a growth section with a high degree of supersaturation while simultaneously generating a rough growth boundary, and the growth rate is reduced in a growth section with a low degree of supersaturation, but the rough growth boundary recovers and is flattened. Thus, according to the present invention, it is possible to achieve uniform single crystal growth at a higher growth rate than when growth is progressed while maintaining a lower degree of supersaturation than a critical value, as seen across all growth sections of the SiC single crystal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 shows (1) a method of periodically varying the degree of supersaturation with respect to a critical value and (2) the principle by which this method achieves a high growth rate while maintaining flat growth, according to the invention.
[0015] FIG. 2 shows the state near the growth boundary during single crystal growth by a solution method.
[0016] FIG. 3 is a pair of photographs showing (1) the end face of a SiC single crystal grown while maintaining a meniscus height below or equal to the critical value (upper limit), and (2) the end face of a SiC single crystal grown while maintaining a meniscus height above the critical value, in the preliminary experiment of Example 1.
[0017] FIG. 4 is a set of graphs showing three different variation patterns for the meniscus height used in Example 1.
[0018] FIG. 5 is a set of photographs showing the end faces of SiC single crystals grown by each of the variation patterns of FIG. 4 .
[0019] FIG. 6 is a pair of photographs showing (1) the end face of a SiC single crystal grown while maintaining a temperature gradient at the critical value (upper limit), and (2) the end face of a SiC single crystal grown while maintaining a temperature gradient above the critical value, in the preliminary experiment of Example 2.
[0020] FIG. 7 is a graph showing a variation pattern for the temperature gradient used in Example 2.
[0021] FIG. 8 is a photograph showing the end face of a SiC single crystal grown by the variation pattern of FIG. 7 .
[0022] FIG. 9 is a pair of photographs showing (1) the end face of a SiC single crystal grown while maintaining a meniscus height below or equal to the critical value (upper limit), and (2) the end face of a SiC single crystal grown while maintaining a meniscus height above the critical value, in the preliminary experiment of Example 3.
[0023] FIG. 10 is a pair of graphs showing two different variation patterns for the meniscus height used in Example 3.
[0024] FIG. 11 is a pair of photographs showing the end faces of SiC single crystals grown by each of the variation patterns of FIG. 10 .
DESCRIPTION OF EMBODIMENTS
[0025] Generally in crystal growth from a solution, the degree of supersaturation is a driving force for growth, and therefore increasing the degree of supersaturation can increase the growth rate.
[0026] On the other hand, the degree of supersaturation also strongly affects the condition of the growth boundary. With a degree of supersaturation that is in a range below or equal to a certain critical value, facet growth is continuous and a flat growth boundary is maintained. If the degree of supersaturation exceeds the critical value, however, two-dimensional critical nuclei are generated and roughness is produced at the growth boundary as growth proceeds. When growth proceeds in this manner, defects (such as solvent uptake) are generated due to the roughness of the growth boundary.
[0027] The present invention solves this problem of the prior art.
[0028] The principle of the invention will now be illustrated with reference to FIG. 1 .
[0029] As shown in FIG. 1 ( 1 ), according to the invention the degree of supersaturation D is repeatedly alternated between a high supersaturation growth period A that is higher and a low supersaturation growth period B that is lower, than the critical value (critical degree of supersaturation) Dc.
[0030] As shown in FIG. 1 ( 2 )< 1 >, the growth rate is rapid with growth under the high degree of supersaturation D>Dc, but roughness of the growth boundary increases and defects are generated in the grown crystal. In contrast, as shown in FIG. 1 ( 2 )< 2 >, with growth under the low degree of supersaturation D<Dc, facet growth is continuous and a flat growth boundary is maintained, ensuring uniform single crystal growth, but the slow growth rate and consequent high cost are obstacles to its utility.
[0031] The present inventors have completed this invention upon newly discovering that, as regards the relationship between the degree of supersaturation D and its critical value Dc, the rough, growth boundary can be restored to flat, even with growth with a high degree of supersaturation D>Dc, if it is switched to a low degree of supersaturation D<Dc during growth.
[0032] That is, as shown in FIG. 1 ( 1 ), by repeatedly alternating a high supersaturation growth period A where D>Dc and a low supersaturation growth period B where D<Dc, it is possible to achieve growth at a higher growth rate, compared to conventional growth methods where growth is maintained with a low degree of supersaturation at D<Dc, without generating defects due to roughness of the growth boundary.
[0033] The present invention will now be explained in greater detail by examples.
EXAMPLES
[0034] For Examples 1, 2 and 3 below, there was used a Si solution having a composition of Si/Cr/Ni=54 at %/40 at %/6 at % as the amount charged into the graphite crucible, and including C dissolved from the graphite crucible.
Example 1
Variation in Degree of Supersaturation Due to Variation in Meniscus Height
[0035] FIG. 2 shows the state near the growth boundary during single crystal growth by a solution method.
[0036] A seed crystal was held at the bottom edge of a graphite support shaft, and after contacting the seed crystal with the surface of the Si solution inside the crucible (not shown) and slightly raising it, a meniscus was formed by surface tension of the Si solution between the seed crystal and the Si solution surface. FIG. 2 shows a point of time when a SiC single crystal is growing on the bottom side of the seed crystal, and a meniscus is formed between the SiC single crystal growth boundary and the Si solution. The meniscus height is the height of the SiC single crystal growth boundary that has grown on the bottom side of the seed crystal, from the surface of the Si solution inside the crucible.
[0037] An increasing meniscus height corresponds to increased heat release from the meniscus and a lower solution temperature within the meniscus, which results in a higher degree of supersaturation of C directly under the growth boundary. The increased degree of supersaturation increases the growth rate, and if it exceeds a critical value flat growth can no longer be maintained.
[0038] First, as a preliminary experiment, growth was carried out with the meniscus height kept at different constant values.
[0039] Table 1 shows the change in growth rate with respect to the change in meniscus height, with success and failure of flat growth indicated as “Good” or “Poor”. The Si solution has a surface temperature of 1996° C., an internal temperature of 2011° C. at a depth of 1 cm from the surface, and a temperature gradient of 15° C./cm.
[0000]
TABLE 1
Meniscus height (mm)
0.5
1.0
1.5
2.0
2.5
Growth rate (mm/hr)
0.26
0.30
0.37
0.62
1.0
Flat growth
Good
Good
Good
Poor
Poor
[0040] As shown in Table 1, growth was carried out with the meniscus height kept at five levels from 0.5 to 2.5 mm. As a result, with increasing meniscus height the growth rate increased from 0.26 mm/hr to 1.0 mm/hr. Flat growth was maintained (“Good” in the table) with a meniscus height from 0.5 mm to 1.5 mm, but flat growth could not be maintained (“Poor” in the table) with a meniscus height of 2.0 mm or greater.
[0041] FIG. 3 shows photographs of the end faces of grown crystals obtained thereby.
[0042] FIG. 3 ( 1 ) is a case where the meniscus height was 1.0 mm and flat growth was maintained, and a smooth end face was obtained. The solution adhering section in the photograph is the trace of solution adhering to the end face when lifting from the solution surface after growth, and is unrelated to the success of crystal growth.
[0043] In contrast, FIG. 3 ( 2 ) shows that flat growth could not be maintained with a meniscus height of 2.0 mm, there was severe roughness of the growth boundary, and a large amount of solution was adhering upon lifting.
[0044] Based on the results of this preliminary experiment, the upper limit, i.e. critical value for the meniscus height allowing flat growth to be maintained, was set at 1.5 mm.
[0045] Next, growth was carried out while varying the meniscus height above and below the critical value in order to change the degree of supersaturation. The three different variation patterns shown in FIG. 4 were used. As shown here, it repeatedly alternated between a growth period A with a high degree of supersaturation D>Dc and a growth period B with a low degree of supersaturation D<Dc.
[0046] In the variation pattern shown in FIG. 4 ( 1 ), the value Sb, which is the difference between the low meniscus height of 1.0 mm during the low supersaturation growth period B and the critical height of 1.5 mm, integrated over the growth period B, is ½ of the value Sa, which is the difference between the high meniscus height of 2.5 mm in the high supersaturation growth period A and the critical height of 1.5 mm, integrated over the growth period A, or in other words, Sb=0.5Sa.
[0047] In the variation pattern of FIG. 4 ( 2 ), the integrated value Sa for the high supersaturation growth period A and the integrated value Sb for the low supersaturation growth period B are equal, or in other words, Sb=Sa.
[0048] In the variation pattern of FIG. 4 ( 3 ), the integrated value Sb for the low supersaturation growth period B is 1.5 times the integrated value Sa for the high supersaturation growth period A, or in other words, Sb=1.5Sa.
[0049] FIG. 5 is a set of photographs showing the end faces of SiC single crystals grown by each of the three different variation patterns.
[0050] FIG. 5 ( 1 ) shows the state of the end face obtained by the variation pattern of FIG. 4 ( 1 ), in which the growth rate was 0.57 mm/hr, but roughness of the growth boundary was severe and a large amount of solution was adhering.
[0051] FIG. 5 ( 2 ) shows the state of the end face obtained by the variation pattern of FIG. 4 ( 2 ), in which the growth rate was 0.51 mm/hr, but roughness of the growth boundary was severe and a large amount of solution was adhering.
[0052] FIG. 5 ( 3 ) shows the state of the end face obtained by the variation pattern of FIG. 4 ( 3 ), in which a growth rate of 0.52 mm/hr was obtained, the end face was smooth and flat growth was achieved. The growth rate was significantly improved compared to the growth rate of 0.37 mm/hr obtained with a critical meniscus height of 1.5 mm in which flat growth was obtained in the preliminary experiment.
[0053] Thus, according to the invention it is possible to significantly increase the growth rate while ensuring flat growth, by periodically varying the meniscus height with respect to the critical height, whereby the degree of supersaturation D of C at the growth boundary with respect to the critical value Dc is also periodically varied, and appropriately selecting the ratio of the integrated values Sa and Sb for the differences in the high supersaturation growth period A and the low supersaturation growth period B.
[0054] In this example, it is judged that it is possible to increase the growth rate while maintaining flat growth, in a range in which the relationship for the integrated differences is Sb≧1.5Sa. However, a larger Sb value will presumably slow the growth rate.
Example 2
Variation in Degree of Supersaturation Due to Variation in Internal Temperature Gradient of Solution
[0055] The temperature gradient in the Si solution was controlled by a two-stage high-frequency induction coil for crucible heating. A higher temperature gradient increases the degree of supersaturation directly under the growth boundary. The growth rate also increases concomitantly, but if the critical value is exceeded it is no longer possible to maintain flat growth.
[0056] First, as a preliminary experiment, growth was carried out with the temperature gradient kept at different constant values. The temperature gradient was defined as the difference between the surface temperature of the Si solution and the internal temperature at a depth of 1 cm from the surface.
[0057] Table 2 shows the change in growth rate with respect to the change in temperature gradient, with success and failure of flat growth indicated as “Good” or “Poor”. The surface temperature of the Si solution was as shown in Table 2, with the meniscus height at a fixed value of 1 mm.
[0000]
TABLE 2
Solution surface temperature (° C.)
1996
2008
2001
Temperature gradient (° C./cm)
15
30
40
Growth rate (mm/hr)
0.30
0.39
0.85
Flat growth
Good
Good
Poor
[0058] As shown in Table 2, growth was carried out while maintaining three levels for the temperature gradient in the Si solution: 15, 30 and 40° C./cm. As a result, the growth rate increased to 0.30, 0.39 and 0.85 mm/hr in response to the increase in temperature gradient. While flat growth was maintained with a temperature gradient in the range of 15° C. to 30° C./cm (“Good” in the table), flat growth could not be maintained when the temperature gradient increased to 40° C./cm (“Poor” in the table).
[0059] FIG. 6 shows photographs of the end faces of grown crystals obtained thereby.
[0060] FIG. 6 ( 1 ) is a case where the temperature gradient was 30° C./cm and flat growth was maintained, and a smooth end face was obtained.
[0061] In contrast, FIG. 6 ( 2 ) is a case where flat growth could not be maintained with a temperature gradient of 40° C./cm, there was severe roughness of the growth boundary, and a large amount of solution was adhering upon lifting.
[0062] Based on the results of this preliminary experiment, the upper limit, i.e. critical value for the temperature gradient allowing flat growth to be maintained was set at 30° C./cm.
[0063] Next, growth was carried out while varying the temperature gradient above and below the critical value in order to change the degree of supersaturation. The variation pattern was such that, based on the results of Example 1 and as shown in FIG. 7 , the integrated value Sb for the differences between the low temperature gradient of 15° C./cm in the low supersaturation growth period B and the critical value of 30° C./cm was 1.5 times the integrated value Sa for the difference between the high temperature gradient of 40° C./cm in the high supersaturation growth period A and the critical value of 30° C./cm, i.e. Sb=1.5Sa. Because of the long time required for variation compared to the pattern of Example 1, the variation in the temperature gradient had a stronger degree of curvature at the boundary, as shown in FIG. 7 .
[0064] FIG. 8 is a photograph showing the end face of a SiC single crystal grown by this variation pattern. As shown in the photograph, the end face was smooth and flat growth was achieved. Furthermore, the growth rate was 0.48 mm/hr, which was significantly improved compared to the growth rate of 0.39 mm/hr obtained with a critical temperature gradient of 30° C./cm in which flat growth was obtained in the preliminary experiment.
[0065] Thus, according to the invention it is possible to significantly increase the growth rate while ensuring flat growth, by periodically varying the temperature gradient with respect to the critical value, whereby the degree of supersaturation D of C at the growth boundary with respect to the critical value Dc is also periodically varied, and appropriately selecting the ratio of the integrated values Sa and Sb for the differences in the high supersaturation growth period A and the low supersaturation growth period B.
[0066] In this example, it is judged that it is possible to increase the growth rate while maintaining flat growth, in a range in which the relationship for the integrated differences is Sb≧1.5Sa. However, a larger Sb value will presumably slow the growth rate.
Example 3
Effect of Temperature Gradient in Vertical Direction of Support Shaft
[0067] For this example, the effect of the temperature gradient (ΔX) in the vertical direction of the support shaft was examined. A greater value for ΔX results in greater heat loss from the support shaft, a higher degree of supersaturation and a larger growth rate.
[0068] Specifically, ΔX=80° C./cm in Examples 1 and 2. In this example, the value was larger, i.e., ΔX=85° C./cm, and the degree of supersaturation was varied by varying the meniscus height as in Example 1. The value of ΔX is the mean temperature gradient from the seed crystal to 20 cm above on the support shaft.
[0069] First, as a preliminary experiment, growth was carried out with the meniscus height kept at different constant values.
[0070] Table 3 shows the change in growth rate with respect to the change in meniscus height, with success and failure of flat growth indicated as “Good” or “Poor”. The Si solution has a surface temperature of 1996° C., an internal temperature of 2011° C. at a depth of 1 cm from the surface, and a temperature gradient of 15° C./cm.
[0000]
TABLE 3
Meniscus height (mm)
1.0
1.3
1.5
2.0
Growth rate (mm/hr)
0.56
0.60
0.77
1.0
Flat growth
Good
Good
Poor
Poor
[0071] As shown in Table 3, growth was carried out with the meniscus height kept at four levels from 1.0 to 2.0 mm. As a result, with increasing meniscus height the growth rate increased from 0.56 mm/hr to 1.0 mm/hr.
[0072] In this example, heat loss from the support shaft resulted in a higher growth rate compared to the growth rate of 0.30 to 0.62 mm/hr with the same meniscus height range of 1.0 to 2.0 mm as in Example 1.
[0073] Flat growth was maintained (“Good” in the table) with a meniscus height from 1.0 mm to 1.3 mm, but flat growth could not be maintained (“Poor” in the table) with a meniscus height of 1.5 mm or greater.
[0074] FIG. 9 shows photographs of the end faces of grown crystals obtained thereby.
[0075] FIG. 9 ( 1 ) is a case where the meniscus height was 1.0 mm and flat growth was maintained, and a smooth end face was obtained. The solution adhering section in the photograph is the trace of solution adhering to the end face when lifting from the solution surface after growth, and is unrelated to the success of crystal growth.
[0076] In contrast, FIG. 9 ( 2 ) shows that flat growth could not be maintained with a meniscus height of 2.0 mm, there was severe roughness of the growth boundary, and a large amount of solution was adhering upon lifting.
[0077] Based on the results of this preliminary experiment, the upper limit, i.e. critical value for the meniscus height allowing flat growth to be maintained was set at 1.3 mm.
[0078] Next, growth was carried out while varying the meniscus height above and below the critical value in order to change the degree of supersaturation. The two different variation patterns shown in FIG. 10 were used. As shown here, it repeatedly alternated between a growth period A with a high degree of supersaturation D>Dc and a growth period B with a low degree of supersaturation D<Dc.
[0079] In the variation pattern shown in FIG. 10 ( 1 ), the value Sb, which is the difference between the low meniscus height of 1.0 mm during the low supersaturation growth period B and the critical height of 1.5 mm, integrated over the growth period B, is ¼ of the value Sa, which is the difference between the high meniscus height of 2.5 mm in the high supersaturation growth period A and the critical height of 1.3 mm, integrated over the growth period A, or in other words, Sb=0.25Sa.
[0080] In the variation pattern of FIG. 10 ( 2 ), the integrated value Sb for the low supersaturation growth period B is 1.25 times the integrated value Sa for the high supersaturation growth period A, or in other words, Sb=1.25Sa.
[0081] FIG. 11 is a set of photographs showing the end faces of SiC single crystals grown by each of the two different variation patterns.
[0082] FIG. 11 ( 1 ) shows the state of the end face obtained by the variation pattern of FIG. 10 ( 1 ), in which the growth rate was 0.68 mm/hr, but roughness of the growth boundary was severe and a large amount of solution was adhering.
[0083] FIG. 11 ( 2 ) shows the state of the end face obtained by the variation pattern of FIG. 10 ( 2 ), in which a growth rate of 0.72 mm/hr was obtained, the end face was flat and flat growth was achieved. The growth rate was significantly improved compared to the growth rate of 0.60 mm/hr obtained with a critical meniscus height of 1.3 mm in which flat growth was obtained in the preliminary experiment. In addition, this growth rate was significantly improved with respect to the maximum growth rate of 0.52 mm/hr obtained by variation pattern ( 3 ) in Example 1.
[0084] Thus, according to the invention the temperature gradient in the vertical direction of the support shaft is increased (the heat loss effect from the support shaft is reinforced), thereby resulting in a more notable effect of increase in the rate of flat growth by the variation pattern of the invention. In addition, based on Examples 2 and 3, it is judged that the relationship Sb≧1.25Sa is suitable in order to increase the growth rate while maintaining flat growth.
INDUSTRIAL APPLICABILITY
[0085] According to the invention there is provided a method for manufacturing a SiC single crystal wherein, for growth of a SiC single crystal by a solution method, it is possible to maintain flat growth that allows continuous uniform single crystal growth, while also achieving an improvement in growth rate necessary for realizing high productivity.
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Provided is a SiC single crystal manufacturing method whereby growing speed improvement required to have high productivity can be achieved, while maintaining flat growth in which uniform single crystal growth can be continued at the time of growing a SiC single crystal using a solution method. In this SiC single crystal manufacturing method, a SiC single crystal is grown in a crucible from a Si solution containing C. The SiC single crystal manufacturing method is characterized in alternately repeating: a high supersaturation degree growing period, in which the growth is promoted by maintaining the supersaturation degree of C in the Si solution higher than an upper limit critical value at which flat growth can be maintained, said supersaturation degree being at a growing interface between the Si solution and a SiC single crystal being grown; and a low supersaturation degree growing period, in which the growth is promoted by maintaining the supersaturation degree lower than the critical value.
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BACKGROUND OF THE INVENTION
This invention relates to a digital-to-analog (D/A) converter of the current cell type comprising a plurality of current mirrors and selecting means therefor. More particularly, this invention relates to such a D/A converter formed by taking into consideration the effects of parasitic resistances of conductive lines through which power is supplied to the current mirrors.
FIG. 6A shows, for illustration, the circuit structure of a prior art D/A converter of the current cell type having six current mirrors, or six pairs of transistors Tr0+Tr1, Tr0+Tr2, Tr0+Tr3, Tr0+Tr4, Tr0+Tr5 and Tr0+Tr6, and a decoder (selecting means) 3 for decoding a digital input D and generating and outputting selection signals to the current mirrors. As an analog output A is generated corresponding to the digital input D by totaling output currents from those of the transistors Tr1-Tr6 selected by the selection signals, output currents i1-i6 of the plurality of current mirrors are selected to form the analog output A according to the digital input D.
Explained more in detail, transistor Tr0 is a MOS transistor on the input side of the current mirrors, its drain being connected to a power source line 1, its source being connected to a constant current source 2 for a reference current i0 and its gate being connected to the gates of the transistors Tr1-Tr6. In other words, transistor Tr0 serves as an input transistor for providing a constant reference current.
Transistor Tr1 is a MOS transistor on the output side of one of the current mirrors. Its drain is connected to the power source line 1, and its source, through which mirror current i1 flows, is connected through a switch SW1 to an output line for the analog output A. Transistor Tr2, too, is a MOS transistor on the output side of a current mirror, its drain being connected to the power source line 1 and its source, through which mirror current i2 flows, being connected through another switch SW2 to the output line for the analog output A. The other transistors Tr3-Tr6 may be similarly described, each being a MOS transistor on the output side of a corresponding current mirror, the drain of each being connected to the power source line 1 and the source of each being connected through a corresponding one of switches SW3-SW6 to the output line for the analog output A and having a corresponding mirror current i3, i4, i5 or i6 to flow therethrough. In summary, transistors Tr1-Tr6 are all transistors on the output side, having the same transistor (Tr0) in common on the input side. The aforementioned plurality of pairs of transistors Tr0+Tr1, Tr0+Tr2, Tr0+Tr3, Tr0+Tr4, Tr0+Tr5 and Tr0+Tr6 form a partially overlapping plurality of current mirrors, and their output currents i1-i6 may or may not be included in the analog output A, depending on whether the corresponding switches SW1-SW6 are in the conductive or closed (ON) condition or in the cut-off or open (OFF) condition.
The decoder 3 serves to switch on by simple means a suitable number of the switches SW1-SW6 corresponding to the digital input D while the selection signals to the current mirrors, or their ON and OFF conditions, are controlled. As the value of the digital input D increases from "0" sequentially to "1", "2", "3", "4", "5" and "6", for example, the decoder 3 switches on switches SW1, SW2, SW3, SW4, SW5 and SW6 from OFF to ON positions at each of the corresponding points in time. Similarly, when the value of the digital input D decreases, these switches are switched off from the ON to OFF positions in the reverse order. In other words, the decoder 3 usually selects the output transistors in the order of their proximity to the input transistor Tr0 when the digital input D increases (and in the reverse order when the digital input D decreases).
If each current mirror of such a D/A converter functioned ideally, the currents i1-i6 would be all equal, and the current values i1, i1+i2, i1+i2+i3, . . . , i1+i2+i3+i4+i5+i6 of the analog output A corresponding to the values of digital input D "0", "1", "2", . . . "6" would form a step function curve with equal steps, as shown by two-dot dashed line in FIG. 6B. In the case of a D/A converter of a similar structure with an increased number of current mirrors corresponding to an increased number of bits for the digital input D, the input-output curve would become a straight line with a constant slope, as shown by a two-dot dashed line in FIG. 6C.
In reality, however, the power source line 1 has parasitic resistance and the current which flows therethrough is fairly large. Thus, unless the resistance of the power source line 1 can be reduced to a negligible level, the conversion characteristic of the D/A converter is significantly different from the ideal situation described above.
What is herein referred to as the power source line 1 actually includes not only the line from the power supply terminal of the source voltage Vdd to the transistor Tr0 on the input side but also the first branch line branching therefrom and reaching the first transistor Tr1, the second branch line branching from the first branch line and reaching the second transistor Tr2, and so on to the last branch line branching from the penultimate branch line and reaching the last transistor Tr6. In other words, resistances Ra-Rf and R0-R6 are parasitically distributed among the lead lines as shown in FIG. 6A such that the currents i1-i6 are not all equal but tend to sequentially decrease, or i1>i2>i3>i4>i5>i6. As a result, the input-output characteristic of such a D/A converter is usually a step function curve with unequal steps (as shown by a solid line in FIG. 6B). In the case of such a D/A converter with an increased number of bits for the digital input D, the deviation from the ideal situation becomes greater as the value increases as shown by a solid line in FIG. 6C.
Japanese Patent Publication Tokkai 7-154260 disclosed a method of counteracting such ill effects of parasitic resistances in conductive lines. According to this technology, the power source terminal and each conductive line are duplicated such that the output currents from the individual current mirrors can be uniformized and a layout is made such that the sums of the lengths of the paths will become equal.
This method, however, cannot solve the problem for all cases because there are situations wherein it is difficult to duplicate the power source terminal or the conductive lines. There may also be situations wherein, although such duplication is not impossible to carry out, it is still not desirable to increase the number of power source terminals or the area for the wiring or the layout of the wiring may be difficult. Thus, it is not desirable to resort to such a conventional duplication method just in order to counteract the ill-effects of parasitic resistances of the conductive lines on the conversion characteristic.
For D/A converters to be mounted to an LSI circuit, limitations on the design become severer regarding the number of terminals, the area for the wiring and the layout as a whole because LSI circuits are requires to be miniaturized and highly integrated.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide D/A converters with superior conversion characteristic without necessarily increasing the number of power-supplying points.
A D/A converter embodying this invention, with which the above and other objects can be accomplished, may be characterized not only as comprising one single input transistor and a plurality of output transistors to together form current mirrors and a decoder serving as a selecting means for sequentially selecting these current mirrors in response to a digital input but wherein this single input transistor is centrally located with respect to the output transistors. The purpose of thus centrally disposing the input transistor is to uniformize as much as possible the resistances which are parasitic to conductive lines connecting to the individual current mirrors. Thus, if the single input transistor which is used in common by all these current mirrors is centrally located, the difference between the maximum and minimum distances between this input transistor and the plurality of output transistors is reduced. Since the parasitic resistance of conductive lines between two transistors increases generally proportionally to the distance therebetween, this means that the difference between the maximum and minimum parasitic resistances between the input transistor and the output transistors can also be reduced by centrally disposing the input transistor.
In another aspect of this invention, the decoder, which serves as the selecting means for sequentially selecting the plurality of current mirrors to be switched on or off as the digital input is sequentially increased or decreased, is so programmed as to select alternately an output transistor which is relatively far from the input transistor and another which is relatively near to the input transistor, instead of in the order of their separations from the input transistor. With the decoder thus operated, the curve of conversion characteristic becomes more straight than if the selection were made in the order of distance because relatively large and relatively small mirror currents are alternately selected and added to form the analog output.
If the output transistors are divided into two groups such that those of the output transistors of one of the groups are all connected to a power source line sequentially on one side of a middle point at which the input transistor is connected while those of the output transistors of the other of the groups are all connected to the power source line sequentially on the opposite side, the decoder may be preferably so operated that output transistors of different groups are alternately selected to be switched on or off, as the digital input is sequentially increased or decreased. The conductive lines which connect the input transistor with the output transistors may be in a lattice formation with the single input transistor connected to a central lattice.
With a D/A converter thus structured, ill-effects of the parasitic resistances on the conductive lines connecting the input and output transistors can be minimized and the conversion characteristic can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1A is a circuit diagram of a D/A converter according to a first embodiment of this invention, FIG. 1B is its input-output characteristic, and FIG. 1C is the input-output characteristic when the number of bits for the digital input is increased;
FIG. 2A is a circuit diagram of a D/A converter according to a second embodiment of this invention, FIG. 2B is its input-output characteristic, and FIG. 2C is the input-output characteristic when the number of bits for the digital input is increased;
FIG. 3A is a circuit diagram of a D/A converter according to a third embodiment of this invention, FIG. 3B is its input-output characteristic, and FIG. 3C is the input-output characteristic when the number of bits for the digital input is increased;
FIG. 4A is a circuit diagram of a D/A converter according to a fourth embodiment of this invention, FIG. 4B is its input-output characteristic, and FIG. 4C is the input-output characteristic when the number of bits for the digital input is increased;
FIG. 5 is a circuit diagram of a portion of a D/A converter according to a fifth embodiment of this invention; and
FIG. 6A is a circuit diagram of a prior art D/A converter, FIG. 6B is its input-output characteristic, and FIG. 6C is the conversion characteristic when the number of bits for the digital input is increased.
Throughout herein like and corresponding components are indicated by numerals which are the same or related and may not necessarily be explained repetitiously.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows a D/A converter according to a first embodiment of this invention, which is different from the prior art D/A converter described above with reference to FIG. 6A wherein the input transistor Tr0, as well as the conductive lines from the steady-current source 2 and the power source Vdd which are directly connected thereto, is moved from the left-hand side (with reference to FIG. 6A) of the first transistor Tr1 to a center position of the circuit between the third transistor Tr3 and the fourth transistor Tr4. More generally, the D/A converter according to this embodiment of the invention may be characterized as having the input transistor positioned at the center of a plurality of current mirrors.
As a result, the power source lines 1 to the output transistors Tr1-Tr6 of the current mirrors are divided into a right-hand side, portion and a left-hand side portion with respect to the input transistor Tr0 in common which is at the center. Thus, the parasitic resistances Ra-Rf and R0-R6 distributed over the power source lines 1 are also distributed to the right-hand side and to the left-hand side. The output currents i1-i6 from the transistors Tr1-Tr6 are now related as follows:
i3≅i4>i2≅i5>i1≅i6.
The difference between the largest and the smallest of these currents is only about a half of that in the case of the prior art D/A converter.
FIG. 1B shows (by a solid line) the input-output characteristic of the D/A converter explained above with reference to FIG. 1A, and FIG. 1C shows (by a solid line) a general characteristic curve when the number of bits has been increased. In both FIGS. 1B and 1C, the one-dot dashed line represents the situation where the increase is in equal steps.
As the value of the digital input D to the D/A converter of FIG. 1A increases from "0" sequentially to "1", "2", "3", "4", "5" and "6", the current intensity of the corresponding analog output A changes sequentially as i1, i1+i2, . . . , i1+i2+i3+i4+i5+i6. As shown in FIG. 1B, this step-wise increase is not uniform. Compared to the step function curve with equal steps (shown by a one-dot dashed line in FIG. 1B), the step function curve shown in FIG. 1B by a solid line is lower when the value of the digital input D is low but catches up with the equal-step curve in the middle. It becomes higher thereafter but the two curves match each other once again for the highest input value. The same characteristics are also seen in FIG. 1C when the number of bits of the digital input is increased.
In summary, not only does the characteristic curve match the equal-step (or straight) curve when the digital input D is at a medium value but even the maximum difference becomes about one half Thus, the conversion characteristic of this D/A converter according to this invention is closer to be straight (shown by the one-dot dashed line in FIG. 1C) than that of the prior art D/A converter (shown by a solid line in FIG. 6C and reproduced by a broken line in FIG. 1C). For comparison, the two-dot dashed line of FIG. 6C is also shown in FIG. 1C.
FIG. 2A shows another D/A converter according to a second embodiment of this invention which is similar to the D/A converter described above with reference to FIG. 1A but different therefrom wherein the decoder 3 in the first embodiment is replaced by another decoder 30 adapted to switch on and off the switches SW1-SW6 in a different order. As the value of the digital input D is increased from "0" sequentially to "1", "2", "3", "4", "5" and "6", this decoder 30 switches on the switches SW1-SW6 in the order of SW6, SW3, SW5, SW2, SW4 and SW1 from the OFF position to the ON position at each point in time of the increase in the digital input D. When the value of the digital input D is decreased, the switches SW1-SW6 are switched off from the ON position to the OFF position in the reverse order. In other words, as the value of the digital input D is sequentially increased or decreased, those of the output transistors Tr1-Tr6 closer to the input transistor Tr0 and farther away therefrom are alternately selected to be switched on or off.
Thus, if the value of the digital input D is increased from "0" sequentially to "1", "2", "3", "4", "5" and "6", the corresponding analog output A (or the value of the outputted total current from this D/A converter) changes sequentially as i6, i3+i6, i3+i5+i6, i2+i3+i5+i6, i1+i2+i3+i5+i6 and i1+i2+i3+i4+i5+i6, as shown by a solid line in FIG. 2B. Compared to the curve with equal steps (shown by a one-dot dashed line again in FIG. 2B), each step of the solid line is alternately above and below by only a slight difference. If the number of the current mirrors is increased according to an increase in the number of bits of the digital input D, the height difference at each step becomes smaller and the conversion characteristic of the D/A converter becomes nearly straight as shown in FIG. 2C by a solid line. The two-dot dashed lines in FIGS. 2B and 2C are the same as those in FIGS. 6B and 6C, shown for comparison.
FIG. 3A shows still another D/A converter according to a third embodiment of this invention which is similar to the D/A converter according to the first embodiment described above with reference to FIG. 1A but different therefrom wherein the power supply point (at which the source voltage Vdd is applied) is moved to the right-hand end (with reference to FIGS. 1A and 3A), that is, next to the last transistor Tr6. As a result, one half of the branch points of the conductive lines leading to the output transistors Tr1-Tr6 of the plurality of current mirrors (indicated by numerals 40, 41 and 42) are now found on the conductive line connecting the power supply terminal with the input transistor Tr0. As a result, the conductive lines to the transistors Tr4-Tr6 connected to these branch points 40, 41 and 42 are characterized as having a smaller parasitic resistance than that of the conductive line to the input transistor Tr0. Thus, the output currents i4-i6 from these transistors Tr4-Tr6 are increased. If the ideal amplification ratio of the current mirror is n, the following relationship exists among the output currents i1-i6 from the transistors Tr1-Tr6: i1<i2<i3<(i0×n)<i4<i5<i6.
FIG. 3B shows with a solid line the input-output characteristic of this D/A converter and FIG. 3C shows its conversion characteristic when the number of bits for the digital input D is increased. When the digital input D is increased and reaches its maximum value "6", the current intensity i1+i2+i3+i4+i5+i6 for the corresponding analog output A is approximately equal to i0×n×6, or the ideal maximum value at the time of its designing because the decreased in currents i1-i3 and the increases in current i4-i6 cancel each other. The two-dot dashed line of FIG. 3B is the same two-dot dashed line of FIG. 6B, shown for comparison.
With this D/A converter, the analog output is lower when the digital input D is of an intermediate value, as can be seen more clearly by a two-dot chain line in FIG. 3C. If the power supply point at which the source voltage Vdd is applied is moved instead to the left-hand (with reference to FIGS. 1A and 3A), that is, next to the first transistor Tr1 if the order of selection by the decoder 3 is reversed so as to be SW6→SW5→SW4→SW3→SW2→SW1, the conversion characteristic (shown by dotted line in FIG. 3C) is above the two-dot dashed line.
FIG. 4A shows still another D/A converter according to a fourth embodiment of this invention which is similar to the D/A converter according to the third embodiment described above with reference to FIG. 3A but different therefrom wherein the decoder 3 shown in FIG. 3A is replaced by another decoder 31 adapted to switch on and off the switches SW1-SW6 in still another different order. As the value of the digital input D is increased from "0" sequentially to "1", "2", "3", "4", "5" and "6", this decoder 31 switches on the switches SW1-SW6 in the order of SW1, SW6, SW2, SW5, SW3 and SW4 from the OFF position to the ON position at each point in time of the increase in the digital input D. When the value of the digital input D decreases, the switches SW1-SW6 are switched off in the reverse sequence. In other words, as the value of the digital input D is sequentially increased, those of the output transistors Tr1-Tr6 closer to the input transistor Tr0 and farther away therefrom are alternately selected, that is, SW1→SW6→SW2→SW5→SW3→SW4 to be switched on.
Thus, if the value of the digital input D is increased from "0" sequentially to "1", "2", "3", "4", "5" and "6", the corresponding analog output A (or the value of the outputted total current from this D/A converter) changes sequentially as i1, i1+i6, i1+i2+i6, i1+i2+i5+i6, i1+i2+i3+i5+i6 and i1+i2+i3+i4+i5+i6, as shown by a solid line in FIG. 4B. Compared to the "ideal" curve with equal steps as intended at the time of its designing (shown by a two-dot dashed line in FIG. 4B), each step of the solid line is alternately above and below by only a slight difference. If the number of the current mirrors is increased according to an increase in the number of bits of the digital input D, the height difference at each step becomes smaller and the conversion characteristic of the D/A converter becomes a nearly straight line as shown in FIG. 4C, having the intended slope.
In summary, D/A converters according to this invention can be easily designed and structured so as to have a desired conversion characteristic without increasing the area for wiring or the number of power supply points.
FIG. 5 shows still another D/A converter according to a fifth embodiment of this invention, which is different from the D/A converter shown in FIG. 4A firstly in that the input and output transistors are arranged in a matrix formation with 5 rows and 5 lines, secondly in that the, power supply line 1 shown in FIG. 4A is replaced by power supply lines 1 in a lattice formation with each lattice having a corresponding one of the transistors attached thereto, thirdly in that the decoder 31 shown in FIG. 4A is replaced by still another decoder 32, and fourthly in that the power source terminal at which the source voltage Vdd is to be applied is at the top left-hand side (referring to FIG. 5) of the lattice formation. In summary, the conductive lines for this D/A converter for connecting the power supply terminal with the plurality of current mirrors are in a network formation.
The input transistor Tr0 in common for the current mirrors is at line 3, row 3 of the matrix formation, that is, attached to the center lattice of the power lines 1. The other lattice areas each correspond to a different one of the 24 output transistors Tr11-Tr55 (except Tr33) of the current mirrors. Each of the transistors is connected to a conductive line of the corresponding lattice in the same manner. In summary, the input transistor Tr0 is in the middle of a plurality of current mirrors whether seen in the row or line direction of the matrix formation and there are several branch points on the conductive line between the power supply point and the input transistor, each branch point connecting to the output transistor of one of the current mirrors.
The decoder 32 serves to sequentially switch on and off the switches SW11-SW55 (except SW33) as the digital input D increases and decreases, as explained above with reference to other embodiments of this invention but such that the D/A converter will exhibit an ideal conversion characteristic. For this purpose, the sequence of selection is preferably such that if one switch is selected, another switch at least approximately symmetrically opposite therefrom with respect to the center of the matrix formation be selected next (such as SW55→SW11→. . . ). If such a sequence is difficult, the next switch to be selected should be on the opposite side either in the row or line direction alone. If it is difficult to arrange the transistors in a strictly matrix formation as shown in FIG. 5, the distribution of the transistors and the arrangement of the conductive lines need not be exactly in a perfect lattice formation. In such a situation, the sequence of selection by the decoder is determined not necessarily on the basis of geometrical shape or distances but more importantly by considering the effective resistance of the conductive lines between the power source and each of the transistors.
In summary, D/A converters according to this invention are characterized as having conductive lines connecting the power source with the input and output transistors of a plurality of current mirrors arranged such that variations among the output currents from these current mirrors are minimized and that the conversion has improved linear characteristics.
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A D/A converter has one single input transistor used in common with a plurality of output transistors to together form current mirrors, and a decoder serves to sequentially select the current mirrors in response to a digital input, causing to generate a corresponding analog output from currents from selected ones of the current mirrors. The commonly used input transistor is centrally located with respect to the current mirrors such that the difference between the maximum and minimum distances, or that between the maximum and minimum parasitic resistances, between the input transistor used in common and the output transistors is reduced and the conversion characteristic can be improved.
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This application is a continuation of Ser. No. 08/466,240 filed Jun. 6, 1995, now U.S. Pat. No. 5,553,112.
A portion of the disclosure of this patent document contains material subject to copyright protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a measuring apparatus and method for radiosurgery/stereotactic radiotherapy alignment. More particularly, the present invention relates to a method and apparatus for precisely measuring the isocenter of a target volume for a linear accelerator ("Linac") based radiosurgery/stereotactic radiotherapy system, thereby also compensating for or correcting alignment errors during treatment planning, such as errors due to misalignment of room laser alignment systems and couch (or table) or gantry sag, shifts, or misalignments.
2. Description of Related Art
Historically, several Linac based techniques have been used for the delivery of high-energy photon beams as a means for radiosurgery/stereotactic radiotherapy. These various methods have been reviewed by E. B. Podgorsak, Physics for Radiosurgery with Linear Accelerators, in Neurosurgery Clinics of North America, Vol. 3, No. 1, January, 1992. As therein noted, the system of multiple co-planar arcs is by far the most prevalent. These techniques have also varied with regard to the method of stereotactic head fixation during treatment, wherein the aim is to accurately align a target volume (isocenter in the patient's head or body part) within the centers of rotation of the couch/gantry coordinate system of the linear accelerator. The most common methods employed include either fixation of the stereotactic head frame to the radiotherapy couch ("couchmount systems") or fixation to a rigid floorstand mounted in the revolving floor plate of the Linac radiotherapy couch ("floorstand systems"). See, e.g., Podgorsak, supra; U.S. Pat. No. 5,027,818.
In the practice of the art, it is generally accepted that accuracy requirements for delivery of a radiation beam to a target volume isocenter should have fractions of a millimeter of accuracy, and some authors of floorstand systems have reported such accuracy in mechanical localization. In addition, floorstand systems have generally relied upon the use of phantom test targets that are x-rayed as part of the simulation set-up with the Linac for localization. This method of calibration makes use of a phantom test target placed at a given stereotactic coordinate, and then placed at the center of rotation of the Linac couch/gantry system. The Linac is then used to take test target x-rays with the couch and gantry in several different positions of rotation for the purpose of accurately aligning the stereotactic reference system. Couchmount systems are generally not as accurate as floorstand systems and have relied upon fixed room laser lights projected on a phantom carriage device for target localization within the Linac couch/gantry coordinate system. See, e.g., U.S. Pat. Nos. 4,123,143 and 4,223,227.
Although head fixation to a floorstand mounted in the Linac floor turret has historically been regarded by many as the most reliable and accurate method, it greatly limits the accessibility to the patient's head. This is particularly noticeable for lesions in the posterior portions of the head that frequently require that the patient be treated in the prone position when using such floorstand-based systems. In addition, floorstand-based systems require that the gantry of the Linac be specially rigged to protect against the possibility of accidental collision of the gantry with the floorstand during the execution of any treatment plan. Couchmount systems, on the other hand, have the advantage of being able to treat a given patient with the potential of a full 360 degrees of gantry rotation and, thereby, allowing the patient to be treated in a natural supine position, while also avoiding the need for gantry collision protection. See, e.g., Podgorsak, supra; U.S. Pat. No. 5,107,839.
The couchmount systems are desirable for the above-noted reasons; yet they have a significant disadvantage in that patient head fixation and stabilization within the coordinate system of the couch/gantry rotations of the Linac are generally not as accurate as floorstand-based systems. This is due to sagging and/or tilting of the couch which can occur in couchmount systems when weight, as weight of a patient's body, is applied to the couch tabletop after initial alignment. Such positional shifts are a source of error in couchmount systems. Some have attempted to solve this problem by cumbersome methods of bracing the couch tabletop, or the use of fixed, intersecting laser beams arranged as intersecting lines and emitted from laser alignment devices attached to the ceilings and walls of the room in which the Linac is housed for the purpose of referencing the origin of the Linac couch/gantry axes of rotation. U.S. Pat. Nos. 4,223,227 and 4,123,143. Such laser lights are commonly employed in the art of radiation therapy, are also known in the art to frequently shift and require recalibration or alignment, and can introduce yet another source of error in target alignment within the couch/gantry coordinate system. Furthermore, such laser beams are usually 2-3 mm wide and can also reduce the accuracy of alignment because of the thickness of the alignment beams and parallax. This aforementioned method relies on the use of lasers for visual alignment and no method, until the Applicants' invention, has been developed for the use of lasers for precise measurement of distances as a means for target volume localization within the couch/gantry coordinate system of a Linac-based radiosurgery/stereotactic radiotherapy system.
Therefore, a need exists for an apparatus and method for precisely measuring the isocenter of a target volume for a Linac based radiosurgery or stereotactic radiotherapy system, particularly in couchmount systems.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a laser measuring apparatus and method for radiosurgery/stereotactic radiotherapy alignment that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
Additional features and advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the apparatus and method particularly pointed out in the written description and claims of this application, as well as the appended drawings.
To achieve these and other advantages, and in accordance with the purpose of the invention as embodied and broadly described herein, the invention is a method and apparatus for precisely aligning the isocenter(s) of a stereotactic target volume within the centers of rotation of the couch/gantry coordinate system of the Linac by the use of a laser measuring device (laser displacement sensors), having fractions of a millimeter of accuracy, which device is attached to the Linac gantry and emits a laser beam which projects onto and reflects off the surfaces of a precision reference box (or other such reference fixture or surface) for the purpose of precisely measuring and centering isocenters within the couch/gantry coordinate system.
In another aspect, the present invention is a system for aligning a radiosurgery/stereotactic radiotherapy system. The system includes a linear accelerator, including a gantry and a collimator, a couch, and a stereotactic reference system mounted on the couch. The system further includes a laser measuring device mounted on the gantry, the laser measuring device having a laser generator element for generating a laser light beam and a laser displacement sensor. The system also includes a reference fixture, attached to the stereotactic reference system, having at least one reflective surface for reflecting the laser light beam to the laser displacement sensor.
In another aspect, the present invention is a method for aligning a stereotactic system. The system includes a linear accelerator having a gantry, a laser measuring device mounted on the gantry, a stereotactic reference system, a reference fixture affixed to the stereotactic reference system, the stereotactic reference system having a stereotactic coordinate system. The method comprises determining an origin of the stereotactic coordinate system relative to the said laser measuring device; measuring an isocenter of a target structure located within the stereotactic reference system; and adjusting the stereotactic reference system within the reference fixture so that the isocenter is positioned at the origin.
In yet another aspect, the present invention is an apparatus for aligning a stereotactic system, the stereotactic system including a linear accelerator having a gantry, a couch, and a stereotactic reference system mounted on the couch. The apparatus comprises generating means, mounted on for gantry, for generating a laser light beam; reflecting means, attached to the stereotactic reference system, for reflecting the laser light beam; and sensing means, mounted on the gantry, for measuring a distance between the reflecting means and the sensing means.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, to illustrate the embodiments of the invention, and, together with the description, to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates the laser measuring assembly mounted on a Linac gantry.
FIG. 1B illustrates the stereotactic headring with the stereotactic localization box fitted to a patient's head.
FIG. 2 shows a Linac with stereotactic collimators mounted on the gantry and stereotactic headring mounted on the couch.
FIG. 3 is an enlarged view of couch and gantry with laser measurer (laser displacement sensor) mounted on the gantry of the Linac to the left of the collimators.
FIG. 4 is a diagrammatical representation of a laser displacement sensor with digital readout meter for distances measured to 1000ths of a millimeter.
FIG. 5 is a flow chart of laser measuring system for radiosurgery or stereotactic radiotherapy alignment.
FIG. 6 is a diagrammatical representation of determination of zero reference or origin of stereotactic coordinate system within a Linac couch/gantry coordinate system.
FIG. 7 illustrates the determination (measurements) of a stereotactic target position (isocenter) at 5 cm inferior (posterior) and positioned within the Linac couch/gantry coordinate system.
FIG. 8 illustrates the determination (measurements) of a stereotactic target position (isocenter) at 5 cm anterior and positioned within the Linac couch/gantry coordinate system.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
In accordance with the present invention, a laser measuring apparatus and method are provided for aligning a Linac-based radiosurgery/stereotactic radiotherapy system. The laser measuring system for radiosurgery and radiotherapy alignment of the present invention comprises: hardware components that can be used by a neurosurgeon, radiation oncologist, radiation physicist, or technician familiar with the use of Linacs for the performance of radiosurgery/stereotactic radiotherapy; and means for accurately measuring and aligning the isocenter(s) of a treatment volume within a patient's body at the center or origin of axial rotation of the Linac couch/gantry system for the purpose of performing such radiosurgery or radiotherapy.
The invention is particularly useful for the practice of radiosurgery/stereotactic radiotherapy in which a couchmount-type stereotactic frame or reference system is used in the performance of such radiosurgery/stereotactic radiotherapy. The invention is also useful for reducing and/or eliminating errors in stereotactic positioning and localization due to couch or gantry sag, tilt, or rotation by directly measuring the isocenter's position relative to a fixed laser measuring source mounted on the Linac gantry. The method and apparatus of the invention is capable of measurements to within 1000th's of a millimeter.
In the preferred embodiment, the laser measuring system for radiosurgery/stereotactic radiotherapy alignment is initially calibrated by determining the zero reference point or origin of the stereotactic coordinate system (about which a precision localization box is attached) relative to a fixed laser displacement sensor mounted on the Linac gantry. The gantry and couch rotate about a common center that is the origin of the couch/gantry coordinate system. In the art of Linac-based stereotaxy, the stereotactic headring (or other such reference fixtures or surfaces) represents another coordinate system about the head or body part that is adjusted to be aligned within the couch/gantry coordinate system. Target point volumes within the reference coordinate system are, therefore, aligned to be coincident with the Linac coordinate system. The laser displacement sensor is capable of measuring distances in fractions of a millimeter. Such calibration measurements are used in subsequent positioning of a patient's body part, having the attached stereotactic reference system, within the origins of the Linac couch/gantry system for the purpose of performing radiosurgery/stereotactic radiotherapy.
An exemplary embodiment of the laser measuring system for radiosurgery/stereotactic radiotherapy alignment of the present invention is shown in FIGS. 1A, 1B, and 3 and is designated generally by reference numerals 100 and 300. This embodiment can be practiced by practitioners knowledgeable in the art of radiotherapy for the purpose of reducing or eliminating errors due to misalignment of room laser alignment systems and errors due to couch/gantry sag, tilt, and rotation inherent in couchmount radiosurgery/stereotactic radiotherapy systems. The apparatus allows consistent and accurate measurements of stereotactic coordinates and eliminates reliance on intersecting room laser lights for the purpose of aligning stereotactic coordinates.
An exemplary method of the invention is illustrated in FIGS. 5, 6, 7, and 8. Preferably, in this method, laser measurements are performed relative to a precision square or rectangular box placed around the stereotactic reference system to which the patient's head or body part is attached. Alternatively, non-rectangular reference structures or surfaces may be attached or fixed to a patient's body part (for the purpose of performing stereotactic localization of target volumes or isocenters within the patient's body), and the laser beams of the laser measuring device can be reflected off such surfaces at various fixed angular positions of the gantry about the patient's body for the purpose of measuring a given isocenter. One or more laser measuring devices (laser displacement sensors) can be employed in the practice of the invention. The preferred steps for practicing the method of the present invention comprise the major steps of:
A. Initial Calibration--Determining the Zero Reference or Origin of the Stereotactic Coordinate System. In this step, the zero reference point or origin of a stereotactic coordinate system (either frame-based or frameless) is determined relative to one or more fixed laser measuring devices (laser displacement sensors) mounted on the Linac gantry.
B. Adjusting by Laser Measurement the Stereotactic Coordinates of an Isocenter to the Linac Couch/Gantry Origin. In this step, the stereotactic coordinates of other stereotactic points within the stereotactic coordinate system are precisely measured by adjustments relative to the zero reference point or origin as determined by appropriately measured coordinate displacement values in relation to the fixed laser measuring device mounted on the Linac gantry.
Step A above may include the performance of various substeps, including, but not limited or solely confined to:
A1. Positioning on, or affixing to, the couch of the Linac system a stereotactic headframe with attached localization box (or appropriate attached reference fixtures or surfaces);
A2. Using a phantom test target to precisely align the stereotactic center (zero reference point or origin) of the localization box (or appropriate attached reference fixtures or surfaces) for the stereotactic headframe in the center of the couch/gantry coordinate system of the Linac in a manner known in the art. See W. L. Lutz, et al., A System for Stereotactic Radiosurgery with a Linear Accelerator, 14 Int'l J. Radiation Oncology and Biological Physics 373 (1988);
A3. Confirming the origin (zero position) by taking anterior/posterior and lateral x-rays with the Linac and incrementally adjusting the zero position or origin so that it is precisely aligned in the center of the couch/gantry coordinate system in a manner known in the art. See Lutz, et al., supra;
A4. Attaching the laser measuring device (laser displacement sensor) to the gantry of the Linac in a fixed and relocatable position;
A5. Rotating the Linac gantry around the localization box in all three coordinate planes to measure the distance of the sides (surfaces) of the localization box from the laser measuring device when the laser beams of the measuring device are perpendicular to the sides (surfaces) of the localization box (or other such reference fixtures or surfaces). See FIG. 6. Measurements of the isocenter in relation to the top of the localization box would require positioning the couch along the axis of rotation of the gantry;
A6. Recording for future calculations the measured values of the distances of the sides (surfaces) of the localization box from the fixed laser displacement sensor, which position represents the spatial position of the localization box (or other such reference fixtures or surfaces) when it is positioned so that the origin of the stereotactic coordinate system (zero reference or origin) is coincident with the origin or center of the couch/gantry axis of rotation; and
A7. Alternatively, when other reference fixtures or surfaces are used, laser measurements can be made to a non-orthogonal reference fixture or surface by placing the gantry at fixed angles along which the distance from the laser measurer to the reflected surfaces are measured. At least three such angles would be required for localization in this manner.
Step B above may include the performance of various substeps, including, but not limited or solely confined to:
B1. Affixing the stereotactic headframe or appropriate reference fixtures or surfaces to the patient's body part and determining the stereotactic coordinates of a target volume or structure by the use of computer tomographic scanning, MR scanning, angiographic imaging, isotope imaging, as in U.S. Pat. Nos. 5,099,846 and 5,398,684;
B2. Mounting the patient's body part with attached stereotactic reference system to the Linac couch (table);
B3. Using the laser measuring device to adjust the stereotactic frame with the localization box (or other such reference fixtures or surfaces) to the desired stereotactic isocenter coordinates so that such coordinate point (isocenter) is precisely positioned at the origin of the Linac couch/gantry coordinate system. This is achieved by adding and/or subtracting the displacement values relative to the previously measured distances (zero reference or origin) of the sides (surfaces) of the localization box to the fixed laser measuring device. See FIGS. 7 and 8. An alternative method, as noted above, can be used if non-orthogonal angles are employed in the localization.
FIG. 1A illustrates a preferred hardware diagram of the laser measuring assembly 100 mounted on the Linac gantry 110 to which a laser calibration plate 120 with attached laser measurer (laser displacement device) 140 is attached. The laser calibration plate is fitted about the collimator housing 130. The gantry 110 with the collimator housing 130, and the laser measurer 140 can be positioned in relation to a precision stereotactic localization box 160 (or other such reference fixtures or surfaces) that are attached to or positioned on the Linac couch. The laser measurer 140 (laser displacement device) emits a laser beam 150 which reflects off the surface of the laser localization box 160 and returns to the laser displacement sensor, as in FIG. 4, for precisely measuring, in fractions of a millimeter, the distance of the surface of the localization box 160 from the fixed position of the laser measurer 140.
The laser measuring box 160, which is shown in FIG. 1B around a patient's head 170, may be used in conjunction with the stereotactic frame and a phantom device for initial calibration and set-up, as noted in the preferred steps for the practice of the method of the present invention, and illustrated in FIG. 5. The laser measuring box 160 may also be positioned about the patient's head (or body part) 170 for subsequent alignment of the stereotactic reference system within the Linac couch/gantry system, as also noted in the preferred steps for practicing the method of the invention and FIG. 5. The localization box 160 is a precision device preferably having square sides with smooth surfaces for performing accurate laser measurements, and the localization box 160 can be fitted around any stereotactic frame 180 (see FIG. 1B).
With reference to FIG. 2, reference numeral 200 depicts a conventional Linac configured for couchmount-type radiosurgery/stereotactic radiotherapy with a stereotactic collimator 130 mounted on the gantry 110 and a stereotactic headring 230 mounted on the couch 240. As noted above, the gantry 110 and couch 240 rotate about a common center (which is indicated in FIG. 2 by the intersection of Lines T and G) that is the origin of the couch/gantry coordinate system.
A preferred apparatus of the invention is illustrated in FIG. 3 (indicated by reference numeral 300). FIG. 3 shows the Linac couch 240 and gantry 110, depicted in FIG. 2, to which the laser measurer (laser displacement sensor) 140 is mounted on the gantry 110 adjacent to the collimator 130. The stereotactic headring 230 is fitted with the stereotactic localization box 160 and mounted to the end of the Linac couch 240. The laser measuring device 140 is positioned so that it is substantially perpendicular to a surface of the localization box 160 such that a laser beam can be reflected off that surface to measure the distance of that surface from the fixed position of the laser measurer 140. The measured distance is displayed on the digital readout (or other display means) (not shown) of the laser measurer 140, which digital readout may sit atop the couch surface.
The laser measurer (laser displacement sensor) 140 is commercially available and is a part of the preferred apparatus of the invention. The laser measurer 140 is further illustrated in FIG. 4, an exemplary measurer being described in the Keylance Laser Displacement Sensor LB1000 Series Instruction Manual, 1992. The laser measurer 140 may include a small housing 410 having a laser diode that emits a laser beam 420 capable of striking a given surface 430 at incremental distances from its fixed position, so that such laser beams 420 are reflected back to sensors contained within the housing 410. The laser sensors within the housing 410 can proportionately register the voltage output induced on a detector that is struck by the reflected laser beam, and such voltage output is proportional to the spatial distance of the reflected surface 430 from the laser measurer (laser displacement sensor) 140. The measured distance may be displayed in 1000th's of a millimeter on a digital readout meter 440.
FIG. 5 is a flow chart of the preferred method of the invention, and lists the steps employed in the practice of the invention. In the preferred method for use of the laser measuring system, a practitioner of the art of radiosurgery/stereotactic radiotherapy positions a given stereotactic reference system 510, with attached precision localization box 160, on a Linac couch 240, and performs phantom tests 520 to precisely align the zero reference, center, or origin of the stereotactic frame 230 in the center or origin of rotation of the Linac couch/gantry system. Confirmation x-rays 530 of the phantom test targets are incrementally taken 540, 555 after the method described in Lutz, et al., supra, until the origin of the stereotactic coordinate system and the origin of the Linac couch/gantry system are precisely aligned. The laser measuring device 160 is mounted in a fixed position 560 on the Linac gantry 110 and is used to measure 570 the distances of the sides (surfaces) of the localization box 160 from the laser measuring device 140 when the origins of the two coordinate systems, stereotactic reference system and couch/gantry system are aligned.
The gantry 110 is rotated about the localization box 160 and measurements may be taken from all surfaces, including the top of the localization box, requiring that the table (or couch) be rotated to a plane coincident with the gantry axis of rotation for such measurements. The measurement data is recorded (saved) 580 for future measurements and calibration. The stereotactic reference system is thereafter fixed to the patient's head or body part, and appropriate localization studies, such as computer tomographic scans, magnetic resonance scans, angiographic scans, isotope scans or x-rays, are used to stereotactically define a target volume and isocenter 590 within the patient's body in a manner disclosed in U.S. Pat. Nos. 5,099,846; 5,398,684; 5,205,289; and, 5,339,812. The displacement values of the determined isocenter(s) of the target volume in different dimensions is determined in relationship to the origin of the stereotactic reference system in a manner noted in FIGS. 6, 7, and 8. The determined isocenter(s) is positioned within the couch/gantry coordinate system by appropriate measurements 599 in each dimension to align the isocenter(s) at the couch/gantry origin.
FIG. 6 illustrates a use of the method and apparatus of the present invention of Step A above, i.e., "Initial Calibration--Determining the Zero Reference or Origin of the Stereotactic Coordinate System." In the practice and use of the apparatus, the precision localization box 160 may be attached to the stereotactic reference system, which is affixed to the Linac couch 240. The phantom test target 695 is positioned at the origin (for example, as shown at X=0, Y=0, Z=0) of a standard stereotactic frame reference system. X-ray localization and phantom test films are taken with the Linac to confirm that the phantom target "T" 695 at the center of the stereotactic reference system is positioned at the center of rotation of the couch/gantry coordinate system.
Still referring to FIG. 6, the precision localization box 160 has sides 610, 620, 630, 640 that may be square and may have smooth, flat surfaces that can reflect a laser light. As described above, the laser measuring device (laser displacement sensor) 140 is mounted in a fixed position on the Linac gantry 110, and the gantry with the laser measuring device 140 is rotated about the precision localization box 160, so that the measuring device 140 is perpendicular at various angles to the surfaces 610, 620, 630, 640 of the localization box 160. In each position, the meter readings 650, 660, 670, 680 are read to record for future calculations the distance of the sides 610, 620, 630, 640 of the localization box 160 from the laser measuring device 140 when the reference system is calibrated at the origin of the stereotactic coordinate system. FIG. 6 is a diagram of such measurements along the "X" and the "Z" ordinates (also see FIG. 1). In order to obtain a calibration measurement for the "Y" coordinate, (see FIG. 1), the couch 240 is rotated so that it is in the plane of rotation of the gantry 110, and the gantry is aligned so that it is perpendicular to the localization box 160 along the horizontal plane. This would not be required in an embodiment in which multiple laser measuring devices (laser displacement sensors) are attached to various other sites on the gantry.
FIGS. 7 and 8 are diagrams of the use of the method and apparatus of the patent of Step B, "Adjusting by Laser Measurements the Stereotactic Coordinates of an Isocenter to the Linac Couch/Gantry Origin." In the practice and use of the apparatus for the localization measurement of a given target position, the distances (displacement values) of a new target 710, 810 are added or subtracted to the calibration value at a given position of the Linac gantry 110 to the precision localization box 160 in order to determine the new laser measurement for positioning of that target (isocenter) 710, 810 at the center of rotation of the Linac couch/gantry system.
For example, FIG. 7 demonstrates a target position 710 at 5 cm inferior (posterior along the "Z" ordinate). In this example, in order to position the Linac couch/gantry center of rotation at this new target 710, the stereotactic reference box 160 would have to be shifted 5 cm anteriorally. Thus, the meter reading when the gantry is perpendicular to the anterior surface 720 would be the meter reading at zero minus 5 cm 730, and a meter reading of the zero meter reading plus 5 cm 740 when the gantry is positioned perpendicular to the posterior surface of the localization box 160. For this new target, there would be no change in the meter readings from the zero reference 750, 760 when the Linac gantry is positioned perpendicular to either the left 770 or the right 780 side of the localization box 160.
Referring now to FIG. 8, likewise, the same method is practiced when the target 810 is positioned at 5 cm anterior. In this example, in order to position the Linac couch/gantry center of rotation of this new target 810, the stereotactic reference box 160 would have to be shifted 5 cm posteriorally. Thus, the meter reading when the gantry is perpendicular to the anterior surface 820 would be the meter reading at zero plus 5 cm 830, and a meter reading of the zero meter reading minus 5 cm 840 when the gantry is positioned perpendicular to the posterior surface 850 of the localization box 160. For this new target, there would be no change in the meter readings from the zero reference 860, 870 when the Linac gantry is positioned perpendicular to either the left 880 or the right 890 side of the localization box 160. In both examples, FIGS. 7 and 8, the meter readings would be the same as the zero meter readings when measurements are taken along the "Y" ordinate (see FIG. 1).
FIGS. 7 and 8 serve as examples of how laser measurements can be used to precisely locate new stereotactic reference targets (isocenters) within the Linac couch/gantry system. In another embodiment, a similar method can be used with other reference fixtures or surfaces having non-orthogonal surfaces. Additional embodiments can also use multiple laser displacement sensors to measure distances.
It will be apparent to those skilled in the art that various modifications and variations can be made in the apparatus and method of the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention, provided they come within the scope of the appended claims and their equivalents.
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An apparatus and method for aligning a radiosurgery/stereotactic radiotherapy system. The system includes a linear accelerator, including a gantry and a collimator, a couch, and a stereotactic reference system mounted on the couch. The apparatus includes a laser measuring device mounted on the gantry, the laser measuring device having a laser generator element for generating a laser light beam and a laser displacement sensor. The apparatus also includes a reference fixture, attached to the stereotactic reference system, having at least one reflective surface for reflecting the laser light beam to the laser displacement sensor, upon which the laser displacement sensor measures the distance between the reflective surface and the laser measuring device.
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BACKGROUND OF THE INVENTION
The present invention relates to cryostat construction and in particular relates to a low-heat transfer stiff suspension system for supporting a cold inner vessel from a warmer surrounding outer vessel. Aspects of the present invention include the provision of a suspension system for use in the construction of nuclear magnetic resonance (NMR) imaging systems and other systems which contain superconducting coils. The suspension system must allow for substantial thermal contraction and expansion, be capable of withstanding forces experienced in operation and in transportation and minimize heat transfer into the cryostat.
Conventional cryostats for these uses commonly "hang" the cold inner vessel from the outer vessel with long thin elements of low thermal conductivity. Many of these designs require disruption of the cryostat vacuum for the purpose of inserting temporary stiffening supports to protect the magnet and internal components during transportation. Other designs attempt to avoid such disruption by providing low thermal conductive pins which the inner vessel contacts during transportation. Avoiding disruption of the cryostat vacuum is very important since the process of drawing the vacuum and the cool down of an NMR magnet assembly can take approximately one week and require the use of cryogens costing over $10,000.
SUMMARY OF THE INVENTION
The present invention is a low heat transfer suspension system for use in supporting an inner circularly cylindrical vessel from an outer circularly cylindrical vessel which encloses and is essentially concentric with the inner vessel. A truss comprised of material with a low coefficient of thermal conduction is attached at a plurality of positions about an outer circumference of the inner vessel at approximately the midplane of the inner vessel, and attached at a plurality of positions about an inner circumference of the outer vessel such circumference being substantially in a plane which is substantially parallel to but axially offset from midplane of the inner vessel.
DESCRIPTION OF THE FIGURES
FIGS. 1 through 12 are schematic diagrams illustrating the principal steps in the assembly of a preferred embodiment of the suspension system of the present invention.
FIG. 13 is a schematic diagram of three typical support struts of a preferred embodiment showing their general shape and relative location.
FIG. 14 is a schematic diagram of the assembled cryostat particularly illustrating the suspension system with a cutaway showing a portion of the suspension system of a preferred embodiment.
FIG. 15 is an enlarged schematic view of the cutaway portion of FIG. 14 illustrating in greater detail some of the principal features of a preferred embodiment.
FIG. 16A and 16B are the side and front view of a cryostat with cutaway views in FIG. 16A illustrating an embodiment of the present invention.
FIGS. 17 and 18 are enlarged cutaway views of a portion of the preferred embodiment shown in FIGS. 16A and 16B.
DETAILED DESCRIPTION OF THE INVENTION
A preferred embodiment of this invention can be described by reference to FIGS. 1-12 which describe the assembly sequence of a superconducting magnet assembly making use the subject invention. As shown in FIG. 1, a coil 2 of the superconducting magnet is wound on a spool 6 having two end faces 10 and a center support 12. As shown in FIGS. 2 and 3, an inner vessel 9 is formed by welding two halves of the inner vessel outer wall 8 to the end faces 10 and the center support 12 of the spool. Support struts 14 are attached as shown in FIG. 4 to the inner vessel 8 at attachment positions 16 around the circumference of the vessel at the location of the center support. Each attachment position may comprise a single attachment point or two attachment points located close to each other. As shown in FIGS. 4 and 5, a support ring 18 to which an outer vessel 19 will be attached is added and a central ring 20 of a heat radiation shield is added. The heat radiation shield 22 is added as shown in FIGS. 6, 7 and 8 completely encircling the inner vessel. Next, the outer walls 24 of the outer vessel are added as shown in FIGS. 9 and 10 and the inner wall 28 of the outer vessel is added as shown in FIG. 11 completing the assembly of principal elements of the cryostat as shown in FIG. 12.
Detailed description of the support struts are shown in FIG. 13. In the preferred embodiment 50 such struts in the general shape of a "dog bone" are used to support an inner annularly shaped vessel having an outside diameter of about 57 inches from the outer wall of an annularly shaped outer vessel which outer wall has a diameter of about 67 inches. Each support strut 14 contains a bolt hole 26 for attachment to the inner vessel and a bolt hole 28 for attachment to the outer vessel and a smaller bolt hole 30 for attachment of a heat shield mounting bracket. In this preferred embodiment each strut makes an angle of approximately 64 degrees with the adjacent strut. The dog bones are fabricated from 3/4"×1/2" epoxy fiberglass G10. This material is a commercial product available from Spaulding Fibre, Tonawanda, New York 14225.
FIG. 14 shows a complete cryostat assembly with a portion cutaway permitting a viewing of the support struts, and this cutaway view is enlarged in FIG. 15. Shown in the cutaway view are the coil 2, the spool 6, which is also the inside wall of the inner vessel, the outer wall of the inner vessel 8, the central ring 20 of the heat radiation shield 22, the heat radiation shield 22, the support struts 14, a radiation heat shield mounting bracket 32, the outer vessel support ring 18 and the outer and inner walls 24 and 28 of the outer vessel.
The struts may be bolted to the vessels, or a number of other methods well known in the art may be utilized to attach the struts. The precise method of attaching the central ring of the heat radiation shield to the struts is not critical, as several methods well known in the art are available, one method being to first attach an appropriate heat shield mounting bracket to each strut, then to attach the central ring of the heat radiation shield to the brackets.
When this invention is utilized in circumstances requiring high intensity magnetic fields produced by superconductive windings, the space inside the inner vessel not occupied by the coil will be filled with a low temperature coolant such as liquid helium which is allowed to boil at atmospheric pressure. Liquid nitrogen, also boiling at atmospheric pressure, may be used to cool the radiation shield; and specially designed electrical connections are required for energizing the coil. The means for introducing these fluids and maintaining them in the proper quantity, and the means for removing vapor as well as the design of appropriate electrical connections, are well known in the art, are not essential elements of this invention, and are not shown in the drawings.
The support structure described above is equivalent to a continuous skirt of shallow conical shape, girding the waist of the cold mass. The skirt imparts great cross-sectional stiffness to the midplane of the outer vacuum vessel shell (i.e., resistance to buckling deformations). Since both the cold support cylinder and the vacuum tank are very stiff against transverse planar distortion, the outer vacuum vessel shell is constrained to react the support loads as a beam with a large moment of inertia -- i.e., as a monocoque. In the preferred embodiment, the attachment positions on the outer vacuum vessel shell are located on a circumference, the plane of which is offset from the plane of the attachment positions on the inner vessel by a distance which is slightly more than 2 times the difference between the radius of the inside surface of the outer vessel and the radius of the outside surface of the outer wall of the inner vessel. (In a second preferred embodiment described below the offset distance is about 4 times this difference in radius.) Thus, the skirt in this embodiment roughly defines an angle with the axis of the two vessels of about 25 degrees. Each strut has a compressive strength of 8,567 lb. at the cold modulus of 4×10 6 in second mode buckling. This is more than sufficient to handle the expected load. For transportation the cryostat is normally placed in a position such that the axis of the two vessels is in the vertical direction. For the preferred embodiment, the 2g axial plus 40,000 lb. load is only 2,594 lb. per strut and the 6g travel load is only 4,932 lbs. per strut. Loads of 2g for operation and 6g for transportation are typical design requirements for NMR magnets. The heat leak through the support structure at a coil temperature of 4.2k is only approximately 1 W.
Another preferred embodiment is described by reference to FIGS. 16A and B, 17 and 18. In this embodiment inner vessel 40 is supported from outer vessel 42 by truss assembly 44 which is shown through cutaway views X and Y in FIG. 16A and in detail in FIGS. 17 and 18. Truss assembly 44 is attached by rivets 46 to the inner vessel along the outside circumference of the inner vessel which defines a plane 48 containing the center of mass of the inner vessel and by rivets 50 to the outer vessel along an inside circumference which lies in a plane parallel to but axially offset from plane 48. The truss assembly 44 is comprised of truss band 52 with struts 60, an aluminum support ring 54 and aluminum support tabs 56. Truss band 52 is cut from a G10 epoxy fiberglass piece 3/16"×4-1/4" and long enough to encircle the 60-inch diameter inner vessel with about 12" overlap. Truss band 52 is attached to ring 54 and tabs 56 with rivets 58. Slightly longer rivets 58 are used to join the two ends of truss band at the 12-inch overlap portion (not shown). The individual struts 60 of truss band 52 form an angle of 90° with each other and are cut so that either the warp or the woof of the G10 fiberglass is parallel to the center line of each strut as shown at 61 in FIG. 18. This second, preferred embodiment may be used to support an inner thermal shield from an outer thermal shield in an NMR magnet assembly where the inner shield weighs up to approximately 350 pounds. If used to support a heavier vessel, the parts of the truss assembly would have to be appropriately designed for the heavier load.
From the above, it can be seen that the present invention is particularly useful in the construction of cryostats. In particular, it is seen that the present invention is particularly suitable for transport of the cryostat in which full vacuum and coolant conditions are maintained. It is also seen that the present invention is also particularly useful in those applications in which it is desired to construct electromagnets employing superconducting windings. Such windings are disposed about the central core of the cryostat so as to be particularly useful in generating high intensity, relatively uniform magnetic fields along the longitudinal axis of the cryostat bore. In this fashion, the present invention provides a useful device for NMR imaging systems. It is also seen that a cryostat using the present invention eliminates both elastomer seals and nonmetallic bore tubes which are permeable to gasses and can result in long-term contamination of interior vacuum conditions. Accordingly, costly periodic pumping of cryostat vacuum is not required. The present invention avoids conditions which result in shutting down and warming up of the magnet. In addition, the present invention provides a means to greatly facilitate the assembly of a cryostat.
While the invention has been described in detail herein in accord with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A low heat transfer suspension system for supporting from a warmer annularly shaped outer vessel an enclosed cold annularly shaped inner vessel is disclosed. The system comprises a truss comprised of a material with low coefficient of thermal conduction attached at a plurality of positions about an outer circumference of the inner vessel at approximately the midplane of the inner vessel and attached at a plurality of positions about an inner circumference of the outer vessel such circumference being substantially in a plane which is substantially parallel to but axially offset from the midplane of the inner vessel.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 11/220,138, filed on Sep. 6, 2005, which claims the priority benefit of U.S. Provisional Patent Application No. 60/608,136, filed Sep. 8, 2004, each of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is broadly concerned with improved electrical producing creams in forms of creams, lotions, gels or solids which are useful in the treatment of a variety of conditions that are ameliorated by increased cell metabolism, circulation, and nerve function. More particularly, in one embodiment, the invention is concerned with electrical producing creams having a gel base with menthol and camphor, and supplemented with potassium and an oxygen source such as an alkali metal chlorite. In another embodiment, the invention is concerned with electrical producing creams having potassium and an oxygen source such as an alkali metal chlorite, and optionally including one or more active ingredients such as menthol and/or camphor and/or capsicum.
[0004] 2. Description of the Prior Art
[0005] A variety of topically applied creams and lotions have been developed in the past for treatment of conditions such as arthritis and muscle pains. One such product is commercialized under the designation SOMBRA. This product contains 3% menthol and 3% camphor, in a gel base, and is used for the temporary relief of minor aches and pains of muscles and joints associated with simple backaches, arthritis, strains, bruises, and sprains. Another such product is commercialized under the name BioFreeze. This product is also used for the temporary relief of pain, and contains 3.5% menthol and 0.2% camphor, in a gel base. Another such product is commercialized under the designation Icy Hot Extra Strength. This product contains 30% methyl salicylate and 10% menthol.
[0006] However, many prior art creams and lotions do not adequately treat these conditions in most people. Furthermore, even those that are successful do not sustain metabolic activity for extended periods of time, thus making any relief experienced rather temporary. There is a need for new treatments that provide relief for a wide variety of conditions and for extended periods of time.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes these problems by broadly providing novel electrical producing creams having improved metabolic activity through small electrical charges (in mV) in contact with dendrite channels.
[0008] In more detail, the inventive electrical producing creams comprise menthol, camphor, potassium, and a source of oxygen. The menthol and camphor can be individually added to the composition, or they can be added via a base composition including menthol, camphor, and capsicum. One preferred base composition is a gel sold under the name SOMBRA. Regardless of the delivery source, the menthol is preferably present in the electrical producing cream at a level of at least about 0.5% by weight, more preferably from about 2-20% by weight, and even more preferably from about 2-4% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. Furthermore, the camphor is preferably present in the electrical producing cream at a level of at least about 0.5% by weight, more preferably from about 2-20% by weight, and even more preferably from about 2-4% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight.
[0009] The potassium is preferably provided in powder form, and it can be obtained from dietary supplements, for example. One preferred source of potassium is potassium chlorite. More preferably, the potassium chlorite is Potassium Chelate (99 mg potency) sold by Nature's Way. Potassium Chelate is provided in the form of a capsule including powder potassium and minor amounts of ground millet. The capsule can simply be opened, and the powder from the capsule used in the present invention. Potassium is preferably present in the electrical producing cream at a level of at least about 0.02% by weight, more preferably from about 0.04-0.5% by weight, and even more preferably from about 0.09-0.2% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. When Potassium Chelate or a similar product is used, preferably from about 1-20 capsules, more preferably from about 1-15 capsules, and even more preferably from about 8-13 capsules are used.
[0010] The source of oxygen can be any source that is capable of delivering the appropriate levels of oxygen to the electrical producing cream. Suitable oxygen sources include those selected from the group consisting of chlorites (and preferably alkali metal chlorites such sodium chlorite and magnesium chlorite), spirulina, and mixtures of the foregoing. The most preferred oxygen source is sold under the name AEROBIC 07, which contains deionized water, sodium chlorite, carbonates, and bicarbonates.
[0011] The oxygen source is preferably present in the electrical producing cream in sufficient quantities to provide oxygen levels of at least about 0.016% by weight, more preferably from about 0.10-0.85% by weight, and even more preferably from about 0.17-0.25% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. When AEROBIC 07 or a similar product is used, it is preferably added at levels of from about 1-13 drops, more preferably from about 1-10 drops, and even more preferably about 4 drops.
[0012] In one alternative embodiment, the electrical producing cream also includes a source of chlorine ions. If sodium chlorite is used as the source of oxygen, it will also functions as a source of chlorine ions. Other suitable sources of chlorine ions include any chlorite (e.g., sodium hypochlorite) such as those found in commercially available bleaching agents (e.g., CLOROX, CALIBEX). In these embodiments, the source of chlorine is included in sufficient quantities to provide chlorine ion levels of from about 0.10-10% by weight, and more preferably from about 0.16-0.85% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight.
[0013] The inventive electrical producing creams can also include a number of optional ingredients, depending upon the final use. Some suitable ingredients include those selected from the group consisting of aloe vera extract, carbomer, decyl plyglucose, deionized water, grapefruit seed extract, green tea extract, orange peel extract, queen of the prairie extract, rose water, silica, sodium hydroxymethyl glycinate, vegetable glycerin, witch hazel, yucca extract, carbonates, bicarbonates, and mixtures of the foregoing. The preferred quantities of these ingredients are set forth in Table 1. These ingredients can be added individually or in a group as part of another composition (e.g., in a base composition such as SOMBRA).
TABLE 1 MORE PREFERRED INGREDIENT BROAD RANGE A RANGE A Aloe Vera Extract 0.10-50% 0.25-1.75% Capsaicin 0.001-10% 0.25%-1.75% Carbomer 1.35-30% 2.75-19.25% Decyl Plyglucose 0.1-9% 0.5-3.5% Deionized Water 20-90% 76.5-90% Grapefruit Seed Extract 0.001-5% 0.25-1.75% Green Tea Extract 0.05-10% 0.5-3.5% Orange Peel Extract 0.001-5% 0.25-1.75% Queen of the Prairie Extract 0.25-20% 2.25-15.75% Rose Water 0.2-7% 0.5-3.5% Silica 0.03-20% 1-7% Sodium Hydroxymethyl 0.05-25% 1.25-8.75% Glycinate Vegetable Glycerin 0.09-50% 1.75-12.25% Witch Hazel 0.02-15% 1-7% Yucca Extract 0.015-30% 0.5-3.5% Carbonates 0.025-3.5% 0.25-1.75% Bicarbonates 0.025-3.5% 0.25-1.75% A The percentages by weight are based upon the total weight of the topical electrical producing cream taken as 100% by weight.
[0014] The inventive electrical producing creams are formed by simply mixing the above ingredients together, preferably in some type of carrier. If SOMBRA is used, then the carrier is provided by that product.
[0015] In a particularly preferred preparation method, a precursor composition containing the camphor and menthol is provided. The precursor composition should comprise:
from about 1-10% by weight menthol, preferably from about 1-5% menthol, and even more preferably about 3% by weight menthol; and from about 1-10% by weight camphor, preferably from about 1-5% camphor, and even more preferably about 3% by weight camphor, based upon the total weight of the electrical producing cream taken as 100% by weight.
The precursor composition can also include some or all of the optional ingredients discussed above.
[0018] A quantity of the precursor composition is added to a container, along with a portion of the potassium. Further respective quantities of the precursor composition and potassium are then added in alternating steps until the desired quantity as been obtained. The precursor composition and potassium within the container are preferably then mixed until substantially homogeneous (e.g., from about 1-3 minutes, and preferably about 2 minutes). Mixing can be carried out by hand or mechanical mixing means (e.g., mixer, shearing in industrial equipment). The source of oxygen is then added to the resulting mixture and further mixing is carried out. Any optional ingredients that were not already added can then be added to the mixture to yield the final electrical producing cream.
[0019] In another embodiment, the inventive electrical producing creams comprise potassium and a source of oxygen. Potassium is preferably present in the electrical producing cream at a level of from about 0.005% to about 15% by weight, more preferably from about 0.16% to about 7.0% by weight, and even more preferably from about 0.06% to about 0.12% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. The source of oxygen can be any source that is capable of delivering the appropriate levels of oxygen to the electrical producing cream. In a particularly preferred embodiment the oxygen source is an alkali metal chlorite, such as sodium chlorite. The oxygen source is preferably present in the electrical producing cream in sufficient quantities to provide oxygen levels of from about 0.005% to about 15% by weight, more preferably from about 0.016% to about 7.0% by weight, and even more preferably from about 0.01% to about 0.05% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight.
[0020] The electrical producing cream may also optionally include one or more active ingredients selected from the group consisting of analgesics, anesthetics, antipruritics, antihistamines, and counterirritants. More preferably the active ingredients are selected from the group consisting of menthol, camphor, and capsicum. If present, the active ingredient may be individually added to the composition, or the menthol and/or camphor and/or capsicum can be added via a commercially-available base composition including menthol and/or camphor and/or capsicum. Regardless of the delivery source, the camphor, when included, is preferably present in the electrical producing cream at a level of from about 0.005% to about 22.0% by weight, more preferably from about 0.030% to about 11.0% by weight, and even more preferably from about 2.90% to about 3.30% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. The menthol, when included, is preferably present in the electrical producing cream at a level of from about 0.005% to about 20% by weight, more preferably from about 1.250% to about 16.0% by weight, and even more preferably from about 2.80% to about 3.20% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight. The capsicum, when included, is preferably present in the electrical producing cream at a level of from about 0.001% to about 8% by weight, more preferably from about 0.025% to about 0.250% by weight, and even more preferably from about 0.220% to about 0.300% by weight, based upon the total weight of the electrical producing cream taken as 100% by weight.
[0021] As will be appreciated by those in the art, although menthol and/or camphor and/or capsicum are particularly preferred active ingredients, other active ingredients known in the art can be substituted in the electrical producing electrical producing cream. Examples of suitable active ingredients (analgesics, anesthetics, antipruritics, antihistamines, and counterirritants) approved by the FDA and which can be included in the inventive electrical producing cream in amounts in accordance with FDA monographs include, but are not limited to: bensocaine, butamben picrate, dibucaine, dibucaine hydrochloride, dimethisoquin hydrochloride, dyclonine hydrochloride, lidocaine, lidocaine hydrochloride, pramoxine hydrochloride, tetracaine, tetracaine hydrochloride, benzyl alcohol, camphor with phenol, camphorated metacresol, juniper tar, phenol, phenol with camphor, phenolate sodium, resoronol, diphenlydramine hydrochloride, tripelennamine hydrochloride, hydrocortisone, hydrocortisone acetate, allyl isothiocyante, ammonia, methyl salicyate, turpentine oil, histamine dihydrochloride, methyl nicotinate, and capsicum oleoresin. The preferred quantities of additional active ingredients that are particularly preferred substitutes in the inventive electrical producing creams are set forth in Table 2 below.
TABLE 2 MORE MOST BROAD PREFERRED PREFERRED ACTIVE INGREDIENT RANGE A RANGE A RANGE A Allyl Isothiocyanate 0-10% 0.480-5.0% 0.50-0.520% Ammonia 0-5.0% 0.98-2.5% 1.0-1.20% Methyl Salicyate 0-95% 9.8-60.0% 10-10.20% Turpentine Oil 0-95% 5.80-50.0% 6.0-6.20% Histamine 0-0.20% 0.020-0.10% 0.025-0.030% Dihydrochloride Methyl Nicotinate 0-2% 0.240-1.0% 0.250-0.260% Capsicum Oleoresin 0-0.5% 0.025-0.300% 0.220-0.250%
[0022] The inventive electrical producing creams can also include a number of optional ingredients depending upon the final use. Some suitable ingredients include those selected from the group consisting of aloe vera, arnica, bosweila, bromelaine, carbonates and bicarbonates, decyl gluco side, distilled water, deionized water, ginger, glycerine, green tea extract, sodium hydroxymethylglycinate, willow bark, witch hazel, fragrance, thickener, and mixtures of the foregoing. The preferred quantities of these ingredients are set forth in Table 3. These ingredients can be added individually or in a group as part of another composition. In a particularly preferred embodiment, the thickener comprises a carbomer polymer, such as a high molecular weight homo- or copolymer of acrylic acid crosslinked with a polyalkenyl polyether. Preferred thickeners are commercially available under the name Carbopol®, and are available in powder or liquid form. A particularly preferred thickener is Carbopol® Ultrez 20. Other thickeners that may be used in the inventive electrical producing creams include: cetearyl alcohol, cetyl alcohol, and sodium alginate.
TABLE 3 MORE MOST BROAD PREFERRED PREFERRED INGREDIENT RANGE A RANGE A RANGE A Aloe Vera 0.02-89% 0.06-44.95% 0.1-0.9% Arnica 0-20% 0.05-10.3% 0.1-0.6% Bosweila 0-10% 0.003-5.01% 0.005-0.02% Bromelaine 0-10% 0.003-5.01% 0.005-0.02% Carbonates 0.002-10% 0.004-5.01% 0.005-0.02% Bicarbonates 0.002-10% 0.008-5.01% 0.005-0.02% Decyl Glucoside 0.01-10% 0.405-5.55% 0.8-1.1% Distilled/Deionized 0-93% 35-91.5% 70-90% Water Ginger 0-10% 0.003-5.01% 0.005-0.02% Glycerine 0-20% 1.5-13% 3-6% Green Tea extract 0-10% 0.003-5.15% 0.005-0.3% Sodium 0.10-3% 0.45-2% 0.80-1% Hydroxymethyl Glycinate Willow Bark 0-10% 0.003-5.15% 0.005-0.3% Witch Hazel 0-15% 1-9.5% 2-4% Thickener 0-10% 0.2-5.5% 0.4-1% Fragrance 0-20% 0.05-10.2% 0.1-0.4% A The percentages by weight are based upon the total weight of the topical electrical producing cream taken as 100% by weight.
[0023] The inventive electrical producing creams are formed simply by mixing or shaking the above ingredients together (with or without the optional ingredients), preferably in some type of container or carrier.
[0024] The amount of thickener present in the electrical producing cream can be varied and will depend upon the final desired viscosity and consistency of the inventive electrical producing creams. The inventive electrical producing cream can be provided in a variety of final forms selected from the group consisting of cream, lotion, gel, solid stick, and sprayable aqueous formulations.
[0025] The inventive topical electrical producing cream is used to treat a portion of the body (human or animal) afflicted with an ailment by simply contacting the electrical producing cream with the afflicted portion of the body. The electrical producing cream is then preferably rubbed into the skin until it is no longer visible. While the cream is neither an antiseptic nor an antimicrobial, it will be appreciated that the electrical producing cream can be used to treat and/or relieve numerous conditions, including diabetic neuropathy, post hepatic neuralgia, scleroderma, psoriasis, restless legs syndrome, muscle spasms, tremors associated with Parkinson's and other neurological disorders, strain, spasticity, headaches, neuropathy secondary to drugs, peripheral neuropathy, leg pain, muscle cramps, muscle aches and pains, bruise, sinusitis, sprain, arthritis, joint pain (arthralgia), and edema. In particular, the inventive electrical producing creams are useful for reducing swelling and providing relief from all forms of arthritis, acute joint and/or muscle pain, chronic joint and/or muscle pain, neck and back pain, shoulder muscle and joint area pain, muscle spasms, strained muscles, sports injuries, menstrual pain, swollen discomfort breast, pelvic pain. The inventive electrical producing creams can also be used for therapeutic or relaxation massage, as well as a skin firming cream. In one embodiment the electrical producing cream is provided for therapeutic massage and comprises potassium and sodium chlorite, in addition to active ingredients selected from the group consisting of menthol, camphor, and capsicum in amounts that are below the FDA monograph. In another embodiment, the electrical producing cream is provided for relaxation massage and comprises potassium and sodium chlorite. The term antiseptic, as used herein, is intended to mean a substance that inhibits the growth and development of microorganisms. The term antimicrobial, as used herein, is intended to mean a drug or other composition used to fight infections caused by bacteria, fungi, and viruses.
[0026] In addition to alleviating pain, the inventive electrical producing cream offers a particularly significant advantage in that it achieves high metabolic activity and maintains that activity over extended periods of time. “Metabolic activity” as used herein refers to energy (in mV) that is created by the potassium ions in the electrical producing cream. That energy is then transferred to the patient at the electrical producing cream location on the skin. An ion channel is an integral cell membrane protein and controls the small voltage gradient across the plasma membrane of all living cells by allowing the flow of ions down their electrochemical gradient. Voltage-gated channels such as sodium or potassium channels, open and close in response to membrane potential. These channels are common in all cells, but are critical in excitable tissues such as neurons and muscle tissue. Though not wishing to be bound by theory, it is believed that the energy created by the electrical producing cream excites and thus opens the sodium-potassium pumps in the cells. This stimulates the nervous system and better allows active ingredients to enter the cells, over an extended period of time. In particular, based upon results from voltage meter testing, thermal imaging, muscle testing, reflex testing, two point discrimination testing, and nerve conduction testing, the electrical producing cream has been found to activate and reactivate itself through interaction with the body's own metabolic tissues and waste.
[0027] Metabolic activity is determined by mixing 1 g of a electrical producing cream with 0.1 g of a commercially available electrolyte material (e.g., one sold under the name ORAL REHYDRATION SALTS, available from Jianas Bros. Packaging Co.). The mixture is then placed onto an electrogel pad, which is “sandwiched” between two ECG patches connected to a voltmeter. Readings in mV are taken over regular intervals (e.g., 5-minute intervals).
[0028] When using the electrical producing creams of the invention, a peak (i.e., highest or maximum) metabolic activity of at least about 10 mV, preferably at least about 30 mV, more preferably at least about 40 mV, and even more preferably from about 40 to about 70 mV is achieved. This peak is preferably achieved within about 30 minutes, and more preferably within about 15 minutes, of application to the afflicted area.
[0029] The inventive electrical producing creams also possess the property of having a retained metabolic activity of at least about 20%, preferably at least about 30%, and even more preferably from about 50-100% over a 45-minute time period. Furthermore, the inventive electrical producing creams possess the property of having a retained metabolic activity of at least about 5%, preferably at least about 20%, and even more preferably from about 25-100% over an 8-hour time period. As used herein, “retained metabolic activity” is determined as follows:
Retained Metabolic Activity = [ metabolic activity after 45 minutes or 8 hours peak metabolic activity ] × 100
[0030] The inventive electrical producing cream has also been found to improve cell metabolism, circulation, and nerve function, alleviating symptoms from nerve pain associated with shingles, and peripheral neuropathy caused by diabetes, radiation treatment, chemotherapy, or unknown causes. For example, in the case of shingles, the electrical producing cream does not attack the virus itself, but rather increases nerve function to alleviate the symptoms caused by the virus. In addition, the inventive electrical producing cream can also be used to stimulate and increase nerve function where the nerves have been damaged by a disease such as multiple sclerosis or spinal chord injuries, by providing a feedback mechanism by stimulating neurons and dendrites through the small electrical force (mV). Specifically, the metabolic activity of the inventive electrical producing cream creates a small electrical force (mV) that stimulates the dendrites at the ends of neurons.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0032] FIG. 1 a is a graph depicting the metabolic activity of a prior art product over a 45-minute time period;
[0033] FIG. 1 b is a graph depicting the metabolic activity of another prior art product over a 45-minute time period;
[0034] FIG. 1 c is a graph depicting the metabolic activity of the inventive electrical producing cream over a 45-minute time period;
[0035] FIG. 1 d is a graph depicting the metabolic activity of the inventive electrical producing cream over an 8-hour time period;
[0036] FIG. 2 is a graph depicting the metabolic activity of the inventive electrical producing cream compared to two prior art products;
[0037] FIG. 3 a is a thermal image scan from Example 8, taken of Patient D's lower extremities before beginning treatment with the inventive electrical producing cream;
[0038] FIG. 3 b is a thermal image scan from Example 8, taken of Patient D's lower extremities 30 minutes after treatment with the inventive electrical producing cream; and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples
[0039] The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
Example 1
Preparation of Topical Electrical Producing Cream
[0040] A 1-gallon plastic jug was tared on a Sunbeam Model SP5 top balance (no shield, small pan balance). The jug was then charged with 5.7 oz of SOMBRA Natural Pain Relieving Gel (available from Sombra Inc., Albuquerque, N. Mex.).
[0041] Thirteen potassium amino acid chelate capsules (99 mg potassium with millet filler; available from Nature's Way, Springville, Utah) were emptied three at a time. The filled capsule weight was 0.78 g, the emptied powder weight was 0.67 g, and the empty capsule weight was 0.67 g (n=1). The level of elemental potassium in the capsule was not given on the label.
[0042] The powder emptied from the capsules was then added to the SOMBRA in the plastic jug as follows:
[0043] (1) The jug was charged with SOMBRA to a weight of 12.1 oz., and the powder from three empty capsules was added;
[0044] (2) The jug was charged with SOMBRA to a weight of 1 lb. 6.1 oz., and the powder from three empty capsules was added;
[0045] (3) The jug was charged with SOMBRA to a weight of 2 lb. 3.9 oz., and the powder from the remaining empty capsules was added; and
[0046] (4) The jug was charged to a final weight of 3 lb. 1 oz. with SOMBRA.
[0047] A cap was placed on the jug, and the jug was shaken by hand for about 2 minutes to substantially evenly distribute the powder. The gel did not adhere to the plastic jug after the potassium amino acid chelate was added.
[0048] AEROBIC 07 (a dietary supplement including deionized water, sodium chlorite, carbonates, and bicarbonates; available from Aerobic Live, Phoenix, Ariz.) was used as a stabilized source of oxygen. Thirteen drops of the Aerobic 07 were added to the plastic jug containing the SOMBRA-potassium amino acid chelate mixture. The jug was again capped and shaken by hand for about 2 minutes to yield the final electrical producing cream. The final electrical producing cream was more viscous than the SOMBRA gel. When comparing a quantity of each, the compounded electrical producing cream did not separate or flow as compared to the SOMBRA gel, which showed some physical separation.
Example 2
Treatment of Patient A
[0000] 1. Patient History
[0049] The topical electrical producing cream prepared in Example 1 was used to treat a patient (hereinafter referred to as “Patient A”). Patient A was a Caucasian female in her 60s, and she was 5′7″ and approximately 220 lb. Patient A exhibited neuropathy of the legs and feet, with the left leg being worse than the right. Patient A's big toe on her right foot and second toe on her left foot were amputated within the preceding 3 years due to diabetes. She had received angioplasty about 9 months prior, and the angioplasty improved blood flow to her lower extremities.
[0050] Both legs below the knees presented open sores about half-way between the knee caps and ankles. The sores were worse on the right leg than the left. She had used Bactroban and Betadine to treat the topical sores for infection.
[0051] Patient A also had an ulcer on the bottom of her right foot. She had begun a second, 2-3 week treatment course of Regranex, applying at bedtime. Previous use of Regranex had worked, but the ulcer recurred, so she then had surgery. She began to use Etherex, which she stated is a generic medicine for Regranex and Bactroban. Her daily medications are shown in Table A-B.
TABLE A PRESCRIPTION MEDICATION DOSAGE Lisinopril 20/12.5 2 p.o. qd Atenolol 50 mg 1½ p.o. qd Lipitor 40 mg 1 p.o. qd Insulin 40 u of N and 10 u of Humalog in morning; 40 u of N and 10 u of Humalog before dinner Paroxitine (Paxil) 40 mg p.o. qd Levothyroxine 0.3 mg p.o. qd Calcitrol 0.25 μg 1 p.o. bid Niaspan 500 mg 1 p.o. q evening Plavix 75 mg 1 p.o. qd Furosemide 80 mg p.o. 1 daily Diovan 320 mg 1 daily Procrit 1 injection q 2 weeks until no longer needed Dynacirc 5 mg 1 p.o. daily
[0052]
TABLE B
VITAMINS AND
OVER-THE-COUNTER
MEDICATIONS
DOSAGE
Multivitamin
1 p.o. daily
Prilosec
1 p.o. daily
Low-Dose Aspirin
1 every evening
Iron
2 “pills” each day for anemia
[0053] Patient A also reported using Walitin (generic for Claritin) and Nasonex as needed for allergies.
[0000] 2. Treatment with Inventive Electrical Producing Cream
[0054] The ambient temperature during treatment ranged from 74-78° F. according to measurements from four different Stress Thermometers used “as is” (Dr. Lowenstein's Model SC911 accuracy +/−1.8° F., 10 ft. lead with fast temperature sensor).
[0055] Patient A was recumbent on a treatment table with a triangular pillow positioned behind both knees so that the knees were bent upward to rise above the ankles. A temperature probe was strapped on each upper ventral thigh and on the inside of each ankle. The probes were covered, and no electrical producing cream was applied to the probes. Equilibration time was approximately 10 minutes after the patient reclined in the prone position. After equilibration time was reached, the temperatures were recorded as shown in Table C.
TABLE C PROBE LOCATION TEMPERATURE right thigh 90.0° F. left ankle 86.7° F. right thigh 92.3° F. right ankle 90.1° F.
[0056] The inventive electrical producing cream was applied to the top and bottom of each thigh and later (as shown in Table D) to the top and bottom of each calf, ankle, and foot. The product was massaged into the skin until nearly invisible to the eye. The dosage level was 0.3 oz. on each thigh and each ankle for a total per leg dosage of 0.6 oz.
[0057] Temperature readings were taken at intervals, beginning 5 minutes after application to Patient A's legs. These readings are set forth in Table D.
TABLE D TIME LOCATION TEMPERATURE (° F.) 5 minutes A left thigh 90.5 left ankle 86.9 right thigh 92.3 right ankle 90.9 Note - Patient A reported feeling heat at 5 minutes. 7 minutes left thigh 90.9 left ankle 86.9 right thigh 92.3 right ankle 90.9 10 minutes left thigh 91.5 left ankle 86.9 right thigh 92.5 right ankle 91.2 Note - Patient A reported heat at same level as at 5 minutes. 15 minutes left thigh 91.4 left ankle 87.1 right thigh 92.1 right ankle 90.7 Note - Patient A reported feeling a warm sensation. There was sweat behind the left knee. Electrical producing cream was applied to left ankle at 17 minutes. A paper towel was placed on the triangular pillow. 20 minutes left thigh 91.2 left ankle 86.7 right thigh 91.9 right ankle 90.1 25 minutes left thigh 91.2 left ankle 86.5 right thigh 91.8 right ankle 90.3 30 minutes left thigh 91.2 left ankle 86.9 right thigh 91.6 right ankle 90.3 35 minutes left thigh 91.6 left ankle 86.9 right thigh 91.8 right ankle 90.5 Note - Electrical producing cream was applied to right ankle at 35 minutes. 40 minutes left thigh 91.4 left ankle 86.9 right thigh 90.3 right ankle 90.5 45 minutes left thigh 91.2 left ankle 86.9 right thigh 88.7 right ankle 90.1 50 minutes left thigh 91.2 left ankle 86.4 right thigh 89.2 right ankle 90.5 55 minutes left thigh 91.2 left ankle 87.3 right thigh 89.4 right ankle 90.1 Note - At 57 minutes, Patient A reported a cool feeling from above the ankle to the heel. 60 minutes left thigh 91.4 left ankle 87.3 right thigh 90.0 right ankle 90.1 65 minutes left thigh 91.2 left ankle 87.4 right thigh 90.5 right ankle 90.5 70 minutes left thigh 91.0 left ankle 87.3 right thigh 90.7 right ankle 90.1 A Five minutes after application to left calf and lower thigh (0 time).
[0058] Patient A rose from the table at 78 minutes, and the thigh probes were removed. Patient A held the readout portion of the thermometers in her hand while the probes were still attached to the ankles to allow her to walk to the restroom and take a further readout of her ankles after 5 minutes elapsed. However, at 82 minutes the left ankle probe came loose so no reading was taken. The right ankle probe gave a reading of 81.1° F. at 82 minutes. Patient A reported that her left side (neuropathic side) felt soothed.
Example 3
Treatment of Patient B
[0000] 1. Patient History
[0059] The topical electrical producing cream prepared in Example 1 was used to treat a second patient (hereinafter referred to as “Patient B”). Patient B was a 60-year old, 5′7″, Caucasian female. She was a non-insulin dependent diabetic and had sensory neuropathy that was worse in her right leg. She did not have any visible wounds. Her daily oral medications were Glucophage (1 in the evening), Toprol, Diovan, and Lipitor (1 in the evening).
[0000] 2. Treatment with Inventive electrical Producing Creams
[0060] The ambient temperature during treatment ranged from 74-75° F. according to measurements from the four different Stress Thermometers as described in Part 2 of Example 2. The probes were applied as described in Part 2 of Example 2. The initial readings are shown in Table E.
TABLE E PROBE LOCATION TEMPERATURE A TEMPERATURE C left thigh 88.7° F. 89.1° F. left ankle 83.8° F. 83.8° F. right thigh 79.0° F. B 90.7° F. right ankle 86.5° F. 86.5° F. A Temperature prior to electrical producing cream application. B The probe came loose from the right thigh, thus resulting in the 79° F. reading. C Temperature at 4 minutes after temperature reading in middle column.
[0061] Temperature readings were taken as described in Part 2 of Example 2. These readings and the times of electrical producing cream application to Patient B's legs are set forth in Table F.
TABLE F TIME LOCATION TEMPERATURE (° F.) 5 minutes A left thigh 90.5 left ankle 81.5 right thigh 91.6 right ankle 86.2 Note - The inventive electrical producing cream was applied to the entire left leg at 5 minutes. At 7 minutes, Patient B reported that her left leg was cool. 10 minutes left thigh 90.5 left ankle 81.5 right thigh 91.9 right ankle 85.8 15 minutes left thigh 90.7 left ankle 81.5 right thigh 92.3 right ankle 85.8 20 minutes left thigh 90.9 left ankle 81.1 right thigh 92.1 right ankle 85.5 Note - Patient B reported feeling a stinging sensation behind her left knee, and that the toes on her left foot felt strange. 25 minutes left thigh 91.0 left ankle 81.1 right thigh 92.3 right ankle 84.7 Note - Patient B reported that she still felt a stinging sensation behind her left knee. 30 minutes left thigh 91.6 left ankle 81.1 right thigh 92.8 right ankle 84.7 35 minutes left thigh 91.6 left ankle 81.1 right thigh 93.0 right ankle 82.9 Note - The inventive electrical producing cream was applied to the entire right leg at 35 minutes. 40 minutes left thigh 91.9 left ankle 81.0 right thigh 93.6 right ankle 83.3 45 minutes left thigh 92.1 left ankle 80.6 right thigh 93.6 right ankle 83.7 Note - Patient B reported feeling a burning on her left side. She stated that her right leg felt cool, and that she felt a sensation as if a thumb were being pressed into the middle of the arch on her right foot. She reported that she had a stress fracture of the calchaneal bone on the right heel. 50 minutes left thigh 91.9 left ankle 80.2 right thigh 93.6 right ankle 83.7 Note - Patient B reported that she thought the doctor was touching her right foot, but he was not. 55 minutes left thigh 91.9 left ankle 80.1 right thigh 93.7 right ankle 83.3 Note - Patient B reported that her left leg was feeling restless. 60 minutes left thigh 92.7 left ankle 80.1 right thigh 93.9 right ankle 83.3 65 minutes left thigh 93.0 left ankle 80.1 right thigh 94.1 right ankle 83.3 Note - Patient B rose at 66 minutes. 70 minutes left thigh 91.0 left ankle 79.7 right thigh 91.0 right ankle 82.8 A Five minutes after first temperature reading in Table E.
[0062] The probes were removed after 70 minutes.
Example 4
Determination of Metabolic Activity
[0063] The topical electrical producing cream prepared in Example 1 was applied to the left inner forearm (below the elbow) of a patient. The treated area was then swabbed with a glass slide that was subsequently sandwiched between two ECG patches attached to leads to a Radio Shack digital, multi-meter. The initial reading (time=0) was 0.0 mV. Subsequent readings were taken at different intervals, and those results are reported in Table G.
TABLE G TIME READING (minutes after initial reading) (mV) 1 0.2 32 0.9 33 0.8 43 0.9 51 1.0 52 0.9 56 1.0 72 1.2 73 1.4 74 1.2 121 1.5
[0064] This test was carried out to show that oxygen activation from the compounded electrical producing cream occurs following the application to human skin with or without sweat.
[0065] This test was repeated using electrical producing cream that had been swabbed from another patient's back. However, the cream tuned green in color and did not reproduce similar results with the ECG patches. It also took about 6 hours and 20 minutes for this person to notice the heat activation in the location where the electrical producing cream had been applied to the back.
Example 5
Metabolic Activity Comparison
[0066] In this test, the metabolic activity of the topical electrical producing cream prepared in Example 1 was determined following the steps set forth in Example 4. The same steps were followed to determine the metabolic activity of two prior art products. FIG. 1 a shows the metabolic activity of one prior art product (non-modified SOMBRA) over a 45-minute time period. FIG. 1 b shows the metabolic activity of another prior art product (non-modified BIO-FREEZE) over a 45-minute time period. FIG. 1 c shows the inventive electrical producing cream's metabolic activity over a 45-minute time period. A comparison of these figures shows that metabolic activity of the prior art peaks and then drops substantially over the 45-minute time period while the inventive electrical producing cream's metabolic activity maintains very high levels even after peaking. FIG. 1 d shows the electrical producing cream's metabolic activity over an 8-hour time period. This graph shows that this activity drops slowly over the 8-hour time period, thus providing prolonged treatment periods as compared to prior art products.
Example 6
Treatment of Patient with Inventive Electrical Producing Creams
[0067] The patient in this example (hereinafter referred to as “Patient C”) was a Caucasian female in her late 50s. Patient C was suffering from neuropathy in her feet, with symptoms including sharp, stabbing pains and contractures due to over-stimulation of muscles. The condition had caused Patient C to take disability from work.
[0068] The topical electrical producing cream prepared in Example 1 was applied to Patient C's feet. Within 10 minutes, the contractures in her feet started to release, and she reported that her feet felt 90% better. Also, the sharp, stabbing pain was relieved for 6 hours after treatment.
Example 7
Preparation of Topical Electrical Producing Cream
[0069] Purified water was mixed with Carbopol® Ultrez 20 by stirring in a 1-gallon jug to evenly disperse the polymer. Camphor gum and menthol crystals were then mixed together and then added to the ingredients in the jug.
[0070] Next, the following ingredients were mixed together until a homogenous mixture was formed: glycerin, decyl glucoside (Plantaren® 2000 available from Cognis Corporation), capsaicin frutescens oleoresin, boswellin extract, zingiber officinale (ginger) root extract, bromelaine extract, salix alba (willow) bark extract, arnica cordifolia extract, aloe vera gel, hamemelis virginiana (witch hazel), and camellia sinensis (green tea) leaf extract. This mixture was then added to the ingredients in the jug and stirred until the mixtures were completely combined.
[0071] Then, potassium amino acid chelate was mixed with AEROBIC 07 (sodium chlorite, carbonates, and bicarbonates), and added to the ingredients in the jug. The ingredients in the jug were stirred until the potassium and oxygen sources were completely incorporated.
[0072] Next, sodium hydroxymethylglycinate (Suttocide® A available from International Specialty Products) was added to the ingredients in the jug and mixed by stirring. Finally, a small amount of fragrance was added to the ingredients in the jug and mixed by stirring to yield the final electrical producing cream.
[0073] The percentages by weight of the total ingredients in the electrical producing cream are set forth in Table H, below.
TABLE H INGREDIENTS % BY WEIGHT A Purified Water 83.100 Carbopol Ultrez 20 0.850 Camphor Gum 3.100 Menthol Crystals 3.000 Glycerin 4.000 Decyl Glucoside 1.000 Capsicum Frutescens Oleoresin 0.250 Boswellin Extract 0.010 Ginger Root Extract 0.010 Bromelaine Extract 0.010 Willow Bark Extract 0.100 Arnica Cordifolia Extract 0.200 Aloe Vera Gel 0.300 Witch Hazel Extract 3.000 Green Tea Leaf Extract 0.100 Potassium Amino Acid Chelate 0.090 Sodium Chlorite 0.010 Carbonates 0.010 Bicarbonates 0.010 Sodium Hydroxymethylglycinate 0.600 Fragrance 0.250 A Percentages are based upon the total weight of all ingredients in the electrical producing cream taken as 100% by weight.
Example 8
Treatment of Patient with Inventive Electrical Producing Cream
[0074] The topical electrical producing cream prepared in Example 7 was used to treat a patient (hereinafter referred to as “Patient D”). Patient D was a Caucasian female, 60 years old, and she was 5′1″ approximately 160 lbs. Patient D had originally fractured her back in a skiing accident in 1969. In 1988, Patient D underwent two surgeries where surgeons removed segments of a disc that had worn a hole into the patient's spinal chord. More than 10 years later, Lumbar Vertebras L4/L5/S1 were fused together due to instability and movements. In 2005, the patient had a Dynesys® Spine System device implanted to keep the Lumbar Disc open at L2/L3/L4. Subsequently, the patient had a Spinal Chord Implant installed with a control device imbedded into the upper buttocks.
[0075] At the time of treatment, the patient exhibited the following conditions: arthritis, spinal stenosis, spinal chord arachnoditis, scar tissue adhesions, right low back nerve damage with radiating symptoms into mainly the right leg into the foot, and was in need of a knee replacement to the left knee. The patient's left knee had severely restricted range of motion due to arthritis and swelling (edema). The patient's left foot was also infected. The patient's posterior/anterior thoracolumbar spinal movement was also extremely limited.
[0076] The topical electrical producing cream prepared in Example 7 was applied to the left knee of the patient. After 30 minutes, the patient exhibited a significantly increased range of motion of the left knee, and reported that movement of the knee was less painful.
[0077] The topical electrical producing cream prepared in Example 7 was then applied to the patient's back along the thoracolumbar spine area. After 15 minutes, the patient's forward range of motion was significantly increased, and the patient reported that she was able to comfortably bend forward much farther than before the electrical producing cream had been applied. After 30 minutes, the patient was asked to bend forward again, and the patient's range of motion was measured with a JTECH Dualer IQ™ Inclinometer, available from JTECH Medical. The results indicated that the patient's throacolumbar range of motion had increased by 14 degrees, 30 minutes after application of the topical electrical producing cream. Patient D also reported that the implanted Spinal Chord stimulator was not needed for over 24 hours after application of the topical electrical producing cream due to temporary relief of chronic symptoms.
[0078] Patient D was then laid face down on a treatment table and a thermal image scan ( FIG. 3 a ) was taken of the patient's lower extremities and specific data points on the patient's legs and feet were recorded. The patient's left foot temperature was greatly elevated due to the infection. There was also a noticeable difference between the right and left feet, attributed to the spinal chord and nerve root injuries to the right lower back. The topical electrical producing cream prepared in Example 7 was then applied to the top and bottom of each calf, ankle, and foot.
[0079] After 30 minutes another thermal image scan ( FIG. 3 b ) was taken of the patient's lower extremities and the data was recorded. No patient movement was allowed during this time.
[0080] The temperature of the left foot was greatly reduced due to increased nerve and circulation function. It was also observed that there was less of a temperature difference between the right and left feet, as the temperature of the left foot decreased and the temperature of the right foot increased.
[0081] After 50 minutes another thermal image scan was taken of the patients lower extremities and the final temperature for selected data points were recorded.
[0082] The results of the thermal image scans are provided below in Table I. The ambient temperature of the room ranged from 77.9-78° F.,
TABLE I TEMPERATURE (° F.) at RECORDED TIMES DATA POINT 0 minutes 30 minutes 50 minutes ball of left foot 96.8 94.4 92.5 arch of left foot 94.4 85.0 left calf 91.1 90.5 88.1 left knee 91.2 90.2 left thigh 88.8 88.9 88.6 ball of right foot 91.5 93.8 92.1 arch of right foot 90.9 83.8 right calf 92.4 90.4 88.3 right knee 91.5 90.2 right thigh 88.7 88.9 87.5
[0083] Before beginning treatment, the average temperature difference between the patient's right and left legs and feet was about 4.3° F., After 50 minutes, the average temperature difference between the patient's right and left legs and feet was decreased to about 0.4° F. The topical electrical producing cream was observed to increases circulation in infected area, lowering the temperature, while simultaneously increasing circulation in the area of nerve damage and raising the temperature.
Example 9
Treatment of Patient with Electrical Producing Cream
[0084] The electrical producing cream prepared in Example 7 was used to treat and/or relieve symptoms of Multiple Sclerosis in a patient (hereinafter referred to as “Patient E”). Patient E was a female, 55 years old, 5′11″ tall and approximately 180 lbs. In 1997, Patient B was diagnosed with Multiple Sclerosis. Patient E exhibited reduced range of motion in the right knee flexion.
[0085] Patient E was laid face down on a treatment table and asked to bend her right knee to bring her heel towards her thigh. The patient was able to flex her knee approximately 5 degrees.
[0086] Next, the electrical producing cream was applied to the patient's right leg on and around the knee area. After 20 minutes, the patient was again asked to bend her right knee to bring her heel towards her thigh. Due to the stimulation of the patient's nervous system by the electrical current (mV) produced by the inventive cream, the patient's range of motion in the right knee flexion was visually observed to increase by approximately 20 degrees, for a total flexion of 25 degrees.
Example 10
Treatment of Patient with Electrical Producing Cream
[0087] The electrical producing cream prepared in Example 7 was used to treat and/or relieve symptoms of Multiple Sclerosis in a patient (hereinafter referred to as “Patient F”). Patient F was a female, 27 years old, 5′3″ tall and approximately 102 lbs. In 2001 Patient F was diagnosed with Multiple Sclerosis, and is now living in an assisted-living environment and unable to care for herself Patient F exhibited multiple physical impairments. For example, all of the patient's movement in the extremities and trunk of her body were rigid/ratcheting tremor movements. The patient was unable to steady her hands to put her glasses on with one hand, such that she used both hands making several attempts to position her glasses correctly. The patient's mobility was restricted to using a walker to get around. Without the walker, the patient would stammer towards an object and fall into it if near enough. Severe tremors were observed while the patient was laying down or attempting to stand with the walker.
[0088] Patient F was laid face down, with assistance, on a treatment table and asked to keep her knees straight and raise her right leg into the air. The patient was able to lift her right leg high enough to obtain an angle of 17 degrees. Next she was asked to keep her knee straight and raise her left leg into the air. The patient was able to lift her left leg high enough to obtain an angle of 11 degrees.
[0089] Next, the electrical producing cream prepared in Example 7 was applied to the patient's right and left legs and right and left arms and lumbar area. After 15 minutes, the patient was again asked to keep her knees straight and raise her right leg into the air. The patient was able to lift her right leg to an angle of 26 degrees with reduced tremors. Next she was asked to keep her knees straight and raise her left leg into the air. The patient was able to lift her left leg to an angle of 20 degrees with reduced tremors.
[0090] Next, Patient F was asked to get up and walk towards a dining area that was about 120 feet away, using her walker. The patient stood up and proceeded to walk towards the door of her room, towards the dining room. After the patient reached her room door with the walker, she took it upon herself to grasp an assistance rail on the wall and leave her walker behind. Patient F continued towards the dining area without assistance, using the rail and periodically grasping it for increased support, but never for more than 15 feet at a time. Patient F sat down at a dining table and was observed to place her glasses on using only her right hand and with little ratcheting tremors. Next she was observed for 15 minutes from a distance while eating. Due to the stimulation of the patient's nervous system by the electrical current (mV) produced by the inventive cream, Patient F was able to bring food to her mouth with little trouble, and it was observed that the ratcheting tremors were greatly reduced. The patient reported that the effects of the electrical producing cream lasted for several hours, allowing for an increased quality of life while performing what are called “simple daily activities.”
[0091] All recorded angle measurements were determined using a JTECH Dualer IQ™, Inclinometer, available from JTECH Medical, placing the Inclinometer on the back of the thighs for measurements.
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New electrical producing creams are provided. In one embodiment, the electrical producing creams comprise menthol and camphor, preferably provided as part of a base gel, supplemented with potassium and a source of oxygen. The most preferred base gel is sold under the name SOMBRA. In another embodiment, the electrical producing creams comprise potassium and a source of oxygen supplemented with optional active and inactive ingredients. The most preferred source of oxygen is a chlorite (e.g., sodium chlorite) and/or spirulina. The electrical producing creams provide high metabolic activities and sustain those activities over prolonged periods of time, thus being useful for treating a large variety of ailments, including diabetic neuropathy, post hepatic neuralgia, scleroderma, psoriasis, strain, spasticity, headaches, neuropathy secondary to drugs, peripheral neuropathy, leg pain, muscle cramps, muscle aches and pains, bruise, sinusitis, sprain, arthritis, joint pain (arthralgia), and edema.
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PRIORITY REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application No. 60/964,233, entitled CALL SHUFFLING, filed on Aug. 9, 2007 by inventors Itay Sherman, Eyal Bychkov, Hagit Perry and Uri Ron.
FIELD OF THE INVENTION
The present invention relates to automated scheduling of phone calls.
BACKGROUND OF THE INVENTION
People often find themselves in situations where they have a large number of phone calls to make. A salesperson, for example, may have a large number of contacts to follow up on with phone calls. Or a professional returning to his office from vacation may find a large number of phone messages on his answering machine which require return phone calls. Or a person may want to stay in touch with a large number of friends and family on a regular basis, and call them from time to time.
When such people have free time, and would like to use the time to make some of their phone calls, it is cumbersome to sort out who to call. Free time may arise sporadically when people are waiting for a service or for an appointment. Free time may also arise in predictable ways when people are exercising or traveling on a train or taxi. Even when people write themselves notes of phone calls to make, using computerized calendars or slips of paper, the notes are not always available with them during their free time. Or the notes may be extensive and difficult to sort through and prioritize.
Thus it would be of advantage to have an automated way of making phone calls during free time.
SUMMARY OF THE DESCRIPTION
The present invention provides a simple and efficient way for a person to automatically schedule phone calls to make, whenever he has free time to make some of his calls. The present invention provides a call shuffler that arranges the person's calls that have to be made in order of priority, and places the calls. The person does not have to sort through and review his notes to determine what calls to make.
The present invention organizes a person's contacts into groups, one group being contacts that a person wants to call. The contacts are assigned priorities based on factors including inter alia importance, deadlines and special dates such as birthdays and anniversaries, and length of time since the person last spoke with a contact. Whenever the person has free time, the contacts are sorted in terms of priority, contacts with the same priority are randomly sorted, and phone calls are placed accordingly.
Priorities are updated dynamically, when factors influencing priorities change, and after phone calls are made.
There is thus provided in accordance with an embodiment of the present invention a method for automatically scheduling phone calls, including dynamically assigning priorities to each of a plurality of a user's contacts, selecting one of the plurality of the user's contacts based on highest priority, wherein random selection is used in case more than one contact has the highest priority, placing a phone call to the selected contact, and updating the priority of the selected contact, if the placing a phone call successfully reaches the selected contact.
There is additionally provided in accordance with an embodiment of the present invention a telephone with an automatic call scheduler, including a memory for storing a plurality of a user's contacts and priorities assigned thereto, a prioritizer coupled with the memory for dynamically assigning the priorities to the plurality of the user's contacts, and for updating the priority of a contact when a phone call is successfully made to the contact, a scheduler coupled with the prioritizer and with the memory for selecting one of the plurality of the user's contacts based on highest priority, wherein the scheduler uses random selection in case more than one contact has the highest priority, and a dialer coupled with said scheduler for automatically placing a phone call to the selected contact.
There is moreover provided in accordance with an embodiment of the present invention a computer readable storage medium storing program code for causing a telephone to dynamically assign priorities to each of a plurality of a user's contacts, to select one of the plurality of the user's contacts based on highest priority, wherein random selection is used in case more than one contact has the highest priority, to place a phone call to the selected contact, and to update the priority of the selected contact, if the placed phone call successfully reaches the selected contact.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and appreciated from the following detailed description, taken in conjunction with the drawings in which:
FIG. 1 is a simplified block diagram of a telephone with automated call scheduling, in accordance with an embodiment of the present invention;
FIG. 2 is a simplified block diagram of an automated call scheduling component of the telephone of FIG. 1 , in accordance with an embodiment of the present invention;
FIG. 3 , which is an illustration of a modular cell phone being inserted into a jacket/host, in accordance with an embodiment of the present invention;
FIG. 4 is a simplified illustration of a communication system constructed and operative in accordance with an embodiment of the present invention;
FIG. 5 is a simplified flowchart of a method for automatically scheduling phone calls, in accordance with an embodiment of the present invention; and
FIG. 6 is a simplified block diagram of a communication system with functionality for notifying a user when a contact's status becomes “available” on an Internet communication service, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The present invention relates to automatic phone call scheduling for some or all of a user's contacts. The user's telephone stores his list of contacts, and includes a profile for each contact. Shown in TABLE I is a sample contact profile, in accordance with the present invention. In addition to the contact's name, phone number and relation to the user, the contact profile includes fields for preferred calling dates and times, excluded calling dates and times, one or more special occasions and desired frequency of calls.
The contact profile also includes a free-text field for storing comments. The free-text field may include reminders as to why the user wants to speak with the contact. The contact profile also includes a schedule call flag. Setting the schedule call flag to ON indicates that the user would like to call the contact when he has the time to do so. For example, the contact may be waiting for a return phone call from the user, or the contact may be someone the user wants to stay in touch with professionally or personally.
TABLE I
Sample Contact Profile
Name
John Smith
Phone Number
123-456-7890
Relation
Friend
Preferred calling dates & times
Sundays, 12 PM-2 PM
Excluded calling dates & times
Fridays, 8 AM-10 AM
Last time called
Jun. 20, 2007, 12:32:12
Special occasion
Birthday, Apr. 1, 1975
Desired frequency of calls
Every second day
Free-text
Invite John to the barbeque on Saturday
Schedule call flag
ON
Status
Busy
Reference is now made to FIG. 1 , which is a simplified block diagram of a telephone 100 with automated call scheduling, in accordance with an embodiment of the present invention. Telephone 100 may be a land-line telephone or a cellular telephone. Telephone 100 is operated by a user, or by a number of users.
As shown in FIG. 1 , telephone 100 includes a central processing unit (CPU) 110 , a power subsystem 120 , an audio subsystem 130 , a keyboard 140 for user input, a display 150 for output, a SIM card 160 , and a power amplifier 170 . Power subsystem 120 generally includes a rechargeable battery. Keyboard 140 generally includes a small keypad for dialing phone numbers and entering SMS messages. Display 150 is generally a small LCD display. Power amplifier 170 is connected to a GSM antenna.
Telephone 100 also includes a memory unit 180 , which stores user data such as contact information for the user's contacts, SMS messages and phone settings. In accordance with an embodiment of the present invention, user contact information is imported from external databases, such as Facebook® databases managed by Facebook, Inc. of Palo Alto, Calif, or databases from such other social or dating services.
Memory unit 180 also stores program code 190 that executes application programs, such as an Internet browser and a personal organizer. In accordance with the present invention, program code 190 also executes an automated call scheduler 200 , which is used to schedule and dial telephone calls.
Reference is now made to FIG. 2 , which is a simplified block diagram of automated call scheduler 200 of telephone 100 of FIG. 1 , in accordance with an embodiment of the present invention. Shown in FIG. 2 is a data store 210 , within memory unit 180 , which stores a user's contacts and their profiles. Some or all of the contacts are designated by the user as being “shuffle-able”; i.e., contacts that the user would like to call when he has free time to do so. For example, the user may designate that contacts that are waiting for a reply phone call from him are shuffle-able. He may also designate that certain friends and family are shuffle-able, as a way of staying in touch with them. In accordance with an embodiment of the present invention, a contact is designated as shuffle-able by setting the schedule call flag in the contact's profile to ON.
A dynamic prioritizer 220 dynamically assigns a priority to each of the user's shuffle-able contacts, based on a variety of factors. The priorities assigned to the contacts are stored in data store 210 , together with the contacts' profiles. The factors influencing the calculation of a contact's priority include inter alia:
a special date relating to the contact, such as the contact's birth date or wedding anniversary, or Mother's Day or Father's Day; the time remaining until a designated deadline for calling the contact; the time elapsed since the user last spoke with the contact; the desired frequency for which the user wishes to speak with the contact; a metric of importance assigned to the contact; a status of the contact, such as “busy”, “available”, “running” and “on another phone call”; contact's preferred dates and times to call him; and contact's excluded dates and times to call him.
In accordance with an embodiment of the present invention, telephone 100 includes an activation button for activating automated call scheduler 200 . Thus, when the user has free time to make some of his calls, he may activate automated call scheduler 200 by pressing on the activation button. Phone call scheduler 230 then dynamically sorts the shuffle-able contacts in terms of their priorities, and selects the highest priority contact for placing a phone call. In case multiple contacts have the highest priority, phone call scheduler 230 chooses randomly among them. As such, in a case where all priorities are the same, phone call scheduler 230 uses random selection among all the shuffle-able contacts.
After selecting a shuffle-able contact to be called, a user prompter 240 notifies the user of the selected contact, for his confirmation. Such notification may be visually or vocally, or both. User prompter 240 is configured to present information from the selected contact's profile to the user, to remind the user why he wanted to call the selected contact, and to assist the user in deciding whether to confirm or decline making the call. Information presented to the user by prompter 240 may include inter alia the free-form text from the selected contact's profile, the last date and time that the user made a phone call to the selected contact, and any special occasion related to the selected contact.
If the user confirms the call, then an automated dialer 250 places the call. If the phone call to the selected candidate is successful, then phone call scheduler updates the contact's priority appropriately. An unsuccessful phone call to a contact is a call for which a busy signal is reached, or for which the contact is not available. In accordance with an embodiment of the present invention, success or non-success of a call is measured by the duration of the call. Calls with duration over 15 seconds, for example, may be deemed successful.
Generally a contact's priority is reset to a low value after a successful call to the contact is made. However, in certain cases the contact's priority may remain high, such as when the user needs to call the contact back again in order to finish the discussion. The call may have been cut off, or the user or the contact may have run out of time, or the user may need to get more information from the contact.
It will thus be appreciated by those skilled in the art that the telephone of FIG. 2 enables the user to manage a large number of phone calls that he would like to make, and automatically select one or more phone calls whenever the user has free time to speak with his contacts.
In an embodiment of the present invention, the user's shuffle-able contacts may be grouped in categories, such as “sports contacts”, “family contacts” and “dating contacts”. When activating automated call-scheduler 200 , the user may designate a specific group of contacts, in which case phone call scheduler 230 selects from among the designated group of shuffle-able contacts.
In some embodiments of the present invention, telephone 100 is implemented as a modular cell phone that attaches to other electronic devices. There are two general types of devices to which the modular cell phone may be attached; namely, jackets and hosts. A jacket is a device that provides a user interface for the modular cell phone, enriches the capabilities of the modular cell phone, and is not able to operate independently when the modular cell phone is not pouched therewith. Conversely, a host is a device that is able to operate independently when the modular cell phone is not pouched therewith, and whose capabilities are enriched by the modular cell phone when the modular cell phone is attached thereto. Generally a host does not have communication functionality independent of the modular cell phone.
In this regard, reference is now made to FIG. 3 , which is an illustration of a modular cell phone 300 being inserted into a jacket/host 400 , in accordance with an embodiment of the present invention. Jacket/host 400 as shown in FIG. 3 includes a hollow cavity at the top for insertion of modular cell phone 300 therein.
Reference is now made to FIG. 4 , which is a simplified illustration of a communication system constructed and operative in accordance with an embodiment of the present invention. Shown in FIG. 4 are a variety of modular cell phones 300 a - 300 c , including 2.5G communicators for a GSM network, 3G communicators for GSM network, and CDMA communicators for a CDMA network. It will be appreciated by those skilled in the art that the networks in FIG. 4 are exemplary of a wide variety of networks and communication protocols that are supported by the wireless communicators of the present invention, such networks and communication protocols including inter alia WiFi, Bluetooth and WiMax.
Also shown in FIG. 4 are a variety of jackets/hosts 400 a - 400 h , including car jackets/hosts, sports jackets/hosts, camera jackets/hosts, gaming jackets/hosts, etc. In accordance with an embodiment of the present invention, each modular cell phone 300 a - 300 c may be attached to any of the jackets/hosts 400 a - 400 h , so as to operate in combination therewith. The modular cell phones 300 a - 300 c are substantially of the same form factor and, as such, are able to be attached to each of the various jackets/hosts 400 a - 400 h.
Reference is now made to FIG. 5 , which is a simplified flowchart of a method for automatically scheduling phone calls, in accordance with an embodiment of the present invention. At step 510 a user has time to speak with his contacts, and selects a “shuffle-call” function on his telephone. Some or all of the user's contacts are designated as being “shuffle-able”; i.e., contacts that the user would like to call when he has the time to speak with them.
In an alternative embodiment of the present invention, the shuffle-call is pre-scheduled by the user. For example, the user may insert a shuffle-call event into his calendar.
In yet another embodiment of the present invention, the shuffle-call is automatically suggested to the user when specific conditions prevail. The shuffle-call may be automatically suggested to the user inter alia:
when his calendar is empty, but is generally not empty most of the time; when the user changes his status on Facebook®, or on an instant messaging service, to “available”; when a user's contact changes his status to “available” on Facebook®, or on an instant messaging service; and when telephone 100 is a modular cell phone 300 , and the user inserts the communicator into a car jacket/host 400 .
At step 520 priorities are assigned to the user's shuffle-able contacts, based on various factors as described hereinabove with reference to prioritizer 220 . It will be appreciated by those skilled in the art that step 520 may be performed after step 510 , as shown in FIG. 5 , or, alternatively, step 520 may be performed at regular time intervals, such as every 30 seconds, in order that a current prioritization always be readily available. In this alternative embodiment, processing moves from step 510 directly to step 530 .
At step 530 the contact with the highest priority is selected. In case more than one contact has the highest priority, then one of them is chosen by random selection.
At step 540 the user is informed of the selected candidate contact, and given the opportunity at step 550 to confirm whether or not he wishes to call the contact now. In accordance with an embodiment of the present invention, at step 540 any free-text comments in the contact's profile are presented to the user, so that the user can be reminded why he wanted to call the contact. Other information from the contact's profile may be presented to the user instead of or in addition to the free-text comments, such as the last date and time the user spoke with the contact, or today being a special occasion related to the contact. The choice of which information from the contact's profile to present to the user at step 540 is preferably configured by the user.
If the user declines at step 550 , then processing returns to step 530 where the next contact in line is chosen. If the user confirms, then at step 560 a phone call to the selected contact is automatically placed. The user may configure his telephone to skip step 550 , in which case phone calls to selected contacts are always placed.
The phone call placed at step 560 may or may not be successful, as determined at step 570 . An unsuccessful call to a contact is one where the contact is not available, or where the call reaches a busy signal. In accordance with an embodiment of the present invention, success or non-success of a call may be determined from the duration of the call. For example, calls with duration over 15 seconds may be deemed successful.
If the call was unsuccessful, processing returns to step 530 . If the call was successful, then the contact's profile is updated appropriately at step 580 . Processing then returns to step 520 , as long as the user continues to make phone calls.
It will be appreciated by those skilled in the art that the method of FIG. 5 enables a user to place phone calls without having to decide a-priori which contacts to call. As such, the user saves time by not having to decide who to call, and the user automatically stays in touch with friends and family.
Assignment of Priorities
Step 520 of FIG. 5 involves assigning priorities to user contacts, based on their profiles. In accordance with an embodiment of the present invention, a scoring function is used to accumulate various factors that impact the priority of a user contact. TABLE II below indicates some sample score factors, which cumulatively determine the priority.
TABLE II
Sample cumulative score factors for calculating
priority for a user's contact
Factor
Score
The current date & time is an excluded date & time
−5
for the contact
The current date & time is a preferred date & time
+2
for the contact
The current date is a special occasion for the contact
+5
Urgency of speaking with the contact
+3 to +5
Length of time since the last phone call with the contact
−3 to +3
Closeness of relationship with the contact
+1 to +3
Time remaining until deadline to speak with the contact
−3 to +3
Successful call made with the contact
−5
Jacket/host type of user
−5 to +5
Jacket/host type of contact
−5 to +5
The “closeness of relationship” factor in TABLE II may be input by the user, or may be automatically derived from external databases. For example, certain contacts may have been designated by the user as “best friends” on one or more social databases.
It will be appreciated by those skilled in the art that the factors shown in TABLE II are representative of a wide variety of factors. The theme of jacket/host 400 used with modular cell phone 300 may be used in calculating priorities; i.e., contacts related to the theme of jacket/host 400 are assigned higher priorities. E.g., if modular cell phone 300 is housed in a sports jacket 400 , then sports contacts are assigned higher priorities; and if modular cell phone 300 is housed in a gaming host, then gaming contacts are assigned higher priorities. Even astrological factors may be used in calculating priorities; e.g., this is a good day to call contact X, since he is an Aries.
In addition to the factors shown in TABLE II, a user's contact's priority may be changed when the contact sends to the user an SMS message requesting a phone call, or when the contact's status changes from “busy” to “available” on an Internet communication service.
Reference is now made to FIG. 6 , which is a simplified block diagram of a communication system with functionality for notifying a user when a contact's status becomes “available” on an Internet communication service, in accordance with an embodiment of the present invention. Shown in FIG. 6 are telephones 100 belonging to a user and to two of the user's contacts, contact # 1 and contact # 2 . Also shown in FIG. 6 are computers 600 belonging to two others of the user's contacts, contact # 3 and contact # 4 . Computers 600 are connected to various web sites 610 , which provide communication services, such as Facebook® or an instant messaging service. The communication services enable contact # 3 and contact # 4 to set an availability status, with settings such as “busy”, “available”, “running” and “on another phone call”. The availability statuses are transmitted to a status server 620 , which communicates with web sites 610 using an API, such as an API for XML exchange, and notifies telephones 100 when contact 3 or contact 4 becomes available.
In accordance with a first embodiment of the present invention, the user's contacts (contact # 3 and contact # 4 ) need not have telephones 100 , and notification of contact availability is performed through a social network. The user's telephone 100 has a Facebook® or instant messaging application installed therein. Web sites 610 report availability of contact # 3 and contact # 4 to status server 620 , using the API. In turn, status server 620 notifies the application in telephone 100 accordingly.
In accordance with a second embodiment of the present invention, the user's contacts (contact # 1 and contact # 2 ) each have a telephone 100 , and notification of contact availability is performed directly through status server 620 . Telephones 100 broadcast availability statuses to status server 620 . Telephone 100 may, for example, send an HTTP request to status server 620 , the request including status information of contact # 1 or contact # 2 , and device information for the contact's telephone 100 . Status server 620 maintains the status/telephone data, and reports back the status of contact # 1 and contact # 2 to the user's telephone 100 . Status server 620 may, for example, send an HTTP response to telephone 100 , or alternatively telephone 100 may download the status information from status server 620 .
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made to the specific exemplary embodiments without departing from the broader spirit and scope of the invention as set forth in the appended claims. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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A method for automatically scheduling phone calls, including dynamically assigning priorities to each of a plurality of a user's contacts, selecting one of the plurality of the user's contacts based on highest priority, wherein random selection is used in case more than one contact has the highest priority, placing a phone call to the selected contact, and updating the priority of the selected contact, if the placing a phone call successfully reaches the selected contact. A telephone and a computer-readable storage medium are also described and claimed.
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PRIORITY INFORMATION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/485,549, filed on Jul. 12, 2006 which is a divisional of U.S. Utility application Ser. No. 10/115,072, filed Apr. 4, 2002, now abandoned, which claims priority to Swedish Application Nos. 0101232-7, filed on Apr. 5, 2001, and 0103754-8, filed Nov. 9, 2001, and the benefit of U.S. Provisional Application Ser. No. 60/281,410, filed Apr. 5, 2001, the content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to new peptides, in particular peptides to be used for immunization therapy for treatment of atherosclerosis, and for development of peptide based ELISA for the determination of immune response against oxidized low density lipoprotein and the diagnosis of the presence or absence of atherosclerosis.
[0004] 2. Brief Description of the Art
[0005] In particular the invention includes:
1) The use of any of the peptides listed in table 1, alone or in combination, native or MDA-modified, preferably together with a suitable carrier and adjuvant as an immunotherapy or “anti-atherosclerosis “vaccine” for prevention and treatment of ischemic 2) cardiovascular disease. 3) The use of the same peptides in ELISA for detection of antibodies related to increased or decreased risk of development of ischemic cardiovascular diseases.
[0009] Atherosclerosis is a chronic disease that causes a thickening of the innermost layer (the intima) of large and medium-sized arteries. It decreases blood flow and may cause ischemia and tissue destruction in organs supplied by the affected vessel. Atherosclerosis is the major cause of cardiovascular disease including myocardial infarction, stroke and peripheral artery disease. It is the major cause of death in the western world and is predicted to become the leading cause of death in the entire world within two decades.
[0010] The disease is initiated by accumulation of lipoproteins, primarily low-density lipoprotein (LDL), in the extracellular matrix of the vessel. These LDL particles aggregate and undergo oxidative modification. Oxidized LDL is toxic and cause vascular injury. Atherosclerosis represents in many respects a response to this injury including inflammation and fibrosis.
[0011] In 1989 Palinski and coworkers identified circulating autoantibodies against oxidized LDL in humans. This observation suggested that atherosclerosis may be an autoimmune disease caused by immune reactions against oxidized lipoproteins. At this time several laboratories began searching for associations between antibody titers against oxidized LDL and cardiovascular disease. However, the picture that emerged from these studies was far from clear. Antibodies existed against a large number of different epitopes in oxidized LDL, but the structure of these epitopes was unknown. The term “oxidized LDL antibodies” thus referred to an unknown mixture of different antibodies rather than to one specific antibody. T cell-independent IgM antibodies were more frequent than T-cell dependent IgG antibodies.
[0012] Antibodies against oxidized LDL were present in both patients with cardiovascular disease and in healthy controls. Although some early studies reported associations between oxidized LDL antibody titers and cardiovascular disease, others were unable to find such associations. A major weakness of these studies was that the ELISA tests used to determine antibody titers used oxidized LDL particles as ligand. LDL composition is different in different individuals, the degree of oxidative modification is difficult both to control and assess and levels of antibodies against the different epitopes in the oxidized LDL particles can not be determined. To some extent, due to the technical problems it has been difficult to evaluate the role of antibody responses against oxidized LDL using the techniques available so far, but, however, it is not possible to create well defined and reproducible components of a vaccine if one should use intact oxidized LDL particles.
[0013] Another way to investigate the possibility that autoimmune reactions against oxidized LDL in the vascular wall play a key role in the development of atherosclerosis is to immunize animals against its own oxidized LDL. The idea behind this approach is that if autoimmune reactions against oxidized LDL are reinforced using classical immunization techniques this would result in increased vascular inflammation and progressive of atherosclerosis. To test this hypothesis rabbits were immunized with homologous oxidized LDL and then induced atherosclerosis by feeding the animals a high-cholesterol diet for 3 months.
[0014] However, in contrast to the original hypothesis immunization with oxidized LDL had a protective effect reducing atherosclerosis with about 50%. Similar results were also obtained in a subsequent study in which the high-cholesterol diet was combined with vascular balloon-injury to produce a more aggressive plaque development. In parallel with our studies several other laboratories reported similar observations. Taken together the available data clearly demonstrates that there exist immune reactions that protect against the development of atherosclerosis and that these involves autoimmunity against oxidized LDL.
[0015] These observations also suggest the possibility of developing an immune therapy or “vaccine” for treatment of atherosclerosis-based cardiovascular disease in man. One approach to do this would be to immunize an individual with his own LDL after it has been oxidized by exposure to for example copper. However, this approach is complicated by the fact that it is not known which structure in oxidized LDL that is responsible for inducing the protective immunity and if oxidized LDL also may contain epitopes that may give rise to adverse immune reactions.
[0016] The identification of epitopes in oxidized LDL is important for several aspects:
[0000] First, one or several of these epitopes are likely to be responsible for activating the anti-atherogenic immune response observed in animals immunized with oxidized LDL. Peptides containing these epitopes may therefore represent a possibility for development of an immune therapy or “atherosclerosis vaccine” in man. Further, they can be used for therapeutic treatment of atheroschlerosis developed in man.
Secondly, peptides containing the identified epitopes can be used to develop ELISAs able to detect antibodies against specific structure in oxidized LDL. Such ELISAs would be more precise and reliable than ones presently available using oxidized LDL particles as antigen. It would also allow the analyses of immune responses against different epitopes in oxidized LDL associated with cardiovascular disease.
[0017] U.S. Pat. No. 5,972,890 relates to a use of peptides for diagnosing atherosclerosis. The technique presented in said US patent is as a principle a form of radiophysical diagnosis. A peptide sequence is radioactively labelled and is injected into the bloodstream. If this peptide sequence should be identical with sequences present in apolipoprotein B it will bind to the tissue where there are receptors present for apolipoprotein B. In vessels this is above all atherosclerotic plaque. The concentration of radioactivity in the wall of the vessel can then be determined e.g., by means of a gamma camera. The technique is thus a radiophysical diagnostic method based on that radioactively labelled peptide sequences will bound to their normal tissue receptors present in atherosclerotic plaque and are detected using an external radioactivity analysis. It is a direct analysis method to identify atherosclerotic plaque. It requires that the patient be given radioactive compounds.
SUMMARY OF THE INVENTION
[0018] The technique of the present invention is based on quite different principles and methods. In accordance with claim 1 the invention relates to fragments of apolipoprotein B for immunisation against cardiovascular disease as well as a method for diagnosing immuno reactions against peptide sequences of apolipoprotein B. Such immuno reactions have in turn showed to be increased in individuals having a developed atherosclerosis. The present technique is based in attaching peptide sequences in the bottom of polymer wells. When a blood sample is added the peptides will bind antibodies, which are specific to these sequences. The amount of antibodies bound is then determined using an immunological method/technique. In contrast to the technique of said US patent this is thus not a direct determination method to identify and localise atherosclerotic plaque but determines an immunological response, which shows a high degree of co-variation with the extension of the atherosclerosis.
[0019] The basic principle of the present invention is thus quite different from that of said patent. The latter depends on binding of peptide sequences to the normal receptors of the lipoproteins present in atherosclerotic tissue, while the former is based on the discovery of immuno reactions against peptide sequences and determination of antibodies to these peptide sequences.
[0020] Published studies (Palinski et al., 1995, and George et al., 1998) have shown that immunisation against oxidised LDL reduces the development of atherosclerosis. This would indicate that immuno reactions against oxidised LDL in general have a protecting effect. The results given herein have, however, surprisingly shown that this is not always the case. E.g., immunisation using a mixture of peptides #10, 45, 154, 199, and 240 gave rise to an increase of the development of atherosclerosis. Immunisation using other peptide sequences, e.g., peptide sequences #1, and 30 to 34 lacks total effect on the development of atherosclerosis. The results are surprising because they provide basis for the fact that immuno reactions against oxidised LDL, can protect against the development, contribute to the development of atherosclerosis, and be without any effect at all depending on which structures in oxidised LDL they are directed to. These findings make it possible to develop immunisation methods, which isolate the activation of protecting immuno reactions. Further, they show that immunisation using intact oxidised LDL could have a detrimental effect if the particles used contain a high level of structures that give rise to atherogenic immuno reactions.
[0021] WO 99/08109 relates to the use of a panel of monoclonal mouse antibodies, which bind to particles of oxidised LDL in order to determine the presence of oxidised LDL in serum and plasma. This is thus totally different from the present invention wherein a method for determining antibodies against oxidised LDL is disclosed.
[0022] U.S. Pat. No. 4,970,144 relates to a method for preparing antibodies by means of immunisation using peptide sequences, which antibodies can be used for the determination of apolipoproteins using ELISA. This is thus something further quite different from the present invention.
[0023] U.S. Pat. No. 5,861,276 describes a recombinant antibody to the normal form of apolipoprotein B. This antibody is used for determining the presence of normal apolipoprotein B in plasma and serum, and for treating atherosclerosis by lowering the amount of particles of normal LDL in the circulation.
[0024] Thus in the present invention the use of antibodies are described for treating atherosclerosis. However, contrary to the U.S. Pat. No. 5,861,276, these antibodies are directed to structures present in particles of oxidised LDL and not to the normal particle of LDL. The advantage is that it is the oxidised LDL, which is supposed to give rise to the development of atherosclerosis. The use of antibodies directed to structures being specific to oxidised LDL is not described in said US patent.
SUMMARY OF THE INVENTION
[0025] Oxidation of lipoproteins, mainly LDL, in the arterial wall is believed to be an important factor in the development of atherosclerosis. Products generated during oxidation of LDL are toxic to vascular cells, cause inflammation and initiate plaque formation. Epitopes in oxidized LDL are recognized by the immune system and give rise to antibody formation. Animal experiments have shown that some of these immune responses have a protective effect against atherosclerosis. Antibodies are generally almost exclusively directed against peptide-based structures. Using a polypeptide library covering the complete sequence of the only protein present in LDL, apolipoprotein B, the epitopes have been identified in oxidized LDL that give rise to antibody formation in man. These peptide-epitopes can be used to develop ELISAs to study associations between immune responses against oxidized LDL and cardiovascular disease and to develop an immunotherapy or anti-atherosclerosis “vaccine” for prevention and treatment of ischemic cardiovascular disease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1-6 show antibody response to the different peptides prepared in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] A molecular characterization of the epitopes in oxidized LDL has been performed that give rise to antibody-dependent immune responses in man. The approach used takes advantage of the fact that immune reactions almost exclusively are directed against 5-6 amino acid long peptide sequences. LDL only contains one protein, the 4563 amino acid long apolipoprotein B. During oxidation apolipoprotein B is fragmented and aldehyde adducts coupled to positively charged amino acids, in particularly lysine. This means that peptide sequences not normally exposed because of the three dimensional structure of apolipoprotein B become accessible to immune cells and/or that normally exposed peptide sequences becomes immunogenic because haptenization with aldehydes.
[0028] It has thereby been determined that the following peptides, native or MDA derivatives possess such an efficiency as producing an immuno-response, these. These peptides are:
[0000] FLDTVYGNCSTHFTVKTRKG, (SEQ ID NO: 1) PQCSTHILQWLKRVHANPLL, (SEQ ID NO: 2) VISIPRLQAEARSEILAHWS, (SEQ ID NO: 3) KLVKEALKESQLPTVMDFRK, (SEQ ID NO: 4) LKFVTQAEGAKQTEATMTFK, (SEQ ID NO: 5) DGSLRHKFLDSNIKFSHVEK, (SEQ ID NO: 6) KGTYGLSCQRDPNTGRLNGE, (SEQ ID NO: 7) RLNGESNLRFNSSYLQGTNQ, (SEQ ID NO: 8) SLTSTSDLQSGIIKNTASLK, (SEQ ID NO: 9) TASLKYENYELTLKSDTNGK, (SEQ ID NO: 10) DMTFSKQNALLRSEYQADYE, (SEQ ID NO: 11) MKVKIIRTIDQMQNSELQWP, (SEQ ID NO: 12) IALDDAKINFNEKLSQLQTY, (SEQ ID NO: 13) KTTKQSFDLSVKAQYKKNKH, (SEQ ID NO: 14) EEEMLENVSLVCPKDATRFK, (SEQ ID NO: 15) GSTSHHLVSRKSISAALEHK, (SEQ ID NO: 16) IENIDFNKSGSSTASWIQNV, (SEQ ID NO: 17) IREVTQRLNGEIQALELPQK, (SEQ ID NO: 18) EVDVLTKYSQPEDSLIPFFE, (SEQ ID NO: 19) HTFLIYITELLKKLQSTTVM, (SEQ ID NO: 20) LLDIANYLMEQIQDDCTGDE, (SEQ ID NO: 21) CTGDEDYTYKIKRVIGNMGQ, (SEQ ID NO: 22) GNMGQTMEQLTPELKSSILK, (SEQ ID NO: 23) SSILKCVQSTKPSLMIQKAA, (SEQ ID NO: 24) IQKAAIQALRKMEPKDKDQE, (SEQ ID NO: 25) RLNGESNLRFNSSYLQGTNO, (SEQ ID NO: 26) SLNSHGLELNADILGTDKIN, (SEQ ID NO: 27) WIQNVDTKYQIRIQIQEKLQ, (SEQ ID NO: 28) TYISDWWTLAAKNLTDFAEQ, (SEQ ID NO: 29) EATLQRIYSLWEHSTKNHLQ, (SEQ ID NO: 30) ALLVPPETEEAKQVLFLDTV, (SEQ ID NO: 31) IEIGLEGKGFEPTLEALFGK, (SEQ ID NO: 32) SGASMKLTTNGRFREHNAKF, (SEQ ID NO: 33) NLIGDFEVAEKINAFRAKVH, (SEQ ID NO: 34) GHSVLTAKGMALFGEGKAEF, (SEQ ID NO: 35) FKSSVITLNTNAELFNQSDI, (SEQ ID NO: 36) FPDLGQEVALNANTKNQKIR, (SEQ ID NO: 37) as well as the non antibody-producing peptide ATRFKHLRKYTYNYQAQSSS, (SEQ ID NO: 38)
or an active site of one or more of these peptides.
Material and Methods
[0029] To determine which parts of apolipoprotein B that become immunogenic as a result of LDL oxidation a polypeptide library consisting of 20 amino acid long peptides covering the complete human apolipoprotein B sequence was produced. The peptides were produced with a 5 amino acid overlap to cover all sequences at break points. Peptides were used in their native state, or after incorporation in phospholipid liposomes, after oxidization by exposure to copper or after malone dialdehyde (MDA)-modification to mimic the different modifications of the amino acids that may occur during oxidation of LDL.
Peptides
[0030] The 302 peptides corresponding to the entire human apolipoprotein B amino acid sequence were synthesized (Euro-Diagnostica AB, Malmö, Sweden and K J Ross Petersen A S, Horsholm, Denmark) and used in ELISA. A fraction of each synthetic peptide was modified by 0.5 M MDA (Sigma-Aldrich Sweden AB, Stockholm, Sweden) for 3 h at 37° C. and in presence of liposomes by 0.5 M MDA for 3 h at 37° C. or by 5 μM CuCl 2 (Sigma) for 18 h at 37° C. The MDA-modified peptides were dialyzed against PBS containing 1 mM EDTA with several changes for 18 h at 4° C. The modification of the peptides was tested in denatured polyacrylamide gels (Bio-Rad Laboratories, Hercules, Calif.), suitable for separation of peptides. Peptides were numbered 1-302 starting at the N-terminal end of the protein.
[0031] Other aldehydes can be used for preparing derivatives, such hydroxynonenal and others.
Liposomes
[0032] A mixture of egg phosphatidylcholine (EPC) (Sigma) and phosphatidylserine (PS) (Sigma) in a chloroform solution at a molar ratio of 9:1 and a concentration of 3 mM phospholipid (PL) was evaporated in a glass container under gentle argon stream. The container was then placed under vacuum for 3 hours. A solution containing 0.10 mM peptide (5 ml) in sterile filtered 10 mM HEPES buffer pH 7.4, 145 mM NaCl and 0.003% sodium azide was added to the EPC/PS dried film and incubated for 15 min at 50° C. The mixture was gently vortex for about 5 min at room temperature and then placed in ice-cold water bath and sonicated with 7.5 amplitude microns for 3×3 min (Sonyprep 150 MSE Sanyo, Tamro-Medlab, Sweden) with 1 min interruptions. The PL-peptide mixture, native or modified by 0.5 M MDA for 3 h at 37° C. or 5 mM CuCl 2 for 18 h at 37° C., was stored under argon in glass vials at 4° C. wrapped in aluminum foil and used within 1 week. The MDA-modified mixture was dialyzed against PBS containing 1 mM EDTA with several changes for 18 h at 4° C. before storage. The modification of the mixture was tested in denatured polyacrylamide gels (Bio-Rad Laboratories AB, Sundbyberg, Sweden), suitable for separation of peptides.
Plasma Samples
[0033] Plasma samples from 10 patients with cardiovascular disease (AHP) and 50 plasma samples, 25 women and 25 men, from normal blood donors (NHP) were collected and pooled. The two pools were aliquoted and stored in −80° C.
ELISA
[0034] Native or modified synthetic peptides diluted in PBS pH 7.4 (20 μg/ml), in presence or absence of liposomes, were absorbed to microtiter plate wells (Nunc MaxiSorp, Nunc, Roskilde, Denmark) in an overnight incubation at 4° C. As a reference, one of the peptides (P6) was run on each plate. After washing with PBS containing 0.05% Tween-20 (PBS-T) the coated plates were blocked with SuperBlock in TBS (Pierce, Rockford, Ill.) for 5 min at room temperature followed by an incubation of pooled human plasma, AHP or NHP, diluted 1/100 in TBS-0.05% Tween-20 (TBS-T) for 2 h at room temperature and then overnight at 4° C. After rinsing, deposition of auto-antibodies directed to the peptides were detected by using biotinylated rabbit anti-human IgG- or IgM-antibodies (Dako A/S, Glostrup, Denmark) appropriately diluted in TBS-T. After another incubation for 2 h at room temperature the plates were washed and the bound biotinylated antibodies were detected by alkaline phosphatase conjugated streptavidin (Sigma), incubated for 2 h at room temperature. The color reaction was developed by using phosphatase substrate kit (Pierce) and the absorbance at 405 nm was measured after 1 h of incubation at room temperature. The absorbance values of the different peptides were divided with the absorbance value of P6 and compared.
[0035] The sequences in apolipoprotein B that were recognized by antibodies in human plasma are shown as Seq. Id 1-37 in the accompanying drawing. Both AHP and NHP contained antibodies to a large number of different peptides. Antibodies against both native and modified peptides were identified. Generally antibody titers to MDA modified peptides were higher or equal to that of the corresponding native peptide. Comparison between native, MDA-modified, copper-oxidized peptide showed a high degree of correlation and that the highest antibody titers were detected using MDA-modified peptides. The use of peptides incorporated into liposomes did not result in increased antibody levels. Antibodies of the IgM subclass were more common than antibodies of the IgG subtype.
[0036] The peptides against which the highest antibody levels were detected could be divided into six groups with common characteristics (Table 1):
[0000] (A) High levels of IgG antibodies to MDA-modified peptides (n=3).
(B) High levels of IgM antibodies, but no difference between native and MDA-modified peptides (n=9).
(C) High levels of IgG antibodies, but no difference between native and MDA-modified peptides (n=2).
(D) High levels of IgG antibodies to MDA-modified peptides and at least twice as much antibodies in the NHP-pool as compared to the AHP-pool (n=5).
(E) High levels of IgM antibodies to MDA-modified peptides and at least twice as much antibodies in the NHP-pool as compared to the AHP-pool (n=11)
(F) High levels of IgG antibodies, but no difference between intact and MDA-modified peptides but at least twice as much antibodies in the AHP-pool as compared to the NHP-pool (n=7).
(G) No level of IgG or IgM antibodies
[0000]
TABLE 1
A. High IgG, MDA-difference
P 11.
FLDTVYGNCSTHFTVKTRKG (SEQ ID NO: 1),
P 25.
PQCSTHILQWLKRVHANPLL (SEQ ID NO: 2),
P 74.
VISIPRLQAEARSEILAHWS (SEQ ID NO: 3),
B. High IgM, no MDA-difference
P 40.
KLVKEALKESQLPTVMDFRK (SEQ ID NO: 4),
P 68.
LKFVTQAEGAKQTEATMTFK (SEQ ID NO: 5),
P 94.
DGSLRHKFLDSNIKFSHVEK (SEQ ID NO: 6),
P 99.
KGTYGLSCQRDPNTGRLNGE (SEQ ID NO: 7),
P 100.
RLNGESNLRFNSSYLQGTNQ (SEQ ID NO: 8),
P 102.
SLTSTSDLQSGIIKNTASLK (SEQ ID NO: 9),
P 103.
TASLKYENYELTLKSDTNGK (SEQ ID NO: 10),
P 105.
DMTFSKQNALLRSEYQADYE (SEQ ID NO: 11),
P 177.
MKVKIIRTIDQMQNSELQWP (SEQ ID NO: 12),
C. High IgG, no MDA difference
P 143.
IALDDAKINFNEKLSQLQTY (SEQ ID NO: 13),
P 210.
KTTKQSFDLSVKAQYKKNKH (SEQ ID NO: 14),
D. NHS/AHP, IgG-ak > 2, MDA-difference
P 1.
EEEMLENVSLVCPKDATRFK (SEQ ID NO: 15),
P 129.
GSTSHHLVSRKSISAALEHK (SEQ ID NO: 16),
P 148.
IENIDFNKSGSSTASWIQNV (SEQ ID NO: 17),
P 162.
IREVTQRLNGEIQALELPQK (SEQ ID NO: 18),
P 252.
EVDVLTKYSQPEDSLIPFFE (SEQ ID NO: 19),
E. NHS/AHP, IgM-ak > 2, MDA-difference
P 301.
HTFLIYITELLKKLQSTTVM (SEQ ID NO: 20),
P 30.
LLDIANYLMEQIQDDCTGDE (SEQ ID NO: 21),
P 31.
CTGDEDYTYKIKRVIGNMGQ (SEQ ID NO: 22),
P 32.
GNMGQTMEQLTPELKSSILK (SEQ ID NO: 23),
P 33.
SSILKCVQSTKPSLMIQKAA (SEQ ID NO: 24),
P 34.
IQKAAIQALRKMEPKDKDQE (SEQ ID NO: 25),
P 100.
RLNGESNLRFNSSYLQGTNQ (SEQ ID NO: 26),
P 107.
SLNSHGLELNADILGTDKIN (SEQ ID NO: 27),
P 149.
WIQNVDTKYQIRIQIQEKLQ (SEQ ID NO: 28),
P 169.
TYISDWWTLAAKNLTDFAEQ (SEQ ID NO: 29),
P 236.
EATLQRIYSLWEHSTKNHLQ (SEQ ID NO: 30),
F. NHS/AHP, IgG-ak < 0.5, no MDA-difference
P 10.
ALLVPPETEEAKQVLFLDTV (SEQ ID NO: 31),
P 45.
IEIGLEGKGFEPTLEALFGK (SEQ ID NO: 32),
P 111.
SGASMKLTTNGRFREHNAKF (SEQ ID NO: 33),
P 154.
NLIGDFEVAEKINAFRAKVH (SEQ ID NO: 34),
P 199.
GHSVLTAKGMALFGEGKAEF (SEQ ID NO: 35),
P 222.
FKSSVITLNTNAELFNQSDI (SEQ ID NO: 36),
P 240.
FPDLGQEVALNANTKNQKIR (SEQ ID NO: 37),
G.
P 2.
ATRFKHLRKYTYNYQAQSSS (SEQ ID NO: 38).
[0037] All of these 38 peptide sequences represent targets for immune reactions that may be of importance for the development of atherosclerosis and ischemic cardiovascular diseases. These peptides may therefor be used to develop ELISAs to determine the associations between antibody levels against defined sequences of MDA-modified amino acids in apolipoprotein B and risk for development of cardiovascular disease.
[0038] These peptides also represent possible mediators of the protective immunity observed in experimental animals immunized with oxidized LDL and may be used for testing in further development of an immunization therapy or “vaccine” against atherosclerosis.
[0039] Thus 38 different sequences in the human apolipoprotein B protein have been identified that give rise to significant immune responses in man. These epitopes are likely to represent what has previously been described as antibodies to oxidized LDL. Since most immune responses are directed against peptide sequences and apolipoprotein B is the only protein in LDL the approach used in this project should be able to identify the specific epitopes for essentially all antibodies against oxidized LDL-particles. A family of phospholipid specific antibodies including antibodies against cardiolipin has been described to react with oxidized LDL but the specificity and role of these antibodies remain to be fully characterized.
[0040] In many cases antibody titers were higher to MDA-modified polypeptides than to native sequences. If antibodies were detected against a MDA modified sequence it was almost always associated with presence of antibodies against the native sequence. A likely explanation to this is that the immune response against an MDA-modified amino acid sequence in apolipoprotein B (the MDA-modification occurring as a result of LDL oxidation) leads to a break of tolerance against the native sequence. For other sequences there was no difference in antibody titers against MDA-modified or native sequences. This would suggest that the immune reactions are directed against the native sequences. There should be no immune response against amino acid sequences in protein normally exposed to the immune system. In the native LDL particle large parts of the apolipoprotein B protein is hidden in phospholipid layer of LDL and therefore not accessible for the immune system. During oxidation of LDL the apolipoprotein B amino acid chain is fragmented leading to changes in the three-dimensional structure. This is likely to lead to exposure of peptide sequences normally not accessible for the immune system and to generation of antibodies against these sequences which may explain the presence of antibodies against native apolipoprotein B sequences observed. Alternatively, the true immune response is against MDA-modified sequences but the cross-reactivity with native sequences is so great that no difference in binding can be demonstrated.
[0000]
TABLE 2
Associations between antibodies to different peptides and
atherosclerosis in the carotid artery assessed as intima/media
thickness in 78 subjects (26 subjects who later developed
myocardial infarction, 26 healthy controls and 26 high-risk
individuals without disease).
Peptide
IgG
IgM
Native
MDA-modified
Native
MDA-modified
301
+
10
+
+
11
++
+
25
+
+
++
+++
30
++
31
++
32
33
+
34
+
45
++
++
+++
74
++
+
+
++
99
100
+
++
102
103
+
105
129
++
+++
143
+
+
++
+
148
+
154
+++
++
162
+
++
199
210
+
240
++
+, r > 0.2 < 0.3, p = <0.05;
++, r > 0.3 < 0.4, p = 0.01;
+++, r > 0.4, p = <0.001, grey, peptide antibody levels significantly increased in the group suffering from myocardial infarction.
[0041] The possibility that the ELISAs based on these peptides (native or MDA-modified) can be used to determine associations between immune reaction against defined epitopes in oxidized LDL and presence and/or risk for development of cardio-vascular disease was investigated in a pilot study. The study was performed on subjects participating in the MalmöDiet Cancer study a population based study in which over 30,000 individuals were recruited between 1989 and 1993. Antibody levels against the 24 out of 38 peptides listed in Table 1 were determined in base line plasma samples of 26 subjects who developed an acute myocardial infarction during the follow-up period and 26 healthy controls matched for age, gender and smoking. An additional group of 26 subjects, matched for age, gender, and smoking, but all with LDL cholesterol levels above 5.0 mmol/L was also included to study antibody levels in a high-risk group that has not developed cardiovascular disease.
[0042] For 19 out of the 24 peptides analyzed, significant correlations were identified between IgM antibody levels against MDA-modified peptides and the severity of atherosclerosis in the carotid artery (intima/media thickness) as assessed by ultrasound investigation of common carotid artery, i.e., the higher antibody levels the more atherosclerosis (Table 2). For many of these peptides significant correlations also existed between antibody levels to native peptides and carotid intima/media thickness. Only 4 peptides showed a significant correlation between IgG antibodies and carotid intima/media thickness. These observations suggest that ELISA using these MDA-modified peptides (alone or in combination) may be used to identify subjects with increased atherosclerosis.
[0043] Four of the peptides tested were not only associated with increased presence of atherosclerosis but were also significant elevated in the group of subjects that later suffered from a myocardial infarction (Table 2). Data for one of these peptides (peptide 240) is shown in FIG. 7 . These observations also demonstrate that peptide-based ELISA also may be used to identify subjects with an increased risk to develop myocardial infarction.
[0044] There were also significant increases in IgG antibody levels for native peptides 103, 162 and 199, as well as MDA modified 102 in the group that later suffered from myocardial infarction. However, the IgG antibodies against these peptides were not significantly associated with the presence of atherosclerosis in the carotid artery.
[0045] A particularly interesting observation was made with antibodies against MDA-modified peptide 210 for which there was significantly higher levels of IgM antibodies in the healthy controls and the high-risk group (LDL cholesterol above 5.0 mmol/L) than in the group that developed a myocardial infarction. Accordingly antibodies against MDA-modified peptide 210 may represent a marker for individuals with a decreased risk to develop cardiovascular disease.
[0046] It has now been demonstrated that immunization with native and MDA-modified apo B-100 peptide sequences results in an inhibition of atherosclerosis in experimental animals (Nordin Fredrikson, Söderberg et al, Chyu et al). The mechanisms through which these athero-protective immune responses operate remain to be fully elucidated. However, one likely possibility is that the athero-protective effect is mediated by antibodies generated against these peptides sequences. These antibodies could, for example facilitate the removal of oxidatively damaged LDL particles by macrophage Fc receptors.
[0047] Macrophage scavenger receptors only recognize LDL with extensive oxidative damage (9). Recent studies have identified the existence of circulating oxidized LDL (10, 11). These particles have only minimal oxidative damage and are not recognized by scavenger receptors. Binding of antibodies to these circulating oxidized LDL particles may help to remove them from the circulation before they accumulate in the vascular tissue (12).
[0048] Several studies have supported a role for antibodies in protection against atherosclerosis. B cell reconstitution inhibits development of atherosclerosis in splenectomized apo E null mice (13) as well as neointima formation after carotid injury in RAG-1 mice (unpublished observations from our laboratory). Moreover, it has been shown that repeated injections of immunoglobulins reduce atherosclerosis in apo E null mice(6).
[0049] As discussed above antibodies against MDA-modified peptide sequences in apo B-100 may be generated by active immunization using synthetic peptides. This procedure requires 2-3 weeks before a full effect on antibody production is obtained.
[0050] In some situations a more rapid effect may be needed. One example may be unstable atherosclerotic plaques in which oxidized LDL is likely to contribute to inflammation, cell toxicity and risk for plaque rupture. Under these circumstances a passive immunization by injection of purified, or recombinantly produced antibodies against native and MDA-modified sequences may have a faster effect.
[0051] Another situation in which a passive immunization by injection of purified, or recombinantly produced antibodies may be effective is coronary heart disease in older individuals. Our studies have shown that a decrease in antibodies against apo B peptide sequences occurs with increasing age in man and is associated with an increase in the plasma level of oxidized LDL (Nordin Fredrikson, Hedblad et al). This may suggest a senescence of the immune cells responsible for producing antibodies against antigens in oxidized LDL and result in a defective clearance of oxidatively damaged LDL particles from the circulation. Accordingly, these subjects would benefit more from a passive immunization by injection of purified, or recombinantly produced antibodies than from an active immunization with apo B-100 peptide sequences.
[0052] Synthetic native peptides (Euro-Diagnostica AB, Malmö, Sweden) used in the following were peptide 1, 2 and 301 from the initially screened polypeptide library. Peptide 1 (amino acid sequence: EEEMLENVSLVCPKDATRFK, n=10; (SEQ ID NO: 15)) and peptide 301 (amino acid sequence: HTFLIYITELLKKLQSTTVM, n=10; (SEQ ID NO: 20)) were found to have higher IgG or IgM antibody response to MDA modified form than native peptide, respectively and both titers are higher in healthy subject. These peptides were chosen based on the assumption that antibody response to these peptides might be protective against atherosclerosis.
[0053] Peptide 2 (amino acid sequence: ATRFKHLRKYTYNYQAQSSS, n=10; (SEQ ID NO: 38)) elicited no antibody response in the initial antibody screening, hence it was chosen as control peptide. Mice receiving Alum served as control (n=9).
[0054] Apo E (−/−) mice received subcutaneous primary immunization at 6-7 weeks of age, followed by an intra-peritoneal booster 3 weeks later. Mice were fed high cholesterol diet from the onset of immunization and continued until sacrifice at the age of 25 weeks. At the time of sacrifice, there was no significant difference in body weight among 4 groups of mice. Nor there was statistically significant difference in serum cholesterol as measured using a commercially available kit (Sigma). Their mean serum cholesterol levels were all above 715 mg/dl.
[0055] The area of the descending aorta covered by atherosclerotic plaque was measured in an en face preparation after oil red O staining. In comparison to the control group, mice immunized with peptide No. 2 and No. 301 had substantially reduced atherosclerosis ( FIG. 2 ). Immunization with Peptide No 1 did not produce a significant reduction in atherosclerosis in comparison to control. In contrast to the descending aorta, extent of atherosclerosis in the aortic root and aortic arch did not differ among the 4 experimental groups ( FIG. 3 ).
[0056] There were no difference among 4 groups in terms of aortic sinus plaque size or its lipid content (Table A). Mean plaque sizes in the aortic arches from 4 groups of mice were not different. However, en face evaluation of plaque sizes from descending thoracic and abdominal aorta by oil red O staining revealed that control group and peptide No. 1 group had similar amount of atherosclerotic plaque in the aorta, whereas peptide No. 2 and No. 9 groups had a significantly reduced atherosclerotic burden in the aorta (Table A). The observation that peptide immunization did not affect aortic sinus or aortic arch plaque size but reduced descending aortic plaque is intriguing and suggests that peptide immunization might reduce new plaque formation but does not affect the progression of plaques.
[0057] It was further tested whether peptide immunization modulates the phenotype of atherosclerotic plaques. Frozen sections form aortic sinus plaques were immunohistochemically stained with monocyte/macrophage antibody (MOMA-2, Serotec). In concordance with the findings from en face observation, peptide No. 2 significantly reduced macrophage infiltration in the plaques ( FIG. 1 ). Trichrome staining revealed a mean collage content of 40.0±7.7% in the aortic sinus plaques from peptide 2 group; whereas mean collagen content in alum control group, peptide 1 group and peptide 9 group were 32.3±5.3%, 35.6±8.5% and 29.4±9.6%, respectively.
[0058] Antibody response against immunized peptide in each group was determined. Antibody titer after immunization increased 6.1±3.1 fold in peptide 1 group, 2.4±1.0 fold in peptide 2 group and 1.8±0.6 fold in peptide 9 group; whereas alum group had a 3.9±2.7 fold increase of antibody titer against peptide 1, 2.0±0.5 fold increase against peptide 2 and 2.0±0.9 fold increase against peptide 9. It is surprising the parallel increase of antibody titer against immunized peptides both in immunized and alum treated group. This may mean the following possibilities: (1) mechanism(s) other than humoral immune response (such as cellular immune response) may be involved in modulating atherosclerosis; or (2) this increase of antibody was a by-stander response to hypercholesterolemia with time.
[0059] Although there is no clear speculative mechanism to explain why peptide immunization reduced atherosclerosis and/or modulate plaque phenotype, the novelty of this invention is the concept of using peptides of LDL as immunogen and its feasibility as an immunomodulation strategy. This peptide-based immunization strategy modulates atherosclerotic plaques. Immunization using homologous oxLDL or native LDL as antigen had been shown to reduce plaque size 1-3 , however, the availability, production, infectious contamination and safety of homologous human LDL make this approach unappealing for clinical application. Here it is demonstrated that peptide-based immunotherapy is feasible although our final results differ from our initial hypothesis that immunization using peptides with higher IgM or IgG antibody response in normal subjects may protect experimental animals from developing advanced atherosclerotic plaques.
[0060] It is surprising to find that immunization using peptide No. 2 protected animal from developing new atherosclerotic lesions in descending aorta and reduced macrophage infiltration and a higher collagen content in plaques since this peptide did not render any antibody response from initial human screen. It may be because (a) peptide No. 2 may be a part of human apo-B-100 protein structure that was not exposed to human immune system. Hence, no antibody was generated and detected from healthy human serum pools; (b) the amino acid sequence of peptide No. 2 is foreign to mice therefore mice developed immune response against this peptide, which modulates new atherosclerotic lesion formation and its phenotype.
[0061] The effect of homologous LDL immunization on plaque size varied when plaque sizes were evaluated at different portions of aortic tree. For example, Ameli et al showed in hypercholesterolemic rabbit native LDL immunization resulted in a reduction of plaque formation in aorta 1 , whereas Freigang et al. showed reduction of plaque size in aortic sinus but not in aorta 2 . Taken their findings and the present ones together, it was speculated that peptide immunization modulates not only plaque sizes but also plaque composition. The plaque-reducing effect was only observed in descending aorta. Apo E (−/−) mice are known to develop atherosclerotic lesions at various stages of evolution in a single animal, especially when fed high cholesterol diet. The initial appearance of atherosclerotic lesion in young animal was in the aortic sinus 6, 7 and after 15 weeks on high fat-high cholesterol diet lesions at aortic sinus were advanced plaques; whereas earlier stage of atherosclerosis was present in descending aorta. 6 Since the temporal course of plaque maturation and development in the descending aorta is late compared to that of aortic sinus, the finding that immunization reduced lesion sizes in the descending aorta but not in aortic sinus suggested immunization affects early stage of atherosclerosis formation. It is possible that as animal aged and in the presence of supra-physiological level of serum cholesterol the plaque reducing effect of immunization is overcome by the toxic effect of hypercholesterolemia. It is also possible that aortic sinus plaques mature faster and sacrifice at 25 weeks is too late to detect any difference in plaque size. Though lesion size was not modulated in the aortic sinus plaque, peptide immunization did modulate plaque compositions. The present experimental design prevented from studying the composition of the plaques in their earlier stage of development in descending aorta.
[0062] The experimental findings highlight the feasibility of using peptide sequences of LDL associated apo B-100 as immunogens for a novel approach to preventing atherosclerosis and or favorably modulating plaque phenotype despite severe hyperlipdemia. This peptide-based immunization strategy is potentially advantageous over the use of homologous oxLDL or native LDL as antigen because such a strategy could eliminate the need for isolation and preparation of homologous LDL and its attendant risks for contamination. The plaque-reducing effect of immunization with Peptide No 2 and 301 was only observed in descending aorta. These findings are consistent with previous reports where other therapeutic interventions have also been shown to have a greater effect on descending aorta compared to the aortic arch 14-17 , presumably because lesions develop more rapidly in the aortic root and the arch than the descending aorta thus creating a smaller window of opportunity for intervention 14, 15, 16, 18, 19 . Since the temporal course of plaque maturation and development in the descending aorta is late compared to that of aortic sinus and the aortic arch, the finding that immunization reduced lesion sizes in the descending aorta but not in aortic sinus and arch suggest that immunization preferentially prevents early stage of atherosclerosis formation. It is possible that as animal aged and in the presence of supra-physiological level of serum cholesterol the plaque reducing effect of immunization is overcome by the toxic effect of severe hypercholesterolemia. Though the lesion size was not modulated in the aortic sinus or arch, immunization with Peptide No 2 did modulate plaque composition in a favorable direction creating a more stable plaque phenotype with reduced macrophage infiltration and increased collagen content. In summary, it is demonstrated a novel peptide-based immunomodulatory approach for inhibition of atherosclerosis in the murine model.
[0063] In summary, it is demonstrated a novel peptide-based immunomodulatory approach in modulate atherosclerotic plaques. Although the change in atherosclerosis formation in our model was only modest, yet this peptide-based immunization may provide an alternative tool in studying, preventing or treating atherosclerosis.
Methods
[0064] Peptide preparation. Peptides were prepared using Imject® SuperCarrier EDC kit (Pierce, Rockford, Ill.) according to manufacturer's instruction with minor modification. One mg peptide in 500 μl conjugation buffer was mixed with 2 mg carrier in 200 μl deionized water. This mixture was then incubated with 1 mg conjugation reagent (EDC, 1-ethyl-3-[3-dimethylaminopropyl]carbodiimide HCl) in room temperature for 2 hours. This was then dialyzed against 0.083 M sodium phosphate, 0.9 M sodium chloride pH 7.2 solution overnight at 4° C. The dialyzed conjugate was diluted with Imject dry blend purification buffer to a final volume of 1.5 ml. Alum was used as immunoadjuvant and mixed with peptide conjugate with 1:1 dilution in volume. The amount of peptide in each immunization was 33 μg/100 μl per injection.
[0065] Animal protocol. Apo E (−/−) mice from the Jackson Laboratories (Bar Harbor, Me.) received subcutaneous primary immunization at 6-7 weeks of age, followed by an intra-peritoneal booster 3 weeks later. Mice were fed high cholesterol diet from the onset of immunization and continued until sacrifice at the age of 25 weeks. Blood samples were collected 2 weeks after booster and at the time of sacrifice. Mice receiving Alum served as control. Experimental protocol was approved by the Institutional Animal Care and Use Committee of Cedars-Sinai Medical Center. All mice were housed in an animal facility accredited by the American Association of Accreditation of Laboratory Animal Care and kept on a 12-hour day/night cycle and had unrestricted access to water and food. At the time of sacrifice, mice were anesthetized by inhalation Enflurane. Plasma was obtained by retro-orbital bleeding prior to sacrifice.
[0066] Tissue harvesting and sectioning. To evaluate the effect of peptide immunization on atherosclerosis formation, the plaque size at aortic sinus was assessed, aortic arch and descending thoracic and abdominal aorta. After the heart and aortic tree were perfused with normal saline at physiological pressure, the heart and proximal aorta were excised and embedded in OCT compound (Tissue-Tek) and frozen sectioned. Serial 6-μm-thick sections were collected from the appearance of at least 2 aortic valves to the disappearance of the aortic valve leaflets for aortic sinus plaque evaluation. Typically 3 consecutive sections were on one slide and a total of 25-30 slides were collected from one mouse and every fifth slide was grouped for staining. Ascending aorta and aortic arches up to left subclavian artery were also sectioned and processed similarly. Descending thoracic and abdominal aorta were processed separately for en face evaluation of plaque formation after oil red O staining. En face preparation of descending thoracic and abdominal aorta
[0067] Chicken egg albumin (Sigma) in a concentration of 0.8 g/ml water was mixed 1:1 with glycerol. Sodium azide was added to make a final concentration of sodium azide 0.2%. After descending thoracic and abdominal aorta was cleaned off surrounding tissue and fat, the segment of aorta from left subclavian artery to the level of renal artery was then carefully removed for overnight fixation in Histochoice (Amresco). Aorta was then carefully opened longitudinally and placed with luminal side up on a slide freshly coated with egg albumin solution. After albumin solution became dry, the aorta was stained with Oil red O to assess the extent of atherosclerosis with computer-assisted histomorphometry.
[0068] Immunohistochemistry and Histomorphometry. The sections from aortic sinus were immunohistochemically stained with MOMA-2 antibody (Serotec) using standard protocol. Trichrome stain to assess collagen content and oil red O stain for plaque size and lipid content were done using standard staining protocol. Computer-assisted morphometric analysis was performed to assess histomorphometry as described previously. 8
[0069] Antibody titer measurement. To measure the antibody response after peptide immunization, an ELISA was developed. Antibody titer against immunized peptide was measured using blood collected at 2 weeks after booster and at sacrifice. Antibody response against 3 peptides was also determined in Alum group at the same time-points. In brief, native synthetic peptides diluted in PBS pH 7.4 (20 μg/ml) were absorbed to microtiter plate wells (Nunc MaxiSorp, Nunc, Roskilde, Denmark) in an overnight incubation at 4° C. After washing with PBS containing 0.05% Tween-20 (PBS-T) the coated plates were blocked with SuperBlock in TBS (Pierce) for 5 min at room temperature followed by an incubation of mouse serum diluted 1/50 in TBS-0.05% Tween-20 (TBS-T) for 2 h at room temperature and then overnight at 4° C. After rinsing, deposition of antibodies directed to the peptides was detected by using biotinylated rabbit anti-mouse Ig antibodies (Dako A/S, Glostrup, Denmark) appropriately diluted in TBS-T. After another incubation for 2 h at room temperature the plates were washed and the bound biotinylated antibodies were detected by alkaline phosphatase conjugated streptavidin (Sigma), incubated for 2 h at room temperature. Using phosphatase substrate kit (Pierce) developed the colour reaction and the absorbance at 405 nm was measured after 1 h of incubation at room temperature. Mean values were calculated after the background was subtracted. Other assay models is of course applicable as well, such any immunoassay detecting an antibody, such as radioactive immunoassay, Western blotting, and Southern blotting, as well as detection of antibodies bound to peptides, enzyme electrodes and other methods for analysis.
Statistics
[0070] Data are presented as mean±Std. Statistical method used is listed in either text, table or figure legend. P<0.05 was considered as statistically significant.
[0000]
TABLE A
Aortic sinus plaque size and its lipid content, aortic arch plaque size
and percent of plaque in descending aorta.
Oil red
Total plaque
O (+) area
Aortic arch
% of plaque
size in aortic
(% of aortic
plaque
in aorta
sinus (mm 2 )
sinus plaque)
size (mm 2 )
(flat prep.)
Alum
0.49 ± 0.13
21.7 ± 4.4
0.057 ± 0.040
20 ± 4.7
Peptide 1
0.48 ± 0.14
32.0 ± 8.1
0.054 ± 0.027
17 ± 4.3
Peptide 301
0.46 ± 0.16
23.8 ± 4.1
0.050 ± 0.024
8.9 ± 2.2*
*Significant different from Alum group. ANOVA followed by Tukey-Kramer test was used for statistical analysis.
[0071] Further data on the effect of immunization with apolipoprotein B-100 peptide sequences on atherosclerosis in apo E knockout mice is given below in Table B
[0000]
TABLE B
Effect of immunization with apolipoprotein B-100 peptide sequences
on atherosclerosis in apo E knockout mice
Effect on atherosclerosis
in the aorta
Immunizations using mixtures of several peptide sequences
1. Peptide sequences 143 and 210
−64.6%
2. Peptide sequences 11, 25 and 74
−59.6%
3. Peptide sequences 129, 148 and 167
−56.8%
4. Peptide sequences 99, 100, 102, 103 and 105
−40.1%
5. Peptide sequences 30, 31, 32, 33 and 34
+6.6%
6. Peptide sequences 10, 45, 154, 199 and 240
+17.8%
Immunizations using a single peptide sequence
1. Peptide sequence 2
−67.7%
2. Peptide sequence 210
−57.9%
3. Peptide sequence 301
−55.2%
4. Peptide sequence 45
−47.4%
5. Peptide sequence 74
−31.0%
6. Peptide sequence 1
−15.4%
7. Peptide sequence 240
0%
[0072] Administration of the peptides is normally carried by injection, such as subcutaneous injection, intravenous injection, intramuscular injection or intraperitoneal injection. A first immunizing dosage can be 1 to 100 mg per patient depending on body weight, age, and other physical and medical conditions. In particular situations a local administration of a solution containing one or more of the peptides via catheter to the coronary vessels is possible as well. Oral preparations may be contemplated as well, although particular precautions must be taken to admit absorption into the blood stream. An injection dosage may contain 0.5 to 99.5% by weight of one or more of the fragments or peptides of the present invention.
[0073] The peptides are normally administered as linked to cationized bovine serum albumine, and using aluminium hydroxide as an adjuvant. Other adjuvants known in the art can be used as well.
[0074] Solutions for administration of the peptides shall not contain any EDTA or antioxidants.
[0075] The peptides can also be used as therapeutic agents in patients already suffering from an atheroschlerosis. Thus any suitable administration route can be used for adding one or more of the fragments or peptides of the invention.
[0076] Initial studies focused on determining which type of oxidative modifications of peptides led to recognition by antibodies in human plasma. These studies were done using peptides 1-5 and 297-302. During oxidation of LDL polyunsaturated fatty acids in phospholipids and cholesteryl esters undergo peroxidation leading to formation of highly reactive breakdown products, such as malone dialdehyde (MDA). MDA may then form covalent adducts with lysine and histidine residues in apo B-100 making them highly immunogenic. Oxidation of LDL also results in fragmentation of apo B-100 that may lead to exposure of peptide sequences not normally accessible for the immune system. In these experiments peptides were used in their native state, after MDA modification or after incorporation into phospholipid liposomes followed by copper oxidation or MDA-modification. IgM antibodies were identified against native, MDA- and liposome oxidized peptides, with antibody titers MDA-peptide>MDA-modified liposome peptides>liposome oxidized peptide>native peptide. Specificity testing demonstrated that binding of antibodies to MDA-modified peptides was competed by both MDA-LDL and copper oxidized LDL.
[0077] We then performed a screening of the complete peptide library using pooled plasma derived from healthy control subjects and native and MDA-modified peptides as antigens. Antibodies to a large number of sites in apo B-100 were identified. Using twice the absorbance of the background control as positive titer cut off, antibodies were detected against 102 of the 302 peptides constituting the complete apo B-100 sequence. IgM binding was substantially more abundant than that of IgG. Generally, binding was higher to MDA modified peptide sequences than to the corresponding native sequence, but these was a striking correlation between the two. Binding to both native and MDA modified sequences was competed by addition of MDA-modified LDL and copper oxidized LDL, but not by native LDL. These observations suggest that immune responses against MDA-modified peptide sequences in apo B-100 results in a cross reactivity against native sequences. The inability of native LDL to compete antibody binding to native apo B-100 peptide sequences is intriguing, but may indicate that these sequences only become exposed after the proteolytic degradation of apo B-100 that occurs as a result of LDL oxidation. Both hydrophilic and hydrophobic parts of the molecule were recognized by antibodies. A second screening of the apo B-100 peptide library was performed using pooled plasma from subjects with clinical signs of coronary heart disease (CHD, acute myocardial infarction (AMI) and unstable angina; n=10). Antibodies in pooled CHD plasma bound to the same sequences and with the same overall distribution as for antibodies in healthy control plasma. However, antibody titers to several peptides (#1, 30-34, 100, 107, 148, 149, 162, 169, 236, 252 and 301) were at least twice as high as in control plasma compared to plasma from CHD subjects, whereas titers against a few peptides (#10, 45, 111, 154, 199, 222 and 240) were higher in plasma from CHD patients compared to controls. We then performed a prospective clinical study to investigate if antibody levels against MDA-modified peptide sequences in apo B-100 predict risk for development of CHD. Using a nested case control design we selected 78 subjects with coronary events (AMI or death due to CHD) and 149 controls from the MalmöDiet Cancer Study. Neither cases nor control individuals had a history of previous MI or stroke. The median time from inclusion to the acute coronary event was 2.8 years (range 0.1-5.9 years) among cases. Antibody levels were determined in baseline plasma samples supplemented with antioxidants. Using the carotid intima-media thickness (IMT) as assessed by ultrasonography at baseline we also analyzed associations between antibody levels and degree of existing vascular disease. We studied 8 MDA-modified peptide sequences that in the initial screening studies were associated with high plasma antibody levels (#74, 102 and 210) and/or marked differences between control and CHD plasma pools (#32, 45, 129, 162 and 240). Controls were found to have higher IgM levels against MDA peptide 74 (0.258, range 0-1.123 absorbance units versus 0.178, range 0-0.732 absorbance units, p<0.05), otherwise there were no differences in antibody levels between cases and controls. Associations between IMT and IgM against MDA-peptides #102, 129, and 162 (r=0.233, 0.232, and 0.234, respectively, p<0.05) were observed in cases and between IMT and MDA-peptide 45 (r=0.18, p<0.05) in controls. Weak correlations were observed between antibodies to MDA peptide 129 and total and LDL cholesterol (r=0.19 and r=0.19, p<0.01, respectively), otherwise peptide antibody levels showed no associations with total plasma cholesterol, LDL cholesterol, HDL cholesterol or plasma triglycerides. There were strong co-variations between antibody levels to the different peptides (r values ranging from 0.6 to 0.9). The only exception was antibodies against MDA-peptide 74 that were weakly or not at all related to antibodies against the other peptides.
[0078] Antibodies against all sequences except MDA-peptide 74 was inversely associated with age among cases (r values ranging from −0.38 to −0.58, p<0.010.001), but not in controls. Plasma levels of oxidized LDL, in contrast, increased with age. Again this association was stronger in cases than in controls. To investigate if the associations between immune responses against MDA-modified peptide sequences and cardiovascular disease were different in different age groups a subgroup analysis was performed on cases and controls under and above the median age (61 years). In the younger age group cases had increased antibody levels against peptides 32 and 45 and decreased antibody levels against peptide 74 as compared to controls, whereas no differences were seen in the older age group. Antibodies against all MDA peptide sequences, except peptide 74, were significantly associated with IMT in the younger age group, but not in the older (Table).
[0079] These studies identify a number of MDA-modified sequences in apo B-100 that are recognized by human antibodies. MDA-modification of apo B-100 occurs as a result of LDL oxidation indicating that these antibodies belong to the family of previously described oxidized LDL autoantibodies. This notion is also supported by the observation that antibody binding to MDA-modified apo B-100 peptides is competed by addition of oxidized LDL. Together with the oxidized phospholipids identified by Hörkkö et al, these MDA-modified peptide sequences are likely to constitute the large majority of antigenic structures in oxidized LDL. In similarity with the oxidized LDL antiphospholipid antibodies, antibodies against MDA-modified apo B-100 sequences were of IgM type. This may suggest that also the latter antibodies belong to the family of T 15 natural antibodies. T 15 antibodies have been attributed an important role in the early, T cell independent defense against bacterial infections as well as in the removal of apoptotic cells. It remains to be determined if the MDA-peptide antibodies described here have similar functions. Antibodies were also identified against a large number of native apo B-100 sequences. However, the striking co-variation between antibodies to native and MDA-modified sequences suggests that also these antibodies are formed in response to LDL oxidation. It is also possible that antibodies against an MDA-modified peptide sequence cross reacts with the corresponding native sequence. If antibodies against native apo B-100 sequences bind also to native LDL particles this is likely to have a major influence on LDL metabolism. However, the finding that native LDL does not compete antibody binding to native apo B-100 sequences, as well as the lack of correlation between antibodies against native apo B-100 sequences and LDL cholesterol levels against the existence of such a phenomena.
[0080] Antibodies against MDA-modified peptide sequences decreased progressively with age in the cases, but not in the controls. With the exception of MDA-peptide 74, IgM antibodies against MDA-peptides were significantly associated with carotid IMT in the younger age group (below 62 years), but not in the older age group. These findings suggest that significant changes in the interactions between the immune system and the atherosclerotic vascular wall takes place between ages 50 and 70 years. One possibility is that in younger individuals the atherosclerotic disease process is at a more active stage with a more prominent involvement of immune cells. Another possibility is that the decreased levels of antibodies against MDA-modified peptide sequences in older subjects reflect a senescence of the immune cells involved in atherosclerosis. An impaired function of immune cells due to immunosenescence have been proposed to contribute to an increased susceptibility to infection and cancer in the older population. Interestingly, immunosenescence is inhibited by antioxidants indicating involvement of oxidative stress. Immune cells that interact with epitopes in oxidized LDL are likely to be particularly exposed to oxidative stress. Since oxidized LDL is present in arteries already at a very early age these immune response are being continuously challenged for several decades, which may further contribute to a development of immunosenescence.
[0081] Increased antibodies against two sites in apo B-100 were found to predict risk for myocardial infarction and coronary death in subjects below 62 years of age. Antibodies against these sites showed a high level of co-variation suggesting that they were produced in response to the same underlying pathophysiological processes. The fact that the median time from blood sampling to coronary event was only 2.8 years makes these antibodies particularly interesting as makers for increased CHD risk. Antibody levels against MDA-modified apo B-100 peptide sequences showed no associations with other CHD risk factors such as hyperlipidemia, hypertension and diabetes suggesting that they are independent markers of CHD risk. The CHD cases in the present study were not extremely high-risk individuals and in this respect representative of the common CHD patient. The finding that IgM against MDA-modified apo B-100 sequences predicts short-term risk for development of acute coronary events in individuals that would not have been identified as high risk by screening of established risk factors suggest that it may become a useful instrument in identifying individuals in need of aggressive preventive treatment. However, considerably larger prospective studies with multivariate analysis are required before the clinical value of determining antibodies against apo B-100 MDA-modified peptide sequences can be fully established. Another limitation of the present clinical study is that we have only analysed antibodies against a small number of the antigenic sites in apo B-100 and that antibody titers against other sites may be even better markers of cardiovascular risk.
[0082] In subjects below age 60 antibodies against a large number of MDA-modified sites in apo B-100 were correlated with the extent of existing vascular disease as assessed by carotid IMT. IgM antibodies were more closely associated with carotid IMT than IgG antibodies. Although carotid IMT has obvious limitations as a measure of general atherosclerotic burden these observations still suggest that determination of IgM against MDA-modified sequences in apo B-100 may be one method to assess the severity of existing atherosclerosis. These observations are also in line with several previous studies that have reported associations between coronary and carotid artery disease and IgM antibodies against oxidized LDL.
[0083] Antibodies against peptide 74 differed against other apo B-100 peptide antibodies in many respect. They were higher in controls than in cases, they did not decrease with age and were not associated with the extent of carotid disease. Accordingly, antibodies against this peptide sequence represent interesting candidates for an athero-protective immune response.
[0084] An important question is why these associations occur. They clearly demonstrate that immune responses against MDA-modified apo B-100 sites somehow are involved in the atherosclerosic disease process. Since high antibody levels are associated with more severe atherosclerosis and increased risk for development of acute coronary events one obvious possibility is that these immune responses promote atherogenesis. Studies demonstrating that immune responses against heat shock proteins, such as HSP 65, are atherogenic provide some support for this notion. However, experimental animal studies have shown an athero-protective effect of oxidized LDL immunization. B cell reconstitution of spleen ectomized apo E null mice results in a decrease in atherosclerosis. Reduced atherosclerosis has also been observed in apo E null mice given repeated injections of immunoglobulin. The present observations do not necessarily argue against an athero-protective role of immune responses against oxidized LDL. These immune responses are activated by pro-atherogenic processes such as LDL oxidation. Accordingly, they are also likely to be in proportion to the severity of the disease process and could serve as makers of disease severity and CHD risk without contributing to disease progression. The finding that immunization of apo E null mice with apo B-100 peptide sequences inhibits development of atherosclerosis reported in two accompanying papers demonstrates that this is likely to be the case. Indeed, the most important outcome of the present study may well be the identification of structures that could be used as components of a vaccine against atherosclerosis. The observation that the decrease in antibodies against MDA-modified peptide sequences in apo B-100 that occurs with age is accompanied by an increase in plasma levels of oxidized LDL suggest that an increased clearance of minimally oxidized LDL from the circulation may be one mechanism by which these antibodies could protect against atherosclerosis.
Methods
Study Population
[0085] The study subjects, borr between 1926-45, belong to the Malmö“Diet and Cancer (MDC)” study cohort. A random 50% of those who entered the MDC study between November 1991 and February 1994 were invited to take part in a study on the epidemiology of carotid artery disease. Routines for ascertainment of information on morbidity and mortality following the health examination, as well as definition of traditional risk factors, have been reported.
[0086] Eighty-five cases of acute coronary heart events, i.e. fatal or non-fatal MI or deaths due to coronary heart disease (CHD) were identified. Participants who had a history of myocardial infarction or stroke (n=6) were not eligible for the present study. For each case two controls without a history of myocardial infarction or stroke was individually matched for age, sex, smoking habits, presence of hypertension and month of participation in the screening examination and duration of follow-up. Due to logistic reason (blood samples were not available in sufficient quantity for assessment of peptides) only one control was available for seven cases and no controls for one case. This case was excluded from analysis. Thus the study population consists of 227 subjects, 78 cases and 149 controls, aged 49-67 (median 61) years at baseline.
Laboratory Analyses
[0087] After overnight fasting blood samples were drawn for the determination of serum values of total cholesterol, triglycerides, HDL cholesterol, LDL cholesterol and whole blood glucose. LDL cholesterol in mmol/L was calculated according to the Friedewald formula. Oxidized LDL was measured by ELISA (Mercordia).
B-Mode Ultrasound Vasculography
[0088] An Acuson 128 Computed Tomography System (Acuson, Mountain View, Calif.) with a MHz transducer was used for the assessment of carotid plaques in the right carotid artery as described previously.
Development of ELISAs Against Apo B-100 Peptide Sequences
[0089] The 302 peptides corresponding to the entire human apolipoprotein B amino acid sequence were synthesized (Euro-Diagnostica AB, Malmö, Sweden and K J Ross Petersen A S, Horsholm, Denmark) and used in ELISA. A fraction of each synthetic peptide was modified by 0.5 M MDA (Sigma-Aldrich Sweden AB, Stockholm, Sweden) for 3 h at 37° C. and in presence of liposomes by 0.5 M MDA for 3 h at 37° C. or by 5 mM CUCl 2 (Sigma) for 18 h at 37° C. The MDA modified peptides were dialysed against PBS containing 1 mM EDTA with several changes for 18 h at 4° C. The modification of the peptides was tested in denatured polyacrylamide gels (BioRad Laboratories, Hercules, Calif.), suitable for separation of peptides.
[0090] A mixture of egg phosphatidylcholine (EPC) (Sigma) and phosphatidylserine (PS) (Sigma) in a chloroform solution at a molar ratio of 9:1 and a concentration of 3 mM phospholipid (PL) was evaporated in a glass container under gentle argon stream. The container was then placed under vacuum for 3 hours. A solution containing 0.10 mM peptide (5 ml) in sterile filtered 10 mM HEPES buffer pH 7.4, 145 mM NaCl and 0.003% sodium azide was added to the EPC/PS dried film and incubated for 15 min at 50° C. The mixture was gently vortex for about 5 min at room temperature and then placed in ice-cold water bath and sonicated with 7.5 amplitude microns for 3×3 min (Sonyprep 150 MSE Sanyo, Tamro-Medlab, Sweden) with 1 min interruptions. The PL-peptide mixture, native or modified by 0.5 M MDA for 311 at 37° C. or 5 mM CUCl 2 for 18 h at 37° C., was stored under argon in glass vials at 4° C. wrapped in aluminum foil and used within 1 week. The MDA-modified mixture was dialyzed against PBS containing 1 mM EDTA with several changes for 18 h at 4° C. before storage. The modification of the mixture was tested in denatured polyacrylamide gels (BioRad Laboratories AB; Sundbyberg, SE), suitable for separation of peptides.
[0091] Native or modified synthetic peptides diluted in PBS pH 7.4 (20 leg/ml), in presence or absence of liposomes, were absorbed to microtiter plate wells (Nunc MaxiSorp, Nunc, Roskilde, Denmark) in an overnight incubation at 4° C. As a reference, one of the peptides (P6) was ran on each plate. After washing with PBS containing 0.05% Tween-20 (PBS-T) the coated plates were blocked with SuperBlock in TBS (Pierce, Rockford, Ill.) for 5 min at room temperature followed by an incubation of pooled human plasma, diluted 1/100 in TBS-0.05% Tween-20 (TBS-T) for 2 h at room temperature and then overnight at 4° C. After rinsing, deposition of auto-antibodies directed to the peptides were detected by using biotinylated rabbit anti-human IgG- or IgM-antibodies (Dako A/S, Glostrup, Denmark) appropriately diluted in TBS-T. After another incubation for 2 h at room temperature the plates were washed and the bound biotinylated antibodies were detected by alkaline phosphatase conjugated streptavidin (Sigma), incubated for 2 h at room temperature. The color reaction was developed by using phosphatase substrate kit (Pierce) and the absorbance at 405 nm was measured after Ih of incubation at room temperature. The absorbance values of the different peptides were divided with the absorbance value of P6 and compared.
Statistics
[0092] SPSS was used for the statistical analyses. The results are presented as median and range and as proportions when appropriate. Boxplot and scatterplots were used till illustrate the relationship between age and selected peptides among cases and corresponding controls. Corresponding graphs were also used to illustrate the relationship between age and selected peptides, cases and controls, respectively, below and above the median age (61 year) at baseline and separately for cases and controls below the median age. In cases and controls, separately, partial correlation coefficients, adjusted for age and sex, were computed between selected peptides and blood lipid levels and common carotid IMT. Age- and sex adjusted partial correlation coefficients were also computed between common carotid IMT and selected peptides in cases and controls below and over the median age. An independent sample t-test was used to assess normally distributed continuous variables and a Chi-square test for proportions between cases and controls. Non-parametric test (Mann-Whitney) was used to assess non-normally distributed continuous variables between cases and controls. All p-values are two-tailed.
[0000]
TABLE
Age- and sex adjusted correlation coefficient for different baseline
MDA peptides and common carotid artery intima-media thickness
among younger (49-61 years) and older (62-67 years) cases with
myocardial infarction and their corresponding controls
matched for age, sex, smoking and hypertension.
CASES plus CONTROLS
CASES plus CONTROLS
PEPTIDE
Aged 49-61 year, n = 116
Aged 62-67 year, n = 111
IGM
MDA 32
0.235t
−0.101
MDA 45
0.366$
−0.030
MDA 74
0.178
0.063
MDA 102
0.255$
−0.039
MDA 129
0.330$
−0.009
MDA 162
0.2451
0.001
MDA 210
0.254
0.013
MDA 240
0.284$
0.006
IGG
MDA 215
0.119
−0.059
p < 0.05; $/x0.01
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The present invention relates to antibodies raised against fragments of apolipoprotein B, in particular defined peptides thereof, for immunization or therapeutic treatment of mammals, including humans, against ischemic cardiovascular diseases, using one or more of said antibodies.
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BACKGROUND OF THE INVENTION
The present invention relates to apparatus for turning circular knit hose inside out, sectioning it into a required number of unit hoses and closing each toe thereof with stitches on a continuous line.
In the production of hosiery, such as stockings and socks, a commonly-called "rib knitter" or a double cylinder knitting machine is employed to knit a long continuous circular hose. In this process it is necessary to section a long continuous hose band into unit hoses. To this end waste portions must be interposed between adjacent unit hoses. The stitches around the sectioned part are picked up by the operator's fingers. This is an extremely labor- and time-consuming operation, which of course reflects in the price of the product.
In addition, to effect the subsequent linking operation on each toe, it is previously required to turn each hose inside out. After the linking operation is finished, the normal side is again turned outside so as to enable the unit hose to be vapor set. This is also very time-consuming.
OBJECTS AND SUMMARY OF THE INVENTION
The present invention aims at solving the problems mentioned above, and to provide an improve apparatus for turning a circular knit hose inside out, sectioning it into a required number of unit hoses, closing each toe thereof, and turning the normal side out in an automatic manner.
Other objects and advantages of the present invention will become apparent from the detailed description given hereinafter; it should be understood, however, that the detailed description and specific embodiment are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
According to the present invention, there is provided apparatus for turning a circular knit hose inside out, sectioning the knit hose into unit hoses, and linking each toe portion thereof with stitches, the apparatus comprising a suction pipe for pulling a knit hose by suction therethrough, a cutter unit mounted on a movable carrier, the cutter unit having means whereby the knit hose is stretched so as to ensure an easy cutting, an apron conveyor having slats transversely provided, each of the slats including a hollow cylinder for allowing a circular knit hose to be supported thereon, and a clamp unit located at the opposite side to the cylinder, the clamp unit being capable of tilting toward the cylinder, a linking device located at a position where the clamp unit is tilted, means for releasing the knit hose from the clamp unit, and a suction duct for pulling the unit knit hose by suction, the suction duct being communicatable with the rear end of the cylinder which comes to the turning point of the conveyor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing an apparatus embodying the present invention;
FIG. 2 is a plan view on an enlarged scale of the section indicated II in FIG. 1, at which the knit hose is stretched for cutting;
FIG. 3 is a front view on an enlarged scale of a cutter unit;
FIG. 4 is a left side view, partly omitted, of the cutter unit;
FIG. 5 is a front view on an enlarged scale of a guide unit;
FIG. 6 is a left side view of the guide unit;
FIG. 7 is a plan view showing one section of an apron conveyor in which a slat is provided to support a hollow cylinder and a clamp unit;
FIG. 8 is a right side view of the section shown in FIG. 7;
FIG. 9 is a front view, partly omitted, of the section shown in FIG. 7;
FIG. 10 is a schematic view showing the relationship between the guide unit and the clamp unit;
FIG. 11 is a schematic view showing the state at which the knit hose is stretched by engagers;
FIG. 12 is a schematic view showing the clamp unit holding a sectioned unit hose;
FIG. 13 is a schematic view showing the state at which the clamp unit is tilted at 90° thereby to cause the toe portion to stand upright for stitching;
FIG. 14 is a plan view showing the state of FIG. 13;
FIG. 15 is a schematic view showing the operation of the clamp unit;
FIG. 16 is a schematic view showing the relationship of the clamp unit and a pushing rod.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a long continuous knit hose band 1 is fed from a double cylinder knitting machine (not shown) to an air suction pipe 2. The forward end of the knit hose 1 is placed around the `tail end` of the pipe 2 by an operator as shown in FIG. 1. The reference numeral 3 designates a pair of contact rollers, which are capable of rolling on the air suction pipe 2 while keeping contact with the surface thereof, whereby the knit hose 1 is caused to slide on the surface of the air suction pipe 2 towards the `top end` thereof until the forward end of the knit hose reaches the depth of the air suction pipe 2. At this stage the terminating end of the knit hose 1 projects slightly beyond the `tail end` of the air suction pipe 2. When the air in the pipe 2 is sucked, the knit hose 1 is sucked into the air suction pipe 2. The air suction device is a known type, and a description thereof is omitted. The knit hose 1 which is turned inside out is taken out at an outlet 4. The process mentioned above is hereinafter referred to as the knit hose turning section 5.
Referring to FIGS. 1 and 2, there is provided a bed 6 on which a crank disc 7 coupled to a driving shaft of an electric motor M 1 is mounted. The crank disc 7 has a rod 8 suspended downwards. The downward end of the crank rod 8 is fastened to a carrier 10 capable of vertically moving on a pair of rails 9 provided on the bed 6.
The knit hose band 1 is previously provided with a toe portion 1' and a welt portion 1" between which the knit hose is additionally provided with a separating section 11. The separating section 11 is thin sufficiently to produce steps against the toe portion and the welt portions. The steps are intended to be engaged by an upper engager 12 having an upper cutter 12', and a lower engager 13 having a lower cutter 13'. As shown in FIGS. 2 and 3, the upper engager 12 and the lower engager 13 are mounted on the carrier 10, wherein the upper engager 12 is supported on a bracket 14 such that the height of the upper engager 12 is adjustable with respect to the knit hose 1, whereas the lower engager 13 is fixed to the carrier 10. In FIG. 3 the reference numeral 15 designates a cutting blade pivotally supported on the carrier 10. The cutting blade 15 is connected to a crank rod 17 of a crank disc 16 driven by an electric motor M 2 by means of a connecting rod 15'.
There is provided an upper guide 18 opposedly to the side of the upper engager 12, the guide 18 being supported on a bracket 20 upright on the bed 6 such that the height thereof is adjustable with respect to the knit hose 1. Likewise, there is provided a lower guide 19 slightly spced from the upper guide 18, the lower guide 19 being fixed to the bed 6. The positional relationship among the engagers 12 and 13, the guide members 18 and 19, and the knit hose 1 is best illustrated in FIG. 11. As shown in FIG. 10, the separating section 11 of the knit hose 1 is placed between the upper and the lower cutters 12' and 13', and between the upper and the lower guides 18 and 19. At this stage both engagers 12 and 13 are moved by energizing the motor M 1 in the direction indicated by the arrow in FIG. 10. Thus the separating section 11 is stretched as shown in FIG. 11, and cut at a point adjacent to the welt portion 1" by means of the cutting blade 15. The reference numeral 21 designates an apron conveyor, which consists of a series of slats 22. As best shown in FIG. 8, each slat 22 is provided with a pair of brackets 23 at the inner side thereof, the brackets pivotally supporting a first plate member 26 to which a second plate member 25 is pivotally coupled. The two plate members 25, 26 are capable of pivotal movement in the direction indicated by the arrow in FIG. 8, so that they take a position indicated by dotted lines therein. FIG. 8 is a side view whereas FIG. 9 is a front view in which, unlike FIG. 8 the raised position is shown in dotted lines. The second plate member 25 is provided with a recess 25' at its top end as shown in FIG. 9, which recess 25' is engaged by a metal piece 27 fixed to an end face of the first plate member 26 so as to secure the union of the two plate members 25 and 26. The second plate member 25 is additionally provided with a projecting part 25" at the opposite end, which is adapted for engagement with a spring member 28 fixed to the opposite end face of the first plate member 25. By engagement with the spring member 28 the second plate member 25 undergoes an upward urge. The contacting faces of the two plate members 25, 26 are formed in a saw-tooth form so as to enable both plates, when met, to function as a clamp suitable for holding a soft material, such as knit hose. The unit of the two plate members will be hereinafter referred to as the clamp unit 30.
In addition to the clamp unit 30, each slat 22 is provided with a short cylinder 24 at the opposite side to the brackets 23, that is, at the outer side of the apron conveyor 21, the short cylinder being held in parallel with the top surface of the slat 22 but spaced therefrom as best shown in FIG. 8. The short cylinder 24 is used to support a unit knit hose 1 which is placed around it. The short cylinder 24 is supported by a bracket (not numbered) or any other known means.
At the position indicated by the II in FIG. 1 an electric motor M 3 is supported on a stand (not numbered) on the carrier 10 as shown in FIG. 15, and a cam plate 29 is coupled to the shaft of the motor M 3 . The cam plate 29 comes into contact with the second plate member 25 during rotation, thereby enabling the second palte member 25 to come into engagement with the first plate member 26. In this way the two plate members 25 and 26 are met between which the toe portion 1' is clamped with the indented faces. The knit hose 1 is fed in a continuous band to the position II at which it is sectioned into unit hoses, each of which is clamped by the clamp unit 30 and transported to a position III (FIG. 1). At the position III a pushing rod 31 is provided on the bed 6, at a position adjacent to the path along which the clamp units 30 pass. The pushing rod 31 is used to push the clamp unit 30 toward the short cylinder 24. The clamp unit 30 is inwardly tilted as shown in FIG. 16. When the clamp unit 30 is half tilted, the gravitation acts thereon to allow same to make flat. Thus the toe portion 1' is upwardly directed at which posture the toe portion is linked with stitches.
The reference numeral 32 designates a linking device whereby the toe portion 1' is stitched, the stiching device is located above the apron conveyor 21. The linking device 32 includes a crank disc 33 located at the position 1V (FIG. 1), a pushing rod 34 reciprocally moved in association with the rotation of the crank disc 33 while keeping contact with the periphery of the crank disc 33, wherein the pushing rod 34 is passed through the bed 6 in a diagonally upward posture as shown in FIG. 8. The pushing rod 34 causes the clamp unit 30 to stand uprightly when the clamp unit 30 reaches the position 1V with the toe portion 1' having its open ends stitched. The pushing rod 34 further advances, and lowers the second plate member 25 so as to disengage same from the first plate member 26. In this way the knit hose 1 is released from the clamp unit 30. At this stage the knit hose 1 is supported on the short cylinder 24, and reaches the position V.
At the position V there is provided a suction duct 37 whereby the knit hose 1 is again turned inside out such that its normal side comes outside. The reference numeral 37' designates a catcher reciprocally moved by means a crank rod 36 pivoted on a crank disc 35, the catcher 37' being connected to the suction duct 37. The catcher 37' is placed into engagement with the rear end of each short cylinder 24 as shown in FIG. 1.
At the position V where each slat 22 changes its posture from horizontal to vertical in accordance with the turning of the conveyor 21, there is provided a rotor 38 driven by a motor M 4 , the rotor being adapted to cause the knit hose supported around the short cylinder 24 to advance toward the opening of the cylinder by friction. At this stage the short cylinder 24 is in communication with the suction duct 37 via the catcher 37'. The knit hose 1 half hung at the inner opening of the cylinder 24 is ready to be sucked into the suction duct 37 under pressure. The reference numeral 39 designates a bracket on which the motor M 4 is mounted. The bracket 39 is movable by a motor M 5 such that the rotor 38 is placed into contact with the knit hose on the short cylinder 24 and out of contact therefrom. In FIGS. 8 and 9 the reference numeral 40 designates carriers linked to each other so as to support the slats 22. The reference numeral 41 designates cams located in opposite sides of the conveyor 21, whereby the toe portion 1' of the knit hose reaching beneath the linking device 32 is raised upwards so as to facilitate the linking operation.
In operation, the forward end of a long continuous knit hose band 1 is placed around the `tail end` of the suction pipe 2 by hand. The contact rollers 3 are started to rotate and advance to the `tail end` of the suction pipe 2, then returns to the depth of the suction pipe 2 while pulling the knit hose band by friction. At this stage the terminating end of the knit hose band 1 slightly projects beyond the `tail end` of the suction pipe 2. Then the air in the pipe 2 is sucked, thereby causing the knit hose band to be sucked from its terminating end into the suction pipe 2. In this way the knit hose is turned inside out. The contact rollers 3 are reversely rotated and advanced so as to facilitate the long knit hose band 1 being sucked into the pipe 2. The turned knit hose band 1 is taked out of the outlet 4 by the operator. At the position I (FIG. 1) the knit hose band 1 is placed around each short cylinder 24 one by one, and at the position II the separating section 11 of the knit hose 1 is placed between the upper and the lower cutters 12', 13', and between the upper and the lower guides 18, 19. The motor M 1 is switched on, and the carrier 10 is moved, thereby causing the engagers 12, 13 to separate from the guides 18, 19. Thus the separating section 11 is stretched as shown in FIG. 11. At this moment the motor M 3 is switched on, and the cam plate 29 is rotated, thereby pressing the second plate member 25 against the first plate member 26 so as to hold the toe portion 1' of the knit hose therebetween. Then the motor M 2 is switched on, and cutting blade 15 cuts the knit hose in its separating section 11. The clamp unit 30 continues to hold the knit hose 1, and at the position IV the clamp unit 30 comes into engagement with the pushing rod 31, whereby the clamp unit 30 is tilted at 90° thereby to cause the toe portion 1' to direct upwards. At this moment the slat 22 is raised toward the linking device 32 by the action of the cams 41. The linking operation is started on the toe portion 1'. When the clamp unit 30 comes into engagement with the pushing rod 34 at the position IV, the clamp unit 30 is caused to stand upright, and the pushing rod 34 raises the second plate member 25 thereby to release the toe portion 1' from the clamp unit 30.
When the knit hose 1 held on the short cylinder 24 reaches the position V, the motor M 5 is switched on, and the rotor 38 is moved above the short cylinder 24. Simultaneously, the catcher 37' is placed into engagement with the rear end of the short cylinder 24 so as to secure the internal communication therebetween. When the suction duct 37 is connected to the short cylinder 24 through the catcher 37', the motor M 4 is switched on, and the rotor 38 is rotated in the direction in which the toe portion 1' is displaced toward the forward opening of the short cylinder by friction. The suction is started through the suction duct 37, whereby the knit hose 1 is turned inside out again, which means that its normal side comes outside.
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An apparatus for turning a circular knit hose inside out, sectioning the knit hose into unit hoses, and linking each toe portion thereof with stitches, characterized in that the apparatus comprising an air suction pipe for pulling a long knit hose by air suction therethrough, a cutter unit mounted on a movable carrier, the cutter unit having means whereby the knit hose is stretched so as to ensure an easy cutting, an apron conveyor having slats transversely provided, each of the slats including a hollow cylinder for allowing a circular knit hose to be supported thereon, and a clamp unit located at the opposite side to the cylinder, the clamp unit being capable of tilting toward the cylinder, a linking device located at a position where the clamp unit is tilted, means for releasing the knit hose from the clamp unit, and a suction duct for pulling the unit knit hose by suction, the suction duct being communicatable with the rear end of the cylinder which comes to the turning point of the conveyor.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system and method for providing information concerning a live event, tourist attraction, etc. to a material object via a kiosk, the Internet, a personal computer, or other electronic system.
BACKGROUND OF THE INVENTION
[0002] Kiosks have been used for providing tickets and greeting cards. These prior art uses relate to providing textual material which can be inserted at designated locations on a card. These cards have prestored graphic design elements.
[0003] U.S. Pat. No. 5,615,123 relates to a system for creating and producing custom card products. The patent relates to a method of and apparatus for creating and producing printed card products, such as greeting cards for various applications, whereby a customer can select a card product for a desired application and customize or personalize certain portions of the selected card product. A terminal area or kiosk is provided at which the customer selects from a monitor screen display one of a number of different general applications for which they want to obtain a card product. Upon entry of the selection, one or more prestored groups of card product design formats pertaining to the selected general application are determined, and further inquiries are made to elicit information relating to a specific use or application for the desired card product. Once this information is entered, certain ones of the determined card product design formats are identified as pertinent and displayed to the customer who can choose a card product format to customize. The customized card product is then created.
[0004] U.S. Pat. No. 5,687,087 relates to a card printing and dispensing system located at the venue of an ongoing or recently completed entertainment event and including a video display monitor, a customer interface, a printer, and a computer control. A customer interested in purchasing a card selects using the customer interface from a variety of options displayed on the video monitor a desired card unique to the particular ongoing or recently completed entertainment event for printing and dispensing by the system. The system is particularly suited to printing and dispensing unique baseball cards which would include information corresponding to an individual game or series of games and available only at the venue where the individual game or series of games were actually played.
SUMMARY OF THE INVENTION
[0005] The present invention comprises a system and method for dispensing information material which was presented at a live event.
[0006] The present invention relates to a system for dispensing information material which was presented at a live event. The information can be produced during the event, immediately after the event or at a later time. The system comprises a recording apparatus for recording a live event. The recording apparatus is connected to a computer which stores information regarding the event. The computer is connected to a dispensing apparatus which dispenses the information onto a material object. The dispensing apparatus has a customer interface where a user selects the information to be downloaded onto the material object. The system further comprises a printing apparatus for download the information from the computer to a material object. The printing apparatus may download a picture onto a card, download music onto a CD, or download video onto a cassette. Material objects can be stored in the dispensing apparatus or placed in the dispensing apparatus for downloading the information.
[0007] It is an object of the present invention for the material objects to include, cards, tapes, CDs, floppy disks, videos and sheets of paper. It is an object of the present invention for the material objects to have preprinted information on it concerning the live event. It is an object of the present invention for the information to be an audio of an event or portions of an event. It is an object of the present invention for the information to be a video of an event or portions of an event.
[0008] It is a further object of the present invention for the dispensing apparatus to comprise Kiosks, Internet, a personal computer or other electronic devices. It is an object of the present invention for the dispensing apparatus to be located at the site of an event, such as a sporting event, concert, or at a tourist attraction. It is an object of the present invention for the dispensing apparatus is located at a user's home, or office.
[0009] It is an object of the present invention for the kiosk to be stocked with an inventory of material objects, i.e., cards or paper for printing, or stocked with tapes, CDs, or floppy disks for audio or videos.
[0010] It is an object of the present invention for the customer interface to be a keypad, touch screen or microphone. It is an object of the present invention for the recording apparatus to be a video camera, digital still camera, or sound recording device.
[0011] It is an object of the present invention for the system to further comprise a system for accepting payment. It is an object of the present invention for the system for accepting payment to comprise; a slot for receiving monetary denominations, a device for sweeping a credit card or a system for verifying of credit or debit card by a remote database having verification information.
[0012] It is an object of the present invention for the computer to have information prestored on it relating to the persons performing at the live event.
[0013] The present invention relates to a method for dispensing information material which was presented at a live event comprising; inputting information into a dispensing apparatus regarding downloading information to a material object. The information is received by a computer that interacts with a customer through a video monitor or via a wireless device. The user searches for a particular action that happened during an event or the system provides the user with a choice of actions to have printed on the material object. Based on the user's choice, the system provides to the user a sample of written information about an action, displays a picture of what will be printed on the material object or provides a partial recording to a user from the system. The user then confirms the selection or chooses a further selection. Once a selection is chosen, the information is downloaded onto the material object and delivered to the user.
[0014] It is an object of the present invention for the material objects to include, cards for printing, tapes, CDs, floppy disks, videos and sheets of paper. It is an object of the present invention to provide information regarding a live event on cards printed and dispensed at a kiosk which is operable by a user. It is an object of the present invention to provide information in the form of an audio of an event or portions of an event. It is an object of the present invention to provide information in the form of a video of an event or portions of an event.
[0015] It is an object of the present invention for the dispensing apparatus to comprise a kiosk, or personal computer, etc. It is an object of the present invention for the dispensing apparatus to be located at the site of an event, such as a sporting event, concert, or at a tourist attraction. It is an object of the present invention for the dispensing apparatus to be located at a user's home, or office.
[0016] It is an object of the present invention to provide a dispensing apparatus at other locations other than the event which can dispense video, audio or other information from a live event onto a material object. It is an object of the present invention to provide a kiosk which is stocked with an inventory of material objects, i.e., cards or paper for printing, or stocked with tapes, CDs, or floppy disks for audio or videos.
[0017] It is an object of the present invention for the merchandise to be controlled through a customer interface, such as a keypad or touch screen, and information regarding the transaction is displayed to the customer on a video monitor. It is an object of the present invention to allow a user to request the information via voice interaction. The customer inputs what they are requesting and the request is received by a computer that interacts with the customer through the video monitor or via a wireless device.
[0018] The customer can either search for a particular action that happened during the event or the dispensing apparatus through a monitor can provide a user with a choice of actions to have printed on the material object. In one embodiment, the system can provide written information about an action or show a picture of what will be printed on the material object. Once a selection is made by the user, the system sends the information to the material object and dispenses the material object to the user.
[0019] It is an object of the present invention to provide sports cards. It is an object of the present invention to provide concert cards. It is an object of the present invention to provide tourist site cards.
DETAILED DESCRIPTION OF THE INVENTION
[0020] In one embodiment, a user attends an event. At the event is located a kiosk which has stored in it a number of blank material objects, or a user can provide the blank material objects to the kiosk. In one embodiment, the material objects are blank or preprinted cards. In a second embodiment, the material objects are tapes or CDs, etc. for burning an audio. In a further embodiment, the material objects are tapes or other devices for playing a video. The kiosk is connected to a device which is taping the event live.
[0021] A user goes up to the kiosk and chooses the type of action which they want printed onto the material object. The kiosk can either give the user a choice of actions to choose from or the user can provide information to the kiosk regarding which action the user wishes to purchase. For instance, if the user is attending a concert, the kiosk monitor can offer different photos of events during the concert. These photos can be shown to the user as actual photos which will be printed on a card or can be written information describing what will appear on the card. In a preferred embodiment, the cards can also have printed information displayed on the front or back of the card. This information can include the date of the event or other information regarding the event. This information can be prestored on the cards or be printed when the action is chosen to be printed on the card. In a further embodiment, the user can search for or describe what action they would like printed on the card. For example since the kiosk can be connected to a system that is taping the event live, the user may know where in the concert an action occurred and search for that action at the kiosk. When a user finds the action they want to print, they can instruct the kiosk to print the action onto the material object.
[0022] In a further embodiment, a user at an event can approach a kiosk and request an audio tape of an event or portions of an event. For example, a user can attend a concert, and either during the concert or after the concert approach a kiosk and request certain songs from the concert be downloaded or burned onto a CD, recorded onto a tape or downloaded to a Rio, Palm Pilot, Lap Top or Real Player. In an embodiment, the video monitor of the kiosk can provide the names of the songs, which the user can choose. In a further embodiment, the user can search for the songs that they request be downloaded.
[0023] In a further embodiment, a user can approach a kiosk and select video of the event that they were attending. The video can then be downloaded onto a material object. The user can, for example, select from actions which are identified on the monitor of the screen. For example, if a user attends a sporting event, the list of actions can include great plays that occurred during the game or bloopers that occurred during the game. The user can choose specifically a player and have a video regarding that player downloaded onto a material object. The user can also download a still picture of that player during that play or from a pre-recorded gallery of portraits/photos.
[0024] In a further embodiment, a user can go to a dispensing, apparatus, i.e., kiosk, or personal computer, which is connected to a system which is gathering information, i.e., video and/or audio, of a live event. The dispensing apparatus does not have to be located at the event, but can be located anywhere including a mall, office building, or a home.
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A system and method for providing information concerning a live event, tourist attraction, etc. to a material object via a kiosk, the Internet, a personal computer or other electronic system.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a parking brake for a motor vehicle, in particular for a tractor.
[0002] As is known, a parking brake, referred to commonly as “hand brake,” enables parking of the motor vehicle just by acting on the brake lever located in the cab. Consequently, the operator, even in the case where the engine of the motor vehicle is turned off, must engage the parking brake manually.
[0003] It has thus appeared desirable to provide a parking brake that may be activated automatically whenever the engine of the motor vehicle is turned off, and which, in any case, may be able to function as a traditional hand brake, and hence can be engaged manually by the operator, even when the engine of the motor vehicle is on. In the latter case, the motor vehicle should not have any gear engaged and, hence, be in neutral.
[0004] Consequently, a purpose of the present invention is to provide a parking brake that will carry out the aforesaid functions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention will now be described further, by way of example, with reference to the accompanying drawings showing a non-limiting example of embodiment thereof, in which:
[0006] FIG. 1 illustrates, as a whole, a parking brake according to the invention;
[0007] FIG. 2 is a front view of a braking device used in the parking brake according to the invention;
[0008] FIG. 3 is a cross-sectional view according to the line A-A of the braking device of FIG. 2 ;
[0009] FIG. 4 is a perspective view of the braking device of FIGS. 2 and 3 ;
[0010] FIG. 5 is a perspective view of some elements belonging to the braking device shown in FIGS. 2-4 ;
[0011] FIG. 6 is a perspective view, from another angle with respect to that of FIG. 5 , of some elements belonging to the braking device shown in FIGS. 2-5 ;
[0012] FIG. 7 is a perspective view of some elements used in the braking device of FIGS. 2-6 ;
[0013] FIG. 8 is a perspective view of some elements used in the braking device of FIGS. 2-7 ; and
[0014] FIG. 9 is a plan view of a cam used in the braking device illustrated in FIGS. 2-8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] FIG. 1 shows a parking brake 100 according to the preferred embodiment. The parking brake 100 comprises a manual operating lever 10 which is pivoted on a fulcrum 11 and is located in a control cab (not illustrated) of a motor vehicle (not illustrated).
[0016] The parking brake 100 has the purpose of braking a bevel pinion 12 , which meshes with a fitted crown wheel 13 , which transfers the motion to two axle shafts 14 ( FIG. 1 shows only one of them) on which are mounted two drive wheels W (only one shown in FIG. 1 ) of the motor vehicle.
[0017] A spindle 15 , unitary connected with the pinion 12 , carries a plurality of brake disks 16 actuated by a braking device 50 , the constructional elements of which will be described in greater detail hereinafter with particular reference to the other annexed figures. In order to operate the braking device 50 , a cable 17 (preferably of a Bowden type, although other cables or even other types of linkages may be used) is disposed between the lever 10 and the braking device 50 .
[0018] More in particular, the cable 17 ( FIG. 1 ) is connected, on one side, to an eyelet 18 made on the lever 10 , whilst, on the other side, it is connected to an eyelet 51 provided on a relay lever 52 , which forms an integral part of the aforementioned braking device 50 (see further).
[0019] It is to be understood that in the ensuing description only the items present in the attached drawings that are essential for an understanding of the present invention will be numbered and described.
[0020] Referring now to FIGS. 2 and 3 , the braking device 50 comprises a main body 53 , which provides, preferably as a single unit, a plate 53 a for fixation to the frame (not shown) of the motor vehicle, a cylinder 53 b, and projecting portions 53 c, which are designed to support the brake disks 16 (visible only in FIG. 1 ). Furthermore, the plate 53 a comprises six through holes 54 , each of which is provided with a respective bolt 55 for fixing to the rear transmission case (not illustrated) of the motor vehicle. The cylinder 53 b is closed at its bottom end by a disk 56 fixed thereto with means known and not described.
[0021] As shown in FIG. 3 , defined within the cylinder 53 b is a chamber 57 designed to house a piston 58 , on which an adjustment pin 59 rests. One end 59 a of the adjustment pin 59 is in turn screwed to an internal threaded portion of a bushing 60 provided with a terminal flange 61 . The bushing 60 is housed partially in a through hole 60 a made in the disk 56 and can slide freely in said through hole 60 a.
[0022] Between the terminal flange 61 and the disk 56 , a pack of Belleville washers 62 are tightly fitted; the washers 62 carrying out an indirect elastic action on the piston 58 via the bushing 60 and the adjustment pin 59 screwed thereto. Connected to the piston 58 on the other side of the adjustment pin 59 is a stem 64 terminating with a fork 65 .
[0023] Also the other end 59 b of the adjustment pin 59 is threaded. Screwed to this end 59 b is an adjustment detent 63 a which is variably tightened for reasons that will be explained in greater detail hereinafter. As best shown in FIGS. 2 and 3 , the aforesaid adjustment detent 63 a is set between a nut 63 screwed onto the lower end of the adjustment pin 59 and the bottom surface of the disk 56 .
[0024] To return to the chamber 57 , it may be noted that a portion 57 a is designed to receive pressurized oil coming from a hydraulic circuit (not shown) of the motor vehicle. More particularly, with reference to FIGS. 2 and 3 , it will be seen that the pressurized oil is brought to the portion 57 a by means of a hydraulic line 66 , inflow of oil being controlled by a solenoid valve 67 ( FIG. 2 ). In addition, the oil contained in the portion 57 a is discharged, when needed (see later), through a port 68 , visible in FIG. 3 , connected directly to the rear-transmission case (not illustrated) of the tractor.
[0025] The fork 65 connects the stem 64 via a pin 69 to a crank 70 provided with a circular cavity 71 ( FIG. 2 ) coupled to a shaft 72 (see FIGS. 2 and 5 ). The coupling of the circular cavity 71 to the shaft 72 is such as to enable free rotation of the crank 70 with respect to the shaft 72 . Between the pin 69 and the shaft 72 , the crank 70 has a seat 73 designed to receive a pawl 74 for the purposes that will be described more fully hereinafter. The pawl 74 is idle with respect to its own seat 73 .
[0026] As shown in particular in FIGS. 5-8 , the shaft 72 is coupled to a cam 76 ( FIG. 8 , and shown in greater detail in FIG. 9 ) by means of splines 75 ( FIG. 7 ). In its central part, the cam 76 comprises a toothed seat 77 ( FIG. 9 ) that is coupled to the splines 75 provided on the shaft 72 in such a way that said cam 76 is angularly fixed with respect to the shaft 72 . Furthermore, on the periphery of the cam 76 , as shown again in FIG. 9 , there are provided two shaped cavities 78 , 79 , which have substantially the same shape and are obtained by removing part of the material constituting the periphery of the cam 76 or by casting the cam 76 with the shaped cavities 78 , 79 formed in the periphery.
[0027] The shaped cavity 79 has a length L much greater than the diameter D 1 of the pawl 74 (see FIG. 8 ). In fact, the pawl 74 , in use, is located within the shaped cavity 79 , as shown in FIG. 9 .
[0028] The shaft 72 (see FIGS. 7 and 8 ) is in turn elastically stressed, via the cavities of the cam 76 , by a spring 80 wound in a spiral about the longitudinal axis of symmetry (a) of the shaft 72 . A first end 80 a of the spring 80 rests on an abutment element unitary provided on the main body 53 (not shown), whilst a second end 80 b is fixed to a small pin 81 fitted into a seat 81 a ( FIG. 9 ) made in the cam 76 . The reasons for the presence of the spring 80 will be explained hereinafter.
[0029] Provided at one end of the shaft 72 is a shaped element 82 (see FIGS. 4-8 ), rotation of which, as will be seen more clearly hereinafter, packs together the brake disks 16 so as to brake the wheels W.
[0030] As regards the relay lever 52 , at the end opposite to the one where the eyelet 51 is located, there is provided a circular seat (not visible in the figures) engaged by the shaft 72 . More particularly, the relay lever 52 can rotate freely with respect to the shaft 72 . The cam 76 is thus located between the crank 70 and the relay lever 52 , as shown in FIGS. 4 and 5 .
[0031] The relay lever 52 in turn has a pawl 83 (resting idle in its seat 83 a in the lever 52 ), which, in use, is located within the shaped cavity 78 . The pawl 83 has a diameter D 2 ( FIG. 5 ) smaller than the length L of the shaped cavity 78 so as to enable its free displacement within the shaped cavity 78 .
[0032] Consequently, two commands can reach the cam 76 .
[0033] The first command can be imparted by the piston 58 , which, to all effects, forms an integral part of a hydraulic actuator 84 comprising, the elements already described in relation to the cylinder 53 b (see above).
[0034] Conversely, the second command can reach the cam 76 via the relay lever 52 operated manually by the operator using, for this purpose, the lever 10 (see FIG. 1 ).
[0035] In use, when the engine (not shown) of the motor vehicle is running, also the hydraulic circuit is pressurized. Consequently, from said circuit a certain amount of oil under pressure is deviated, which, through the hydraulic line 66 and the control of the solenoid valve 67 ( FIG. 2 ), fills the portion 57 a of the chamber 57 . Consequently, the piston 58 moves down, compressing at the same time the pack of Belleville washers 62 . Driven by the stem 64 , by the fork 65 and by the crank 70 , the pawl 74 will be positioned closely to the side 79 a of the shaped cavity 79 (see FIGS. 5, 7 , and 9 ), so that the only way for the user to engage the parking brake remains the traditional one of acting manually on the relay lever 52 with the modalities referred to previously. Under the condition where the engine is running, the pawl 83 is located closely to the side 78 a of the shaped cavity 78 . For simplicity reasons, FIG. 9 shows both pawls 74 and 83 in a middle position of their respective cavities 78 , 79 although this does not correspond to an operating position.
[0036] Consequently, in the case where the engine is on, the only way to apply the parking brake of the motor vehicle is to rotate the relay lever 52 , and hence the cam 76 , in the direction indicated by the arrow F 1 (see, for example, FIG. 2 ). In this case, the pawl 83 , which is already in the proximity of the side portion 78 a of the shaped cavity 78 , is immediately pushed against the wall 78 a of the shaped cavity 78 , causing rotation in the direction of the arrow F 1 of the shaft 72 and of the shaped element 82 , which, as has been said, actuates the brake disks 16 . Such a rotation is enabled because pawl 74 is close to wall portion 79 a and thus there is a considerable gap between said pawl 74 and the wall portion 79 b.
[0037] In other words, when the engine is on, each of the pawls 74 and 83 is located in an almost extreme upward position of its own shaped cavity 79 and 78 , respectively. In this condition, when the brake is operated manually, the pawl 83 will immediately contact the top portion 78 a and will cause rotation of the cam 76 in the direction of the arrow F 1 . This is possible because there is a sufficient amount of space between the other pawl 74 and the bottom portion 79 b of the shaped cavity 79 . When the engine is off and the handbrake is not operated, the pawl 74 will move upward and immediately contact the top portion 79 a (on account of the pressure drop in the cylinder) and will set the cam 76 again in rotation in the direction of the arrow F 1 . This is again rendered possible by the fact that there is a sufficient space between the pawl 83 and the bottom portion 78 b of the shaped cavity 78 , since at the instant when the engine is still on, the pawl 83 is located close to the wall portion 78 a.
[0038] If the operator so desires, he can have both systems active at the same time. With the engine off, and consequently the brake on by the action of the pawl 74 , the operator is still able to also put the handbrake on, by pulling the lever 51 in the direction of arrow F 1 and thereby moving pawl 83 towards and in contact with wall portion 78 a. At this instance, both pawls 74 and 83 are in contact with the respective wall portions 79 a and 78 a and braking is thus ensured both by the hydraulic system and the mechanical system. Should the engine by switched on again, the pawl 74 will release wall portion 79 a and move in the direction of wall portion 79 b. The cam 76 however will not rotate because it is prevented from doing so by pawl 83 still pressing against wall portion 78 a. The brake therefore will remain on until the handbrake lever 10 also has been released.
[0039] As appears again from FIG. 9 , the bottom ends of the shaped cavities 78 , 79 are slightly curved because said cavities 78 , 79 are preferably made with a ball-end two-fluted mill with a circular path. In so far as the path of the two pawls 83 and 74 , respectively, is circular, there consequently is no need for the bottom ends to be rectilinear, as long as the pawls 74 and 83 do not interfere with the slightly raised middle portion of the respective cavities 78 and 79 during their circular movement therethrough.
[0040] When the operator wants to disengage the hand brake (once again with the engine on) all he has to do is to release the lever 10 ( FIG. 1 ), and the system will return to the initial position thanks to the elastic action exerted by the spring 80 on the cam 76 . In this case, both the relay lever 52 and the cam 76 will rotate in the direction identified by the arrow F 2 (see for example FIG. 2 ).
[0041] Conversely, in the case where the engine is turned off, the hydraulic circuit is connected to the discharge. Consequently, also the pressurized oil present in the portion 57 a is discharged through the port 68 . Hence, the pack of Belleville washers 62 is allowed to push the bushing 60 upwards, as well as the adjustment pin 59 , the piston 58 , the stem 64 , the fork 65 , the crank 70 , and the pawl 74 , which will exert a thrust on the wall of the top portion 79 a of the shaped cavity 79 ( FIG. 9 ). Also in this case, the cam 76 will turn in the direction of the arrow F 1 and will engage the brake according to what has been said previously. It is to be noted that the action of the Belleville washers 62 overcomes the oppositely directed action of the spring 80 .
[0042] A further function of the parking brake 100 is the park-lock function. Acting on the solenoid valve positioned in point 67 , it is possible to discharge the pressurized oil present in the portion 57 a through the port 68 obtaining the same result as in the case described previously. This is a particular function that is required from the motor vehicle with the engine running when the driver wants to be certain that the vehicle will remain still in particular conditions of maneuver without having to operate the lever 10 in the cab.
[0043] In the park-lock situation, to disengage the parking brake, it is sufficient to re-supply the solenoid valve with electrical current in order to send pressurized oil again into the portion 57 a.
[0044] Consequently, it may be stated that, with the parking brake 100 forming the subject of the present invention, the system for blocking the wheels W will be activated automatically whenever the engine of the motor vehicle is turned off or else when the signal to the control solenoid valve of the device is intentionally interrupted, whilst there will always be the possibility of engaging the hand brake manually both with the engine off and with the engine on. In addition, it should be noted that, both when the actuator 84 goes into action and when the relay lever 52 is pulled manually, the same cam 76 provided with the two shaped cavities 78 , 79 is used.
[0045] If there were a breakdown such as to cause the engine to be turned off, or some fault of the hydraulic circuit, or else a failure of a signal to arrive to the solenoid valve for control of the braking device, the oil would be discharged by the portion 57 a through the port 68 , and the hand brake would remain engaged owing to the action of the actuator 84 .
[0046] However, in this case, to enable the towing of the motor vehicle, the hand brake can be disengaged by resorting to an emergency device 85 , which basically comprises the nut 63 and the adjustment detent 63 a (see for example FIG. 3 ). If the adjustment detent 63 a is screwed on the threading provided on the end 59 b until it presses against the bottom of the disk 56 , the emergency pin 59 will be pulled down, allowing the other elements connected thereto to move downwards, including the cam 76 , which will rotate in the direction of the arrow F 2 . In this connection, it should be noted that the permanent contact of the tip of the adjustment pin 59 with the bottom wall of the piston 58 is ensured by the presence of the return spring 80 which will cause a return action on respectively the cam 76 , the pawl 74 , the fork 65 , the stem 64 , and ultimately the piston 58 , which, consequently, will always remain pressed against the tip of the adjustment pin 59 .
[0047] Advantages of the present parking brake are the following:
assurance that, when the engine is off, the motor vehicle will, in all cases, have its parking brake automatically engaged; and commands unified in a single cam, both in the case of automatic engagement of the parking brake and in the case of manual operation via a lever rotated by the operator in the cab.
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A parking brake for a motor vehicle includes: a manual operating lever; a braking device designed to act on brake disks applied on a bevel pinion for transmission of the motion to the wheels of the motor vehicle; and a cable for transmission of the command imposed via the lever on the braking device. The brake is activated either automatically by a hydraulic actuator when the engine of the motor vehicle is turned off, or alternatively, by a manual command imposed by the operator through the lever whether or not the engine of the motor vehicle is running.
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This application is based on and claims priority to Ser. No. 61/266,535, filed Dec. 4, 2009.
TECHNICAL FIELD
This application relates generally to the protection of sensitive data, such as credit card information, in a networked environment.
BRIEF DESCRIPTION OF THE RELATED ART
Distributed computer systems are well-known in the prior art. One such distributed computer system is a “content delivery network” or “CDN” that is operated and managed by a service provider. The service provider typically provides the content delivery service on behalf of third parties. A “distributed system” of this type typically refers to a collection of autonomous computers linked by a network or networks, together with the software, systems, protocols and techniques designed to facilitate various services, such as content delivery or the support of outsourced site infrastructure. Typically, “content delivery” means the storage, caching, or transmission of content, streaming media and applications on behalf of content providers, including ancillary technologies used therewith including, without limitation, DNS query handling, provisioning, data monitoring and reporting, content targeting, personalization, and business intelligence.
The distributed and shared network infrastructure as described above is used, among other purposes, to deliver content from a plurality of web sites. Representative web sites include e-commerce retailers at which end users may shop and purchase products and services. In the prior art, CDN service providers provide the content delivery for these on-line retailers but, when it comes time for an end user to complete a purchase, the associated payment services typically are handled by third parties. In part, this is because such payment services involve the processing and storage of sensitive data, such as end user credit card data.
BRIEF SUMMARY
Using cryptographic techniques, sensitive data is protected against disclosure in the event of a compromise of a content delivery network (CDN) edge infrastructure. These techniques obviate storage and/or transfer of such sensitive data, even with respect to payment transactions that are being authorized or otherwise enabled from CDN edge servers.
The foregoing has outlined some of the more pertinent features of the invention. These features should be construed to be merely illustrative. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention as will be described.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a simplified block diagram of a content delivery network (CDN) in which the disclosed techniques herein may be implemented;
FIG. 2 is a simplified block diagram of a representative CDN edge machine on which the disclosed techniques may be implemented; and
FIG. 3 is a block diagram of an edge server process interacting with a merchant origin server and an third party credit card issuer according to the teachings of this disclosure.
DETAILED DESCRIPTION
In a known system, such as shown in FIG. 1 , a distributed computer system 100 is configured as a content delivery network (CDN), and it is assumed to have a set of machines 102 a - n distributed around the Internet. Typically, most of the machines are servers located near the edge of the Internet, i.e., at or adjacent end user access networks. A network operations command center (NOCC) 104 manages operations of the various machines in the system. Third party sites, such as web site 106 , offload delivery of content (e.g., HTML, embedded page objects, streaming media, software downloads, and the like) to the distributed computer system 100 and, in particular, to “edge” servers. Typically, content providers offload their content delivery by aliasing (e.g., by a DNS CNAME) given content provider domains or sub-domains to domains that are managed by the service provider's authoritative domain name service. End users that desire the content are directed to the distributed computer system to obtain that content more reliably and efficiently. Although not shown in detail, the distributed computer system may also include other infrastructure, such as a distributed data collection system 108 that collects usage and other data from the edge servers, aggregates that data across a region or set of regions, and passes that data to other back-end systems 110 , 112 , 114 and 116 to facilitate monitoring, logging, alerts, billing, management and other operational and administrative functions. Distributed network agents 118 monitor the network as well as the server loads and provide network, traffic and load data to a DNS query handling mechanism 115 , which is authoritative for content domains being managed by the CDN. A distributed data transport mechanism 120 (comprising a metadata control server and a set of staging servers) may be used to distribute control information (e.g., metadata to manage content, to facilitate load balancing, and the like) to the edge servers.
As illustrated in FIG. 2 , a given machine 200 comprises commodity hardware (e.g., an Intel Pentium processor) 202 running an operating system kernel (such as Linux or variant) 204 that supports one or more applications 206 a - n . To facilitate content delivery services, for example, given machines typically run a set of applications, such as an HTTP proxy 207 (sometimes referred to as a “global host” or “ghost” process), a name server 208 , a local monitoring process 210 , a distributed data collection process 212 , and the like. The For streaming media, the machine typically includes one or more media servers, such as a Windows Media Server (WMS) or Flash server, as required by the supported media formats.
A CDN edge server is configured to provide one or more extended content delivery features, preferably on a domain-specific, customer-specific basis, preferably using configuration files that are distributed to the edge servers using a configuration system. A given configuration file preferably is XML-based and includes a set of content handling rules and directives that facilitate one or more advanced content handling features. The configuration file may be delivered to the CDN edge server via the data transport mechanism. U.S. Pat. No. 7,111,057 illustrates a useful infrastructure for delivering and managing edge server content control information, and this and other edge server control information can be provisioned by the CDN service provider itself, or (via an extranet or the like) the content provider customer who operates the origin server. U.S. Pat. No. 7,240,100 describes techniques for applying the edge server content control information at the edge server. The CDN may include a storage subsystem, such as described in U.S. Pat. No. 7,472,178. The CDN also may operate a server cache hierarchy to provide intermediate caching of customer content; one such cache hierarchy subsystem is described in U.S. Pat. No. 7,376,716. These disclosures are incorporated herein by reference.
The CDN may provide secure content delivery such as described in U.S. Publication No. 20040093419, or as described in U.S. Pat. No. 7,363,361. Secure content delivery as described therein enforces SSL-based links between the client and edge server process, on the one hand, and between the edge server process and an origin server process, on the other hand. This enables an SSL-protected web page and/or components thereof to be delivered (to the end user client browser) via the edge server. Typically, an SSL-protected web page is served to an end user process when an end user navigates to a web site merchant checkout page from an e-commerce web site that is being delivered via the CDN). The merchant checkout page typically is delivered from the origin server (not the CDN) and, in particular, from an application server (within the origin infrastructure) that comprises part of an order management system or gateway. In the past, the CDN service provider has not been involved in the processing of the actual order, in large part due to the sensitivity of handling credit card data during the payment transaction itself. As noted above, this techniques disclosed herein enable the CDN service provider to facilitate the payment transaction.
As used herein, the term “sensitive data” should be broadly construed, depending on the context. Thus, for example, in connection with an e-commerce transaction, which is the preferred embodiment, the term typically refers to any PCI sensitive data, such as credit or debit card number, bank account number, and the like. The “sensitive data” also may be identity information (such as personally identifiable information (PII)), health care information (such as HIPAA-related data), finance information (such as GLBA-related data), other confidential information, and the like.
Handling Sensitive Data
As noted above, the distributed and shared network infrastructure as described above is used, among other purposes, to deliver content from web sites, typically the web sites of CDN customers. Representative web sites include e-commerce retailers at which end users may shop and purchase products and services. In the prior art, CDN service providers provide the content delivery for these on-line retailers but, when it comes time for an end user to complete a purchase, the associated payment services are handled by third parties. This is the case even if the CDN provides secure content delivery, e.g., over SSL or TLS links, such as described in U.S. Publication No. 20040093419.
The disclosed subject matter extends the CDN infrastructure to facilitate payment services within that infrastructure. Because the providing of payment services involves the handling of end user credit card and other sensitive user data, there is a need to enhance the operation of the CDN to ensure that such data remains fully protected. A method of securing sensitive data (e.g., end user credit card information) is described below. In short, the technique allows the CDN service provider to process credit cards (and perhaps other personally identifiable information or “PII”) without storing any data that could be exploited by a hacker to retrieve the actual card numbers (or other PII). Even if a hacker recovered everything that the CDN has stored, the hacker would not be able to reveal any confidential information.
The high level technique is now described. According to this disclosure, and in the context of protecting PCI data, a CDN key pair (PK_I, SK_I) is created for each card issuer I (e.g., VISA or AMEX). Thus, for issuer I, PK_I is the public key, and SK_I is the secret key. According to this disclosure, the value of SK_I is not stored on or in association with the CDN but, rather, only at the site of card issuer I (or some other location designated by the issuer but, once again, not on the CDN).
An end user visits the e-commerce web site in the usual manner. Typically, the CDN serves the non-secure pages of the site in the usual manner, such as described in U.S. Pat. No. 7,596,619. As the end user navigates through the site, he or she may identify certain products or services that he or she desires to purchase. One common technique that is used for this purpose is to associate a “shopping cart” (or, more generally, a data structure) with the user's browsing session. When the user selects an item for purpose, information about the item is stored in the cart. Then, when the user indicates a desire to “checkout” from the site (i.e., to purchase the items in the shopping cart), typically the CDN sets up a pair of SSL-links (although the shopping session may have initiated over SSL). In the usual case, a first secure link is established between the end user browser and the edge server, and a second link is established between the edge server and the origin server order management application.
After the SSL links are established, the origin server typically serves a “checkout” page. The end user then enters his or her credit card or other PII-related information, and hits “enter” on his or her browser. This creates an HTTP POST message, which includes the sensitive data. The sensitive data thus is received at the CDN edge server. According to the subject disclosure, however, instead of passing this data on through to the origin server, the edge server recognizes the POST, removes the PCI data, and computes a function. In particular, if the end user's credit card (CC) is from some issuer J, the CDN edge server process computes V=PK_J (CC) and then immediately discards the true credit card CC. In particular, the CC data is not stored on disk or other persistent store, and in-memory storage is kept to a minimum (just what is necessary to facilitate the above-described computation). According to this disclosure, all future processing of the card (and thus the CC) is done using V.
Preferably, the edge server maintains a database of tokens. The database may be in the form of an array, a linked list, an index table, or any other convenient data structure. A hash table may also be used. A token (or, more generally, a “data string”) associates a value V with an identifier W associated with a web site (or portion thereof, including sub-domain). In response to receipt of the POST and the calculation of the value V, the edge server process then performs a lookup in the database to determine if the CDN has processed V for this web site W. If so, a token T for (V,W) will be present in the database. If (as a result of the lookup) it is determined that the CDN has processed V for this web site W before, the edge server sends the token T for (V,W) to the order management system to which the edge server is now coupled (on its forward processing side). If, however, it is determined that the CDN has not processed V for this site (because there is no such token in the database), the server randomly creates a new token T for (V,W). The new token is unique for W. The edge server process adds the new token to its database and then sends T to the web site over the forward connection.
The processing of tokens proceeds in the natural way until the web site order management system wants the CDN to process a request for authorization, or request for payment for a token T. The order management system communicates with the edge server process over the connection that is maintained (preferably in a persistent manner) between the two. When the edge server receives a response from the order management system indicating that the CDN edge server process should then “authorize” the transaction or make the actual payment request, the CDN edge server uses the token T and the value W to retrieve the value of V. The CDN edge server processor then opens up a new connection, to a card issuer network for J. Because the CDN edge server no longer maintains CC, however, it cannot transmit it; instead, the CDN edge server just sends V to the card issuer network. This value is sent via an intermediate (or subordinate) request, as the request typically is made while the overall checkout process is on-going. In a process external to the CDN, the card issuer J (or its delegate) then uses the secret key value SK_J to decrypt and retrieve CC.
For additional security, the decryption by or on behalf of card issuer J using SK_J preferably is done only if the transmission of V has been authenticated to have come from a CDN server.
A key advantage to this approach is security. Even if the CDN edge server is compromised, no credit card data is lost because the CDN edge server does not maintain such data. Moreover, because only the secret key SK_J can be used to retrieve the card numbers, access to the CDN edge server does not compromise the PCI data, because the secret key preferably resides only at the issuer (or on some server that the issuer has some degree of control over). (A CDN server may also be positioned at the card issuer). Thus, using this approach, a CDN service provider has no greater risk of exposure for payment services than it would if it were just passing the credit card to the CDN customer. Indeed, the risk is lower because the CDN provider no longer sends the card anywhere using the described above. While it is possible that the values of PK_J (CC) might be exposed by a hacker, these values are only of use if they are sent by the CDN. Thus, if PK_J (CC) is sent by another entity, then the card issuer would have knowledge, a priori, that the edge server has been compromised (and the value stolen) because it would have been encrypted using a CDN service provider key pair but not sent from a CDN machine.
FIG. 3 illustrates a typical use case scenario. In this example, the client browser (or equivalent rendering engine) sends an HTTP POST (or equivalent) message to the edge server 300 during an order checkout to the merchant origin server 302 . Origin server 302 has an associated order management system and database 304 . The edge server 300 also interfaces to a card issuer payment gateway 306 that is associated with payment gateway database 308 . The edge server comprises a token database, a public key PK associated with each issuer (such as the issuer associated with gateway 306 ), together with software (one or more computer programs, processes, utilities or the like) to carry out the above-described functionality. In particular, this software receives the HTTP POST, parses it to remove the sensitive data, generates the value V, retrieves (or creates the token T), and forwards the POST with the sensitive data replaced with the token. When the merchant origin server 302 requests transaction authorization or payment (e.g., by returning the token T), the CDN edge server performs this function by making the intermediate (subordinate) request to the payment gateway (which holds the secret key SK needed), passing the value V, and receiving the response (e.g., the payment authorization or the like). In this manner, the edge server performs or facilitates the payment service without exposing the sensitive data, which is deleted upon generation of the value.
The disclosed technique may have many variants. Thus, for example, instead of discarding the CC, the CDN edge server process may maintain some small portion thereof, such as the last four (4) digits, or some arbitrary CDN customer-defined data payload. As another alternative, the edge server process may first pad the CC with CDN-specific data before generating PK_J (CC). Optionally, the edge server process may extend this step to add other obfuscation data to prevent rainbow attacks against the token store. The functionality described herein may be used with or without credit card tokenization, which is a technique whereby a credit card number is exchanged with a token (by a third party token provider).
As another variant, the encryption step may be carried out on an end user device using CDN-provided client software, thereby ensuring that the credit card number is never even received with the edge server infrastructure.
The public key PK_J may be maintained secret for added security.
In another alternative approach, a second level of encryption using a secret CDN key is also used. In this approach, a public decryption key is then provided to the card issuer (or its delegate). This enables an extra level of authentication, namely, a way to verify that the transmission comes from the CDN and not some unauthorized intermediary. Other cryptographic techniques may be used as required. Thus, for example, the edge server may apply a digital signature to the value V.
The method described here covers the case where the protected information (e.g. a credit card number) only needs to be sent to a single entity (e.g., the network for the card issuer). The subject disclosure is not limited to this scenario. In the event the sensitive data (e.g., a medical record or the like) needs to be sent to multiple entities (e.g., various hospitals), then the edge server process creates and stores an encrypted copy of the data for each entity that requires it (using the secret key for each such entity). This requires that the CDN know ahead of time the identities of those entities. If this is not possible, the CDN service provider may retain a copy of a secret key in a highly secure location and manner so that it can recover the original version of the protected information (and, in particular, so that it could be encrypted later using an as-yet unknown public key).
The above-described technique may be used to secure any sensitive data within the context of a CDN service.
The above-described edge server process preferably is implemented in computer software as a set of program instructions executable in one or more processors, as a special-purpose machine. In one embodiment, the edge server process is an HTTP proxy that has been enhanced to provide the recited functions. Typically, an instance of the process is instantiated per HTTP request received from an end user browser, and that process instance maintains appropriate data structures to facilitate the processing described. The edge server process comprises a front end portion to which the client browser is coupled, and a back end portion to which the process is coupled to the origin server gateway (or the card issuer network, as described). The edge server process is capable of opening up and maintaining multiple connections. Control over the edge server process may be maintained using XML-based metadata provided to the edge server. Thus, because the edge server typically is handling content for multiple CDN customers, each CDN customer may provide its own unique configuration that is enforced at the edge server.
Representative machines on which the subject matter herein is provided may be Intel Pentium-based computers running a Linux or Linux-variant operating system and one or more applications to carry out the described functionality. One or more of the processes described above are implemented as computer programs, namely, as a set of computer instructions, for performing the functionality described.
Having described our invention, what we now claim is set forth below.
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Using cryptographic techniques, sensitive data is protected against disclosure in the event of a compromise of a content delivery network (CDN) edge infrastructure. These techniques obviate storage and/or transfer of such sensitive data, even with respect to payment transactions that are being authorized or otherwise enabled from CDN edge servers.
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This application is the national stage of PCT/EP03/00379 filed on Jan. 16, 2003 and also claims Paris Convention priority of DE 102 25 514.8 filed on Jun. 10, 2002.
BACKGROUND OF THE INVENTION
The invention concerns a machine for superfinishing workpieces by honing or precision grinding according to the independent claim.
SUMMARY OF THE INVENTION
Honing machines are used for the above-mentioned tasks. A honing tool is provided with an appropriate coating (e.g. of diamond or corundum) and is introduced into a bore while simultaneously being turned and reciprocated to process the inner surface of the bore. To take into account the wear of the honing tools, these are i.a. designed to have honing strips provided with a honing layer which can be adjusted in a radial direction by means of a widening bar which rotates along with the honing tool but can be displaced therein in an axial direction.
Machines can moreover be used, with which a tool must be mounted to the device in a direction which corresponds to the axial direction of the rotational motion of the machine. These may be honing tools (e.g. for so-called “mandrel honing”) and also lapping tools. They could also be precision grinding tools to subject e.g. pre-ground valve seat surfaces to final superfinishing, wherein only a few micrometers must be removed in an exactly defined manner thereby simultaneously improving the surface.
The lifting motion of the carriage supporting the honing spindle of honing machines has generally been conventionally effected via a hydraulic drive, while the rotational motion of the honing spindle and thereby also that of the honing tool disposed therein, is effected by a common electromotor. The simultaneous rotational and lifting motions of the honing tool during honing produces a cross-grinding pattern on the surface to be processed, which is typical for this type of treatment, this pattern being important for the bearing and lubricating properties of the processed workpiece and also for the fitting accuracy of further components (e.g. pistons). For processing smaller bores having a diameter of only a few millimeters and simultaneous increase of the rotational speed of the honing tool to reduce the processing time, the stroke speed must be correspondingly increased. The hydraulic drives used to provide the stroke motion are thereby limited with regard to speed and reversibility of the system during operation. This is particularly true when the strokes are short as is the case when the processing depth of the bores is in the range of a few millimeters.
It is the underlying purpose of the invention to eliminate these disadvantages. In particular, means should be provided for the stroke motion which permit higher stroke speeds while thereby maintaining high reversal accuracy to ensure that small and short bores can also be processed more exactly and rapidly at higher honing tool rotational speeds. This object also addresses the problem of exactly realizing very short delivery paths for the carriage supporting the honing spindle, such as those which occur e.g. during precision grinding of valve seat surfaces. Moreover, the entire construction should be simplified by reducing the number of moving parts thereby also reducing costs.
This object is achieved in accordance with the invention with the elements recited in the claims.
A so-called linear motor is used which permits higher lifting and delivery speeds, has considerably less components, can be reversed with more precision and allows short stroke paths at high speed.
The use as honing machine, i.e. use of a honing tool with radially adjustable honing strips, is facilitated in that the widening bar for radial adjustment of the honing strips, which is actuated by a connecting rod disposed in the honing machine, can also be actuated in a more simplified manner using a servomotor which, in turn, may preferably be flanged coaxially to the coupling housing and disposed as a linear extension to the spindle housing. The connecting rod can also be preferably adjusted via a further linear drive. The invention may then also be used to perform a rapid and precise, minimum, exactly defined, stroke motion of a precision grinding tool, e.g. for processing a valve seat.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the invention are described in more detail below with reference to the enclosed drawings.
FIG. 1 shows a schematic view of a honing machine which is designed in accordance with an embodiment of the invention;
FIG. 2 shows a honing spindle housing 8 of the honing spindle 7 , the carriage 12 and the sliding rails 14 as well as the carrier 15 carrying the sliding rails 14 and disposed on the machine frame 16 , the view being tilted by 90° with respect to FIG. 1 ;
FIG. 3 shows a view in the direction of the arrows III—III of FIG. 2 ;
FIG. 4 shows a section through the spindle housing 8 ;
FIG. 5 shows a section through the coupling housing 51 which is flanged to the spindle housing 8 ;
FIG. 6 shows a section through the coupling housing 51 of a second embodiment of the invention which is suited, in particular, for small stroke motion in an axial direction;
FIG. 7 shows a view in the direction of arrows VII—VII of FIG. 6 ;
FIG. 8 shows a schematic representation of a workpiece 301 and an associated tool 300 which can be used with the embodiment of FIGS. 6 and 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a honing machine. A workpiece 2 is clamped on a processing platform 1 for honing a bore 3 thereof. The honing tool 4 which is received in a cone 6 at the end of the honing spindle 7 is lifted and lowered with the honing spindle 7 thereby providing the conventional stroke motion of the honing process, as is part of the honing method. The axial displacement of the honing spindle 7 serves to generate this stroke motion. The honing tool 4 has radially adjustable honing strips 5 . The honing spindle 7 is driven by an electromotor 9 which is integrated in the spindle housing 8 . A coupling housing 51 is flanged to the upper end (in FIG. 1 ) of the spindle housing 8 , and a servomotor 10 is coaxially flanged to the coupling housing 51 . The servomotor 10 provides axial displacement of a widening bar 11 which is disposed in the honing tool 4 and passes through the rotating honing spindle 7 for radial adjustment of the honing strips 5 .
The spindle housing 8 is disposed on a carriage 12 in which the primary part 13 of a linear motor 18 is integrated. The primary part 13 forms a linear motor 18 together with the secondary part 17 which is integrated in the vertically extending carrier 15 (see FIG. 3 ). This linear motor 18 effects the lifting motion of the spindle housing 8 . The carrier 15 is mounted to the machine frame 16 . The carriage 12 with Integrated primary part 13 can be lifted and lowered on the sliding rails 14 , which, In turn, are fixed to the carrier 15 . The primary part 13 is the moving part and the secondary part 17 is the stationary part of the linear motor.
Use of a linear motor whose moving part carries the honing spindle and thereby performs the stroke motion with the required speed and reversal accuracy is of primary importance to the invention. To process the bore 3 , the spindle housing 8 , including honing spindle 7 and honing tool 4 received therein, is lowered to such an extent that the honing strips 5 penetrate into the bore 3 . The honing spindle 8 is simultaneously reciprocated (lifted and lowered) and turned. These two motions are matched to generate the “cross-grinding pattern”, which is typical for honing, on the workpiece surface at an angle of e.g. 10° to 50°. For smaller diameters of the bore to be processed and high rotational speeds, this pattern requires a relatively fast lifting and lowering of the honing spindle 8 , which is ensured by the linear motor 18 . An inventive honing machine with e.g. a stroke of 80 mm can have a stroke speed of 50 m/min with a reversal accuracy of ≦0.05 mm (reversal is the change of motion from one direction to the opposite direction). With a stroke of 20 mm, it can have a stroke speed of 25 m/min with a reversal accuracy of ≦0.04 mm.
As is shown in FIG. 3 , the primary part 13 of the linear motor 18 is mounted to the carrier 15 via screws 19 and the sliding rails 14 are mounted to the carrier 15 via screws 20 . The profile of the sliding rails 14 corresponds to the profile of the sliding elements 21 , which are mounted to the carriage 12 via screws 22 . The primary part 13 of the linear motor 18 is mounted in the carriage 12 via screws 23 .
The person skilled in the art is familiar with linear motor construction and an exact description is therefore unnecessary herein. Linear motors can be obtained from various manufacturers. They are driving elements which are developed from a normal rotary current electromotor by “cutting open” the stator and unfolding it into a plane. The rotor is also planar such that it moves along the linear extension of the stator in correspondence with the alternating electromagnetic field which propagates along the windings of the stator. In the present case, the primary part 13 corresponds to the stator, the secondary part 17 to the rotor of an electromotor. It is a synchronous device and is designed as a long stator motor. The speed is controlled via frequency variation in a frequency converter of an associated control. A programmable control (not shown) permits adjustment of corresponding speed as stated above.
A carrier frame 171 is mounted on the carrier 15 using screws 170 , only one of which is visible, and a measurement transducer 173 is disposed on the carrier frame 171 via screws 172 . It contains conventional measurement markings (not shown) which generate measuring signals in sensors (not shown) disposed on the carriage during motion of the carriage 12 perpendicular to the plane of the drawing of FIG. 3 , the measuring signals showing the instantaneous position of the carriage 12 and transmitting it to the control (not shown). 174 designates a cover plate.
The structure of the spindle housing 8 is shown in FIG. 4 . The electromotor 9 is integrated in the spindle housing 8 . It causes rotation of the honing spindle and consists of a stator 25 with windings 25 ′ and rotor 26 . The stator 25 is pressed into a sleeve 37 which is screwed to the end plates 33 , 34 using screws 36 (only shown at 34 ). The rotor 26 is pressed onto the outside of the honing spindle 7 . The stator 25 is supplied with current via the connections 27 . The motor 26 is a permanent magnet. The spindle housing 8 is screwed to the carriage 12 using screws 30 . The honing spindle 7 is supported in the spindle housing 8 via bearings 31 or 32 in front and rear end plates 33 and 34 . The end plates 33 or 34 are screwed to the spindle housing 8 using screws 35 . The sleeve 37 has a spiral cooling channel 38 which is supplied with coolant via the coolant delivery line 39 . The coolant discharge is not shown: It is disposed on the opposite side.
The radial coupling housing 51 which joins the connecting plate 34 on the left-hand side, and the servomotor 10 which adjusts the widening bar 11 of the honing strips 5 of the honing tool 4 are shown in FIGS. 4 and 5 .
The honing spindle 7 has a continuous bore 40 in which the connecting rod 110 is disposed to be displaceable in an axial direction. The lower end of the connecting rod 110 has a bore 112 with inner thread into which the widening bar 11 is rigidly screwed, such that the connecting rod 110 and the widening bar 11 form a unit and can be commonly displaced in the longitudinal direction (axial direction) of the axis of rotation. The honing strips 5 are thereby radially displaced towards the outside. Honing tools 4 of this type are known In the art. During operation, the honing strips are radially pulled inward through springs and have inclined adjustment surfaces on their inner sides which cooperate with correspondingly inclined adjustment surfaces at the end of the widening bar 11 such that, when the widening bar 11 is axially displaced, the honing strips 5 are radially adjusted (spreading mechanism).
The connecting rod 110 and the widening bar 11 rotate together with the honing spindle 7 but can also be axially displaced therein (in the longitudinal direction) as mentioned above. This is realized in that the connecting rod 110 is penetrated by a pin 46 whose ends are guided in opposite grooves 46 ′ in the honing spindle 7 . The bore 40 in the honing spindle 7 has a shoulder 43 onto which a ring 41 is urged via a spring 45 which is supported with its other end on the pin 46 . At rest, the connecting rod 110 is forced by the spring 45 in its outermost upper position shown in FIG. 4 . The connecting rod 110 may then be downwardly displaced against the force of the spring 45 .
The plunger 47 is a continuation of a coupling piece 49 into the axial recess 49 ′ of which the driven shaft 50 of the servo motor 10 projects. Coupling in the rotational direction with is realized by a tongue/groove connection formed by a groove 151 and wedge (“spring”) 152 .
The coupling housing 51 is screwed to the front end plate 34 of the spindle housing 8 . The screws are not shown. A sleeve 52 is Inserted into the coupling housing 51 . The sleeve 52 can be axially displaced in the coupling housing 51 , since a block 160 , which is screwed into the sleeve 52 and radially projects past it, projects into a groove 161 in the sleeve 53 and is guided therein. The sleeve 52 can be displaced relative to the coupling housing 51 through a stroke H. The upper end of the connecting rod 110 is rotatably disposed in the sleeve 52 using bearings 165 . The inner shells of the bearings 165 are rigidly connected to the connecting rod. A lid 166 is screwed to the connecting rod 110 to fix the bearing 165 .
The sleeve 52 also receives an adjusting sleeve 53 which rotates therewith and can be displaced and adjusted in a longitudinal direction. This connection is also realized through a tongue and groove connection which is formed by the wedge 54 and the groove 55 . The adjustment sleeve 53 is penetrated by a bore which has an Inner thread 56 . An outer thread 56 ′ of the plunger 47 engages therein. The adjustment sleeve 53 is secured in the sleeve 52 through a lid 167 which is screwed to the sleeve 52 . When the servomotor 10 and thereby also its driven shaft 50 rotate, the coupling piece 49 is also rotated due to the tongue and groove connection 151 , 152 . Due to engagement of the threads 56 , 56 ′, the sleeve 52 is displaced in an axial direction and the connecting rod 110 together with the widening bar 11 are displaced in a downward direction against the force of the spring 45 , thereby effecting radial adjustment of the honing strips 5 within the honing tool 4 as mentioned above.
170 is a sensor having an end switch which transmits the shown end position consisting of sleeve 52 , block 160 , bearing 165 and connecting rod 110 , and a corresponding measured signal to the control (not shown).
A further embodiment is described below with reference to FIGS. 6 and 7 . The servomotor 10 is replaced by a linear motor and supplies a superfinishing tool 30 which is disposed at the end of the bar 306 . It is connected to the connecting rod 120 . The connecting rod 120 is rotatably disposed in the adjustment sleeve 253 using bearings 265 , wherein the lid 266 is screwed into the adjustment sleeve 253 such that the connecting rod 120 can be rotated in the adjustment sleeve 253 but not be displaced in an axial direction thereto. The runner, i.e. the movable primary part 201 of a further linear motor 200 is rigidly connected to the adjusting sleeve 253 . The linear motor 200 also has a secondary part (not shown). It is a construction type of a linear motor, wherein the runner is round and the inner space of the stator is also round. Such construction types of linear motors are also known per se. It is clear that the use of a linear motor requires much less components, including those for the adjustment motion of the connecting rod 110 and of the bar 306 connected thereto. Moreover, these components are subjected to much less wear. FIG. 7 shows suspension of this further linear motor 200 using a clamping plate 210 .
The embodiment with axial delivery of the bar 306 in accordance with FIGS. 6 and 7 addresses a processing task which is explained by means of FIG. 8 . The tool is a conical precision grinding body 300 which serves for processing a valve seat surface 305 . The valve seat surface 305 must thereby be removed by a defined amount, e.g. a few hundreths of a millimeter, which is calculated e.g. using a sensor. The shape and surface must be simultaneously improved. The conical precision grinding body 300 is disposed on the bar 306 which has a threaded pin 307 at its end which is connected to the end of the connecting rod 120 . In this manner, minimum stroke paths can be realized by means of the servomotor 10 or the further linear motor 200 . This may be effected either with one stroke motion or several small stroke motions which are intermittently applied, e.g. for sparking out after only relatively few rotations or for rinsing with coolant after each stroke.
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A honing machine for super finishing workpieces, e.g. by honing using a tool spindle ( 7 ), can be rotatably driven and can receive a tool. A motor rotates the tool spindle, the tool spindle ( 12 ) being arranged on a carriage ( 12 ), which can be displaced on a machine frame ( 16 ), by means of a drive device, in the direction of the rotational axis of the tool spindle. The drive device consists of a flat primary part ( 13 ) and a secondary part ( 17 ) of an electric linear motor ( 18 ), the secondary part being linearly displaceable along the primary part. One ( 13 ) of the components primary part/secondary part ( 13, 17 ) of the linear motor ( 18 ) is disposed on the machine frame ( 16 ), and the other ( 17 ) on the carriage ( 12 ).
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FIELD OF THE INVENTION
[0001] The present invention relates to a disposable absorbent article, more specifically a disposable absorbent article comprising three or more longitudinal panels separated by channels and capable of a generally reciprocal pivoting movement, thus providing a product dynamically adaptable to the user's body and able to quickly absorb the body fluids released on it.
BACKGROUND OF THE INVENTION
[0002] Disposable absorbent articles are consumption articles widely known in the state of the art. Typical examples are diapers for children and incontinent adults, women's napkins, bandages for wounds, breast protectors for mothers in the milk-feeding phase, sweat absorbers, and the like.
[0003] In the following, for the sake of disclosure and only for exemplification reasons, women's intimate napkins (generally referred to as “women's napkins” or even merely as “napkins”), the object of the preferred embodiment of the present invention, are disclosed and described without excluding the protection of any other type of disposable absorbent article the features of which are inserted in the scope of the invention and claimed in the end of this specification.
[0004] Also in the text below there are references to the “top layer” and the “coating layer” which are comprised in absorbent articles known in the state of the art. In general, the known absorbent articles comprise an absorbing core sandwiched between two so-called top layer and coating layer.
[0005] The top layer, which is usually flexible and fluid permeable, is designed to contact the user's body, and aims at allowing the flow of the body fluid towards the absorbing core. In a quite common way, it is a non-woven layer or perforated plastic film.
[0006] The coating layer is impervious or resistant to the flow of fluids and is designed to prevent the fluid from leaking from the absorbing core which could otherwise contaminate and dirty the user's clothes. In a quite common way, it is a thin non-perforated plastic layer.
[0007] The top layer and the coating layer can be single or composed of more than one material having one or more coats, and typically its dimensions are a little higher than those of the absorbing core between them, so that they are joined (glued, adhered, sealed, welded, sewn, or by any another means known in the state of the art) to one another along its perimeter.
[0008] Also, in the text below mention is made to “absorbing core”, another element known by those skilled in the art. In a very common way, it is comprised of cellulose fibers, paper coats, polymeric fibers, superabsorbent materials (for example, acrylate based particles or fibers which produce gel when in contact with humidity), turf moss, combinations of those materials with one another, and the like. Its purpose is to absorb and retain the body exudates, for example blood, urine, milk, sweat, etc.
[0009] In the text below, mention is also made to “side edges” (or simply “sides”) and “longitudinal ends” (or simply “ends”). They are references to the peripheral parts of an absorbent article, where “side edges” are the edges parallel to the length of the absorbent and “longitudinal ends” are the tips or ends transversal to the length of the absorbent.
[0010] It should also be understood in the text below that “upper face” of the absorbent refers to the face facing the user's body and “lower face” means the face opposing the higher one facing the user's clothes.
[0011] Among several desirable aspects in the performance of a woman's napkin, the anatomical adaptation, the fast absorption of body fluids and the retention of the napkin in its place during the use are especially important. Those aspects immediately reflect on the comfort and prevention of leaks during the use.
[0012] An example of state of the art articles the aim of which is the anatomical adaptation is the hourglass shape used in women's napkins, for example shown in U.S. Pat. No. 3,805,790 (Kimberly-Clark Corp.) and U.S. Pat. No. 4,758,241 (Elissa D. Papajohn). That configuration takes into account the narrow space between the legs close to the vaginal area, thus propitiating an improvement in relation to rectangular shape articles.
[0013] Still another example in the state of the art of a more anatomical shape is the provision of a protuberance in the central region of a woman's napkin, in such a way that the absorbent material is close to the site the menstrual fluid is discharged. U.S. Pat. No. 5,057,096 (Francis Faglione) and patent document EP249405 (Smith & Nephew Assoc. Co. PLC) are examples thereof.
[0014] With regard to higher efficacy and/or speed in the absorption of fluids, the following can be mentioned as examples of the state of the art:
[0015] U.S. Pat. No. 3,954,107 (Colgate Palmolive) that discloses two longitudinal parallel absorbing cores provided with a channel therebetween, the function of which is to serve as a deposit of fluid and is a means for directing the fluid to the longitudinal ends of the article.
[0016] U.S. Pat. No. 3,411,504 (J. A. Glassman) that discloses an absorbing core provided with longitudinal embossed lines for faster fluid transport towards the ends.
[0017] More recently, the state of the art has disclosed attempts to combine anatomical aspects with efficacy in the fluid absorption. For example, U.S. Pat. No. 5,591,148 (R. R. McFall et al.) discloses a woman's napkin comprising an absorbing core consisting of three longitudinal absorbing panels, the central panel being more prominent and supported on an element that acts as a spring to keep it at a higher position, therefore closer to the user's vagina during the use. It is a product of a complex and expensive construction, different from the one of the present invention.
[0018] Still in that sense, U.S. Pat. No. 5,695,324 (D. M. Weirich) discloses a woman's napkin provided with two absorbing cores, one vertically positioned with relation to the other, the aim of which is a partial penetration in the great lips of the user's genitalia. There are no joints between any of the absorbing cores, in such a way that the displacement of on affects another one, different from the present invention.
[0019] By evaluating the state of the art related to these aspects it can be noticed that there has been a constant search for an absorbent article having a better performance as to both the anatomical requirements and the absorption efficacy.
SUMMARY OF THE INVENTION
[0020] The present invention provides an improved alternative of the state of the art through the provision of a disposable absorbent article of simple and cheap construction, propitiating a dynamic and static adaptation to the user's body, concomitantly with an optimized fluid absorption.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention is directed to a disposable absorbent article characterized by comprising an absorbing core provided with three or more substantially independent absorbing panels, longitudinally oriented and separated in the transverse direction by channels, and joining means between said absorbing panels.
[0022] In an example of a typical embodiment of the present invention, three independent, parallelepipedical parallel panels of cellulosic fiber of wood pulp constitute the absorbing core of a woman's napkin. The bases of the three absorbing panels are affixed to a liquid impermeable coating layer, and a liquid permeable top layer wraps the remaining part of its surfaces. The top layer is sealed to the coating layer between the bases of the adjacent absorbing panels, along a longitudinal line or band. This sealing generates a joining means that allows for the pivoting of one panel in relation to another adjacent panel. As in general the external faces of the absorbing panels (except for the bases) are wrapped by the top layer, and said same top layer is sealed to the coating layer in the space existing between each panel, a slot or channel is generated between every two adjacent panels.
[0023] When put in use, the two side absorbing panels can pivot in relation to the central absorbing panel, being laterally conformed to the geometry of the space existing between the user's legs. By receiving the discharge of body fluid, the channels allow the absorption along the whole extension of the body-facing upper surface of the absorbing panel, but also along the exposed side faces of the adjacent absorbing panels, besides serving as a reservoir and longitudinal directing means for the fluid towards the napkin ends.
[0024] Some important aspects of the present invention are:
[0025] both static and dynamic adaptation of the article to the user's body in view of the ability to move from one absorbing panel to the another, either in the time its is put into place or when the user moves, for example, by walking, seating, crossing her legs, etc;
[0026] effective absorption, in view of the higher available surface area for receiving the fluid (the walls of the channels are surfaces that can allow the fluid to flow towards the absorbing core);
[0027] effective leak prevention, for the channels between the absorbing panels store and direct the released fluid longitudinally, mainly in the case of abundant discharges;
[0028] effective retention of the napkin in its place during the use, since the tensions due to the body/clothes/absorbent article interaction are substantially absorbed and/or dissipated by the movement of an absorbing panel in relation to another one.
[0029] As mentioned above, the absorbing core of the woman's napkin of the invention comprises absorbing panels which are “substantially independent in the transverse direction”, wherein this expression denotes a sufficient physical separation in the direction transversal to the length, mainly in the central third of the article, for allowing one panel to pivot in relation to another one. A continuous absorbing core, contrary to that of the present invention, does not allow such movement, for the intrinsic flexibility of a continuous length of absorbent material does not allow for the pivoting in the sense of this invention. Also, it is not considered as making it possible to pivot an absorbing panel with longitudinal embossed lines (that is, resulting from a strong compression on the absorbent material), that even allow a certain degree of arching of the absorbing core applied thereto, but not enough to allow for the pivoting of an absorbing region in relation to another one. However, the present invention can encompass embodiments wherein embossed lines are used and they are perforated, segmented, partially disrupted or otherwise submitted to a mechanical or chemical treatment that can eliminate or minimize the intrinsic rigidity, thus allowing an absorbing region to pivot in relation to an adjacent one. The present invention also encompasses adjacent absorbing panels which, despite being provided with a common absorbing and/or structural base, can pivot in relation to another one.
[0030] Within the scope of the invention, the absorbing core comprises three or more absorbing panels. Advantageously, an odd number of absorbing panels is used, thus defining a central panel that stays closer to the great lips of the vulva and tends to be inserted therebetween, thus diminishing the possibility of leak.
[0031] Preferably, the woman's napkin of the invention comprises three to five absorbing panels, and still more preferentially only three.
[0032] The absorbing panels of the absorbing core of the invention are “longitudinally oriented”, that is, generally they follow the orientation of an imaginary longitudinal axis parallel to the length direction of the absorbent article. Preferably, said absorbing panels are substantially parallel to said imaginary longitudinal axis, but configurations wherein one or more absorbing panels show some inclination, for example, between 10 and 40 degrees with relation to the longitudinal, are not excluded. Still preferably, the absorbing panels are parallel to one another.
[0033] The absorbing panels of the absorbing core of the present invention are “separated by channels”, that is, there is a substantial physical discontinuity of a panel in relation to another adjacent one, and the space between a panel and another one is deemed to be a channel which can have a varying geometry (mainly with respect to the cross-section area) during the use of the napkin, when a panel is moved in relation to the others, typically pivoting like two halves of a hinge. Any other geometry, volume or orientation of said channels are not excluded.
[0034] The absorbing panels of the absorbing core of the present invention comprises “joining means” among themselves. That means that there is a means, construct or arrangement between one absorbing panel and an adjacent absorbing panel that allows one panel to pivot in relation to the other. As used in the invention, the pivoting of a panel or absorbent region in relation to another is the one that occurs in a similar way to the rotation of the halves of a hinge, one in relation to the other, without the occurrence of any substantial physical change (discontinuity, partial disruption, wrinkle, and the like) of the absorbent material involved. Preferably, without excluding any another alternative, the joining means is provided as a sealing joint (line, band, points, etc.) of the top layer over the coating layer, between adjacent absorbing panels. The joining means can be situated close to any region along the thickness of the absorbing panels, and is preferably situated close to the base of said panels. The joining means can have any extension, and is typically between 30% and 100% of the length of the absorbing panels. The rotation of an absorbing panel in relation to the other is preferably between about 10 degrees about 180 degrees, and more preferably between about 15 degrees and 120 degrees.
[0035] Within another alternative embodiment of the invention, the material of the joining means between adjacent absorbing panels allows the expansion, for example, flexible, elastic or corrugated material, thus allowing a higher absorption of the tensions imposed to the absorbent article of the invention. Examples of said material would be foams, corrugated plastic films, crimped non-woven material, films with elastic zones in the region of the channels, etc.
[0036] Typically in the configuration shown in the present invention is that the base of said channels placed between the absorbing panels is the joining means itself, and is preferred that the joining means is composed by the association of the top layer with the coating layer. Alternatively, the joining means is comprised only by the top layer, or only by the coating layer, or still by the association of a distinct construct of two layers with one layer, or with another one, or both, or still any other arrangement that allows an absorbing panel to pivot in relation to another adjacent panel.
[0037] The multiple absorbing panels of the absorbing core of the invention can have identical or distinct conformations among themselves. Preferably, there is a bigger central panel which is thicker, (i.e. having a greater caliper) and is thus more protruding than the other adjacent panels to, as already mentioned, tend to perform a vaginal penetration and thus diminish the possibility of leaks.
[0038] Alternatively, the central absorbing panel is provided with structure which can be made conformable by filling the absorbing panel with from about 5 to 75% by volume of spheroidal elements having a diameter in the range between 0,1 mm and 5 mm, the spheroidal elements being confined in a recess of said absorbing panel or a closure distinct from the absorbing panel and inserted therein. Suitable spheroidal elements include, but are not limited to polymeric beads such as polystyrene beads.
[0039] In another alternative way, the absorbing panels of the article of the present invention, in particular the central absorbing panel, comprise fluid pockets, for example air. In accordance with this embodiment, one or more pockets filled with air are incorporated the into the article to transmit a feeling of a higher initial thickness to the users who feel apprehended before using a thin product to absorb their menstrual fluid.
[0040] Preferably, the cross-section of the absorbing panels retains the same area and geometry throughout its length, but alternatives with geometric changes along its length are not excluded.
[0041] The geometric shape of the cross-section of the absorbing panels of the invention can be any one, and can not be same for all the absorbing panels. For the preferred case of three absorbing panels, some advantageous examples can be cited (the sequence below refers to shapes of the cross-section of the side panel, the central panel and the other side panel, respectively):
[0042] quadrilateral, quadrilateral, quadrilateral;
[0043] right triangle, quadrilateral, right triangle spectral to the other side panel;
[0044] isosceles triangle, isosceles triangle, isosceles triangle;
[0045] circular, circular, circular;
[0046] capital L profile, isosceles triangle, inverted capital L profile (┘).
[0047] The channels between the absorbing panels are preferably straight and have advantageously a constant minimum width close to the joining means, between about 0.5 mm and about 10 mm, preferably between about 2 mm and 6 mm. When an absorbing panel pivots in relation to the other, the cross-section geometry of the channel changes, increasing the distance between the panels in a non-parallel way (that is, the longer the radial distance from a point to the rotation axis, the longer the distance from the adjacent absorbing panel). Alternatives with curved, winding, zigzag, and the like channels along its length are within the scope of the invention.
[0048] In an alternative embodiment of the invention, one or more absorbing panels are fully wrapped by the permeable top layer, and this way they are joined (welded, glue, or by any another adequate means) on a coating layer that preferably, in this situation, also performs the function of a joining means.
[0049] Preferably, the absorbing panels are fixed directly on the coating layer, but also it is encompassed in the scope of the invention the alternative where the panels are fixed to an intermediate construct (for example, foam, one or more thin layers of absorbent material of the paper or non-woven type, plain or corrugated material to facilitate the pivoting, etc.) which in turn is attached to or associated with the coating layer.
[0050] The absorbing panels which make out the absorbing core of the invention are typically separated, in the transverse direction, by longitudinal channels that run from a longitudinal end to the opposite one, in such a way that the absorbing panels have not absorbent material in common.
[0051] In an alternative embodiment of the invention, next to the longitudinal ends, the absorbing panels are connected to one another by a transverse band of absorbent material; in other words, the channels are interrupted before reaching the longitudinal ends, without affecting substantially the pivoting capacity, that is, the dynamic conformation of the woman's napkin of the invention. In a suitable way, said transverse band of absorbent material in the longitudinal ends is between about 1 and 3 cm wide. Still within this embodiment, the central absorbing panel (or the central absorbing panels, if there are more than one), in the longitudinal ends of the channels, can alternatively be provided with transverse embossed lines that run from one channel to the next channel, in such a way to generate a trend of a better distribution of the fluid in the transverse bands of absorbent material in the longitudinal ends of the absorbent article.
[0052] In another alternative embodiment of the invention, the absorbing panels can also comprise transverse channels or embossments along their length. Preferably, only the central panel, or central panels if that is the case, are provided with transverse channels. That configuration increases the available surface area for fluid absorption and minimizes the random wrinkling of the absorbing panels (which would otherwise occur during the use of the article and could eventually favor leaks).
[0053] The women's napkins of the invention are in a especially preferred way provided with wings or borders that extend laterally from the side edges of the article—they are elements known by those skilled in the art and their purpose is to assist the attachment of the absorbent to the external face of the region between the legs in the user's panties. It is known that said wings are side extensions of the top layer and/or coating layer, eventually comprising absorbent material.
[0054] In that conformation with side borders, an alternative of the present invention foresees that the adjacent absorbing panels to the side edges of the absorbent extend and run partially or fully inside said borders, whose upper and lower faces, like the higher layer and lower layer, are respectively provided with permeability and impermeability. The purpose of that conformation is to prevent the absorbent from leaks. Preferably, in that embodiment, about one third of the dimension of the side border adjacent to the connection with the body of the absorbent article, in the transverse direction, is filled with absorbent material.
[0055] The present invention brings about an additional benefit to women's napkins provided with side borders, that is, the dissipation of the tensions that are generated along the generally longitudinal connection between the side borders and the body of the woman's napkin. In an usual way, the side borders are provided with adhesive regions to promote its attachment to the external surface of the region between the legs in the user's panties. That attachment is subject to tensions which grow stronger as the longitudinal ends of said ends connections are closer, so that the movements of the user nullify said attachment. The arrangement of several adjacent absorbing panels according to the invention, allowing for the movement of a panel in relation to the other, attenuates or even eliminates such tensions and limits the trend “to pull” the attachment region.
[0056] In another alternative embodiment of the invention, the channels between the absorbing panels can be continuous, as if creating islands of absorbent material in the region inside the perimeter of the woman's napkin, and in this alternative those that create substantially oblong or ellipsoidal pathways are preferred. That configuration keeps the independence of the absorbing panels in the transverse direction, thus allowing the pivoting of one in relation to the other, and the absorbing core is provided with auxiliary transverse channels in the distribution of the fluid.
[0057] In another alternative embodiment of the present invention, only one channel (although it is also possible with more than one channel) of spiral configuration is used. Also in this configuration the independence of the absorbing panels is retained in the transverse direction, allowing the pivoting of one in relation to the other, and the absorbing core is provided with auxiliary transverse channels in the distribution of the fluid.
[0058] The woman's napkin of the invention can comprise any other elements known in the state of the art, like deodorants, ion exchanging resins, superabsorbents, zeolites, multiple adhesive regions for attachment of the article to the user's clothes, additional layers for spreading the fluid, etc.
[0059] With regard to the localization of adhesive regions in the lower face of the absorbent article, preferably in the case where the absorbent is provided with an odd number of absorbing panels, preferably three, it is preferred that the central absorbing panel or panels is/are not provided with adhesive regions. Or, alternatively, it is preferred that only the lower face of the side absorbing panels (there are at least two of them) is provided with adhesive regions. That alternative embodiment allows the central panels to move more freely, therefore bringing about a better conformability, and higher dissipation of tensions, the result of which is a better attachment of the napkin to the user's underclothes.
[0060] The women's napkins encompassed by the invention can have any thickness, from a few millimeters in the thinnest ones to two or more centimeters in the thickest ones. The pivoting effect of the invention has been found to be more pronounced in thicker napkins, for thicker panels are less flexible than thin absorbing panels.
[0061] Practical examples of embodiments of the invention are given below, in order to better disclose the inventive aspects thereof. The figures presented below are schematic representations without showing precise measures or dimensions, given only for exemplification purposes to elucidate the inventive aspects of the present invention. Both the examples and the figures encompass any other alternative embodiment of the invention covered by the accompanying claims.
[0062] [0062]FIGS. 1, 2 and 3 attached hereto show the same preferred alternative embodiment of the invention, wherein FIG. 1 is a top view of a woman's napkin, FIG. 2 a cut view of FIG. 1 along transverse line AA, and FIG. 3 is another cut view, but with the absorbent article in use.
[0063] It is an external woman's napkin 10 , provided with side borders 15 , a top layer 20 made of a thin perforated plastic film (polyethylene, weight of 25 g/m 2 , thickness of 0.04 mm, 30% open area), a coating layer 30 made of a thin impervious plastic film (polyethylene, weight of 25 g/m 2 , thickness of 0.04 mm), three longitudinal parallelepiped absorbing panels 40 , 40 ′ and 40 ″, with a width of 2 cm, a thickness of 1 cm and a length of 150 mm, in a total 5.5 g of wood pulp. 0.5 g of an acrylate-based superabsorbent material is uniformly distributed within the wood pulp. The distance between each absorbing panel is about 0.5 cm, and each one of them forms a region 41 , 42 and 43 covered by the top layer 20 in the upper and side faces, and the coating layer 30 in the base, respectively. Each absorbing panel is adhered to the coating layer 30 along a longitudinal adhesive band 70 (adhesive Findley H2465, from AtoFindley Inc., Milwaukee, USA).
[0064] It is important to remember that the above mentioned components (plastic films, absorbent materials, adhesives, etc) are quite common and can be replaced by equivalents known by those skilled in the art without departing from the scope of the invention.
[0065] There is a set 50 of adhesive 55 covered by a removable protection layer 60 in the lower face of each side border.
[0066] The joining means between each absorbing panel is configured as a longitudinal band 71 resulting from the attachment between the top layer 20 top and the coating layer 30 . Channels 44 and 45 (of a geometry that changes as the panels 40 pivot) are formed between the absorbing panels, as can be seen in FIG. 3, where the protection layer 60 was removed, and article 10 was placed on the user's genital region 11 , and borders 15 have been adhered by means of adhesives 55 on the external face of the region between the legs in the panties 80 .
[0067] [0067]FIG. 4 shows an upper view of another alternative of the invention, where a woman's napkin 12 similar to that of FIG. 1, with the difference that it comprises an absorbing panel 40 provided with two slits 44 ′ e 45 ′, both of length B, herein approximately 70% of the total length of absorbing panel 40 .
[0068] Slits mean regions of physical discontinuity, where there is not substantially any absorbent material.
[0069] Although the embodiments of FIG. 1 and FIG. 4 are similar to the extent that one transverse cut along line A′A′ is practically identical to that shown in FIG. 2 , with absorbing lengths 41 ′, 42 ′ and 43 ′ separated by channels 44 ′ and 45 ′, such channels 44 ′ and 45 ′ have a longitudinal extension limited to a fraction of the length of absorbent article 12 , in such a way that the longitudinal ends are provided with transverse absorbent regions B′. Embossed lines 13 are present over absorbent panel 40 , transversal to absorbing length 42 ′ between channels 44 ′ and 45 ′, close to their ends.
[0070] Other alternative embodiments of the invention are shown in FIGS. 5 through 9. FIGS. 5, 6 and 7 are cross-section views similar to those of FIG. 2, showing the same numerals, except with regard to:
[0071] [0071]FIG. 5: there is only one absorbing panel 40 provided with protuberances 41 , 42 and 43 , and bands 46 with a much lower thickness that any of those sufficient to create a continuity of the absorbent material, but without substantially jeopardizing the ability of protuberances 41 , 42 and 43 to reciprocally pivot. Bands 46 act as joining means, despite the fact that they contain absorbing construct. In FIG. 5, absorbing panel 40 is adhered to the coating layer by means not illustrated, for example, adhesive lines.
[0072] [0072]FIG. 6—a thin sheet of paper 21 is placed between top layer 20 and coating layer 30 , sufficient to provide the base of the article with some absorbing capacity, without jeopardizing the ability of absorbing panels 41 , 42 and 43 to reciprocally pivot.
[0073] Regions 71 , where there is an adhesion between top layer 20 and coating layer 30 , between which is the sheet of paper 21 , are the joining means of the article.
[0074] [0074]FIG. 7: there are three absorbing panels 40 , 40 ′ and 40 ″, individually wrapped by the material of top layer 20 , including its bases, that are adhered to a foam layer 72 along the adhesive lines 70 . Foam 72 is adhered to coating layer 30 by a means not illustrated. Regions 74 are the joining means of the article.
[0075] [0075]FIG. 8 is a top view of an absorbent article 13 comprising only one absorbing panel 40 which is provided with two slits 51 and 52 . Such configuration generates, at least in the central region of the article, regions 46 , 47 , 48 and 49 of absorbent material substantially independent in the transverse direction, and they are capable of substantially reciprocally pivoting.
[0076] [0076]FIG. 9 is a top view of an absorbent article 14 comprising only one absorbing panel 40 provided with only one spiral slit 53 . Such configuration generates, at least in the central region of the article, regions 46 , 47 , 48 and 49 of absorbent material substantially independent in the transverse direction, and they are capable of substantially reciprocally pivoting.
[0077] As well illustrated in the accompanying figures, many possible changes in the embodiments of the present invention are readily noticed by those skilled in the art, always within the scope of protection as defined by the accompanying claims.
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A disposable absorbent article, more specifically to a disposable absorbent article having three or more longitudinal absorbing panels, separated by channels and capable of generally reciprocally pivoting, thus providing a product that can be dynamically adapted to the user's body and provided with fast absorption of body fluids released thereon.
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PRIORITY
This application is a divisional of prior pending U.S. patent application Ser. No. 11/141,358, filed on May 31, 2005, which is herein incorporated by reference in its entirety, and priority is claimed to this application. Any disclaimer that may have occurred during the prosecution of the above-referenced application is hereby expressly rescinded, and reconsideration of all relevant art is respectfully requested.
BACKGROUND
A television remote control and some portable electronic devices, such as a cell phone, are difficult to use for text-based searching with current text input methods, particularly due to the limited set of input keys available on such devices. For example, other than the various configuration and television-specific input keys, a television remote control only has a standard numeric input keypad that includes the numbers zero through nine to input a channel selection. A viewer cannot easily input letters for a text search in an electronic program guide to search for a specific program, music, television content, or various other applications that may be available via the viewer's cable provider or other television system content provider. Further, conventional text searching techniques require that a user-entered search term be spelled correctly to locate the desired term.
Other electronic devices, such as a cell phone for example, are typically equipped with a conventional alphanumeric input keypad that includes the numbers zero through nine along with the alphabetic characters “A” to “Z”. Although zero (0) through nine (9) is a total of ten input keys, an alphanumeric or numeric input keypad is commonly referred to as a “9-key” keypad. The letters on a “9-key” keypad are distributed along with the numbers two (2) through nine (9). For example, the number two (2) includes the letters “A”, “B”, and “C”, the number three (3) includes the letters “D”, “E”, and “F”, and so on with each consecutive number being associated with the next consecutive three letters. The letters “Q” and “Z” may not be included on some keypads, but if they are, the number seven (7) has four associated letters to include “Q” and the number nine (9) has four associated letters to include “Z”.
There are techniques available to enter text with an alphanumeric “9-key” keypad, however they are cumbersome and in some cases, can require more user inputs than would actually be required to input a text string for the word itself, such as with a computer keyboard. For example, multi-tapping (also referred to as triple tap) is a technique to enter text and/or letters with a “9-key” keypad, such as with a cell phone to create a text message. As described above, the letters “A”, “B”, and “C” are associated with the number two (2) input key on the keypad. Pressing the input key once enters an “A”, twice enters a “B”, three times enters a “C”, and four times enters a “4”. Spelling out even short words for a text input can require multiple key entries. For example, to spell out “CAB”, a user would have to press the number two (2) input key a total of six times—three more inputs than would even be necessary with a conventional keyboard.
An alternative text-entry technique is “T9” (“text on nine keys”) which selects a letter that is associated with a key input to spell a word correctly based on a likelihood of letter combinations. With “T9”, a user may only have to press an input key once rather than multiple times as with multi-tapping. For example, to again spell out “CAB”, a user would only have to press the number two (2) input key a total of three times (once for “C”, twice for “CC”, and a third time for “CAB”). The “T9” technique is not without its limitations however. Depending on the presumed likely letter combinations, a user may have to switch back to multi-tapping to create a word that “T9” does not recognize, or the user may have to input several “T9” key combinations to create the word.
Irrespective of the technique implemented to enter text with an alphanumeric “9-key” keypad, the conventional text input techniques are cumbersome, often require more key inputs than would otherwise be necessary, and/or require unnatural combinations of key inputs.
SUMMARY
Gesture based character input is described herein.
In an embodiment of gesture based character input, a character shape is input on a keypad device, via selection of a sequence of keys. The character is determined based upon the shape of the character as represented by the selected sequence of keys. Characters derived from multiple key sequences are assembled to create character strings.
In an embodiment each character in a string of characters is represented by a numeric equivalent of the character.
BRIEF DESCRIPTION OF THE DRAWINGS
The same numbers are used throughout the drawings to reference like features and components.
FIG. 1 illustrates an exemplary data search system in which embodiments of predictive phonetic data search can be implemented.
FIG. 2 illustrates an exemplary data search system in which embodiments of predictive phonetic data search can be implemented.
FIG. 3 illustrates exemplary database components of the data search systems shown in FIGS. 1 and 2 .
FIG. 4 illustrates a shape-based search input initiated with a keypad to implement a predictive phonetic data search.
FIG. 5 illustrates an exemplary method for predictive phonetic data search and is described with reference to generating search terms and numeric equivalents.
FIG. 6 illustrates an exemplary method for predictive phonetic data search and is described with reference to a search request for a particular search term.
FIG. 7 illustrates an exemplary method for predictive phonetic data search and is described with reference to a search request initiated as a shape-based input on a keypad.
FIG. 8 illustrates various components of an exemplary electronic and/or computing device in which embodiments of predictive phonetic data search can be implemented.
FIG. 9 illustrates various devices and components in an exemplary entertainment and information system in which embodiments of predictive phonetic data search can be implemented.
DETAILED DESCRIPTION
Predictive phonetic data search is described in which embodiments provide for improved text searching techniques with a restrictive input device, such as a television remote control, cell phone, or other similar devices that have a conventional “9-key” numeric or alphanumeric input keypad. A user can input a search request to locate a term, such as a particular television program, music channel, network-based application, and the like, where a search “term” can be any form of text, letters, a word, a group of words, and/or any combination of characters and numbers. A numeric index includes a number that matches a numerical equivalent of the term designated in the search request. The numeric index also includes numerical equivalent(s) that correspond to translations of the term and phonetic equivalents of the term so that the term designated in the search request does not have to be spelled correctly when input to locate the search term.
When a numeric equivalent that corresponds to the search term is located in the numeric index, the search term can be obtained from a term index that is mapped to the numeric equivalent(s) which correspond to the search term and/or translations and phonetic equivalents of the search term. The search term can then be returned in response to the search request. For example, the requested search term may be displayed in an electronic program guide on a television that also displays programming information corresponding to the search term, such as for a particular television program. By pre-computing a numeric equivalent for the search term and for the possible translations and/or phonetic equivalents of the search term, the search-and-match process can be executed faster than conventional text-based searching to match the actual characters of a search term.
The terms that are maintained in the term index, and from which the numeric equivalents are determined, are received and identified from any number of text data sources, such as electronic program guide data and/or closed captions data corresponding to television content. The numeric equivalents of each term, the translations of the term, and/or the phonetic equivalents of the term are computed and maintained in the numeric index which can be searched for a requested search term. Each numeric equivalent in the numeric index is mapped to the corresponding search term in the term index such that when a numeric equivalent of the particular search term is located in the numeric index, the corresponding search term in the term index can be returned in response to a search request. This provides that a user need only enter a phonetic equivalent of a term that can be misspelled or does not include all of the letters and/or numbers of the term to minimize the number of keypad inputs, yet still receive a correct response to the search request. Further, the user can enter the search term in one language and receive a response to the search request in another language.
While aspects of the described systems and methods for predictive phonetic data search can be implemented in any number of different computing systems, environments, television-based entertainment systems, and/or configurations, embodiments of predictive phonetic data search are described in the context of the following exemplary system architectures.
FIG. 1 illustrates an exemplary data search system 100 in which embodiments of predictive phonetic data search can be implemented. In this example, the system 100 includes text data sources 102 ( 1 -N), a term manager 104 , and database server(s) 106 . In this example, the text data sources 102 ( 1 - 1 V) include electronic program guide data 102 ( 1 ), closed captions data 102 ( 2 ), and/or any text data from various sources 102 (N). The text data sources 102 ( 1 -N) may also include purchased metadata and/or data that has been edited or translated by hired personnel. In a television-based environment, the system 100 also includes encoding server(s) 108 and a content distribution system 110 . The encoding server(s) 108 can be implemented to receive and process the text data received from the text data sources 102 ( 1 -N) for distribution to client devices via the content distribution system 106 . An exemplary television-based system 900 that includes client devices is described further with reference to FIG. 9 .
The term manager 104 can be implemented to receive the text data from the encoding server(s) 108 and/or directly from the various text data sources 102 ( 1 -N) themselves. The term manager 104 identifies terms in the text data that may be requested in a search and computes a numeric equivalent of each term. For example, the term manager 104 identifies the term “Seinfeld” from the popular television comedy series in either the electronic program data 102 ( 1 ) or in the closed captions data 102 ( 2 ). The term manager 104 then computes a numeric equivalent 112 of the term.
On an alphanumeric keypad, an example of which is shown in FIG. 2 , “S” is associated with the seven (7) input key, “E” is associated with the three (3) input key, “I” is associated with the four (4) input key, “N” is associated with the six (6) input key, “F” is associated with the three (3) input key, “E” is associated with the three (3) input key, “L” is associated with the five (5) input key, and “D” is associated with the three (3) input key. As such, the numeric equivalent 112 of the data text term “Seinfeld” is 73463353. It should be noted that the techniques described herein are equally applicable for terms that include capital letters, small letters, and any combination thereof.
The database server(s) 106 include a terms index 114 and a numeric index 116 , which in an embodiment, are any form of computer readable media that can store and maintain data. The terms index 114 maintains the terms identified by the term manager 104 in the text data received from the text data sources 102 ( 1 - 1 V). For example, the terms index 114 includes the term “Seinfeld” which a user may search for via an electronic program guide to find and watch an episode of the television program. The numeric index 116 maintains the numeric equivalent(s) 118 of each of the data text terms maintained in the terms index 114 . For example, the numeric equivalent 112 (i.e., 73463353) of “Seinfeld” is maintained in the numeric index 116 as the first listed numeric equivalent 120 . The numeric equivalent 120 in the numeric index 116 is mapped to the corresponding term “Seinfeld” in the terms index 114 such that when a numeric equivalent of a particular search term is located in the numeric index 116 , the corresponding search term in the term index 114 can be returned in response to a search request.
The term manager 104 also computes the additional numeric equivalents 118 that each correspond to a phonetic equivalent 122 of the term. The additional numeric equivalents 118 are also maintained in the numeric index 116 and are mapped to the corresponding term in the terms index 114 . The additional numeric equivalents correspond to phonetic equivalents of a particular term in the term index 114 and may be a misspelling of the term, a spelling of the term that includes only consonants and no vowels, and/or a number in place of a word in the term.
For example, the first numeric equivalent 118 that is listed (i.e., 74363353) corresponds to a misspelling of the term “Seinfeld” where a user may input the search term, but misspell the word as “Sienfeld” with an “i” before the “e”. The last numeric equivalent 118 that is listed (i.e., 76353) corresponds to a spelling of the term “Seinfeld” that includes only the consonants of the word “snfld”, and none of the vowels. As such, a user can search for the television show, yet only provide a minimal input with a restrictive input device, such as a television remote control, cell phone, or other similar devices that have a conventional “9-key” numeric or alphanumeric input keypad.
In another example, a user can input search terms where a number is input in place of a word in the search term. For example, a user can search for the television program “Deep Space Nine” by inputting a search for “Deep Space 9”, or as described above “DPSC9” (or by various other letter and number combinations). For another example, a user can search for the television program “Eight is Enough” by inputting a search for “8 is Enough”, or as described above “8ENUF” (or by various other letter and number combinations). It should be noted that the phonetic equivalents 122 shown in FIG. 2 are merely illustrative, and do not need to be maintained or stored in memory, thus saving memory space.
Only the numeric equivalents 118 need be maintained such that the term manager 104 can receive a search input, determine the numerical equivalent of the search input, and then locate the number in the numeric index 116 that corresponds to the numeric equivalent of the search input. For example a user may search for “Star Trek” episodes and enter six (6) keypad inputs for “STRTRK” which the term manager 104 determines to have a numerical equivalent of 787875. Rather than searching for the actual text string of “S,T,R,T,R,K”, the term manager searches the numeric index 116 for “787875”, and when the number is located, obtains “Star Trek” from the terms index 114 to which the number is mapped.
FIG. 2 illustrates an exemplary data search system 200 in which embodiments of predictive phonetic data search can be implemented. The system 200 includes the database server(s) 106 shown in FIG. 1 , and in this example, the term manager 104 is shown as a component of a database server 106 to implement the various embodiments of predictive phonetic data search described herein. The system 200 also includes an exemplary television-based client device 202 that receives program content, program guide data, advertising content, closed captions data, and the like for display on a display device 204 (e.g., a television) via a communication network 206 , such as the content distribution system 110 shown in FIG. 1 . In an embodiment, client device 202 can be implemented with any combination of components described with reference to the exemplary electronic and/or computing device 800 shown in FIG. 8 . Further, an exemplary television-based system 900 is described further with reference to FIG. 9 .
A user can input a search request to locate a term, such as a particular television program, music channel, network-based application, and the like with a restrictive input device, such as a television remote control 208 , a cellular phone 210 , or a PDA 212 that only has a “9-Key” alphanumeric keypad 214 . A search term can be any form of text, letters, a word, a group of words, and/or any combination of characters and numbers. For example, the user may input a search request in an electronic program guide displayed on the display device 204 via the client device 202 with the television remote control 208 . Alternatively, (although not shown) a user may input a search request to the client device 202 via the cellular phone 210 and/or the PDA 212 which may be configured to operate as a television remote control device.
A user may also input a search request with the cellular phone 210 and/or the PDA 212 via a wired or wireless connection 216 that is received by the term manager 104 . The user can input the search request with the “9-Key” alphanumeric keypad 214 on the cellular phone 210 or PDA 212 and have the requested term returned for display on a display component of the cellular phone 210 or PDA 212 . For example, a user may want to search for an upcoming broadcast of a “Seinfeld” episode, and then have the associated programming information displayed via the cellular phone 210 or PDA 212 so that the user will know what time to be home to watch the television program. Although the examples described herein pertain to searching for the “title” of a program, such as “Seinfeld”, a requested search can include any terms that may be associated with a program, movie, gaming application, music, and the like. For example, a user may search for a particular actor, director, singer, or any other criteria or category of data that can be searched to locate a requested term.
A user can enter a search term via a numeric or alphanumeric keypad, such as the “9-Key” alphanumeric keypad 214 , on the television remote control 208 , cellular phone 210 , or PDA 212 as any one of: a sequence of characters, a sequence of letters each associated with a channel number input key on the keypad of the television remote control 208 , as a sequence of letters each associated with a telephone number input key entered on a keypad of the cellular phone 210 , as a text-based input that includes a sequence of characters that correspond to two or more words, as a combination of alphabetic character(s) and numeric character(s), as a phonetic equivalent of the term, as the phonetic equivalent which is a misspelling of the term, as the phonetic equivalent which includes only consonants in the term and no vowels, as the phonetic equivalent that includes a number in place of a word in the term, and/or any combination thereof. This list of search term inputs is not intended to be all-inclusive, but to merely illustrate some of the possible inputs that may be used to minimize the number of keypad entries needed when searching text data with a restrictive input device.
As described, a requested search term can be returned for display via an electronic program guide displayed on display device 204 (e.g., a television), or the requested search term can be displayed on a display component of the cellular phone 210 or PDA 212 . Additionally, a requested search term may return multiple listings or results which can all be displayed for the requesting user. For example, a search for a program listing or television program may return several instances of upcoming scheduled broadcasts of the program. Although an on-demand movie or gaming application does not have a typical broadcast schedule, the information returned for display may include when the on-demand content will become available to order, the associated cost, and/or any other similar information. The information returned for display in response to a requested search term may also be annotated based on a popularity of the results, to identify which of the returned search terms are already designated to be recorded (for a television program, for example), and/or any other annotations associated with the information returned for display.
In another embodiment of predictive phonetic data search, a user can enter a search term in one language with the “9-Key” alphanumeric keypad 214 on the cellular phone 210 or PDA 212 and have the requested term returned for display in another language. For example, a user may want to determine if the movie “Tres Amigos”, which is titled in Spanish, is available for viewing. The user may then enter a search request in English as any one of “3 Friends”, “3friends”, or “3FRNDS” (just for examples) to locate programming information associated with the movie. Optionally, a user may configure a preference such that a response to a request entered in any language is returned in a specified language, such as Spanish. For example, if an English-speaking user is traveling in Mexico, the user can enter a search term in English on the “9-Key” alphanumeric keypad 214 on the cellular phone 210 or PDA 212 and have the requested term displayed in Spanish on a display component of the cellular phone 210 or PDA 212 .
FIG. 3 illustrates exemplary database components 300 that can be implemented as part of the data search systems shown in FIGS. 1 and 2 , and which can be implemented in embodiments of predictive phonetic data search. The database components 300 include the terms index 114 and the numeric index 116 described with reference to FIG. 1 . The database components 300 also include a term instance index 302 and a translations index 304 .
In this example, the terms index 114 includes the illustrative terms “seinfeld”, “terminator”, and “garden” which may be requested in a search by a user. As described above with reference to FIG. 1 , a term in the terms index 114 corresponds to numeric equivalents in the numeric index 116 . For example, numeric equivalents 306 include the numeric equivalent 73463353 that corresponds to the keypad inputs for the term “seinfeld”, and includes numeric equivalents of various phonetic equivalents 308 of the term “seinfeld”. The numeric equivalents 306 in the numeric index 116 are mapped to the term “seinfeld” in the terms index 114 .
Similarly, the numeric equivalents 310 include the numeric equivalent 8376462867 that corresponds to the keypad inputs for the term “terminator”, and includes numeric equivalents of various phonetic equivalents 312 of the term “terminator”. The numeric equivalents 310 in the numeric index 116 are mapped to the term “terminator” in the terms index 114 . Similarly, the numeric equivalents 314 include the numeric equivalent 427336 that corresponds to the keypad inputs for the term “garden”, and includes numeric equivalents of various phonetic equivalents 316 of the term “garden”. The numeric equivalents 314 in the numeric index 116 are mapped to the term “garden” in the terms index 114 . It should be noted that the phonetic equivalents 308 , 312 , and 316 shown in FIG. 3 are merely illustrative to show the derivation of the respective numeric equivalents 306 , 310 , and 314 .
The translations index 304 includes translations of the term “garden” which are mapped to the term “garden” in the terms index 114 . When a user requests a translation of the term “garden” and a numeric equivalent 314 of the search term is located in the numeric index 116 , a translation of the search term can be returned in response to the search request. For example, a user in China may enter a search request for “GRDN” on the keypad of a cellular phone or PDA (or other portable electronic device) which is a phonetic equivalent 316 that is determined to have a numerical equivalent 314 of 4736. The numerical equivalent 314 in the numeric index 116 can be mapped back to the term “garden” in the terms index 114 , and the term “garden” can be mapped to the Chinese translation aM of the term in the translations index 304 . Although translations are only shown for the term “garden” in the translations index 304 in this example, each of the terms in the terms index 114 may have translations included in the translations index 304 .
The term instance index 302 includes service identifiers (i.e., a “Service_Id”) that each correspond to a term in the terms index 114 . A service identifier includes term instances that define how content associated with a term is presented for use by a user if a user selects the term from displayed results. For example, the term “terminator” in the terms index 114 can be returned in response to a user initiated search request and displayed as options for user selection. In this example, the options may correspond to a broadcast of the movie “Terminator”, on-demand availability of the movie, a trailer of the movie, a video game based on the movie, or a soundtrack of the movie.
The term instances 318 corresponding to the “terminator” term indicate that if the user selects to view the trailer of the movie, then the trailer will be received at the user's client device for viewing. Similarly, if the user selects to watch a broadcast of the movie, or orders the movie from an on-demand service, the user's client device will be tuned to receive the broadcast or on-demand presentation of the movie. Alternatively, if the viewer selects the video game option, the video game can also be rendered from an on-demand service and/or an offer to purchase the video game can be displayed for the user. If the user selects the soundtrack option, then the music corresponding to the movie can be streamed to the user's client device such that the user can listen to the soundtrack.
FIG. 4 illustrates an example of a search request that is input as a shape-based search request 400 using a “9-Key” alphanumeric keypad 402 to implement a predictive phonetic data search. In this example, a user inputs a request for a search term “LOUD” and inputs each letter of the term with shape-based pattern movements over the keypad such that the keypad is being utilized as a touch pad. For example, to enter the “L” input of the term at 404 , a user can form an L-shape with keypad entries in a sequence of the one (1) key, four (4) key, seven (7) key, eight (8) key, and nine (9) key.
Similarly, to enter the “0” input of the term at 406 , a user can form an 0-shape with keypad entries in a sequence of the one (1) key, four (4) key, seven (7) key, eight (8) key, nine (9) key, six (6) key, three (3) key, two (2) key, and one (1) key. To enter the “U” input of the term at 408 , a user can form a U-shape with keypad entries in a sequence of the one (1) key, four (4) key, seven (7) key, eight (8) key, nine (9) key, six (6) key, and three (3) key. To enter the “D” input of the term at 410 , a user can form a D-shape with keypad entries in a sequence of the one (1) key, four (4) key, seven (7) key, eight (8) key, six (6) key, two (2) key, and one (1) key.
The term manager 104 (as described with reference to FIG. 1 ) can be implemented to receive the key entry sequences that each correspond to a letter of the requested search term, and determine each of the letters. The term manager 104 can then determine the numerical equivalent of the search input to be 5683 (i.e., the single key inputs for the term “LOUD”), and then locate the number in the numeric index 116 that corresponds to the numeric equivalent of the search term input.
Methods for predictive phonetic data search, such as exemplary methods 500 - 700 described with reference to respective FIGS. 5 , 6 , and 7 , may be described in the general context of computer executable instructions. Generally, computer executable instructions can include routines, programs, objects, components, data structures, procedures, modules, functions, and the like that perform particular functions or implement particular abstract data types. The methods may also be practiced in a distributed computing environment where functions are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, computer executable instructions may be located in both local and remote computer storage media, including memory storage devices.
FIG. 5 illustrates an exemplary method 500 for predictive phonetic data search, and is described with reference to generating search terms and numeric equivalents. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.
At block 502 , text data is received from one or more text data sources. For example, text data can be received from text data source(s) 102 ( 1 - 1 V) ( FIG. 1 ) which can include electronic program guide data 102 ( 1 ), closed captions data that corresponds to television content 102 ( 2 ), and/or any other text data source 102 (M. At block 504 , search terms are identified in the text data. For example, the term manager 104 can identify terms in the received text data that may be requested by a user in a search
At block 506 , a numeric equivalent of each search term is computed. For example, the term manager 104 computes a numeric equivalent 112 of the requested search term. At block 508 , additional numeric equivalents each corresponding to a phonetic equivalent of a search term are computed. For example, the term manager also computes additional numeric equivalents 118 that each correspond to a phonetic equivalent 122 of the requested search term. A phonetic equivalent of a search term can be a misspelling of the search term, a spelling of the search term that includes only consonants and no vowels, and/or a number in place of a word in the search term. The additional numeric equivalents are computed for any one or more of the phonetic equivalents.
At block 510 , the numeric equivalent(s) associated with each search term are maintained in a numeric index. For example, the numeric equivalent(s) 118 are maintained in the numeric index 116 and include the numeric equivalent 120 corresponding to the correct spelling of the search term as well as the additional numeric equivalents 118 that each correspond to a phonetic equivalent 122 of the search term. The numeric equivalent(s) 118 can be searched in response to a search request for a particular search term.
At block 512 , each numeric equivalent in the numeric index is mapped to the corresponding search term in a term index. For example, the numeric equivalents 118 corresponding to the requested search term in the numeric index 116 are mapped to the terms maintained in the terms index 114 such that when a numeric equivalent of a requested search term is located in the numeric index 116 , the corresponding search term in the term index 114 can be returned in response to a search request.
At block 514 , one or more translations of a search term are generated and, at block 516 , the one or more translations of the search term are maintained in a translations index For example, the term manager 104 can generate translations of a term that are maintained in the translations index 304 ( FIG. 3 ). At block 518 , the one or more translations in the translations index are mapped to the corresponding search term in the term index. For example, the translations for the term “garden” in the translations index 304 are mapped to the term “garden” in the terms index 114 such that when the numeric equivalent of a requested search term is located in the numeric index, a translation of the search term can be returned in response to the search request.
FIG. 6 illustrates an exemplary method 600 for predictive phonetic data search, and is described with reference to a search request for a particular search term. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.
At block 602 , a search request is received to locate a term. For example, the term manager 104 ( FIG. 2 ) can receive a search request from a user for a particular term. A search request can be received as inputs to a restrictive input device, such as a television remote control 208 , a cellular phone 210 , or a PDA 212 that only has a “9-Key” alphanumeric keypad 214 . A search request can be received as any one of: a sequence of characters, a sequence of letters each associated with a channel number input key on the keypad of the television remote control 208 , as a sequence of letters each associated with a telephone number input key entered on a keypad of the cellular phone 210 , as a text-based input that includes a sequence of characters that correspond to two or more words, as a combination of alphabetic character(s) and numeric character(s), as a phonetic equivalent of the term, as the phonetic equivalent which is a misspelling of the term, as the phonetic equivalent which includes only consonants in the term and no vowels, as the phonetic equivalent that includes a number in place of a word in the term, and/or any combination thereof.
At block 604 , a numeric index is searched to locate a number that matches a numerical equivalent of the term. For example, the term manager 104 can search the numeric index 116 to locate a numeric equivalent 118 ( FIG. 1 ) of a requested search term. At block 606 , the term is obtained from a term index that is mapped to the number in the numeric index which matches the numerical equivalent of the term. For example, the numeric equivalent 118 of the search term is mapped to the term in the terms index 114 .
At block 608 , the search request is processed to return the term based on a designated response instance of the term. For example, the term manager 104 can return the requested term based on a designated term response instance 318 ( FIG. 3 ) that corresponds to the ‘term in the terms index 114 . At block 610 , the term is returned in response to the search request. For example, the requested term can be returned for display and according to the designated term response instance, as a translation of the term, as a list of likely terms that correspond to the term in response to the search request, or as any one of a program schedule, a broadcast television selection, an on-demand selection, or an application program.
FIG. 7 illustrates an exemplary method 700 for predictive phonetic data search, and is described with reference to a search request initiated as a shape-based input on a keypad. The order in which the method is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method. Furthermore, the method can be implemented in any suitable hardware, software, firmware, or combination thereof.
At block 702 , a sequence of characters are received as a search request to locate a term, the sequence of characters each being entered as shape-based inputs that approximate a character. For example, a user can input a request for a search term by inputting each letter of the requested search term with shape-based pattern movements over a keypad 402 ( FIG. 4 ) such that the keypad is being utilized as a touch pad. At block 704 , the shape-based inputs that approximate a character are converted into at least one of an alphabetic or numeric character for each of the characters in the sequence. For example, the term manager 104 can receive the key entry sequences that each correspond to the letters “L,O,U,D” of the requested search term in the example 400 , and determine each of the letters.
At block 706 , a numerical equivalent of the term is computed as determined from the sequence of characters. At block 708 , a numeric index is searched to locate a number that matches a numerical equivalent of the term. For example, the term manager 104 can then determine the numerical equivalent of the search input to be 5683 (i.e., the single key inputs for the term “LOUD” in FIG. 4 ), and then locate the number in the numeric index 116 that corresponds to the numeric equivalent of the search input. At block 710 , the term is obtained from a term index that is mapped to the number in the numeric index which matches the numerical equivalent of the term. At block 712 , the term is returned in response to the search request.
FIG. 8 illustrates various components of an exemplary electronic and/or computing device 800 in which embodiments of predictive phonetic data search can be implemented. The electronic and/or computing device 800 can be implemented as any one or more of the electronic, computing, and client devices described herein, and as any one or more of the servers, monitors, and managers of the exemplary television-based system 900 described with reference to FIG. 9 .
Electronic and/or computing device 800 includes one or more media content inputs 802 which may include Internet Protocol (IP) inputs over which streams of media content are received via an IP-based network. Device 800 further includes communication interface(s) 804 which can be implemented as any one or more of a serial and/or parallel interface, a wireless interface, any type of network interface, a modem, and as any other type of communication interface. A wireless interface enables device 800 to receive control input commands 806 and: other information from an input device, such as from remote control device 808 , PDA (personal digital assistant) 810 , cellular phonet or from another infrared (IR), 802.11, Bluetooth, or similar RF input device.
A network interface provides a connection between the computing and/or client device 800 and a communication network by which other electronic and computing devices can communicate data with device 800 . Similarly, a serial and/or parallel interface provides for data communication directly between device 800 and the other electronic or computing devices. A modem facilitates device 800 communication with other electronic and computing devices via a conventional telephone line, a DSL connection, cable, and/or other type of connection.
Computing and/or client device 800 also includes one or more processors 812 (e.g., any of microprocessors, controllers, and the like) which process various computer executable instructions to control the operation of device 800 , to communicate with other electronic and computing devices, and to implement embodiments of predictive phonetic data search. Device - 800 can be implemented with computer readable media 814 , such as one or more memory components, examples of which include random access memory (RAM), non-volatile memory (e.g., any one or more of a read-only memory (ROM), flash memory, EPROM, EEPROM, etc.), and a disk storage device. A disk storage device can include any type of magnetic or optical storage device, such as a hard disk drive, a recordable and/or rewriteable compact disc (CD), a DVD, a DVD+RW, and the like.
Computer readable media 814 provides data storage mechanisms to store various information and/or data such as software applications and any other types of information and data related to operational aspects of the computing and/or client device 800 . For example, an operating system 816 and/or other application programs 818 can be maintained as software applications with the computer readable media 814 and executed on processor(s) 812 to implement embodiments of predictive phonetic data search.
For example, device 800 can be implemented as a server and/or client device and the computer readable media 814 includes a program guide application 820 that is implemented to process program guide data 822 and generate program guides for display which enable a viewer to navigate through an onscreen display and locate broadcast programs, recorded programs, video on-demand programs and movies, interactive game selections, and other media access information or content of interest to the viewer. The computer readable media 814 can also includes a speech translator 824 and a term manager 826 to implement embodiments of predictive phonetic data search.
The speech translator 824 can be implemented to receive an audio input of a search term, such as from a microphone or other audio input device (e.g., via a communication interface 904 ), and convert the audio input into a search request to locate the requested term. The term manager 826 can implement the various features and aspects of predictive phonetic data search as described herein, such as described with reference to the methods 500 - 700 described with reference to respective FIGS. 5 , 6 , and 7 . Although the term manager 826 is illustrated and described as a single application configured to implement embodiments of predictive phonetic data search, the term manager 826 can be implemented as several component applications distributed to each perform one or more functions in a server and/or client device in a television-based entertainment and information system.
The computing and/or client device 800 also includes an audio and/or video output 828 that provides audio and video to an audio rendering and/or display system 830 , or to other devices that process, display, and/or otherwise render audio, video, and display data. Video signals and audio signals can be communicated from device 800 to a television 832 via an RF (radio frequency) link, S-video link, composite video link, component video link, analog audio connection, or other similar communication link.
FIG. 9 illustrates an exemplary entertainment and information system 900 in which an IP-based television environment can be implemented, and in which embodiments of predictive phonetic data search can be implemented. System 900 facilitates the distribution of program content, program guide data, and advertising content to multiple viewers. System 900 includes a content provider 902 and television-based client systems 904 ( 1 -M each configured for communication via an IP-based network 906 .
The network 906 can be implemented as a wide area network (e.g., the Internet), an intranet, a Digital Subscriber Line (DSL) network infrastructure, or as a point-to-point coupling infrastructure. Additionally, network 906 can be implemented using any type of network topology and any network communication protocol, and can be represented or otherwise implemented as a combination of two or more networks. A digital network can include various hardwired and/or wireless links 908 ( 1 -M, routers, gateways, and so on to facilitate communication between content provider 902 and the client systems 904 ( 1 -M. The television-based client systems 904 ( 1 -M receive program content, program guide data, advertising content, closed captions data, and the like from content server(s) of the content provider 902 via the IP-based network 906 .
System 900 includes a media server 910 that receives program content from a content source 912 , program guide data from a program guide source 914 , and advertising content from an advertisement source 916 . In an embodiment, the media server 910 represents an acquisition server that receives the audio and video program content from content source 912 , an EPG server that receives the program guide data from program guide source 914 , and/or an advertising management server that receives the advertising content from the advertisement source 916 .
The content source 912 , the program guide source 914 , and the advertisement source 916 control distribution of the program content, the program guide data, and the advertising content to the media server 910 and/or to other television-based servers. The program content, program guide data, and advertising content is distributed via various transmission media 918 , such as satellite transmission, radio frequency transmission, cable transmission, and/or via any number of other transmission media. In this example, media server 910 is shown as an independent component of system 900 that communicates the program content, program guide data, and advertising content to content provider 902 . In an alternate implementation, media server 910 can be implemented as a component of content provider 902 .
Content provider 902 is representative of a headend service in a television-based content distribution system, for example, that provides the program content, program guide data, and advertising content to multiple subscribers (e.g., the television-based client systems 904 ( 1 - 1 V)). The content provider 902 can be implemented as a satellite operator, a network television operator, a cable operator, and the like to control distribution of program and advertising content, such as movies, television programs, commercials, music, and other audio, video, and/or image content to the client systems 904 ( 1 - 1 V).
Content provider 902 includes various components to facilitate media data processing and content distribution, such as a subscriber manager 920 , a device monitor 922 , and a content server 924 . The subscriber manager 920 manages subscriber data, and the device monitor 922 monitors the client systems 904 ( 1 -M (e.g., and the subscribers), and maintains monitored client state information.
Although the various managers, servers, and monitors of content provider 902 (to include the media server 910 in one embodiment) are illustrated and described as distributed, independent components of content provider 902 , any one or more of the managers, servers, and monitors can be implemented together as a multi-functional component of content provider 902 . Additionally, any one or more of the managers, servers, and monitors described with reference to system 900 can implement features and embodiments of predictive phonetic data search.
The television-based client systems 904 ( 1 -M can be implemented to include a client device 926 and a display device 928 (e.g., a television). A client device 926 of a television-based client system 904 can be implemented in any number of embodiments, such as a set-top box, a digital video recorder (DVR) and playback system, a personal video recorder (PVR), an appliance device, a gaming system, and as any other type of client device that may be implemented in a television-based entertainment and information system. In an alternate embodiment, client system 904 (IV) is implemented with a computing device 930 as well as a client device 926 . Additionally, any of the client devices 926 of a client system 904 can implement features and embodiments of predictive phonetic data search as described herein.
Although embodiments of predictive phonetic data search have been described in language specific to structural features and/or methods, it is to be understood that the subject of the appended claims is not necessarily limited to the specific features or methods described. Rather, the specific features and methods are disclosed as exemplary implementations of predictive phonetic data search.
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Gesture-based character input is described. A user inputs a character by selecting keys on a keypad device via a gesture representing the shape of the character. The sequence of keys selected by the user is interpreted to represent a specific character.
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BACKGROUND OF THE INVENTION
This invention relates to the mechanic arts, and particularly to the field of building demolition. It often happens that the site of an urban renewal or other building project is already occupied by structures which are not suited for the new use, or are in ill repair, and hence must be removed. Such structures are frequently of frame construction and contain sheathing, roofing, flooring, and similar boards which would have value for reuse. Usually, however, no attempt is made to salvage this material, and the whole structure is torn apart by a wrecking crane and hauled away as trash to be disposed of. Sometimes this is due to the pressure of time within which the new work must be accomplished, but very often it is simply because the reclamation of such used lumber is not economically feasible. The cost of the labor needed to disassemble a structure in a way which preserves usable materials is one factor, and another factor is the relatively low yield of usable material due, for example, to splitting of boards incidental to the wrecking process. The usual tools employed in demolition are hammers and wrecking bars: occasionally nail pullers are used, but pulling nails individually is a tedious process which is slow and hence expensive in labor costs. The concentrated impact of hammer blows mars the boards, and often causes breakage, while wrecking bars are almost ideally designed to split boards lengthwise in the act of removing them.
I have invented a tool for use in demolishing frame buildings, which is inexpensive, efficient, and easy to use, and which acts on substantially the entire width of the board being removed, rather than along one edge only, to continuously and smoothly separate the board from the timber to which it is nailed. My tool is usable in any position, to remove sheathing, roofing, of flooring boards, wherever access can be had to the rear surface of the boards and the timbers to which they are nailed. My tool involves no impact forces and no cross grain leverage forces, and hence its use results in a high proportion of undamaged boards fit for salvage.
SUMMARY OF THE INVENTION
My demolition tool comprises a frame and means for clamping the frame to a timber behind a board to be removed. Linearly movable in the frame is a member which includes a pressure foot of length only slightly less than the width of the board being removed, and means are provided for causing movement of the member so that the pressure foot first engages the back surface of the board and then forces it away from the timber, thus drawing the nails without splitting the board or damaging either of its faces.
Various advantages and features of novelty which characterize my invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing,
FIG. 1 is a plan view showing my demolition tool in use;
FIG. 2 is a side elevation;
FIG. 3 is a fragmentary view taken along the line 3--3 of FIG. 1;
FIG. 4 is a sectional view taken along the line 4--4 of FIG. 2;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 2;
FIG. 6 is a sectional view taken along the line 6--6 of FIG. 2; and
FIG. 7 is a fragmentary view of the tool showing a modification.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in the drawings, my invention comprises an elongated frame 20 having a longitudinal axis 21 and a longitudinal guideway 22 extending between a first end 23 and a second end 24 of the frame. A member 25 is linearly movable along axis 21, and extends beyond the end 23 of the frame 20 at 26. Member 25 is fastened as by a threaded connection 27 to the body of a nut 30 which slides in guideway 22 without rotating about axis 21. Cooperating with nut 30 is a screw 31. While elements 30 and 31 are shown as cooperating with a plurality of steel balls 32 and recirculating tube 33 to comprise a low friction connection of a well known type, a simple nut and screw with standard Acme or square threads may be used if desired. Screw 31 has an enlarged collar 34 beyond which it extends as a shaft 35 passing through a thrust bearing 36, end 24 of frame 20, and a thrust washer 37. An outer hub 40 is secured to shaft 35 as at 41, and is cross bored to receive a crank 42 having a rotatable knob 43, and secured in hub 40 as at 44.
Member 25 is hollow and the portion of screw 31 which extends beyond nut 30 is contained within the member and carries at its outer end 45 a disc 46 which is a loose fit in the hollow 47 of the member. Frame 20 has a face 50 which is parallel with axis 21. A plurality of teeth 51 extend away from face 50 and are secured to end 23 of frame 20 by suitable fasteners 52.
A pressure foot 53 is removably retained in the end 26 of member 25 beyond end 23 by means such as a ball detent 58, and extends perpendicular to axis 21. It is desirable that the length of this foot be different for different applications, and FIG. 2 shows a second, longer foot 54 as being removably secured on foot 53 by means such as a ball detent 59.
An arm 60 is secured to frame 20 near end 24, and extends from the frame in the same direction as teeth 51. Arm 60 has a pair of substantially parallel faces 61 and 62 generally orthogonal to axis 21, and a carrier 63 is movable along arm 60. At one end, carrier 63 rigidly is connected to a pair of shoes 64 and 65 having first parallel surfaces 66 and 67 spaced by substantially the distance between surfaces 61 and 62. A second pair of surfaces 70 and 71 make dihedral angles with the surfaces 66 and 67, respectively. The vertices of these angles are substantially in a plane parallel to axis 21, but may be slightly offset so that the vertex of shoe 64 is slightly further from, and that of shoe 65 is slightly nearer to, frame 20. The distance between parallel surfaces 70 and 71 is greater than that between surfaces 66 and 67 so that if carrier 63 is rotated in a counter-clockwise direction the fit of the shoes on arm 60 is perceptably looser. A set screw 72 is provided in shoe 65 to hold the carrier in any desired position along arm 60.
A jaw 73 is pivoted to carrier 63 at 74, and a handle 75 is pivoted to carrier 73 at 76. The end of handle 75 is connected to jaw 73 by a link 77, pivoted to the handle at 80 and to the jaw at 81. Members 73 - 81 comprise an overcenter mechanism 82 for locking arm 73 in a desired position. Link 77 may be configured as at 83 to provide a stop in the overcenter condition of the assembly.
In order to make the use of my tool more convenient where boards are to be removed from wider timbers, I provide an extension 84 for member 25, as is shown in FIG. 7. This extension is arranged to cooperate with ball detent 58, and has a similar ball detent 85 for cooperating with pressure foot 53.
OPERATION
My tool is used, as shown in FIG. 1, in the following fashion. It is desired to remove from a timber 90, such as a two-by-four, a board 91 which is held to the timber by nails 92. Set screw 72 is loosened to allow movement of carrier 63 along arm 60, and a foot 54 slightly shorter than the width of the board to be removed is used. With member 25 retracted as far as possible into frame 20 by the use of crank 42, the tool is positioned so that foot 54 is against board 91 near timber 90, and face 50 is toward the timber with teeth 51 touching it. With handle 75 in the broken line position of FIG. 1, carrier 63 is moved along arm 60 toward timber 90 until jaw 73 is close to or touching the timber, and handle 75 is then moved to its solid line position. The causes faces 66 and 67 to engage faces 61 and 62 securely, and draws teeth 51 into the timber. Set screw 72 may be tightened, and the tool is now secured to timber 90. Operation of crank 42 rotates screw 31 to drive nut 30, and with it member 25, toward board 91. Powerful forces are put into action and the board is displaced smoothly from the timber, the nails usually being drawn as well. Sometimes in old work, the head of a badly rusted nail may be pulled through the board, but the hole thus produced is a relatively minor imperfection in used lumber.
Handle 75 is now reversed to allow the teeth to be extracted from the timber, the tool is repositioned, and the work continues. It will be apparent that the operation just described is simple to perform, requires no great strength of the operator, is free from the noise and dust which accompany impact operations, and has no tendency to split the boards.
While I have shown a screw as the driving element for member 25, it will be apparent that mechanical equivalents may be used as preferred. I also contemplate that for major demolition projects, my member 25 may be arranged for pneumatic or hydraulic actuation, when this additional complication is felt justified.
From the above it will be evident that I have invented a demolition tool which is simple, easy to use, relatively inexpensive, quiet and clean, which may be used to remove boards of various widths from timbers of various thicknesses, which causes minimum damage to the lumber being reclaimed, and which may be arranged for either manual or fluidic actuation.
Numerous characteristics and advantages of my invention have been set forth in the foregoing description, together with details of the structure and function of the invention, and the novel features thereof are pointed out in the appended claims. The disclosure, however, is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A tool for use in demolition of frame structures to preserve the lumber for reuse. A frame is secured to a timber, to which a board to be removed is nailed, by quick acting means including an overcenter connection. A pressure foot projecting from the frame bears against the back of the board to be removed. By a screw-acting mechanism in the frame the board is forced away from the timber over its entire width without splitting, pulling the nails as it does so.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to an electrical connector assembly and more particularly to an electrical connector assembly comprising a male part and a female part which are lockably connectable together.
(2) Description of the Prior Art
Hitherto, various kinds of electrical connector assemblies have been proposed for the purpose of providing electrical connection between two electric devices. Some of the connector assemblies are of a type which comprises a plastic male part and a plastic female part which are lockably connectable together by locking means included in each of the parts. Most of the locking means comprise a latch-like member integral with one part and a striker-like member integral with the other part. However, due to the nature of the plastics, the locking function provided by such locking means deteriorates with the lapse of time. This undesirable phenomenon is pronounced in high temperature environments, sometimes leading to unexpected uncoupling of them during usage of same.
SUMMARY OF THE INVENTION
It is thus an object of the present invention to provide an electrical connector assembly which can endure a high temperature environment.
It is another object of the present invention to provide an electrical connector assembly which comprises heat-resisting metallic locking clips for locking the male and female parts thereof together.
It is still another object of the present invention to provide an electrical connector assembly comprising male and female parts which can be assuredly coupled and easily uncoupled.
According to the present invention, there is provided, in an electrical connector assembly comprising first and second matable parts which are respectively provided with first and second groups of terminal elements which are sufficiently mated with one another upon final coupling of the first and second parts, improved locking means for locking the first and second parts when they are finally coupled together. The locking means comprises a locking clip made of resilient metal detachably fixed to the first part, the clip including a first portion lockably fixed to the first part, a second portion having a locking opening formed therein and a third portion having a free end, the third portion being resiliently moved together with the free end thereof toward the first portion when pressed toward the first portion, a projection formed on the second part, the projection being thrusted into the locking opening of the locking clip when the first and second parts are finally coupled, and fulcrum means formed on the first part to support partially the third portion of the clip in such a manner that when the third portion is depressed toward the first portion, the second portion is raised away from the first portion thereby disengaging the locking opening of the clip from the projection of the second part.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of an electrical connector assembly according to the present invention, showing male and female parts in separated condition;
FIG. 2 is a sectional view of the electrical connector assembly, showing the two parts in half-mated condition;
FIG. 3 is a view similar to FIG. 2, but showing the two in full-mated condition;
FIG. 4 is a plan view of a locking clip employed in the present invention;
FIG. 5 is a side view of the locking clip of FIG. 4;
FIG. 6 is a bottom view of the locking clip of FIG. 4; and
FIG. 7 is a sectional view of a modified locking clip employable in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 6, there is shown an electrical connector assembly according to the present invention. As is seen from FIG. 1, the electrical connector assembly comprises generally a pair of matable connector parts, which are a female part 10 and a male part 12. As will become clear as the description proceeds, upon fully mated coupling therebetween, locking means provided on each part is cooperated to latch the parts together.
The female part 10 comprises a housing 14 of molded insulating material, such as glassfiber-reinforced nylon. The housing 14 has a cavity 16 therein and a slot 18 in the lower wall thereof. A column 20 is spacedly arranged in the cavity 16, which extends axially from the bottom of the cavity 16 toward the mouth of the same, as is understood from FIG. 1. The column 20 is formed with two axially extending bores 22 and 24 in which contact socket terminals 26 and 28 (see FIG. 2) are snugly received respectively. The terminals 26 and 28 are secured to wires 30 and 32 which extend rearwardly from the housing 14, as shown. As is shown in FIG. 1, an insulating cover 34 is fixed to the rear half of the female part 10 to cover the wires 30 and 32. For this fixing, the rear end of the housing 14 is axially elongated somewhat, terminating with an enlarged tapered portion 35, as is seen from FIGS. 2 and 3. With the enlarged portion 35, the cover 34 is tightly fixed to the housing 14 of the female part 10. For the purpose which will be described hereinafter, the upper wall of the housing 14 is formed with an internal groove 36 which extends axially from the mouth of the housing 14 toward the rear end of the same, as is seen in FIG. 1. Furthermore, the column 20 is also formed with an axially extending groove 37 at its lower surface.
The male part 12 comprises a housing 38 which is constructed of the same material as the housing 14 of the female part 10. The housing 38 of the male part 12 is so sized and constructed as to be snugly received in the cavity 16 of the female part 10. The housing 38 of the male part 12 has therein an axially extending cavity 40 which is sized and constructed to snugly receive therein the column 20 of the female part 10. Two contact plug terminals 42 and 44 are spacedly arranged in the cavity 40, which terminals extend axially from the bottom of the cavity 40 toward the mouth of the same, as is understood from FIG. 1. Upon proper coupling of the male and female parts 12 and 10, the plug terminals 42 and 44 of the male part 12 are respectively mated with the socket terminals 26 and 28 of the female part 10 to provide electric connection therebetween, as is understood from FIG. 3. The upper surface of the housing 38 and the lower surface of the cavity 40 are respectively formed with axially extending ridges 46 and 48 which, upon coupling of the male and female parts 12 and 10, are slidably received in the afore-mentioned grooves 36 and 37 of the female part 10 to assure proper coupling. Although not shown in the drawings, wires are connected to the plug terminals 42 and 44, which extend rearwardly from the housing 38 of the male parts 12.
Locking means is provided on each part 10 or 12, which functions to lock or latch the male and female parts 12 and 10. The locking means comprises generally two locking clips 50 and 52 of metal detachably fixed to the housing 14 of the female part 10, and two projections 54 and 56 integrally formed on the housing 38 of the male part 12, which are lockably engageable respectively in the manner as will be described hereinafter.
In order to receive therein the locking clips 50 and 52, the lateral sides of the housing 14 of the female part 10 are respectively formed with rectangular recesses 58 and 60 each being bounded by two axially extending parallel banks (no numerals) and a front bank (no numeral) which is perpendicular to the parallel banks. As is understood from FIG. 2 or 3, the bottom portion of each recess 58 or 60 is formed with a considerable opening merged with the cavity 16 of the housing 14, leaving a rear portion 62 or 64 thereof. The rear portion 62 or 64 is integrally formed with a boss 62a or 64a which is projected outwardly. The boss 62a or 64a has an inclined surface with a forwardly facing shoulder portion, as shown. As may be understood from FIGS. 2 and 6, the axially extending parallel banks of each recess 58 or 60 are respectively formed at the inside surface thereof with generally rectangular platforms 66 and 68 or 70 and 72, which serve as fulcrum means for the associated locking clip 50 or 52, as will be clear as the description proceeds.
The two locking clips 50 and 52 have the same constructions, and thus only one clip 50 will be described in detail in the following in order to facilitate the description. Portions of the other clip 52 are indicated by the addition of the same letters (a, b, c . . . k) after the numeral 52 in the drawings.
Referring to FIGS. 4 to 6, there is shown the clip 50 which is of a stamped or press-formed monoblock heat resisting resilient metallic member and comprises generally a rectangular base portion 50a, a front curved portion 50b, a rear curved portion 50c and an upper depressable portion 50d which are combined to define substantially a "hair-pin" shaped cross section, as is understood from FIG. 5. As is seen in FIG. 6, the base portion 50a is formed at its rear portion with a smaller rectangular opening 50e and at its front portion with a larger rectangular opening 50f. The opening 50f is sized to match with the projection 54 on the male part housing 38. The front edge of the larger opening 50f is raised upwardly to provide a curved boss 50g as is best seen in FIG. 5. As is seen FIG. 6, the rear half of the base portion 50a is somewhat enlarged. The front half is so sized as to have a desirable resiliency. The enlarged portion is formed at the rear portions thereof with lateral bosses 50h and 50i each having an inclined surface with a forwardly facing shoulder portion. The front curved portion 50b has the same width as the base portion 50a and extends from the same turning rearward, as is seen from FIG. 5. The rear curved portion 50c extends from the enlarged rear end of the base portion 50a and curves forward to be merged with the upper depressable portion 50d. The front half 50j of the upper portion 50d is reduced in width and bent downwardly at 50k. The leading end or free end of the upper portion 50d is located beneath the leading end of the front ourved portion 50b. Thus, it will be appreciated that upon depression of the upper portion 50d toward the base portion 50a, the free end of the upper portion 50d moves toward the base portion 50a while disengaging from the leading end of the front curved portion 50b. As may be understood from FIG. 6, the width W 1 of the front half of the base portion 50a (and thus, of the front curved portion 50b) is smaller than the distance L between the paired platforms 66 and 68 formed on the parallel banks of the recess 58, while, the width W 2 of the enlarged rear half of the base portion 50a is greater than the distance L. For assembly, the clip 50 is slidably inserted from the rear non-banked portion of the recess 58 and then moved forwardly (that is, leftwardly in FIG. 2) until the boss 62a of the female part housing 14 is lockably engaged with the smaller opening 50e of the clip 50. With the inclined surface of the boss 62a, the insertion of the clip 50 to the locked position is smoothly achieved. In this locked condition, the front half 50j of the upper portion 50d is partially seated on the parallel platforms 66 and 68 as is understood from FIG. 2, and the laterally projected bosses 50h and 50i of the clip 50 abut on the rear ends of the parallel banks of the recess 58 of the housing 14 as may be understood from the same drawing.
As is seen from FIG. 2, each projection 54 or 56 on the male part housing 38 comprises an inclined surface 54a or 56a having a rearwardly facing shoulder portion 54b or 56b.
When coupling of the male and female parts 12 and 10 is required, the male part 12 is put into the mouth of the cavity 16 of the female part 10 with the axially extending ridges 46 and 48 thereof slidably received in the grooves 36 and 37 of the female part 10, respectively. This condition is depicted by FIG. 2. Then, the male part 12 is thrusted deeply into the cavity 16 of the female part 10 until the plug terminals 42 and 44 of the male part 12 are sufficiently mated with the associated socket terminals 26 and 28 of the female part 10. During this movement, the front curved portions 50b and 52b of the locking clips 50 and 52 of the female part 10 ride over the projections 54 and 56 of the male part 12 against the spring force thereof and finally induce instant thrust of the projections 54 and 56 into the openings 50f and 52f of the clips 50 and 52. With this, the two parts 12 and 10 are locked together, as is seen from FIG. 3. The provision of the inclined surfaces 54a and 56a of the projections 54 and 56 of the male part 12 facilitates the riding over action of front curved portions 50b and 52b of the clips 50 and 52.
When uncoupling of the parts 12 and 10 is required, the outwardly expanded sections of the upper portions 50d and 52d of the clips 50 and 52 are depressed toward the female part proper 10. With this, the front halves 50j and 52j of the upper portions 50d and 52d are lifted (that is, moved away from the female part proper 10) using the platforms 66 and 68, 70 and 72 as their fulcrums, thereby lifting the front curved portions 50b and 52b of the clips 50 and 52 away from the associated projections 54 and 56 of the male part 12. Thus, uncoupling of the parts 12 and 10 is easily achieved by pulling them away while pressing the clips 50 and 52 inwardly. It is to be noted that the provision of the curved bosses 50g and 52g of the clips 50 and 52 avoids undesirable entanglement between the clips 50 and 52 and the projections 54 and 56 at the time of the uncoupling.
Referring to FIG. 7, there is shown, in a sectional manner, a modified locking clip 50' (or 52') usable in the invention. In this modification, the free end of the upper depressable portion 50'd is positioned at the rear curved portion 50'c. Similar to the afore-mentioned clip 50, depression of the outwardly expanded section of the upper portion 50'd will raise the front curved portion 50'b by using parallel platforms 66 and 68 as the fulcrum means.
Various other modifications may be made to those skilled in the art without departing from the scope of the invention. For example, the locking clips 50 and 52 may be fixed to the male part 12, and the locking projections 54 and 56 may be formed on the female part 10.
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Herein disclosed is a heat resisting electrical connector assembly which has a heat resisting metallic locking clip. The locking clip is detachably fixed to a female part of the connector assembly and comprises a first portion lockably fixed to the female part, a second portion having a locking opening formed therein and a third portion having a free end, the third portion being resiliently moved together with the free end thereof toward the first portion when pressed toward the first portion. A male part of the connector assembly is formed with a projection with which the locking opening of the clip is engaged upon final coupling of the male and female parts. A fulcrum structure is formed on the female part to support partially the third portion of the clip in such a manner that when the third portion is pressed toward the first portion, the second portion is raised away from the first portion thereby disengaging the locking opening of the clip from the projection.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 10/145,459, filed May 13, 2002 now U.S. Pat. No. 6,844,868, which is a continuation of U.S. application Ser. No. 08/725,642, filed Oct. 15, 1996, now U.S. Pat. No. 6,396,471. This application claims priority to each of these prior applications, and the disclosures of the above applications are considered part of (and are incorporated by reference in) the disclosure of this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to liquid crystal display (LCD) devices, and more particularly to color LCD devices for use with a touch-sensitive pointing input device and an image display method thereof.
2. Description of the Prior Art
Through the trend of complexity in computerization as to diversity of information in the recent past, portable or “handheld” electronic information management tools including personal digital assistants (PDAs) have found increasing applications due to advantages such as small size and light weight. In the thrust to achievement of such advanced handheld information management tools, the pen-input scheme is becoming more important for permission of direct entry of input data or instructions by use of a touch-sensitive coordinate pointing input device known as a “pen” pointer in the art through an associated tough-screen display panel in such a simple and easy way that allows users to “write down” by hand on a memo pad. As such pen-input scheme, several techniques have been proposed until today, including a technique of laminating a pen-input panel (tablet panel) on an associated display panel, a technique of common use of a display panel also as the tablet, and others.
One typical pen-input scheme incorporating the former technique has been disclosed in, for example, Published Unexamined Japanese Patent Application (PUJPA) No. 58-200384 and also in PUJPA No. 7-175591. With the prior art, an input tablet is constituted from two light transmissive substrates having lateral and longitudinal elongate electrodes for position detection. The substrates may be made of glass, polycarbonate or other polymer material. When the pen pointer is manually operated by users to draw a desired locus thereon while rendering the pen pressed onto the surface of the tablet at a tip end thereof, a coordinate detector circuit operates to sense or detect corresponding coordinates of a drawing position every time the coordinates change. A control circuit is responsive to receipt of such detected coordinates for providing adequate image data indicative of character set or graphics as pursuant to the coordinate detection result, allowing a resultant drawing image to be visually indicated on the LCD panel under the control of LCD driver circuitry.
Unfortunately, the prior art LCD devices suffer from the lack of ability to process color images for display. A need has therefore been felt for a color-image displayable LCD device for use with the pen-pointer input device permitting direct entry of input data and instructions.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a new and improved LCD display scheme capable of avoiding the problem as faced with the prior art.
It is another object of the invention to provide an improved color image displayable LCD device while permitting direct entry of necessary data or instructions by use of an associated touch-sensitive pointing input device.
It is yet another object of the invention to provide an improved method of displaying color images on LCD devices while permitting direct entry of input data or instructions using an associated touch-sensitive pointer.
To attain the foregoing objects, the present invention provides an LCD device having a display panel with an array of picture elements or “pixels” organized into a matrix, capable of displaying an image as hand-drawn by use of a touch-sensitive pointing input device, featured in that the display device is arranged so that the image is displayable in more than one color thereon in response to operation of the pointing input device.
In accordance with another aspect of the instant invention, there is provided an LCD device including an LCD panel having an array of rows and columns of pixels defining a matrix, a position commander for determining a certain position for color display on the display panel, a coordinate detector for recognition of the certain position as determined by the commander and for generating and issuing an output signal indicative of a corresponding coordinate data, a color designator for designation of the kind of a color being selected for such color display, a memory device for storage of color data representative of the color as presently designated, a memory controller responsive to receipt of an address generated from the selected coordinate data for controlling the color data to be written into and read from the memory, and an output controller for allowing the color data read from the memory to be output onto the display panel as image data.
In accordance with still another aspect of the invention, the commander includes a pen-shaped touch-sensitive input device for use in drawing any desired locus being subject to color display on the display panel, while the coordinate detector includes a recognition function module for recognizing the locus drawn by the pen pointer thereby to provide an output being issued as X- and Y-coordinate data corresponding to the pixel dots on the display panel.
In accordance with a further aspect of the invention, the recognition function module may include a pressure sensor, an electrostatic sensor or a heat sensor.
In accordance with a yet further aspect of the invention, the color designator is comprised of a color designation area as provided in advance for a respective one of colors on the display panel permitting selection of any desired color in response to the commander. With the invention also, the color designator may be a color selection menu allowing the operation mode to be set in a color selection mode and permitting selection of a desired color through the color selection mode. The display panel may be of the active matrix type having thin-film transistors (TFTs) disposed at the pixels thereon.
In accordance with a still further aspect of the invention, there is provided a method for displaying a color image on an LCD panel with a matrix of rows and columns of pixels by using a pen-like touch-sensitive input device operatively associated therewith, which method includes the steps of designating a color to be displayed in advance, drawing on the display panel a locus being color-displayed by use of the pen pointer input device, providing the address of an associated data storage device based on the resulting coordinate data corresponding to the locus drawn, writing the selected color data into the storage device at the designated address thereof, and reading color data from the storage device thereby generating and issuing the same to the display panel as image data.
In accordance with the invention, the LCD panel has a matrix of rows and columns of pixels. To display a color image, a color designation means acts first to designate or determine the color to be displayed. This color designation may be performed by execution of pointing one of color designation areas each predefined for the individual color on a display panel; or alternatively, the same may be attained by setting the operation mode in a color selection mode through operation of a color selection menu.
Then, a position commander unit operates to instruct a specific position being subject to such color display on the display panel. More practically, the commander may be a touch-sensitive pointing input device, which is generally known as a “pen pointer” tool. This pen pointer is for use in drawing any desired line of locus to be color-displayed on the LCD panel screen. Each position designated by the commander is next recognized by a coordinate detector unit, which generates and issues corresponding coordinate data at an output thereof. The coordinate detector includes a recognizer for recognition of the locus as drawn or defined by movement of the pen pointer in such a way that the detector issues an output of recognizer as data indicative of X- and Y-coordinates corresponding to pixels or dots on the display panel. The recognizer here may be a pressure sensor, electrostatic sensor, heat sensor, or the like.
A storage controller unit is responsive to receipt of the resulting coordinate data for generating and issuing an address selected. Based on the address, the controller also serves to control read/write operations of color data with respect to a memory associated. The color data stored in the memory is then read out under the control of the storage controller to be supplied as video data to the display panel. In this way, it becomes possible to display a color image by use of pen input device.
These and other objects, features and advantages of the invention will be apparent from the following more particular description of one preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an overall configuration of a color LCD device in accordance with one embodiment of the invention.
FIG. 2 is a diagrammatical representation for explanation of a color data storage scheme as employed in the LCD device of FIG. 1 .
FIGS. 3( a ) to 3 ( c ) depict some models of the contents of a memory in the LCD device shown in FIG. 1 .
FIG. 4 illustrates a configuration of table data as stored in a color designator circuit of the embodiment of FIG. 1 .
FIG. 5 shows a configuration of electrical circuitry of an LCD panel as employed in the FIG. 1 embodiment.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , a liquid crystal display (LCD) device in accordance with one preferred embodiment of the invention includes an LCD panel with a matrix of rows and columns of picture elements or “pixels,” which may also be called the “dots” in some cases. The LCD panel comes with a coordinate detector device 2 for detection of coordinates as input by an associated pen-shaped touch-sensitive pointing input device known as an “input pen” or “pen pointer” in the art. Here, the LCD panel is of the active-matrix type which may be configured as shown in FIG. 5 . As shown, the active-matrix LCD panel incorporates a matrix of pixels, each of which is at a corresponding one of cross points or intersections between horizontal scanning lines 52 and vertical signal transmission lines 53 . The individual pixel includes therein a switch element 50 , which selectively turns on and off controlling adequate transfer of image information to an associative display medium. This medium may be a liquid crystal material 51 . The switch element may be a three-terminal element, typically a thin-film transistor (TFT) having the gate, source and drain electrodes. The scan lines 52 are connected to the gates of TFTs 50 , whereas the signal lines 53 are to the sources (or drains) thereof.
As shown in FIG. 1 , the coordinate detector 2 includes a pair of X/Y-coordinate recognition sensors 21 for recognition of the position of an arbitrary point as presently designated by the input pen 1 , by detecting the X- and Y-coordinates thereof on the LCD display panel. The detector 2 also includes a coordinate detector circuit 22 , which is responsive to receipt of the recognition data as derived from the X/Y-position recognition sensors 21 for generating and issuing at the outputs X- and Y-coordinate data that correspond to dots on a one-to-one correspondence basis. The sensors 21 may be pressure sensors, electrostatic sensors, heat sensors, or the like.
The coordinate detector 22 is connected to a memory controller circuit 3 . This controller is to perform physical address settings and read/write control for an associative memory device 4 (described later). More specifically, the controller 3 generates and issues a physical address(es) for data write in memory 4 in response to the coordinate data (X- and Y-coordinate data) as detected by coordinate detector 22 . Controller 3 also receives information sent from a sequence controller circuit 5 (later described) to generate when data write a write command signal such as write enable (WE) at a certain timing. During read mode, controller 3 attempts to control data read operation at memory 4 by providing physical address control for display on the LCD panel and generating a necessary signal (control signal) therefor.
The memory controller 3 is connected to the memory 4 and also to a color designator circuit 6 and a panel display timing signal generator circuit 7 . The coordinate detector 2 , memory controller 3 , color designator 6 and timing generator 7 are connected to the sequence controller circuit 5 so that they operate under the control of it. Memory 4 is connected through an RGB conversion table 8 to an output controller circuit 9 . The panel display timing generator 7 is also connected to output controller 9 .
The memory 4 has in its memory space a prescribed number of addresses as equivalent in number to the resolution of the display panel, namely, equal to the total number of pixel dots thereon. Memory 4 can store therein N-bit data enabling handling of 2 N colors of image data. By way of example, in cases where sixteen (16) different colors are required for display, the memory is designed to be 4-bit data storable memory. Further, memory 4 has N sets of storage regions; for example, in the case of 16 different colors, it is designed to have four sets of storage regions MEM 0 , MEM 1 , MEM 2 , MEM 3 as shown in FIG. 2 , each of which can store therein 4-bit data separately. Note here that FIG. 2 diagrammatically represents a model of the operational correlation of coordinate detector 2 and memory 4 .
The color designator 6 operates when predefined color selection (designation) coordinates are pointed on the LCD display panel to set a certain color data corresponding to the presently pointed color thereon. Here, the “color designation coordinates” may refer to an area as provided on the LCD display panel for the individual color. For instance, in cases where sixteen (16) colors are needed for display, 16 separate areas are provided on the panel, each of which is associated with a corresponding one of such colors required. With such an arrangement, selecting any desired color becomes available by execution, using pen 1 , of “pointing” color designation coordinates (color distinction area) as desired for color display.
It should be noted here that the color data may be specific data variable in value from zero (0) to 2 N−1 that can be handled or processed by memory 4 with N sets of storage regions. For example, in the situations where 16 different colors are to be implemented for use, the data is designed to have any value as selected from “0” to “15” that can be handled by memory 4 with four sets of storage regions MEM 0 –MEM 3 . The color designator 6 has one exemplary built-in table as shown in FIG. 4 . This table shown is for use in 16-color display schemes; for example, when a “black” is selected based on the color selection coordinates, a corresponding digital color data “1111” is set. Alternatively, when a “red” is designated due to color designation coordinates, a color data “0001” will be set. In such cases, allocation between colors and color data items may be determined in an arbitrary manner.
In the illustrative embodiment the color selection coordinates (color distinction area) are arranged on the LCD display panel enabling selection of any desired color for display by use of the “pen-pointing” techniques; this may alternatively be modified such that an exclusive color selection menu is provided at a selected position on the display screen allowing users to operate it to attain selection of any color for display. In other words, operating the color selection menu causes the screen to change in operation mode so that it is set in a color selection mode for permission of color selection by way of such resultant color selection screen. This may advantageously avoid the need of providing in advance the color distinction areas on the LCD display panel enabling more efficient use of display screen in area.
The panel display timing generator 7 functions to generate and issue at its output a write synchronization (sync) signal, an operation clock signal, a reset command signal (an initializing signal) and others for the LCD display panel, memory controller 3 , and output controller 9 . The RGB conversion table 8 is for conversion of data read from the memory 4 into corresponding actual color data during display operation of the LCD panel. Output controller 9 operates to provide retiming, digital-to-analog (D/A) conversion and level-shift operations of video data and display control signals.
In the embodiment thus arranged, a color selected by use of either the color selection coordinates (color distinction area) or the color selection menu on the LCD panel screen is converted by the color designator 6 to a corresponding color data, which is then stored in respective storage regions of the memory 4 . By way of example, assume that sixteen (16) different colors are available for display: in this case, resultant color as selected through operation of the color selection coordinates (color distinction area) or the color selection menu is converted using the table (see FIG. 4 ) of color designator 6 into 4-bit color data, and is then stored in a respective one of the storage regions MEM 0 –MEM 3 of memory 4 shown in FIG. 2 .
The color data stored in the memory 4 in this way is thereafter read out of it under the control of memory controller 3 to be sent forth to the RGB conversion table 8 . RGB conversion table 8 is rendered operative to convert the input color data to RGB data for actual display on the LCD panel screen, which is then passed to the output controller 9 . Output controller 9 attempts based on a signal(s) from the panel display timing generator 7 to display such RGB data on the LCD panel as video information. In this way, any desired color display is available in responding to input by pen 1 .
The operation of the illustrative embodiment will be described in detail as follows.
The following description assumes that sixteen (16) different colors are employed for display. Imagine that as shown in FIG. 2 , a curvature line A is to be displayed in “black” whereas a straight line B is in “red” on the LCD screen. Consider here that the display screen is initially displayed in “white” as its background color.
Under the above condition, the memory 4 has four sets of separate storage regions MEM 0 –MEM 3 as shown in FIG. 2 , while the content of color data being stored in each region is shown in FIGS. 3A to 3C . FIG. 3A shows the initial condition of such storage regions MEM 0 –MEM 3 , all of which store therein logic data “0” since the LCD background color is “while” as mentioned previously. FIG. 3B illustrates the storage contents of respective regions MEM 0 –MEM 3 as observed just after completion of pen-input of the curve A of FIG. 2 , whereas FIG. 3C depicts the contents of regions MEM after pen-input of the straight line B of FIG. 2 .
First, the operator designates in advance his or her desired color to be displayed on the LCD screen. This color designation is attained either by execution of “pointing” the color designation coordinates (color distinction area) or by using a color selection menu as displayed on the screen.
Since this example assumes that the curve A is first displayed in “black,” the operator selects the “black” by pointing the color designation coordinates or by making use of the color selection menu. The resulting color selected is then converted by the color designator 6 into color data. Practically, such designated color is converted using the conversion table (see FIG. 4 ) and is sent forth as output data. In this case, the “black” is converted into a 4-bit digital signal “1111.”
After completion of the color designation for display in the foregoing way, the operator then uses the input pen 1 to draw his or her desired locus on the LCD display panel. In this example the curve A is hand-drawn on the display panel. The resulting locus as drawn on the display panel is output by the coordinate detector 2 as appropriate coordinate data (the data representative of X- and Y-coordinates), and thereafter is input to the memory controller 3 . In responding to this, memory controller 3 generates and issues at its output physical addresses based on the input coordinate data, attempting to sequentially write color data into memory 4 at such addresses generated. The entire storage space of memory 4 is divided into four regions MEM 0 –MEM 3 allowing the 4-bit color data to be written into these regions MEM. The result of such data write into regions MEM is demonstrated in FIG. 3B .
Then, for display of the straight line B in “red” on the LCD panel, the operator selects the “red” through pointing of the color designation coordinates (color distinction area) or using the color selection menu. Any resultant color selected is then converted by the color designator 6 . In this case the selected color is converted by the conversion table (see FIG. 4 ) into 4-bit color data “0001.”
After completion of the color designation for display, the operator attempts to hand-draw using the input pen 1 his or her desired locus, namely, line B of FIG. 2 for example on the LCD display panel. The locus drawn is output by the coordinate detector 2 as X/Y-coordinate data and is then supplied to the memory controller 3 , which generates and issues at its output physical addresses sequentially writing color data into memory 4 at such addresses generated. Practically, the 4-bit color data “0001” is stored in four regions MEM 0 –MEM 3 of FIG. 2 , respectively. The result of such data storage in regions MEM is presented in FIG. 3C .
The resultant color data bits as stored in the memory 4 are later read sequentially from it under the control of memory controller 3 to be supplied in this order to the RGB conversion table 8 . RGB conversion table 8 automatically converts the input color data to corresponding RGB data, which is then fed to the output controller 9 . Output controller 9 executes D/A conversion for the RGB data as input thereto deriving at its output an analog color video signal, which is then supplied to the LCD panel. In this way, the pen-input locus patterns (curve A and straight line B) are finally displayed on the LCD screen in the operator's designated colors, e.g., “red” or “black” in this case.
It will possibly be desired that the locus patterns are in other colors. If this is the case, the aforesaid operation will be repeated while the operator occasionally selects his or her preferred color(s) by execution of pointing the color designation coordinates (color distinction area) or using the color selection menu available at every step for color selection.
As necessary, an extra selection menu for selection of the background color and line colors may be additionally arranged on the display panel. To attain such background-color designation, it should be required that a presently designated color data be written into the memory 4 at corresponding addresses thereof. This may be accomplished by employing a specific scheme as follows: reading data out of memory 4 , and replacing the “old” data being previously stored at an address of the background color data before such background color designation with the updated background color data as presently selected. This data replace scheme may be attained using either one of an exclusive hardware arrangement and software programs.
In addition, while the illustrative embodiment has been described under the assumption that it is applied to the case of 16-color images based on 4-bit data, this invention is not exclusively limited thereto, and may be modified in arrangement to be applicable for any other cases requiring an increased number of colors for display. Furthermore, the pen-input technique as employed in the embodiment may be replaced with any other functionally equivalents, including the use of a multi-layered panel structure with the pen-input panel being stacked on the display panel, the use of a common panel structure allowing a panel to function both as the display screen and as the pen-input sheet.
It has been described that the present invention can provide the LCD display device permitting pen input on its display panel and the display method therefor.
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There is disclosed a color liquid crystal display (LCD) device capable of displaying color images in response to direct entry of input data and/or instructions through operation of an associated coordinate pointing tool. Typically, this tool is a pen-like input device known as the “input pen” for use in determining the individual position for color display on the screen of a built-in LCD panel. A coordinate detector operates to recognize the position as designated by the input pen, generating and issuing an output signal indicative of the corresponding coordinate data. A color designator circuit designates a color as presently selected for color display. A memory device stores therein color data representative of the color designated. A memory controller is responsive to receipt of an address issued from the selected coordinate data for controlling the color data to be written into and read out of the memory. An output controller allows the color data read from the memory to be supplied to the LCD display screen as video data.
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This is a continuation application of Ser. No. 08/147,872, filed Nov. 4, 1993 now abandoned, which is a divisional application of Ser. No. 07/776,199, filed Oct. 15. 1991, now U.S. Pat. No. 5,281,456.
FIELD OF THE INVENTION
This invention relates to insulating ductwork. More specifically, the invention relates to forming lineal corner edging on insulated ductwork and similar structures.
BACKGROUND OF THE INVENTION
It has been the practice in the insulation of heating and air conditioning ductwork to seal the corners of the ducts, whether straight or curved. Typically, ninety degree angle edging made of either sheet metal, plastic or even paper has been used. The insulation industry has traditionally used tin (plated) edges 2"×2" on corners of ductwork, scroll fans and other essentially square edges. These tin plated edges are held in place with tape or contact adhesive which can be brush applied. Thereafter canvas, plastic, or other suitable decorative fabric is stretched around the structure and glued in place. In the case of canvas, further coatings are painted on to shrink the canvas to a tight fit and seal it to provide an attractive finish. Tin edges or galvanized sheet metal are generally made of approximately twenty-four gauge (0.023") thick material.
Murasho Co. Ltd. offers an edging material that is formed in a metal roll consisting of a flat surface with overlapping discrete segments depending from the flat surface at a ninety degree angle. The discrete segments facilitate application of the flat surface on contoured edges. The Murasho product is identified as Roll Kiku-za or squeezed sheet. Similarly, Zeston (Manville Corporation) has marketed a metal end capping product that is essentially the same. A need has arisen for an inexpensive, easy to apply corner edge, starting at 11/2"×11/2" and going up to 3"×3" to accommodate the normal insulation thicknesses used on ductwork and similar structures that are generally 1" to 2" thick (or more).
SUMMARY OF THE INVENTION
It is an objective of the invention to provide edging material for the corners of ductwork and other conduit structures formed with square or somewhat square corners.
It is another object of the present invention to provide polyvinyl chloride edging for ducting.
It is a further object of the invention to provide a process for manufacturing polyvinyl chloride edging material particularly well suited for sealing the corners of ducting and similar structures.
Accordingly, a flat polyvinyl chloride strip is provided with adhesive on one side, release paper covering the adhesive, and an embossed score line linearly disposed over the length of the strip on the adhesive side. The release paper is severed at the score line to provide two discrete strips of release paper.
Application of the strip to corner edges proceeds by cutting the strip to the length desired, bending the strip down its entire length, on the score line, to a 90° angle, removing one of the two release paper strips, adhering the exposed adhesive portion of the strip to the corner edge. The second strip of release paper is then removed and this portion of the strip is pushed down and adhered in place resulting in a 90° (or other angle desired) straight corner edge that covers and seals any raw edges. Where ducts or equipment that are to be edged, turn away from a straight direction, silts can be scissor cut perpendicular to the length of the strip, up to the score line to form segments that are folded along the score line and adhered to the adjacent surface, on the inside radius curves of the article being edged and to itself.
DESCRIPTION OF THE DRAWINGS
The subject invention will be better understood when viewed with the following drawings wherein:
FIG. 1 is a plan view of the edge strip of the present invention;
FIG. 2 is a sectional elevational view of the invention applied to one surface of ducting;
FIG. 3 is the edging material of FIG. 2 shown fully applied to the ducting;
FIG. 4 is a schematic of the process equipment shown forming the edging material of the subject invention;
FIG. 5 is a sectional view of the embossing roll assembly taken through line 5--5 of FIG. 4;
FIG. 6 is a variation of the process for forming the edging material of the subject invention; and
FIG. 7 is the edging material of FIG. 1 applied to an insulated pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention has application in any environment in which angled corners are required to be sealed. However, the present invention will be described principally in the environment of heating, ventilation and air conditioning ducting.
As best seen in FIG. 1, the present invention is comprised of a flat strip of polyvinyl chloride edging material 2 having a centrally disposed linear score line 4; a layer of adhesive formed on the adhesive side 8 of the strip on which the score line 4 is located and optional separate release paper strips 12 and 14 to maintain the adhesive layer in an unexposed condition until application of the edging material 2 to the edge to be sealed. The score line 4 facilitates the bending of the strip edging material into separate regions 5 and 7.
As seen in FIG. 2, the strip is applied to one surface 16 adjacent to the edge 18 being sealed, in this case ducting 20, after removal of a strip of release paper 12. Thereafter, the strip of release paper 14 is removed and the section of the edging material extending beyond the adhered surface is then cut into discrete segments 22 separated by the cut slits 24. The discrete segments 22 are rotated around the score line 4 and the exposed adhesive surfaces of the discrete segments 22 are pressed against the opposite or complementary surface 26 of the ducting 20 to provide a seal at the duct edge 18, best seen in FIG. 3.
The process of forming the edging strip 2 is best seen in FIG. 4 wherein a roll of polyvinyl chloride strip material 28 is formed on an idler mandrel 30, a contact adhesive with silicone paper release tape roll 32 is formed on a separate idler mandrel 34 and the formed edging strip 2 is taken up on a driven mandrel 36. Pressure application rolls 38 are provided to secure the paper release tape to the edging strip and a linear groove adjustable depth embossing roll assembly 40 is provided to form the score line 4.
In operation, the driven mandrel 36 pulls the polyvinyl chloride strip and release paper through the pressure application rolls 38 and the embossing roll assembly 40. The pressure application rolls 38 secure the contact adhesive with silicone paper release strips 32 to the adhesive surface 8 of the polyvinyl chloride strip 2 and the embossing roll assembly 40 forms the score line 4 linearly in a centrally disposed location on the strip 2.
As best seen in FIG. 5, the embossing roll assembly is comprised of an embossing roller 42 with a continuous embossing ridge 44 and a mating roll 46 with a groove 45 corresponding to the embossing ridge 44 against which the embossing ridge 44 reacts through the strip 2 to form the score line 4.
In a variation or modification of the process for forming the corner edge strip 2 of the subject invention, slitting rolls 48 and 50 can be substituted for the embossing roll assembly 40. The slitting rolls 48 and 50, best seen in FIG. 6, are arranged to provide a depth of approximately 0.030 inches when applying the score line 4 to a polyvinyl chloride strip 2. The effect of the slitting roll is to provide both a score line 4 and also sever the release paper into two separate distinct strips 12 and 14, by stretching the polyvinyl chloride strip and tearing the release paper.
The score line 4 on the strip 2, although linearly disposed, can be located off-center. Illustratively, in covering a two inch thick foil faced insulation board, with a four inch corner edge strip 2, a one inch coverage over the foil by the corner edge strip 2 is appropriate with the remaining three inches of the corner edge strip 2 covering the two inches of raw end insulation board and adjacent foil facing. Thus, the strip 2 for that particular application has the linear score line 4 located one inch in from an edge.
Practice has shown that polyvinyl chloride identified as rigid, high impact strength PVC having a thickness of 0.005 inch to 0.0625 inch performs well as the edging strip 2. However, light gauge metal of 0.005 inch to 0.020 inch thickness or more can also serve as the edging material. Further, a composite of aluminum fused to rigid polyvinyl chloride known as VINALUM manufactured by Proto Corporation also performs well as the material of the edging strip 2. The depth of the score line 4 is 0.010 to 0.062 inch and preferably 0.030 inch.
In another embodiment of the invention the corner edging strip may contain a plurality of score lines 4 linearly disposed over the length of the strip 2 which allows for selective forming of the strip to various edges. For example a four inch wide strip may have five score lines, each score line being disposed at least 1/2 inch from the adjacent score line. The score lines 4 on this embodiment would be located 1/2, 1, 11/2, 2 and 21/2 inches from an edge of the strip 2 with the remaining 11/2 inches of the strip 2 being unscored. The strip may then be bent at any of the score lines to form the desired amount of strip material on each side of the article being edged.
The strip 2 with a plurality of score lines 4 is especially suited to edging the terminal ends of insulated pipes.
The terminal end of an insulated pipe is edged by bending the strip 2 at one of the plurality of score lines 4 to create a section of the strip 2 corresponding to the thickness of the insulation on the pipe to be edged. For example, for a pipe 70 covered with 11/2 inch insulation, a four inch strip 2 with five score lines at 1/2 inch intervals would be bent at the score line that is 11/2 inches from the edge of the strip 2. The remaining 21/2 inch strip is then applied to the outer perimeter of the pipe insulation 72. The 11/2 inch portion of the strip 2 is then scissor cut into discrete segments 22 by cutting slits 24 into the strip 2. The discrete segments 22 are then adhered to the exposed terminal end of the pipe insulation with adjacent discrete segments overlapping as seen in FIG. 7.
Once the pipe insulation is edged the edging may be painted with PVC-type adhesive caulkings such as Celulon®, or Clear as made by Red Devil, Inc. of Union, N.J., or All Purpose Adhesive Caulk as made by MacKlanburg Duncan of Oklahoma City, Okla.
The width of strip 2 and number of score lines can be varied to accommodate any pipe insulation thickness or length of lineal pipe covering.
According to this embodiment, one or two rolls of the edging material may be carried by a mechanic to cover the raw ends of pipe coverings rather than ordering specific sized end caps or different roll sizes of the Roll Kiku-za type material.
Many variations of the present invention will suggest themselves to those skilled in the art in light of the above-detailed description. All such obvious modifications are within the full intended scope of the claims.
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The invention relates to a method and an apparatus for forming and applying edging material to the corners of ductwork and other conduit structures.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is based upon and claims priority from U.S. Provisional Application No. 62/040,383, filed Aug. 21, 2014, the contents of which are incorporated by reference in its entirety.
BACKGROUND
[0002] Emergency breathing apparatus are used in situations where fire, smoke, dust and debris, or other impediments prevent normal breathing during a rescue. These breathing apparatus provide oxygen to the user and prevent smoke or other pollutants from entering the device. For safety reasons, many of these devices also include two-way communication devices to assist in rescue or coordination of efforts to fight a fire, etc. Two way communication devices typically comprise microphones powered by direct current batteries, where the voltage is used to amplify a voice for transmission via a transceiver to a remote receiver. An issue that plagues communication in emergency situations is that the microphone picks up and amplifies the heavy breathing and pronounced movement of air, leading to a transmission that is difficult to interpret and makes critical communication challenging.
[0003] FIG. 1 depicts a prior art two wire system for communicating audio signals. In this circuit, a first wire carries both the audio signal and a direct current. A second wire is provided that serves as a ground/return path. The problem with this circuit is that it is impossible to isolate the audio signal and filter it effectively without interrupting the power signal. This results in a noisy audio signal that has poor quality and can lead to dangerous repercussions when communication is critical in an emergency situation. As constructed, the microphone tends to be very sensitive and picks up every minute sound while active. During normal modes of oxygen mask operation, the microphone is active when the wearer is not inhaling (and thus active for speaking) and not active when the wearer inhales. However, during certain modes of oxygen mask operation the microphone is continually active, and the continuous sounds of air rushing over the microphone are captured. This continuous unwanted “noise” is obtrusive and severally impedes effective communication.
SUMMARY OF THE INVENTION
[0004] The present invention addresses the foregoing by establishing a microphone circuit that can filter out higher frequency audible noise created by air rushing over an oxygen mask microphone without a disruption of the DC power signal.
[0005] The audio filter of the present invention may be used for both commercial and consumer products that utilize dual-wire bidirectional audio applications. Note that the term “dual” is not intended to be limiting, and that more than two wires can also be used. The invention channels active filtering in a multi-wire system where one or more electrical conductors contain bi-directional signals using two stages of active isolation (in certain cases, specifically created with op-amps) to separate direct current (DC) power, which is then used to bias active filtering elements. Using active signal conditioning or processing elements, the present invention directionally separates the DC and AC components to allow active conditioning or processing of the AC signal. The present invention can be applied to any application where it is advantageous to actively condition an AC signal that is present on the same wire as a DC voltage.
[0006] These features as well as other advantages will best be understood with reference to the following figures in conjunction with the detailed description of the best mode for carrying out the invention set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic of the prior art dual wire system;
[0008] FIG. 2 is a schematic of a multi-wire system with active filtering;
[0009] FIG. 3 is an exemplary detailed circuit diagram of a first embodiment of an audio filter of the present invention;
[0010] FIG. 4 is a graph comparing an unfiltered and filtered audio response using the present invention;
[0011] FIG. 5 is a plot of a speaking waveform versus time comparison of the present invention; and
[0012] FIG. 6 is a plot of a breathing waveform versus time comparison of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] FIG. 1 illustrates a prior art two wire system for communicating audio signals where a first wire carries both the audio signal and a direct current, and the second wire is a ground/return path. In this situation, it is impossible to isolate the signal and filter it effectively without interrupting the power signal. This leads to unfiltered or poorly filtered audio signals and the opportunity for ineffective communication.
[0014] FIG. 2 illustrates a solution to the problem of FIG. 1 , where a second path for the audio signal is established in parallel with the power signal, such that the audio signal can be isolated and filtered or otherwise processed without disturbing the accompanying power signal on the same path. The filtering of the audio signal takes place in an isolated zone where the audio is separated from the power signal. The filter 20 is represented by dashed lines and receives the dual wire inputs as with the example of FIG. 1 , namely the power wire 22 and the ground wire 24 . The output consists of the power wire 26 and the ground/return wire 28 . Within the filter 20 , the DC power signal is represented by arrow 10 and traveling in a first direction. The DC power signal 10 has a path that can include power filters 12 , 14 to process the power supply if necessary. Within the filter 20 , an audio signal represented by arrows 30 are parallel to the DC power signal 10 , and can include an audio filter 32 powered by the DC power signal 10 via connection 34 . That is, the DC power signal can be used to drive the audio filter 32 although separated from the power signal path. The DC power path 10 and the audio signal path 30 are connected to the ground/return wire 24 , 28 at connection 36 .
[0015] FIG. 3 illustrates an exemplary detailed circuit diagram of an audio filter 20 of the present invention. The DC supply wire 22 and the ground/return wire 24 are connected to the ground 42 and the audio signal output 40 of the filter. The input is the wire 44 from the mask microphone 46 , which should also be connected to the ground 48 . The filter 20 establishes a first path 10 that includes at least a pair of filters 12 , 14 and provides a flow of current (the DC power path 10 ) along an upper path. A tunable resistor 50 controls the current through the DC power path. Resistor 52 precedes the division of the DC power and audio paths, where capacitors 56 and 58 regulate the current through the audio path 30 . A tunable filter 32 is placed in the path of the audio signal to filter out noise and unwanted signal frequencies. The tunable filter 32 allows only the optimal frequencies to be passed through the filter while undesirable frequencies are blocked by the filter 32 , as determined by the circumstances. Capacitors 56 and 58 are tunable as well to improve the output and adjust the noise to output signal ratio.
[0016] FIG. 4 is a graph illustrating a comparison of the filtered versus unfiltered audio signal plot as a function of signal frequency. As can be seen, the reference wave form is steady at −8 dB, and the phase data varies as shown between 20 degrees and −140 degrees. The resultant audio signal shows a high filtering at frequencies above 2 KHz, corresponding with a second order filtering. In this example, the processing of the audio signal is low-pass filtered with a cut-off frequency near 5 kHz. The amplitude roll-off of this filter is consistent with a first order filter. Also, while FIG. 4 denotes a second order filter, the plot only demonstrates a 6 dB/octave of roll-off, as one would expect with a single order filter. In general, the amplitude roll-off is consistent with that of a low-pass filter.
[0017] The filter 20 may utilize Op-Amps as the active elements. However, it would also be possible to establish the filter using transistors connected in a diode configuration. For example, using a BJT the base and collector would be connected together, and the emitter would be the active device output; for a FET, the gate and drain would be connected together and the source would be the active device output. This is an example of other active device configurations that could be used; it is understood that there are other active device configurations possible.
[0018] FIG. 5 depicts a graph of a waveform plot versus time illustrating the effect of the present invention using speech as the input. It can be seen that the unfiltered portion of the output includes a large amount of unwanted noise, whereas the filtered output effectively eliminates the unwanted noise, thereby better enabling communication to occur. That is, the speech waveform suffers minimal degradation using the present invention and the filtered and unfiltered speech waveforms are nearly identical. This results in the desired signal having zero to minimal degradation.
[0019] FIG. 6 illustrates a graph of an emergency breathing waveform (as opposed to speech waveform) versus time. The graph of FIG. 6 shows how significantly the amplitude of the breathing contribution may be eliminated by the filter by the present invention. In situations where noise from breathing can overwhelm the audio signal, the repression of the audio signal due to the breathing contribution demonstrates the benefit of the present invention. The pronounced reduction in noise associated with the user's breathing paves the way for easier and better communication by the user and the listener. The graphs of FIGS. 5 and 6 show that the filter of the present invention can transmit an audio signal where the speech portion of the audio signal is largely intact while the breathing contribution of the audio is significantly filtered, preserving the communication portion of the audio and significantly reducing noise.
[0020] In this circuit, it should be understood that the “filter” represents an active signal conditioning circuit which requires DC power, where this power is transmitted over the same wire as the active signal. Moreover, the invention doesn't have to be limited to single wire bidirectional DC power and AC signals. Rather, the AC signal could be traveling the same direction as the DC power. The invention surrounds the separation of the DC and AC components so that signal conditioning/processing may be performed on either component. Thus, while the foregoing descriptions have been made with reference to a breathing apparatus microphone, the invention is not so limited and may take many forms and applications.
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An audio filter for a breathing apparatus uses active filtering in a multi-wire system where one or more electrical conductors contain bi-directional signals using multiple stages of active isolation to separate direct current (DC) power, which is then used to bias an active filtering element. Using active signal conditioning or processing elements, the audio filter directionally separates the power and audio components to allow active conditioning or processing of the audio signal.
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BACKGROUND OF THE INVENTION
The present invention relates to laser scanners and, more particularly, to an electrical system for continually correcting facet-to-axis errors, facet-to-facet errors, and intensity of the light beam. These corrections are provided dynamically by use of a specially designed photodetector to give a particular waveform output that is used in conjunction with a dynamic memory to provide the various adjustments.
BRIEF DESCRIPTION OF THE PRIOR ART
Prior to the present invention, laser scanners have continuously experienced a problem in controlling the laser beam. In previous laser scanners, spinners with multiple facets were used to project the laser beam onto a photoconductive drum. Because of the accuracy necessary for some of the mirrors, they would cost several thousand dollars and greatly increase the price of a laser line printer or scanner. Cheaper spinners were available, but created problems of facet-to-axis errors due to very minor variations in the angle of the reflecting surface. Because of the expense connected with manufacturing an accurate spinner, it is important to be able to use a more economical, less accurate spinner, yet provide other means for correction of the facet-to-axis errors.
Also because of variations in the reflective nature of each of the surfaces of the spinner, facet-to-facet errors would occur between each line whereby each line would not be started along the same vertical line of the paper. Further, other errors would creep into the system due to variables, such as temperature changes that occur during operation of the laser scanner. These errors, due to a presetting of the laser scanner, would not be corrected, but in the present invention they would be corrected dynamically.
Further, while many different devices have been utilized for correcting variations in the intensity of the laser beam, a dynamic type of adjustment is necessary. A manual adjustment that may be correct initially may not give the correct intensity after a laser scanner has operated for a period of time.
Much of the prior art that has been developed for laser devices has been in the photocopying area, and not for laser scanners that would handle word processing type of equipment. However, since there is some relationship between photocopying using a laser beam, and a laser scanner for data processing, some of this voluminous field of prior art will be discussed in the subsequent paragraphs of this section. One of the better references known by applicants is an article entitled "Correction Of Axial Deflection Errors In Rotating Mirror Systems" by Helmberger, et al. that appeared in Optics & Laser Technology, December 1975. In this article, facet-to-axis errors were corrected manually for each phase of a polygon mirror with multiple facets. The correction for each facet was manually adjusted into the system. Likewise, the intensity was manually adjusted for each mirror facet and set into the system. However, there was not provided any type of dynamic adjustment for variable factors, such as temperature, humidity, machine tolerances, just to name a few, which would change with time.
Various patents issued by the United States Patent and Trademark Office show start-of-scan photodetectors to correct facet-to-facet errors by providing a start-of-scan signal. A typical such patent is U.S. Pat. No. 4,059,833 issued to Kitamura, et al. Other typical patents having start-of-scan detectors include Woywood (U.S. Pat. No. 3,646,568), Dattilo, et al. (U.S. Pat. No. 3,835,249), Oosaka, et al. (U.S. Pat. No. 3,999,010), and Ohnishi (U.S. Pat. No. 4,143,403). Some of the patents, such as Woywood, utilize beam splitters or multiple spinners to provide for correction in the facet-to-facet errors with a start-of-scan signal. Other systems use a motor type of control that has a very slow response time.
Many different types of systems have been devised to dynamically control the intensity of the laser beam, such as shown in Davie, et al. (U.S. Pat. No. 4,144,539), which utilizes a beam splitter with a portion of the beam being used to control the acoustooptic modulator. However, Davie does not provide any type of memory circuit that can give a dynamic correction for each individual facet of the mirror. For multiple facet mirrors as are used in laser line printers, a separate correction is necessary for each facet to enable the manufacturer to use a more economical spinner. Other types of systems to control intensity of a laser beam can be found in Burton (U.S. Pat. No. 3,787,887), Fukumoto, et al. (U.S. Pat. No. 3,811,009), or previously mentioned patent to Dattilo, et al.
Providing both facet-to-facet correction with a start of scan signal and facet-to-axis correction is Walker, et al. (U.S. Pat. No. 3,809,806). A V-shaped window is provided for a photodetector which will adjust the line of scan either up or down depending upon the width of the particular pulse output from the photodetector. However, no type of dynamic memory is shown for continual updating to adjust the scan line either up or down.
While these are only some of the patents found in a voluminous field of prior art, none of the patents known by applicants show the invention as described and claimed hereinafter.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a nonimpact laser scanner with dynamic correction for errors.
It is another object of the present invention to provide dynamic correction in a laser scanner for facet-to-facet errors, facet-to-axis errors, and intensity of the laser beam.
A photodetector with a special mask having an L-shaped window therein is placed close to the photoconductive drum so that each line of scan from the laser beam will first strike the photodetector through the L-shaped window prior to sweeping across the photosensitive drum. If the photodetector and mask are properly positioned, a signal output will be generated in the form of a stepped voltage function. On the leading edge of the signal output from the photodetector, a start-of-scan signal is provided once the output voltage of the photodetector exceeds a predetermined voltage level. The first portion of the signal output will be of a higher voltage magnitude and may be used to control the intensity of the laser beam as will be explained in more detail subsequently. Thereafter, the signal output steps down to approximately half of the preceding voltage. Depending upon the magnitude of the second and lower voltage level, the sweep for that individual facet of a spinner mirror is adjusted either up or down to correct for facet-to-axis errors.
The output from the photodetector feeds through an amplifier into a series of three comparators. The first comparator gives the start-of-scan signal once the output voltage of the photodetector exceeds a first predetermined voltage level. The output of the first comparator also initiates time delays to start the operation of the entire correction circuitry. After a first time delay, a second comparator compares the magnitude of the output signal from the photodetector with a second predetermined voltage level to give an intensity correction signal output. Likewise, after a second time delay, the output from the third comparator will give an output signal dependent upon whether or not the second voltage level exceeds a third predetermined voltage level to give a facet-to-axis correction signal.
A mirror counter is provided that is clocked by the start-of-scan signal with the output of the mirror counter controlling two random access memories for both intensity correction and facet-to-axis correction. Located between the output of the second comparator and the random access memory for intensity correction is a 0-255 bit counter which is initially positioned near the center count thereof. Dependent upon the intensity correction signal, the counter either counts up or down one bit with the output feeding through a digital-to-analog (D/A) converter to adjust the amplitude modulation of the acoustooptic modulator of the laser beam. The output of the counter is in turn stored into the random access memory until that same facet of the spinner again sweeps across the photosensitive drum.
Likewise between the third comparator and the random access memory for controlling facet-to-axis errors, is located another 0-255 bit counter. While the counter is initially positioned near the center count thereof, dependent upon the facet-to-axis correction signal from the third comparator, the counter will count either up or down one bit. The output from the counter, which is stored in memory also feeds through a D/A converter and voltage controlled oscillator to control the frequency modulation of the acoustooptic modulator and thereby correct the position of the line of scan of the laser beam.
The acoustooptic modulator that may be used in the present invention typically has a band width of approximately 40 MHz. Therefore, the output of either of the counters should adjust the acoustooptic modulator over its entire band width with the 40 MHz adjustment being typical. In the present invention, it is envisioned that the laser beam may be positioned up or down over the full range of 0-255 bit output from the counter, which in turn provides the full range of correction for the acoustooptic modulator for facet-to-axis errors. Likewise, a full range of correction for the acoustooptic modulator is provided to correct the intensity of the laser beam over the full range of the band width of the acoustooptic modulator.
The corrections are provided for each facet of the spinner mirror and stored in the random access memories until the same mirror again reflects the laser beam across the photosensitive drum. After a few revolutions of the spinner, the random access memories have stabilized with the correct amplitude modulation being provided to correct the intensity, and the correct frequency modulation being provided to correct the facet-to-axis errors. Thereafter, if the parameters change due to temperature changes, variations in tolerances of shaft bearings, strain by centrifugal forces, etc., the laser beam will automatically be adjusted to compensate for those changes.
The correction techniques envisioned by the present invention will eliminate the commonly called facet-to-facet errors by the output from the first comparator which provides a start-of-scan, the facet-to-axis errors which are corrected by frequency modulation controlled by the output of the third comparator, and by beam intensity correction as provided by the output of the second comparator. These corrections are continuous.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustrative perspective view of an optics bench for a laser line printer or scanner.
FIG. 2 is an enlarged illustrative perspective view of the photodetector and mask shown in FIG. 1.
FIG. 3 is a generalized block diagram of the correction circuitry for the present invention.
FIG. 4 is a more detailed block diagram for the correction circuitry for the present invention.
FIG. 5 is a timing diagram for FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is pictorially illustrated an optics bench for a laser scanner utilizing the present invention. A laser 10 generates a light beam 12 of coherent light in the conventional manner. Any particular type of laser 10 may be used; however, it is presently envisioned that the more economical lasers would be utilized for the present invention. The laser beam, due to the layout of the optics bench, is turned by reflecting mirror 14 and focused by lens 16 to a focal point 18. However, just prior to the focal point 18 is located an acoustooptic modulator 20 to vary either the amplitude or the phase of the laser beam 12. The acoustooptic modulators are also known as "Bragg cells". The acoustooptic modulator must be located immediately prior to the focal point 18 so that the acoustooptic modulator 20 will properly deflect the laser beam 12. There will be motion of the deflected laser beam 12 or spot at the focal point that now corresponds with the image plane of the drum. The position of the acoustoptic modulator 20 is selected to optomize the rise time of the modulator and the amount of light deflection at the drum versus frequency change of the modulator.
Mirror 22 again folds the laser beam 12 to make the optics bench a compact package. Next a stop 24 is located in the path of the laser beam 12 with a hole 26 near the center thereof. The hole 26 is positioned so that as the acoustooptic modulator 20 modulates the coherent light from the laser 10, only the deflected portion of the light passes through hole 20.
Next another mirror 28 again folds the laser beam 12 and directs the laser beam through lens 30 which focuses the laser beam 12 so that the focal point now corresponds approximately with the surface of photosensitive drum 32. However, between the focusing lens 30 and the photosensitive drum 32 is located spinner 34 that has numerous mirror facets 36 thereon with eighteen being a typical number. As the spinner 34 turns, each mirror facet 36 causes the laser beam to sweep across the photosensitive drum 32 as indicated by the direction of the arrow. The focal point of the laser beam 12 now corresponds with the surface of the photosensitive drum 32.
Located immediately adjacent to the photosensitive drum 32 is a photodetector 38 so that as the laser beam 12 sweeps across the photosensitive drum 32, it first sweeps across the photodetector 38. The photodetector 38 through electrical leads 40 controls the acoustooptic modulator 20 through input 42 in a manner as will be subsequently explained in more detail. The photodetector 38 has a mask 46 over the front thereof as shown in more detail in FIG. 2. The mask is so positioned so that as the laser beam 12 sweeps across the mask 46, upon reaching elongated vertical opening 48, the full effect of the laser beam is immediately sensed by the photodetector 38 to give a sharp rise time voltage output. As the laser beam 12 continues to sweep across the photodetector 38, it strikes the quarter mask 50 which is located near the horizontal axis of the photodetector 38. The quarter mask being positioned near the horizontal axis of the photodetector 38 reduces the magnitude of the output voltage from the photodetector 38 to approximately one-half of its earlier output voltage. The actual magnitude of the output voltage is proportional to the position of the spot in the vertical dimension.
Referring to FIG. 3 and the generalized block diagram, the function of the photodetector 38 along with the remaining portions of the correction circuit for the laser line printer is explained in more detail. The output from photodetector 38 feeds through amplifier 52 to give a waveform output 54 as pictorially illustrated adjacent thereto. The sharp rise 56 of waveform output 54 corresponds to the point in time when the laser beam 12 sweeps past the leading edge of the elongated vertical opening 48. Thereafter once the laser beam 12 is fully striking the photodetector 38 (see FIG. 2), the output of the photodetector 38 gives a peak output voltage 58. Thereafter as the laser beam strikes the quarter mask 50 (see FIG. 2) there is a first sharp decline 60 in the output waveform 54. The voltage levels off to give a step-down output voltage 62 that should be approximately one-half of the peak output voltage 58. As the laser beam 12 moves past the opening for the mask 46, the waveform output 54 has a second sharp decline 64 to approximately zero.
From the amplifier 52 the waveform output 54 is then fed to comparators 66, 68 and 70. Feeding into comparator 66 is also reference voltage 1 so that during the sharp rise 56 of waveform output 54, upon exceeding reference voltage 1 comparator 66 gives an output which is a start-of-scan signal. Simultaneously the start-of-scan signal from comparator 66 initiates the beginning of delays 72 and 74. At the end of delay 74, the output waveform output 54 from amplifier 52 should be at its peak output voltage 58. Also feeding into comparator 70 is reference voltage 2 along with the output waveform 54. If at the end of the delay 74, the peak output voltage 58 exceeds reference voltage 2, counter 76 will count up. However, if the opposite is true counter 76 will count down. Counter 76 is a 0-255 bit counter that will not accept a trigger input until the expiration of delay 74. The output signal from the comparator 70 provides the amplitude modulation correction for the acoustooptic modulator 20 by feeding the output from counter 76 through digital-to-analog converter 78, mixer 80, and RF amplifier 82. Also the output from counter 76 feeds into random access memory 84 for storage until the next cycle.
After delay 72 has expired, the output waveform 54 of amplifier 52 should be at the step-down output voltage 62. By feeding reference voltage 3 into comparator 68, either a step-up or step-down output signal is provided into counter 86. Counter 86 which is a 0-255 bit counter either steps up or down depending upon whether or not the reference voltage 3 has been exceeded by the step-down output voltage 64. The stepping up or stepping down of counter 86 provides frequency modulation correction for the acoustooptic modulator 20 via digital-to-analog converter 88, voltage control oscillator 90 which agains feeds through mixer 80, RF amplifier 82 to control the acoustooptic modulator 20. Again the output from counter 86 is fed into random access memory 92 for storage.
The start-of-scan signal from comparator 66 also initiates mirror counter 94 which counts the number of mirrors on the spinner 34. Depending upon which mirror facet 36 is currently reflecting the laser beam 12 across the photodetector 38, the mirror counter 94 will provide an appropriate address code to random access memories 84 and 92. In turn random access memories 84 and 92 will put the proper count into counters 76 and 86, respectively, that had previously occurred at the time the same mirror facet previously reflected across photodetector 38. Therefore, each time a signal is received either from comparators 70 or 68, the counters 76 or 86, respectively, will count either up or down one count.
The amplitude modulation correction provided by reference voltage 2 via comparator 70 adjusts the intensity of the laser beam by controlling the amplitude modulation of the signal provided through the acoustooptic modulator 20.
The frequency modulation correction provided by reference voltage 3 through comparator 68 adjusts the position of the laser beam 12 up or down on the photosensitive drum 32 by frequency modulation of the acoustooptic modulator 20.
The above described cycles are repeated for each facet 36 of the spinner 34. After a few revolutions of the spinner 34 (a matter of less than a second), the random access memories 84 and 92 are basically stabilized to insure the correct amplitude modulation correction and frequency modulation correction for the acoustooptic modulator 20. Thereafter, if the parameters change due to temperature changes, tolerances in shaft bearing, strain of centrifugal forces, etc., the previously described system shown in FIG. 3 will automatically adjust the position of the laser beam 12 on the photosensitive drum 32, as well as changing the intensity. By use of such automatic compensation, a much less expensive spinner 34 may be used with an even better end result than the more expensively machined spinners.
The start-of-scan signal provided by comparator 66 eliminates facet-to-facet errors. The correction provided by comparator 70 for amplitude modulation corrects the intensity of the laser beam 12. The correction provided by comparator 68 for frequency modulation eliminates facet-to-axis errors caused by improper vertical positioning of the laser beam 12.
The acoustooptic modulator 20 has a center frequency of approximately 80 MHz. In the adjustment of the acoustooptic modulator 20 as just described, it may be adjusted over a band width of approximately 40 MHz or ±20 MHz about the center frequency of 80 MHz. Therefore, each count of the 0-255 bit counters 76 and 86 must adjust each proportionate share of the 40 MHz band width. This is important so that the acoustooptic modulator 20 may be controlled over its entire range of correction or band width of 40 MHz.
Referring now to FIG. 4, a more detailed functional diagram of the correction circuitry is given. Like numbers that have previously been used will again be used in FIG. 4 where appropriate. The photodetector 38 is supplied with a voltage of +V with the output of the photodetector 38 feeding into differential amplifier 52. The setting for the amplifier 52 is controlled by resistor 96. The output of the differential amplifier 52, which is essentially waveform 54 previously discussed in connection with FIG. 3, feeds into comparators 66, 68 and 70 which controls the start-of-scan, intensity correction, and facet-to-axis compensation, respectively. Because the comparators 66, 68 and 70 are differential comparators, they must have a reference voltage input. The reference voltage is provided by resistance divider network composed of resistors 98, 100 and variable resistor 102. Voltage reference 2 provides the same reference voltage 2 as previously described in conjunction with FIG. 3. Voltage reference 1 provides the start-of-scan signal through comparator 66, but is also used in the facet-to-axis compensation of comparator 68 in place of reference voltage 3. In other words, reference voltage 3 as discussed in conjunction with FIG. 3 can be identical to the voltage level required for the start-of-scan signal.
Once voltage reference 1 has been exceeded, comparator 66 gives an output signal that sets flip flop 104. The setting of flip flop 104 initiates delay 106 that controls the output of comparator 70. After the delay 106 has expired, the output of comparator 70 is fed into latch 108 for subsequent feeding into counter 76. A further delay 110 is necessary to simply allow setup time for the counter 76. At the end of the time set in by delay 110, the counter 76 either counts up or down one count. If the reference voltage 2 fed into comparator 70 exceeds the voltage waveform 54, then the counter 76 will count up. If just the opposite is true, the counter 76 will count down.
To better explain the sequence of events, a timing diagram is included herewith as FIG. 5. Like numbers used to designate the components parts in FIG. 4 will be used to indicate the waveform of FIG. 5. As can be seen in the waveforms 104, 106 and 110 of FIG. 5, all of the clocking for counter 76 takes place during the peak output voltage 58 of waveform 54.
Further, the output of flip flop 104 actuates delay 112 that controls latch 114. Once the delay 112 has expired, latch 114 will hold the output received from comparator 68. Again, to allow setup time for the counter 88, a further small delay 116 is provided prior to feeding the signal into counter 86. Again, depending on whether or not the step down output voltage 62 exceeds voltage reference 1, the counter 86 will count up or down one count. Again, the timing functions are shown in the waveform diagram of FIG. 5.
Now that both counters 76 and 86 have completed their count, their information should be stored into random access memories 84 and 92, respectively. The information from counter 76 feeds through selector 118 to random access memory 84. The purpose of selector 118 is at the time of power up to the system, the number of 128 will first be fed into random access memory 84 so that each of the facets 36 will have a known value loaded into the random access memory 84 at the time of the first count. The same is true for counter 86 that feeds through selector 120 prior to feeding into random access memory 92.
It is also very important that the intensity adjustment stabilizes prior to engaging the facet-to-axis compensation. Since there are only a total of 256 counts over which the acoustooptic modulator 20 can be adjusted in intensity, facet-to-axis correction signals should not be fed into the random access memory 92 until after 256 cycles. Therefore, flip flop 122 is controlled by counter 124 that counts 256 cycles so that after 256 cycles, flip flop 122 allows the correction of the random access memory 92 to occur through selector 120. Likewise, flip flop 126 prevents correction to random access memory 84 via selector 118 until after one cycle after power up.
The input for counter 124 is controlled by 0-17 bit counter 128 that counts the facets 36 on the spinner 34. This tells the random access memories 84 or 92 which mirror facet is currently reflecting across the photodetector 38. Each time the counter 128 counts from 0-17 bits, it will give an output to address the memories of random access memories 84 and 92. It will also given an output to reset flip flop 126 and to increment counter 124 once each cycle. Going back to the input for counter 128, after delay 112 for the frequency modulation correction and delay 116 for the setup time, an output signal out of delay 116 controls delay 130 which simply allows time for counter 86 to complete its count. After delay 130, the outputs of counters 76 and 86 are written into random access memories 84 and 92. Since a full cycle of correction is now complete, a further delay 132 which is simply long enough to allow random access memories 84 and 92 to complete their storage of information, a signal is fed into counter 128 to indicate the count for that particular facet is complete and it is time to move on to the next facet.
At the end of the line, there is a counter 134 that counts the number of clock pulses provided by pixel bits to indicate when the line of scan is complete. The typical number of pixel bits is presently anticipated to be 2048. After the line of scan is complete, an output from counter 134 resets start-of-scan flip flop 104. The timing as further provided by start-of-scan flip flop 104 and sequencing delays 130 and 132 can be seen in the waveform diagrams of FIG. 5.
The resetting of flip flop 104 loads the counters 76 and 86 from random access memories 84 and 92, respectively, to what the correction value should be for that particular facet, which is about to reflect the laser beam across the photodetector 38. It should be realized that all of the timing functions as shown in FIG. 5 are after counter 124 is counted through 256 revolutions of the spinner 34 immediately after power up. Thereafter, once all of the memories are complete and the correction factors included, 2048 bits of information will be fed to the photoelectric drum 32 via the laser beam 12 per sweep. In FIG. 5 of the timing diagram, only the timing functions at each end of the line of sweep are shown.
The output for counter 76, which feeds through selector 118, is subsequently fed to digital analog converter 76 into the mixer 80 for subsequent control of the acoutooptic modulator 20 by the RF amplifier 82. The output from counter 76 controls the amplitude of the signal received by the acoustooptic modulator and consequently, the intensity of the laser beam striking the photoelectric drum 32.
Likewise the output of counter 86 feeds through selector 120 and digital analog converter 88 into voltage control oscillator 90. The output from voltage control oscillator 90 feeds through mixer 80 into the acoustooptic modulator 20 via RF amplifier 82 to control the frequency modulation of the laser beam 12 and hence to correct for facet-to-axis errors. After the first 256 revolutions, selectors 118 and 120 no longer have an effect on the system until power is turned OFF and turned ON again.
In summary, as the laser beam 12 sweeps across the photodetector 38, an output signal feeds through differential amplifier 52 into comparators 66, 68 and 70. Upon exceeding reference voltage 1, comparator 66 gives a start-of-scan signal that triggers flip flop 44 and initiates delays 106 and 112. After delay 106, the peak output voltage 58 should be received from the photodetector 38. If the peak output voltage 58 exceeds reference voltage 2, counter 76 via latch 108 will count up or if the opposite is true, count down. The output from the counter 76 is stored in random access memory 84 until that particular facet again reflects across photodetector 38. The output from counter 76 feeds through digital analog converter 78, mixer 80, RF amplifier 82, to control the amplitude modulation of acoustooptic modulator 20, and hence the intensity of the laser beam. This correction feature is dynamic and continual.
After the expiration of delay 112, the output from comparator 68 feeds through latch 114 into counter 86. The count already in counter 86 has been fed into the counter 86 by random access memory 92. After counting up or down one count by counter 86, depending upon whether or not the voltage reference 1 has been exceeded, the output is fed into random access memory 92 and through digital to analog converter 88, voltage control oscillator 90, into mixer 80. From mixer 80 through RF amplifier 82, the frequency of the acoustooptic modulator 20 is controlled which adjusts the laser beam up or down to correct for facet-to-axis errors. Again, this correction feature is dynamic and continual.
By use of the start-of-scan signal as provided by comparator 66, all of the facets at the beginning of each line of scan are located along a vertical line thereby eliminating facet-to-facet errors. By use of the total system as just described, a dynamic adjustment is provided that compensates for normal operational variables to correction for (1) facet-to-facet errors, (2) facet-to-axis errors, and (3) intensity in a laser scanner.
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An adaptive system is shown for electronically correcting for errors in a laser scanner. A start-of-scan signal is provided by a photodetector having a special mask with a window over the front of the photodetector. The start-of-scan signal from the photodetector eliminates the facet-to-facet errors. The special mask gives a stepped amplitude signal output from the photodetector with the maximum amplitude of the signal providing amplitude modulation to correct the intensity of the laser beam, and the lower amplitude of the stepped amplitude signal providing frequency modulation to correct the facet-to-axis error. By the use of the delays, counters, and memory, the intensity and facet-to-axis errors are continuously being corrected with each revolution of the spinner.
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BACKGROUND OF THE INVENTION
The invention relates to a multilayered, textile, gas-permeable filter material against toxic chemical substances and, in particular, filter and protective materials for the production of sheet-like filters and protective suits for the civil and military fields.
Previously known filter materials of the type described at the outset have a textile support material, on which adsorber beads, in particular active carbon beads, are adhered via adhesive screens. These beads are, where applicable, protected from any premature wear and tear by a gas-permeable protective layer (EP-B 0 090 073).
In addition, filter materials are known, in which a woven fabric containing activated carbon fibers is adhered to the textile supports with an adhesive screen. If such fabrics containing activated carbon fibers are laminated between two textile layers, the material obtained according to EP-A-0 230 097 is merely one, in which the fabric containing the activated carbon fibers disintegrates to fine dust already at the slightest tensile strain.
The disadvantage of the state of the art is that there is insufficient bonding of the textile support material with the activated carbon material and, furthermore, the actual adsorption layer which contains the activated carbon can only inadequately withstand mechanical stressing such as that occurring, for example, when protective suits made from the protective material are worn.
The object of the invention is to develop the filter material described in EP-A-230 097, which comprises a first layer as textile support layer, a second layer in the form of an adhesive layer bonded to the first layer and a third layer which is applied to the second layer, is bonded thereto and comprises a textile sheet-like layer containing activated carbon fibers, further such that the disadvantages specified above are avoided.
SUMMARY OF THE INVENTION
This object is accomplished in accordance with the invention, in the filter material described at the outset, in that the second layer is an areal adhesive layer consisting of an adhesive spun fiber yarn, fleece or screen, an adhesive foil, a woven or knitted adhesive fabric or the like or an open-cell foamed material layer laminated to the adjacent layer(s) in the flame laminating process and that the second layer is areally bonded to the first and third layers.
This third layer can be additionally protected by a fourth layer in the form of an areal adhesive layer which is applied to the third layer, opposite the second layer, and areally bonded thereto.
Although extremely thin adhesive layers, in particular in the form of spun yarns, fleeces, foils etc., can be used for the adhesive layers, the fourth layer as adhesive layer is, in particular, sufficient to additionally stabilize the third layer with the textile sheet-like layer containing the activated carbon and to protect it against wear and tear. Surprisingly, the fourth layer offers not only an adequate, mechanical protective effect against wear and tear but also leads, in addition and in cooperation with the second layer in the form of an areal adhesive layer, to a strengthening of the third layer held between the two layers so that this can, for the most part, be selected wholly in view of its protective effect, independently of its inherent mechanical stability, and used in the protective material.
A particularly suitable adhesive layer material is available in the form of slotted adhesive coating foils which act as a type of dry melting adhesive.
The adhesive layer material is preferably produced from a thermoplastic polymer material, reference being made in this respect, in particular, to the plastic materials PVC, polyurethane, polyester and polyamide. It is important in the case of the adhesive layers for them to be adequately gas-permeable, i.e. that the foils have, in particular, a perforation, preferably a microperforation, which is retained during the thermal bonding or the thermal activation of the adhesive layer during processing.
Apart from the adhesive layer materials described in the above, an open-cell foamed material layer which is laminated on is particularly suitable and this, due to its foam structure, takes over not only the function of an adhesive but also, simultaneously, the function of a protective layer against mechanical damage to the textile sheet-like layer containing activated carbon fibers. A flame laminating method is preferably used for the lamination process, whereby the thickness of the layer remaining in the finished product--and therefore the protective effect of the foamed material layer--can be predetermined very exactly. The thickness of the foamed material layer can be selected such that the areal filter material is permanently deformable in a subsequent treatment step using heat and pressure.
Moreover, reticulated foamed materials are suitable as adhesive layer materials; these exercise not only the function of an adhesive but also a filtering function, above all in contact with liquids. A mechanical protective effect is also offered by the reticulated foamed materials.
In the case of protective materials, reticulated foamed material is preferably used on the external side as adhesive layer while open-cell foamed material is preferably used on the inner side, i.e. the side facing the skin.
For the first time it is now suggested to use the flame laminating process during the production of textiles which are used in the production of clothing.
The textile sheet-like layer which contains the activated carbon fibers can, in principle, be manufactured according to different technologies, for example according to the teaching of EP 0 079 488 B1, EP 0 230 097 A2 or also DE 33 25 644 C2.
These technologies deal with woven fabrics which comprise activated carbon staple fibers, whereby the first-named EP 0 079 488 discloses woven fabrics made from a composite yarn of textile staple fibers containing a proportion of active carbon staple fibers which is between 5 and 75% by weight. The proportion of staple fibers which does not consist of active carbon staple fibers is essentially responsible for the stability of the composite yarn or the woven fabric formed therefrom.
Alternatively, a process according to EP 0 230 097 A2 is conceivable, where activated carbon fibers are needled to an additional textile material and thereby form a type of areal felt-like layer.
The third type differing herefrom is formed by DE 33 25 644 C2 where a spun yarn made from activated carbon fibers is used.
The greatest adsorption activity is to be expected from the last-named type of fiber or textile sheet-like layer material, whereby it is, however, to be pointed out at the same time that the mechanical strength of this type of adsorber layer is less in comparison with the other two types.
This textile sheet-like layer with the activated carbon fibers can be provided as woven fabric, felt, knitted fabric, fleece etc. As already specified in the above, it is not necessary due to the inventive structure for the textile sheet-like layer with the activated carbon fibers to have a particular mechanical strength since this is given to it by the adhesive layers covering it areally, where applicable, on both sides.
The three, four or more layers are brought together during production to form a pile and pass as a stacked layer through a heating zone which is preferably formed by heating rollers. In the heating zone, the adhesive of the second and fourth (when present) layers is activated and thus provides for an areal bonding of the pile.
During the flame lamination of the foamed material layers, the textile support layer is first of all laminated with a foamed material layer and, subsequently, the textile sheet-like layer containing activated carbon fibers is laminated onto this double layer in an additional laminating process on the side of the free foamed material layer. Alternatively, the three layers, namely the textile support layer, the foamed material layer and the sheet-like layer, can also be processed together and brought together simultaneously in one method step, whereby the two laminating processes then run at the same time.
Depending on the conditions selected for the flame lamination, the thickness of the foamed material layer can be reduced as required during a lamination process and therefore adapted to the intended use of the finished filter material in many respects, for example with regard to the thermal passage value, air permeability, protective effect against mechanical influences etc.
Finally, in a preferred embodiment, a fifth layer can be provided in the form of a microporous, gas-permeable but liquid-impermeable material as additional protective layer. This can rest essentially loosely on the pile of layers one to four or, however, be areally bonded to the fourth layer.
The textile support layer (first layer) is preferably produced from an air-permeable, tear-resistant and dimensionally stable material. The textile support layer can therefore define the mechanical properties for the filter material as a whole, in particular tensile strength and elongation strength, whereby, in particular, the dimensional stability of the material and a correspondingly smaller value for the elastic elongation of the material ensure that the textile sheet-like layer containing activated carbon fibers which is to be protected is not stretched beyond the allowable degree during use of the filter materials.
In view of these desired properties, the textile support layer preferably has a tensile strength of>300N. With regard to the elastic elongation, it is desirable for the textile support layer to have a value of<12%. The conventional materials available for producing the textile sheet-like layer containing activated carbon fibers easily sustain an elastic elongation of<12%. Thereafter, the elastic extensibility of the textile support layer has a limiting effect for the further elongation and thus prevents any tearing of the textile sheet-like layer containing activated carbon fibers within the filter material.
The textile support layer, the essential task of which is first to lend the filter material a dimensional stability and a certain tensile strength, can be selected with a very low weight per unit area of, for example, 30 g/m 2 to 150 g/m 2 so that it contributes little to the weight per unit area of the filter material but, on the other hand, fulfills the functions defined above in full.
The gas permeability of the textile support layer, insofar as this is of significance only in its support function for the filter material, should preferably be between 100 to 500 l/(dm 2 ×min).
If the filter material is intended to be used as protective material in protective clothing, there are cases of use where the textile support layer is preferably produced from a woven microfiber fabric which is, indeed, gas-permeable but protects against strain due to wind. In this case, the gas permeability is then essentially less than previously defined, namely approximately 10 to 30 l/(dm 2 ×min). Then, the support layer preferably has, at the same time, the advantage of water impermeability, namely up to a column of water of at least 500 mm, preferably at least 1000 mm. The support layer can, in this case, function simultaneously as upper layer or cover layer.
The woven microfiber fabric prevents liquid penetrating as far as the sheet-like layer containing activated carbon fibers, wetting the activated carbon fibers and thereby reducing the absorptive capacity and filtering effect for harmful gases.
The foamed material layer in the finished filter material preferably has a thickness of up to 0.7 mm, in addition preferably in the range of approximately 0.3 mm to approximately 0.5 mm.
The thermal insulation value of the three-layered filter material is, in particular when the filter material is used as protective material for protective clothing, preferably≦70×10 3 m 2 K/W. The third layer, which is formed from the textile sheet-like layer containing activated carbon fibers, can be provided with a fourth layer in the form of an open-cell foamed material layer as additional layer improving the strengths of the filter material and, in particular, the mechanical serviceability of the sheet-like layer; this fourth layer is then preferably laminated on likewise by flame lamination. A preferable effect in this case is the fact that the second foamed material layer is laminated on together with a second textile layer so that, in the end, a six-layered laminated material is obtained. The duplicated textile layers and foamed material layers can either be the same as one another or different from one another, depending on the purpose for which the filter material is used.
The foamed material layers can, in particular, have a different thickness, depending on whether they come to be located on the inside or the outside, for example, in a protective material for protective clothing.
In a preferred embodiment of the invention, the first and/or the second foamed material layer is heat-deformable and following the heat-forming step forms an essentially self-supporting structure for the filter material. This can be used for the production of, for example, filter materials having a large surface area and a zigzag structure in the sectional view or filter materials having a certain shape can be formed which make the filter material suitable as a complete filter element in filter devices.
In the following, the invention will be explained in greater detail on the basis of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a four-layered, inventive filter material;
FIG. 1a is a diagram showing the process sequence relating to the filter material of FIG. 1;
FIG. 2 shows a six-layered, inventive filter material;
FIG. 2a is a diagram showing the process sequence relating to the filter material of FIG. 2;
FIG. 3 shows a five-layered, inventive filter material; and
FIGS. 3a and 3b are diagrams showing the process sequence relating to the filter material of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an inventive, multilayered, textile filter material which can be used as protective material in protective clothing, whereby a first, textile layer as support layer is designated with the reference numeral 1, a second layer in the form of an areal adhesive layer which is areally bonded to the first layer is designated with the reference numeral 2, a third layer which is applied to the second layer and areally bonded thereto and comprises a textile sheet-like layer containing activated carbon fibers is designated with the reference numeral 3 and a fourth layer which, like the second layer 2, represents an areal adhesive layer which is applied to the third layer opposite the second and is areally bonded thereto is designated with the reference numeral 4.
Preferably, the support layer 1 has a weave structure while the adhesive layers 2 and 4 are either produced from a relatively dense adhesive spun fiber yarn, fleece or woven fabric or the like but are gas-permeable or they are provided in the form of a foil which has a perforation which essentially remains even after the adhesive process. The third layer 3 is formed by an adsorption layer which consists of a woven fabric produced from a spun yarn made from activated carbon fibers, as described in DE 33 25 644 C2.
The fourth layer 4 functioning as a cover layer is again formed by a PU adhesive fleece or adhesive foil and can consist of the same material as the second layer.
Suitable foils are, in particular, also those foils which have punctiform material concentrations in a regular distribution.
The support layer 1, predominantly a woven, weft-knit or knitted fabric, having a weight per unit area of 50 to 1000 g/m 2 , preferably 100 to 400 g/m 2 , is intended to have an air permeability of 10 to 1000 l/min×100 cm 2 , mainly, however, of 100 to 400 l/min×100 cm 2 , measured at 1 mbar underpressure.
The adsorption layer 3 can either be produced from spun yarns which can consist of activated carbon fibers or of filament yarns which can, again, consist of activated carbons, or the adsorption layer 3 is activated in a second operational step in a water vapor atmosphere at 800° C.
The adsorption layer 3 can equally be formed from spun fiber yarn consisting of carbonaceous materials, in particular on the basis of preoxidized polyacrylonitrile, either to 100% or in a mixture with another spun fiber of comparable length. The composite yarn resulting therefrom consists to 10 to 90% by weight of carbonaceous fiber material, mainly 30 to 70% by weight, and for the rest of textile spun fibers, in particular of natural fibers or chemical fibers, which can again consist of natural polymers on an organic or inorganic basis or of synthetic materials, in particular cotton, wool, silk, polyamide, polyester, polyacryl, aramide or viscose fibers. From a statistical point of view, the spun fibers are present in the yarn core in an even distribution. Either flame-retardant substances can be added to these fibers or they can be impregnated in a flame-retardant manner in an additional finishing process. These fibers preferably have a fineness in the range of 0.4 to 7 dtex, mainly 0.8 to 2 dtex, and a staple length of 10 to 100 mm, mainly of 30 to 60 mm. These fibers can be either smooth or crimped.
Either the fiber is activated or the yarn or a finished textile fabric. The specific surface area of the adsorption layer 3 should be from 100 to 2000 m 2 /g, preferably 800 to 1200 m 2 /g.
The yarns spun from these materials can be produced either according to classic spinning methods, such as, for example, the ring spinning method, or according to newer spinning methods, such as open-end rotor spinning, open-end friction spinning, twist spinning, rubbing (self-twist), respooling method, false-twist method, bonding/heat-sealing or felting.
FIG. 1a shows on the basis of a block diagram a preferred process sequence for producing the filter material shown in FIG. 1. In this respect, the individual four layers 1, 2, 3 and 4 are first brought together and fed to the device for adhesive lamination as a four-layered pile. The result is the multilayered, stacked material 1/2/3/4 areally bonded together.
FIGS. 2 and 3 show filter materials which comprise a combination of three layers as a basic structure, namely a support or cover layer, a soft foam layer and a sheet-like layer containing active carbon fibers. This basic structure is varied in FIGS. 2 and 3 for two different applications, as will be described in the following.
FIG. 2 illustrates a six-layered structure of a filter material which comprises a support layer 1a which can be produced, for example, from a knitted polyester material (warp knit fabric) and in the present case has a weight per unit area of approximately 40 g/m 2 . This is followed by a membrane 2a as second layer on the basis of hydrophilic polyurethane which is applied to the support layer 1a by means of reverse coating with a weight per unit area of approximately 40 g/m 2 . Impraperm of the company Bayer AG is preferably used for this. This membrane 2a is liquid-tight up to and above 700 mm of water column.
A foamed material layer 3a is applied as third layer in the flame laminating process and this can be formed from polyurethane, a soft polyurethane ether foam or a soft polyurethane ester foam. In this case, a material having a bulk density of 42 kg/m 3 is preferably used. The compression hardness of this material is 4.9 kPa, the number of cells per cm 17±3. The thickness of the starting material is, in this example, 1.6 mm, the thickness in the finished product 0.3 mm. The third layer is preferably finished in a flame-retardant manner.
A sheet-like layer 4a consisting of a completely carbonized and activated woven viscose fabric is used as fourth layer, in this example with a weight per unit area of 120 g/ 2 , a thickness of 0.45 mm and a specific inner surface area of 1000 to 1200 m 2 /g.
An adhesive layer 5a in the form of a hydrophilic adhesive coating (polyurethane basis) is laminated as fifth layer to the sheet-like layer 4a, namely with a weight per unit area of approximately 8 g/m 2 . A woven face fabric is applied as last layer in the form of a cover layer 6a and this can, of course, also be replaced by a weft-knit or knitted textile layer. In the present example, a twill cloth is used (65% viscose, 35% Nomex) with a weight per unit area of approximately 260 g/m 2 .
By incorporating a suitable membrane in the structure of the filter material, the protective properties of a protective clothing system made from the material as described can be considerably improved in relation to toxic chemical substances whilst ensuring an adequate water vapor permeability and so it is also possible to use such systems for purposes which could not be covered with permeable protective clothing systems previously known and which had therefore to be accomplished solely with insulating (e.g. rubberized) protective suits. Due to the water vapor permeability of the membrane, the physiological wearing properties can be noticeably improved in comparison with insulating protective clothing systems and therefore longer wearing times can be achieved. By using the material structure as described, such protective clothing systems can, for example, be used, in particular, for ABC defence personnel (of detection, decontamination units, etc.) in the armed forces and in civil defence as well as for combat clothing for ship's crews in the naval forces (battle dress sea with integrated ABC protection).
The flame laminating process which is used according to the present invention for the first time in the production of protective materials for the production of clothing is of particular significance for the lamination of the foamed material layers. The use of foamed material layers as adhesive layers is preferred on account of the advantages described in the above, which are particularly effective in conjunction with the flame laminating process.
FIG. 2a shows a preferred production process for the product shown in FIG. 2 in the form of a block diagram.
First of all, a membrane 2a made of hydrophilic polyurethane is applied to the support layer 1a with a reverse coating process.
This modified support layer 1a/2a is brought together with the foamed material layer 3a and the sheet-like layer 4a made of carbonized woven viscose fabric in a process step and they are bonded to one another in a common flame lamination step. The multilayered material 1a/2a/3a/4a thus obtained is provided with a hydrophilic adhesive coating 5a and brought together with the cover layer 6a and areally bonded in an adhesive lamination step to form the product 1a/2a/3a/4a/5a/6a.
FIG. 3 shows a different type of structure, in which a soft polyurethane foam layer 2b (on the basis of polyurethane ethers or polyurethane esters) is applied to a support layer 1b which can be a woven, knitted, weft-knit fabric etc. A sheet-like layer 3b which contains active carbon fibers is applied to this double layer. A PU soft foam layer 4b can, again, be laminated to this three-layered material and following this foam layer a cover layer 5b, or the layers 4b and 5b are already bonded to one another beforehand in a laminating process and then laminated to the threefold layer consisting of the layers 1b, 2b and 3b as a double layer.
The material structure thus created ensures the required high protective capacity of the protective clothing system with respect to toxic chemical substances with, at the same time, additional, considerable improvement in the microclimate underneath the protective suit. On account of the considerably more favorable physiological wearing properties which are thus achieved the material is suitable, in particular, for protective clothing systems which can be used
as required, as protective suits to be worn over normal uniforms ("overgarment"),
as army combat suits with integrated ABC protection for climatically hot regions or
as protective clothing in civil defence and protection of the civilian population or the like.
Due to the possibilities for varying the individual material layers, both universally usable protective clothing systems as well as clothing systems complying with specific customer requirements can be covered within the scope of the material structure described.
The processes described in the above are shown in a summarized manner in the form of block diagrams in FIGS. 3a and 3b.
According to the process shown in FIG. 3a, the support layer 1b consisting of a linen fabric (65% viscose, 35% Nomex) and having a weight per unit area of approximately 150 g/m 2 is first of all areally bonded to the open-cell foamed material laminating layer 2b (polyurethane ether type) having a bulk density of 42 kg/m 3 , a compression hardness of 4.9 kPa, 17±3 cells per cm, a material thickness of 1.6 mm and a thickness in the finished product of 0.3 mm in a flame lamination step.
The flame-laminated support layer 1b/2b is brought together in the following step with the sheet-like layer 3b (100% activated carbon fibers) having a weight per unit area of approximately 120 g/m 2 , a thickness of 0.45 mm and an inner specific surface area of 1000-1200 m 2 and flame laminated.
The threefold layer 1b/2b/3b is given on the side of the sheet-like layer 3b an adhesive coating 4b consisting of hydrophilic polyurethane having a weight per unit area of approximately 8 g/m 2 and is then brought together with the cover layer 5b. The cover layer preferably consists of non-woven material (Sontara spun fleece) made from Nomex/Kevlar having a weight per unit area of approximately 31 g/m 2 . These superimposed layers are areally bonded to one another in a final adhesive lamination step to form the end product 1b/2b/3b/4b/5b.
Alternatively, the layers 4b and 5b can be brought together according to the process sequence shown in FIG. 3b and bonded in a flame lamination step. The material of the layer 4b is in this case a flame-laminatable foamed material, such as that already used for the layer 2b. Subsequently, the threefold layer 1b/2b/3b (cf. FIG. 3a) is bonded to the double layer 4b/5b in a fourth flame lamination step to form the product 1b/2b/3b/4b/5b.
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In order to improve the handling and filtering characteristics of a multilayered, textile, gas-permeable filter material against toxic chemical substances and, in particular, filter and protective materials for the production of sheet-like filters and protective suits for the civil and military fields, it is suggested that this filter material have a first layer as textile support layer which is bonded to a second layer present in the form of an areal adhesive layer. In addition, the filter material has a third layer applied to the second layer and areally bonded thereto, this third layer comprising a textile sheet-like layer containing activated carbon fibers.
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FIELD OF THE INVENTION
The present invention generally relates to a rear spoiler for a vehicle.
BACKGROUND OF THE INVENTION
Rear spoilers serve to improve vehicle aerodynamics and can correspondingly reduce fuel consumption. They are fitted in the rear region of the vehicle and generally have air-guiding elements that lengthen the contours of the vehicle to the rear, for example with curved surfaces. Rear spoilers of this type can also be fastened to the vehicle roof or to the side walls.
DE 20 2009 014 476 U1, DE 20 2009 014 510 U1 and DE 20 2009 015 009 U1 describe rear spoiler constructions, in which the air-guiding elements or spoiler elements are arranged displaceably or pivotably in order to permit unimpeded opening of the vehicle door.
Pivotable or foldable rear spoilers are generally connected to the hinge of the rear door. DE 102 28 658 A1 describes various folding solutions, in which planar surfaces, which are pivotable via a hinge, are intended to enable aerodynamic optimization in the travel region.
DE 10 2008 036 888 A1 describes constructions of rear spoilers and connections to the vehicle, in which, inter alia, a carrier is fit between the rear door and the air-guiding element, which carrier can be unhinged for a substantially pivoted-out position of the door. As the rear flap is pivoted outward about the vertical pivot axis thereof, the air-guiding element is first also pivoted until it reaches the outer surfaces of the side wall. As the rear flap is subsequently pivoted out, the flexible carrier element is correspondingly compressed.
Such connections of the air-guiding elements in the hinge region generally permit an adjustment of the air-guiding element between the rear door and the side wall when the rear door—as is often provided in the case of utility vehicles—is pivoted outward by 270° in order to be fastened, for example, to the side wall.
However, systems of this type are generally very complex. They have, inter alia, complex joint or hinge constructions. Furthermore, some rear spoiler systems only permit the use of relatively short air-guiding elements, and therefore the improvement in aerodynamics is limited.
Furthermore, the space in the hinge region of the rear door is very confined as the rear door swings open, and therefore more complex rear spoiler constructions may impair the operation to swing open by 270°.
SUMMARY OF THE INVENTION
Generally speaking, it is an object of the present invention to provide a rear spoiler that can be constructed with relatively little outlay and permits reliable adjustment between the driving position and the basic position.
According to an embodiment of the present invention, the rear spoiler device has at least one roof spoiler with a roof air-guiding element; a roof spoiler of this type is preferably provided on each rear door. The roof spoiler is fastened to the rear door or to the door leaf of the rear door and not to the vehicle structure. The roof air-guiding element is automatically adjustable between a driving position and a retracted basic position.
The roof spoiler preferably has a fastening device for fastening to the rear door, wherein the roof air-guiding element is adjustable, in particular pivotable, in relation to the fastening device. For the automatic adjustment, a bearing structure, in particular a cam, is preferably formed on the roof air-guiding element. The bearing structure can, for example, project to the rear in the basic position and, during closing of the rear door, pass onto the vehicle structure such that, as the rear door is closed further, the bearing structure is adjusted, for example by rolling on the vehicle structure, and therefore a pivoting torque is exerted on the roof air-guiding element, the pivoting torque pivoting the latter upward into the driving position thereof.
The fastening device can be placed into the rear door or the door leaf of the rear door, for example, predominately or even exclusively from above; if the rear door is closed on the upper side thereof, corresponding holes can be drilled for this purpose. The fastening device can have, for example, insertion rods that run vertically and engage in the holes in the rear door.
Alternatively, with a rigid coupling between cam and roof air-guiding element, in which the roof air-guiding element in each case always protrudes to the rear when the rear door is closed, the roof air-guiding element can also be manually releasable and retracted when the rear door is closed, for example in order to improve space-saving parking of the vehicle and transport by train or ship.
A number of advantages are afforded by the roof spoiler according to the inventive embodiments. Advantageously, the roof spoiler does not have to be fastened to the vehicle structure or to the vehicle roof; fastening to the rear door is sufficient. The fastening can therefore be accomplished rapidly and is independent of roof types or the design of the roof structure. Since the roof spoiler is preferably even only fastened to the upper edge of the rear door, for example by being fitted in vertically, a rapid fitting operation is possible without constraining the outer surface of the rear doors.
The fastening device can be formed cost-effectively, for example integrally, for example as a metal plate with a corresponding construction of insertion rods or insertion regions, wherein the roof air-guiding element can be designed, for example, as a plastic injection molded part with one or more cams that project to the rear and have a rounded cam surface.
A cost-effective construction, simple fitting to just the rear door, and an automatic adjustment operation during the opening and closing of the rear door are therefore possible in a simple manner.
According to a preferred embodiment, at least one side spoiler for fitting to the rear door is provided in addition to the roof spoiler. In the case of the conventional construction of a vehicle rear with two rear doors in each case swinging open laterally, the rear spoiler device therefore preferably has two side spoilers that can be fitted to one of the rear doors in each case.
The side air-guiding element of the side spoiler can be fitted to the rear door via an additional link. The link can be fitted to the rear door via a first swivel joint, in particular a vertical first axis of rotation having a plurality of swivel joints. The side air-guiding element is coupled to the link preferably via a second axis of rotation. The second axis of rotation is therefore advantageously formed on or between that end of the side air-guiding element that is at the rear in the driving position and that end of the link that is at the rear in the driving position. For this purpose, vertically spaced apart second swivel joints are formed between the end regions of the link and of the air-guiding element.
The side air-guiding element is locked releasably to the vehicle preferably via a locking structure formed at the front end of the side air-guiding element.
A lockable arrangement that, after unlocking, is pivotable or adjustable is therefore formed. The side air-guiding element can be connected to, in particular flush, or aligned with the corresponding side wall of the vehicle. However, unlike in the case of conventional connections of the side air-guiding element to the hinge, the side air-guiding element is unlockable at the front end region thereof in order, after unlocking, to be pivoted about the link and, together with the link, toward the center of the rear door.
This achieves a number of advantages. The otherwise confined construction space in the hinge region of the rear door is not constrained or not constrained to a relevant extent; after being unlocked, the lateral side air-guiding element can be pivoted in about the link toward the center, and therefore the entire rear door can subsequently be pivoted outward by, for example, approximately 270° and can be placed against, or fastened to, for example, the side wall. The side spoiler together with the side air-guiding element and link is therefore accommodated between the rear door and the side wall without having an impeding effect in the hinge region. The entire length of link and side air-guiding element can be selected, for example, such that the side spoiler, which is completely folded over in the basic position, extends somewhat toward the edge of the door (center of the vehicle rear); the fastening of the rear door to the side wall is therefore not impeded by the side spoiler.
The first swivel joint of the link is advantageously fitted to the rear door in a manner sufficiently spaced apart from the hinge, for example at a distance of 10 cm or more from the hinge of the rear door. For the fastening, it is possible, for example, for holes to be drilled into the rear door, the holes then being closed in turn by the first swivel joints.
According to alternative embodiments, the lockable locking structure at the front end of the side air-guiding element can be implemented on the vehicle structure or the side walls, or else on the rear door or the door leaf. In all cases, in the driving position, when the rear door is closed, a stable triangle is formed, the sides of which are formed by the link, the side air-guiding element and the vehicle, and the corners of which are formed by the first swivel joint (or the plurality of first swivel joints), the second swivel joint and the locking structure.
Such triangle construction is stable, even if two or even three of the corners are formed by swivel joints or swivel bearings. The first and second swivel joints therefore do not have to be locked. A construction is produced that also prevents, or keeps light, a fluttering or flexible vibrating of the side air-guiding elements when the vehicle is traveling, since the front end region of the side air-guiding element is locked and the rear end thereof is held by the link. The material of the side air-guiding element can therefore optionally be selected to be freer, for example also thinner, than in the case of conventional constructions with an air-guiding element that is not connected to the rear.
The link can be designed for forming sufficient stability. For example, it can also be designed with a rib structure or recesses for reducing the material consumption and weight. Overall, a relatively low weight and low production costs arise.
It should be appreciated that the side spoiler according to the inventive embodiments permits fitting to different door variants and door systems; in particular, the precise construction of the hinge of the rear doors, which may vary greatly for different manufacturers and types of vehicle, is not relevant; all that need be provided are fastenings of the first swivel bearing to the rear door by, for example, drilling holes, and a locking retainer of the locking structure at the front end or the front edge of the lateral side air-guiding element.
According to one embodiment, the locking of the front end of the air-guiding element to the vehicle can take place on the rear door itself. The stable triangle, which is formed in the driving position, is therefore formed by the link, side air-guiding element and the rear door. In order to permit a flush connection of the side air-guiding element to the side wall, for example, a connector fitted in the region of the front edge of the side air-guiding element, for example a connecting tab, can extend for this purpose laterally to a locking retainer on the rear door. Therefore, even when the air-guiding element is connected to the rear door, a fixed closure of the front end region of the side air-guiding element can be achieved with favorable aerodynamic properties and without the tendency to flutter. The locking structure can be designed, for example, as an eyelet or receiving hole, and the locking retainer can be designed as a fastening pin on the rear door.
In an alternative embodiment, the front end of the side air-guiding element is not fastened to the rear door, but rather to the vehicle structure, that is, to what is referred to as the portal of the rear region of the vehicle, or else to the side walls (if the vehicle has fixed side walls). In this embodiment, the locking structure can be automatically unlatched during the opening of the rear door since, when the rear door swings open, the position of the first axis of rotation in relation to the locking structure is changed. This automatic unlatching can take place, for example, by the pivoting operation, in which the side air-guiding element is pivoted with the front locking structure thereof in the latching retainer.
Synergistic effects occur between the construction of the roof spoiler and of the side spoiler, since, during the opening of the rear door, first the roof spoilers automatically retract (pivot downward) and therefore the link and the side air-guiding element can subsequently be placed thereon, wherein it is optionally also possible to design the link to be shorter vertically such that the link is placed only onto the rear door and does not extend in the vertical direction as far as the roof air-guiding element. The cam, which protrudes to the rear, does not impede the pivoting operation and the application of the side spoilers.
Therefore, during the opening of the rear door, the deadweight of the roof air-guiding element first causes the latter to automatically fold or pivot downward without having an adverse effect on the side spoilers. The side spoilers can subsequently be completely folded over, as described above.
Still other objects and advantages of the present invention will in part be obvious and will in part be apparent from the specification.
The present invention accordingly comprises the features of construction, combination of elements, and arrangement of parts, all as exemplified in the constructions herein set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described below using a number of embodiments with reference to the attached drawings, in which:
FIG. 1 is a perspective rear view of a utility vehicle when the rear doors are closed and with a rear spoiler according to one embodiment of the present invention in the driving position;
FIG. 2 is a rear view, corresponding to FIG. 1 , with a rear door open;
FIG. 3 is an enlarged detail view with a rear door partially open;
FIG. 4 is a perspective view of the rear spoiler according to an embodiment of the present invention for the rear;
FIG. 5 is a rear view of a vehicle door with a roof spoiler according to one embodiment of the present invention;
FIG. 6 illustrates steps of the initial adjustment of the side spoiler during the opening of the rear door and locking of the side air-guiding element to the vehicle structure in accordance with an embodiment of the present invention; and
FIG. 7 shows an embodiment with the side air-guiding element locked to the rear door.
LIST OF REFERENCE CHARACTERS
1 utility vehicle
2 vehicle structure
3 loading space
4 , 5 side walls
6 vehicle roof
7 hinge
8 , 9 rear doors
8 a upper edge of the rear door 8
8 b outer side of the rear door 8
10 rear spoiler
13 , 14 roof spoiler
16 , 17 side spoiler
20 fastening device (bearing part) of the roof spoiler 13 , 14
21 insertion rods
22 holes in upper edge 8 a
23 axis of rotation
24 roof air-guiding element
25 outer surface
26 cam
26 a cam surface
30 link
31 first swivel joints
32 side air-guiding element
32 a front edge of the side air-guiding element 32
33 holes in the rear door
34 second swivel joints between side air-guiding element 32 and link 30
35 path of movement of front edge 32 a of the side air-guiding element 32
36 latching hook (locking hook)
37 locking retainer on the side wall 4 or vehicle structure 2
40 locking tab
42 locking pin (locking retainer)
43 screw or bolt
A pivot axis of the rear doors
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIGS. 1 and 2 , a utility vehicle 1 has a vehicle structure 2 , which, in the rear region, is also called a portal, and a loading space 3 , which is delimited outward by side walls 4 , 5 and upward by a vehicle roof 6 . Side walls 4 , 5 and the vehicle roof 6 can be constructed fixedly or as supporting parts in, for example, a box-type truck and can be correspondingly fixedly connected to the vehicle structure 2 . Furthermore, the construction of the side walls 4 , 5 and optionally of the vehicle roof 6 with tarpaulins is also known.
The loading space 3 can be closed to the rear by two rear doors 8 , 9 , which, starting from the closed position thereof in FIG. 1 , are pivotable about the hinges 7 thereof by approximately 270° outward about the respective pivot axis A thereof and can be placed against, or else can be locked to, for example, the respective side wall 4 , 5 .
A rear spoiler device 10 , which has two roof spoilers 13 , 14 and two side spoilers 16 , 17 is fitted to the utility vehicle 1 .
The two roof spoilers 13 , 14 are advantageously fastened exclusively to the two rear doors 8 , 9 by being inserted from above. According to FIG. 5 , the left roof spoiler 13 (in the direction of travel) has a fastening device (bearing part) 20 that is fastened to the rear door 8 . For this purpose, the fastening device 20 can be, for example, three insertion rods 21 that extend vertically downward and are placed into the rear door 8 from above. If the upper side of the rear door 8 is already open, the insertion rods 21 can correspondingly be inserted directly; when a door leaf is closed, holes 22 can first be drilled into the upper edge 8 a of the rear door, and insertion rods 21 are then subsequently inserted into the holes from above.
Furthermore, the fastening device 20 has an axis of rotation 23 for a roof air-guiding element 24 . The roof air-guiding element 24 is manufactured as an integral plastics part, for example plastic injection molded part, with a planar or slightly curved outer surface 25 , the shaping of which is known. When the rear door 8 is closed, the roof air-guiding element 24 essentially forms a lengthening of the vehicle roof 6 , for example with a slight curvature downward. Furthermore, the roof air-guiding element 24 has one or more cams 26 that are also formed, for example, during production by injection molding.
The fastening device 20 can be formed, for example, from steel or else from plastic. In the embodiment shown, the entire roof spoiler 13 is therefore formed, for example, in two parts with the fastening device 20 and the roof air-guiding element 24 , optionally with an additional axis of rotation 23 . When the fastening device 20 is anchored in the rear door 8 , the cam 26 projects to the rear; the deadweight of the roof air-guiding element 24 causes the latter to pivot downward about the axis of rotation 23 and to bear, for example, against the rear door 8 . If the rear door 8 is subsequently pivoted from the open position shown in FIG. 5 into the driving position of FIG. 4 , the cam 26 projecting to the rear first reaches against the vehicle structure 2 , for example against a cross member in the upper rear region of the utility vehicle 1 . The cam 26 here has a curved cam surface 26 a that rolls on the vehicle structure 2 during the shutting of the rear door 8 , and therefore the entire roof air-guiding element 24 pivots upward about the axis of rotation 23 .
When the rear door 8 is closed, the cam 26 therefore continues to bear with the cam surface 26 a against the vehicle structure 2 and is therefore supported in the upwardly projecting position by the cam 26 or the plurality of cams 26 . If the rear door 8 is subsequently opened again, the cam 26 rolls on the vehicle structure 2 and projects again to the rear; the deadweight of the roof air-guiding element 24 therefore causes the latter to drop automatically from the functional position thereof when the rear door 8 is shut into the downwardly pivoted or downwardly folded basic position in FIG. 5 . An actuation by the user is therefore not required.
The two side spoilers 16 , 17 each have a link 30 and a side air-guiding element 32 . The link 30 is fastened in, for example, four first swivel joints 31 on the outer side 8 b of the rear door 8 , for which purpose, for example, holes 33 can be drilled into the rear door 8 . The side air-guiding element 32 is fastened in turn to the link 30 via two swivel joints 34 . The link 30 can be manufactured, for example, from metal, for example aluminum or steel; the side air-guiding element 32 is advantageously formed from plastic, for example in the form of an injection molded part.
The side air-guiding elements 32 are in each case latched in a locking structure 36 , 40 in corresponding locking retainers 37 , 42 on the utility vehicle 1 . According to alternative embodiments, locking or latching can either take place, according to FIG. 7 , to the respective rear door 8 , 9 or, according to FIGS. 6 and 7 , to the vehicle structure 2 or the side walls 4 , 5 .
In the embodiment of FIG. 7 with locking to the rear door 8 , i.e., to the door leaf itself, a locking tab 40 can be provided, or fitted as an additional component, for example in the region of the front edge 32 a of the side air-guiding element 32 , the locking tab being able to lock in a locking pin 42 , which serves as the locking retainer and is fitted to the rear door 8 or to the outer side 8 b of the rear door 8 . According to FIG. 7 , the front edge 32 a therefore ends flush with the side wall 3 , with secure fastening to the rear door 8 nevertheless being possible via the locking tab 40 projecting toward the center. The locking tab 40 can be manufactured from metal or plastic; it can be fastened, for example, to a corresponding retainer of the side air-guiding element 32 by a screw 43 or bolt.
In the embodiment of FIG. 6 , a latching hook (locking hook) 36 is fitted as the locking structure to the end of the side air-guiding element 32 . The latching hook locks in a locking retainer 37 on the side wall 4 or the vehicle structure 2 .
The side air-guiding elements 32 form a lengthening of the side walls 4 , 5 , as is customary in the case of side spoilers; for this purpose, the side air-guiding elements 32 can have a planar or suitably curved shape. As shown in the drawing figures, the swivel joints 31 , 34 are advantageously formed at the ends of the links 30 . Correspondingly, the second swivel joints 34 and the locking structure 36 , 40 are advantageously provided in end regions of the side air-guiding elements 32 .
The link 30 and the side air-guiding element 32 therefore form, together with the vehicle 1 , together with the respective rear door 8 or 9 of the vehicle 1 according to FIG. 7 , a stable triangle, the corners of which are formed by the two swivel joints 31 , 34 and the latching connection between the locking structure 36 , 40 and the locking retainer 37 or the locking pin 42 .
From the driving position, the rear spoiler device 10 is retracted into the basic position thereof by the rear doors 8 , 9 first being opened somewhat. However, by this, the respective left and right roof air-guiding element 24 of the roof spoilers 13 , 14 drops downward and therefore bears against the respective rear door, 8 , 9 . By opening of the rear doors 8 and 9 , in the embodiment of FIG. 6 in position a), the locking hook 36 can already be automatically unlatched from the locking retainer 37 . However, a construction with manual unlatching is also possible. A manual unlatching is always provided when the side air-guiding element 2 is fastened to the locking pin 42 of the rear door 8 or 9 according to FIG. 7 .
All the side spoilers 16 , 17 are subsequently in each case retracted toward the center by, for example, a user grasping the respective side air-guiding element 32 and pivoting the latter inward in a large pivoting movement such that the side air-guiding element 32 pivots about the second swivel joints 34 on link 30 and link 30 into the first swivel joints 31 on the rear door 8 or 9 . During this adjustment into the basic position, the link 30 is folded over, for example, by approximately 100° and the side air-guiding element 32 is additionally pivoted in relation to the link 32 by, for example, approximately 100° in turn. FIG. 3 shows the path of movement 35 of the front edge 32 a of the side air-guiding element 32 . The links 30 can preferably come to bear flat directly against the rear door 8 or 9 ; the upper region of the side air-guiding element 32 can come to bear against the respective downwardly folded roof air-guiding element 24 .
The rear doors, 8 , 9 are then folded over completely to the outside about the pivot axes A thereof, with a total pivoting angle of approximately 270°. The rear spoiler 10 with roof spoilers 13 , 14 and side spoilers 16 , 17 is therefore accommodated between the rear door 8 or 9 and the side wall 3 or 4 .
In the locked or latched driving position, the front edge 32 a of the side air-guiding element 32 advantageously bears against or behind the vehicle structure 2 . An outer surface 32 b (air-guiding surface) of the side air-guiding element 32 therefore ends flush with the left side wall 4 , and therefore turbulence does not form in the transition region.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made without departing from the spirit and 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.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention that, as a matter of language, might be said to fall there-between.
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A rear spoiler system for a vehicle has at least one roof spoiler comprising a roof air-deflector element. The roof spoiler is configured to be secured only on a rear door of the vehicle without being secured on the vehicle structure. The roof air-deflector element can be raised into a driving position automatically when the rear doors are closed, and can be moved automatically into an idle position when the rear doors are open.
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[0001] This application claims the benefit and priority of DE 20 2015 101 339.6, filed Mar. 16, 2015. The entire disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The invention relates to a switch cabinet arrangement which comprises a switch cabinet with an installation frame accommodated therein, which delimits an accommodation space for switch cabinet fixtures and which comprises a cooling air duct, wherein the installation frame comprises two parallel separated vertical profiles which establish a first attachment plane for the switch cabinet fixtures and wherein the cooling air duct comprises a partition which extends between the vertical profiles and a respective associated switch cabinet side wall. Such a switch cabinet arrangement is known from DE 10 2007 034 437 A1.
BACKGROUND
[0003] Switch cabinet arrangements according to the preamble are frequently designed in order to provide, in an area between the installation frame and the back wall of the switch cabinet, cold air from a cooling apparatus, which is suctioned backwards by the switch cabinet fixtures, for example, IT apparatuses such as servers and the like, and blown out as heated air on the front side. However, IT apparatuses are also known that are designed for lateral suctioning or injecting of cooling air. In order to ensure a sufficient cooling air supply for such switch cabinet fixtures as well, a channel system for the targeted cooling air supply is known from DE 20 2013 100 338 U1. In the latter, instead of the partition or integrated in said partition, a cooling air channel with perforations to be opened if needed is provided, to which an air supply channel can be connected in order to supply the cooling air to a certain switch cabinet component in a targeted manner. However, the channel system has the disadvantage that its design is relatively expensive.
SUMMARY
[0004] Therefore, the problem of the invention is to refine a switch cabinet arrangement according to the preamble in such a way that it allows the targeted cooling air supply for switch cabinet fixtures with lateral cooling air supply using the simplest possible means.
[0005] This problem is solved by a switch cabinet arrangement having the features of the various embodiments of the invention.
[0006] Accordingly, the partition comprises at least one perforation to which at least one air supply channel is fluidically connected, which leads cooling air introduced via the perforation into the air supply channel in the direction of the accommodation space. Instead of providing a channel system, the invention thus proposes to use, in a switch cabinet arrangement according to the invention, the partition that is present in any case between the installation frame and the switch cabinet housing for the cooling air supply, by providing it with perforations to which the air supply channels can be connected if needed.
[0007] It is possible to provide that the perforations have an opening cross section that is greater than the inlet cross section of the air supply channel. In the process, it is possible moreover to provide that, in areas to which no air supply channel is connected, the perforations can be closed with a closure, for example, a blind plug. The partition can have a plurality of perforations in vertical direction, which are separated from one another by webs, in order to confer sufficient torsional rigidity to the partition.
[0008] The air supply channel can be designed so that the cooling air flowing in through its air inlet side is deflected by substantially 90°. The air supply channel can moreover be designed as a diffuser, that is to say it can have a larger cooling air outlet as cooling air inlet. Moreover, it is possible to provide that the cooling air is supplied to the accommodation space via a cooling air outlet of the air supply channel to the side and parallel relative to the attachment plane. The air supply channel can provide a deflection by substantially 90° of the cooling air flow flowing out via the perforations.
[0009] It is provided particularly advantageously that at least one supply or data line is led through the air supply channel. In the process, the supply or data line can be led from a switch cabinet fixture accommodated in the accommodation space through the air supply channel and through the perforation in the partition. Moreover, the air supply channel can have a passage for the introduction of a supply or data line into the interior of the air supply channel. The passage here can be formed on a front side of the air supply channel facing away from the partition. The air supply channel can thus also have a cable management function, for example, in order to implement an ordered cable routing in the case of a plurality of switch cabinet fixtures arranged vertically one above the other on the installation frame.
[0010] As already known from DE 20 2013 100 338 U1, the air supply channel can be designed so it can be telescoped in its longitudinal direction and in the process it can have two channel sections that are movable relative to one another. Now it can be provided, in addition, that the air supply channel is fluidically connected to the perforation via the first channel section, wherein the second channel section has the front side with the passage for the cable feedthrough.
[0011] In an embodiment, the passage is formed in a wall section of the front side of the air supply channel which is arranged at an angle where 90°<α<180°, preferably at an angle where 110°<α<150°, and particularly preferably at an angle of 135° relative to the longitudinal direction (telescoping direction) of the air supply channel.
[0012] The switch cabinet arrangement can have a switch cabinet with a cuboid rack, which is formed from four vertical and eight horizontal struts. Such a rack is known, for example, from DE 196 47 814 C2 or from DE 296 23 065 U1. Moreover, it is possible to provide that the two switch cabinet side walls are flat parts connected to the rack, as known from DE 198 01 720 C1. Now, it is possible to provide here that the partition extends between the vertical profiles of the installation frame and the respective associated flat part and is in contact with the flat part via a sealing element. The partition here can have a sheet metal part, or consist of such a sheet metal part, which is connected to one of the vertical profiles, preferably by screw connection, wherein, at a longitudinal edge of the sheet metal part facing the switch cabinet side wall, the sealing element is put on. The sealing element can here be a brush strip, for example.
[0013] It is particularly preferable for the installation frame to be an installation frame for the 19″ switch cabinet interior construction. For the installation of the air supply channel, it is possible to provide that the installation frame comprises, adjoining the partition, or at a fixed distance from said partition, a vertical profile side with a system perforation extending in vertical direction consisting of regularly spaced attachment accommodations. In principle, the air supply channel can also be connected directly to the partition. For the attachment, it is preferable to use attachment means that do not require the use of a tool, such as clips or the like, in order to be able to vary the vertical arrangement of the air supply channel without large expense in case of need.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Further details of the invention are explained in reference to the following figures.
[0015] FIG. 1 shows a perspective front view of an embodiment of the switch cabinet arrangement;
[0016] FIG. 2 shows a detail enlargement of FIG. 1 ;
[0017] FIG. 3 shows a perspective rear view of the embodiment according to FIGS. 1 and 2 ;
[0018] FIG. 4 shows a detail view of FIG. 3 ;
[0019] FIG. 5 shows a perspective view into the interior of an air supply channel; and
[0020] FIG. 6 shows a perspective outside view of the air supply channel according to FIG. 5 .
DETAILED DESCRIPTION
[0021] FIG. 1 shows a switch cabinet arrangement which has a switch cabinet 1 with a rack 1 . 1 . For greater clarity, the flat parts covering the rack 1 . 1 are not represented. In the representation, the foremost side of the rack 1 . 1 forms the door side, while the facing side forms the back side of the switch cabinet 1 . Accordingly, in FIG. 1 the depth direction T is indicated.
[0022] In the switch cabinet interior formed by the rack 1 . 1 , a first and a second installation frame 2 are accommodated, which in each case form a 19 ″ installation plane for 19 ″ switch cabinet fixtures such as servers and the like. The installation frames 2 in each case have two vertical profiles 4 that are parallel and at a distance from each other and that are connected at the ends to one another by horizontal rails which in turn are then connected to the horizontal profiles of the rack 1 . 1 , in order to arrange the installation frame 2 in the interior of the switch cabinet 1 and at a certain grid spacing in the depth direction, which is predetermined by the system perforation of the horizontal profiles of the rack 1 . 1 .
[0023] The rear installation frame 2 in the representation has a partition 5 which extends from one of the vertical profiles 4 in the direction of the side wall of the switch cabinet 1 , in order to thus partition off the accommodation space 3 for the switch cabinet fixtures from an area which is formed behind the rear installation frame 2 and the back wall of the switch cabinet 1 , and into which cooling air can be injected. The partition 5 can have a brush strip 11 on its longitudinal edge facing the switch cabinet side wall, brush strip which is used as sealing element.
[0024] The partition 5 has a plurality of perforations 6 that are vertically separated from one another and separated from one another by webs, in order to confer in this manner sufficient stability to the partition 5 formed, for example, as a sheet metal part. The air supply channel 7 represented is fluidically connected via its air inlet side to one of the perforations 6 . On its front side facing the air inlet side the air supply channel 7 has a passage 9 for the introduction of supply or data lines.
[0025] The installation of the air supply channel 7 on the vertical profile 4 of the installation frame 2 as well as the supply of the supply or data line is shown more precisely in FIG. 2 . Here, one can see that the supply or data line 13 is introduced via the passage 9 formed on the front side 10 of the air supply channel 7 into the interior of the air supply channel 7 . More precisely, the front side 10 has a wall section 10 . 1 in which the passage 9 is formed, wherein the wall section 10 . 1 is oriented by an angle α of approximately 135° relative to the longitudinal direction x of the air supply channel 7 , in order to simplify the cable introduction. FIG. 2 moreover shows the vertical profile 4 of the rear installation frame 2 according to FIG. 1 , which has a system perforation formed along its vertical direction and consisting of circular passages and rectangular passages. The air supply channel 7 can be connected, for example, by a clip to the vertical profile 4 . It is also possible to provide that cage nuts are inserted into the vertical profile 4 , which are used for screwing the air supply channel 7 to the vertical profile 4 .
[0026] Moreover, in FIG. 2 , one can see that the air supply channel 7 does not completely cover the opening cross section of the perforation 6 of the partition 5 . It is possible to provide that, if needed, in the opening cross sections of the perforation 6 that are not covered by the represented air supply channel 7 , additional air supply channels 7 are arranged in order to supply cooling air to switch cabinet fixtures located higher in the vertical direction or deeper. However, it is also possible to provide that the opening cross sections of the perforation 6 that are not covered by an air supply channel 7 are closed by a blind plug or if desired by a cover that can be engaged in the perforations 6 .
[0027] The partition 5 can be produced as a shaped sheet metal part or from an injection molded plastic. Along the longitudinal edge of the partition 5 facing away from the vertical profile 4 , a sealing element 11 is put on, which can be a brush strip, for example, in order to seal the partition 5 with respect to a side wall (not shown) of the switch cabinet 1 .
[0028] FIGS. 3 and 4 show the switch cabinet arrangement according to FIGS. 1 and 2 in the rear view. In FIG. 3 , one can see that, via the sealing elements 11 formed on the facing vertical profiles 4 , an area between the back wall and the rear installation frame 2 is partitioned off, which is used, for example, for injecting cooling air via a cooling apparatus, so that the cooling air provided by the cooling apparatus can be provided in a targeted manner via the perforations 6 and the air supply channels 7 to the switch cabinet fixtures. In the case of use, the switch cabinet fixtures are arranged between the vertical profiles 4 of the installation frame. To the extent that the entire installation height of the installation frame is not equipped with fixtures, the areas that remain free can be covered with blind covers in order to prevent an undesired cooling air pressure loss.
[0029] FIG. 4 shows that the vertical profile 4 of the installation frame 2 has, adjoining the partition 5 , a vertical profile side 4 . 1 with a system perforation 4 . 2 extending in vertical direction and consisting of regularly spaced attachment accommodations for the installation of the air supply channel 7 . As one can see when looking at FIGS. 3 and 4 together, the vertical profile side 4 . 1 is one of three side walls of a profile projection of the vertical profile 4 , of which two are connected parallel to one another via a third profile side. When the air supply channel 7 is installed, the profile protrusion engages into a recess 14 on the air inlet side of the first channel section 7 . 1 of the air supply channel 7 , as a result of which a preliminary positioning of the air supply channel 7 is achieved. Via this profile protrusion, the air supply channel 7 can now be moved only vertically, that is to say it can be moved along the perforations 6 , so that the air supply channel 7 , when it has been put on the profile protrusion, can be immobilized via the system perforation in the projection in a desired position.
[0030] As one can see in FIGS. 5 and 6 , the air supply channel 7 is composed of a first and a second channel section 7 . 1 , 7 . 2 , which can be moved relative to one another in the longitudinal direction x of the air supply channel, in order to adjust in this way the air outlet cross section 8 in accordance with the existing air inlet cross section of the switch cabinet fixtures concerned. In an angled wall section 10 . 1 on the front side 10 , the second channel section 7 . 2 has a passage 9 through which a supply or data line 13 (see FIG. 2 ) can be introduced into the interior of the air supply channel. The air supply channel 7 has an inlet cross section 15 through which cooling air is introduced into the air supply channel 7 . The outlet cross section 8 of the air supply channel 7 is designed to be larger than the air inlet cross section 15 , so that the air supply channel moreover has the function of a diffuser. Adjoining the air inlet cross section 15 , the recess 14 is formed, through which the air supply channel 7 can be slid onto a vertical profile 4 of an installation frame 2 (see also FIGS. 2 and 4 ). Associated with the recess 14 there are attachment accommodations 13 which lead into the recess 14 , so that, via the latter, the air supply channel 7 can be secured, for example, by screw connection, to the profile protrusion inserted into the recess 14 .
[0031] The features of the invention disclosed in the above description, in the drawings as well as in the claims can be essential for the implementation of the invention both individually and also in any desired combination.
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A switch cabinet arrangement which includes a switch cabinet ( 1 ) with an installation frame ( 2 ) accommodated therein, which delimits an accommodation space ( 3 ) for switch cabinet fixtures and which comprises a cooling air duct ( 5, 6, 7 ), wherein the installation frame ( 2 ) comprises two parallel separated vertical profiles ( 4 ) which establish a first attachment plane (a) for the switch cabinet fixtures and wherein the cooling air duct ( 5, 6, 7 ) comprises a partition ( 5 ) which extends between the vertical profiles ( 4 ) and a respective associated switch cabinet side wall ( 12 ), characterized in that the partition ( 5 ) comprises at least one perforation ( 6 ) to which at least one air supply channel ( 7 ) is fluidically connected, which leads cooling air introduced via the perforation ( 6 ) into the air supply channel ( 7 ) in the direction of the accommodation space ( 3 ).
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BACKGROUND
1. Field
The present embodiments relate generally to systems and methods for providing individuals to host electronic open-ended betting pools for the benefit of individuals even beyond their known circles of acquaintances anywhere in the world where gambling is legal, and more specifically to systems, methods and services for making closed-ended betting pools open-ended.
2. Background
All betting pools hosted by individuals at workplaces or in communities are closed-ended i.e. limited to people within the workplace or the community of which they are part of. Such betting pools are also non-auditable and limit financial gains up to a total amount wagered by members of the betting pool which is closed-ended (individuals known to each other within the workplace or community). Individuals and communities usually form a betting pools predicting the outcome of local, regional, national or international sporting, social, political and other kinds of events.
Existing betting companies including internet based betting companies do not provide systems, methods or service for individuals or communities to host their own open-ended betting pools nor closed-ended betting pools. Such companies do have the two extremes of making or losing money depending on the outcome of the event on which the bets were placed. In most cases such companies could end up not sharing any proceeds from the betting event with even a minority of the individuals who placed bets on the event.
Present systems, methods and services do not provide any form of tiered payments to individuals whose bets were placed on the outcome within certain threshold of the results of the event. Present systems, methods and services also do not allow the host of closed-ended betting pools to increase the placement of bets from outside the community or workplace to maximize the money in the pool.
SUMMARY
Embodiments disclosed herein address the above stated needs by considering the opportunity for individuals and communities participating in betting pools. Accordingly, embodiments of the invention include methods and systems for enabling open-ended betting pools. The service based on methods and systems described below will allow individuals and communities to establish and manage open-ended betting pools across geographic boundaries, jurisdictions and time zones, regardless of base currency of the country in which the individual is placing a bet from, which can be audited as well. Participation in the betting pool will be restricted to individuals hereinafter referred as “bidders” from countries in which gambling is legal and conform to local gambling laws.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute part of the specification, illustrate various embodiments of the invention. Together with the general description, the drawings serve to explain the principles of the invention. In the drawings:
FIG. 1 illustrate, system for implementing various embodiments of the invention;
FIG. 2 illustrates logic elements in accordance with at east one embodiment of the invention; and
FIG. 3 is a flowchart illustrating methods in accordance with at least cine embodiment of the invention.
DETAILED DESCRIPTION
Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the scope of the invention. Additionally, well-known elements of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the invention” does not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
Further, many embodiments are described in terms of sequences of actions to be performed by, for example, elements of a computing device. It will be recognized that various actions described herein can be performed by program instructions being executed by one or more processors, or by a combination of both. Additionally, these sequence of actions described herein can be considered to be embodied entirely within any form of computer readable storage medium having stored therein a corresponding set of computer instructions that upon execution would cause an associated processor to perform the functionality described herein. Thus, the various aspects of the invention may be embodied in a number of different forms, all of which have been contemplated to be within the scope of the claimed subject matter. In addition, for each of the embodiments described herein, the corresponding form of any such embodiments may be described herein as, for example, “logic configured to” perform the described action.
Embodiments of the invention allow bidders to participate in pools setup either by themselves, friends, family or unknown hosts and communities. This method allows bidders to increase the potential size of their winning by participating in an open-ended pool which would have otherwise been limited to bidders only known to each other. This invention will also allow bidders to bet on pools set up for local, regional and global sporting, political, social, financial and other types of events which are either set up by the service provider or pool owners.
Bidders can view live pools, number of participants in a pool, names of other bidders who have listed the bidder as a buddy, wager required, total wager in the pool before placing their own wager. Pool owner at their discretion can prevent other interested bidders from participating in their own pool. First time bidders will be required to register with pool service provider using the logic described below for the partner relationship management (PRM) module 320 .
The logic modules can receive input from each partner through the web interface which will be validated through web services from public domain as well as internally developed web services. For example, the following list of variables can be obtained for setting up a partner profile:
Key
Element
Attribute
Length
Values
Mandatory
Y
Partner Type
AlphaNum
1
B - bidder/pool participant, C - content provider, S -
Y
non-financial service provider, P - payment service
provider
Y
Partner Identifier Number
Num
16
Should be unique except for partners who have
Y
more than 1 relationship with our entity, generated
by system
Partner name
AlphaNum
30
Y
Address Line 1
AlphaNum
40
Y
Address Line 2
AlphaNum
40
N
City
AlphaNum
25
Y
Postal Code
AlphaNum
10
Y
State/Region
AlphaNum
20
Y
Country
Alpha
3
ISO ALPHA-3 code
Y
(http://unstats.un.org/unsd/methods/m49/m49alpha.htm)
Home Phone Number
Num
15
Y
Mobile Phone Number
Num
15
N
e-mail address
AlphaNum
35
Y
Creation Date
Date
8
YYYYMMDD, ISO 8601
Y
Creation Time
Time
6
HH:MM:SS, ISO 8601
Y
Last Update Date
Date
8
YYYYMMDD, ISO 8601
Y
Last Update Time
Time
6
HH:MM:SS, ISO 8601
Y
Financial information required for settling debits and credits to accounts will be based on set up of billing profile unless partner payment preference is a 3 rd party-payment service provider such as PayPal. For example, the following list of variables can be obtained for setting up a partner profile:
Key Element Attribute Length Values Mandatory Y Partner Type AlphaNum 1 Derived from Partner Relationship Table Y Y Partner Identifier Number Num 16 Derived from Partner Relationship Table Y Partner name AlphaNum 30 Derived from Partner Relationship Table Y Home Phone Number Num 15 Derived from Partner Relationship Table Y Mobile Phone Number Num 15 Derived from Partner Relationship Table N e-mail address AlphaNum 35 Derived from Partner Relationship Table Y Billing Address Line 1 AlphaNum 40 Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. If same as primary address, allow copying details from primary table Billing Address Line 2 AlphaNum 40 Required for only Partner Type “B” unless 3rd N party payment service provider is associated. If same as primary address, allow copying details from primary table Billing City AlphaNum 25 Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. If same as primary address, allow copying details from primary table Billing Postal Code AlphaNum 10 Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. If same as primary address, allow copying details from primary table Billing State/Region AlphaNum 20 Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. If same as primary address, allow copying details from primary table Billing Country Alpha 3 Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. ISO ALPHA-3 code (http://unstats.un.org/unsd/methods/m49/m49 alpha.htm) Payment Type Alpha Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. AMEX/Visa/MasterCard/PayPal Credit Card Number Num Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. Name on Credit Card Alpha Required for only Partner Type “B”unless 3rd Y party payment service provider is associated. Expiration Date Date Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. MMYY format Security Code Num Required for only Partner Type “B” unless 3rd Y party payment service provider is associated. Bank Name Alpha Used only if no credit card details provided Y Bank Account Number Num Used only if no credit card details provided Y IBAN AlphaNum Used only if no credit card details provided, Y mutually exclusive of SWIFT code SWIFT Code Used only if no credit card details provided, Y mutually exclusive of IBAN code 3rd Party Payment Service PayPal support for now Provider Creation Date Date 8 YYYYMMDD, ISO 8601 Y Creation Time Time 6 HH:MM:SS, ISO 8601 Y Last Update Date Date 8 YYYYMMDD, ISO 8601 Y Last Update Time Time 6 HH:MM:SS, ISO 8601 Y
Once the details in the partner profile are validated, the partner is activated for conducting transactions through this system.
Referring to FIG. 1 , a system level diagram is illustrated showing an exemplary architecture according to at least one embodiment of the invention. For example, bidders 110 / 140 known to each other can setup a pool for an event (Event 1 ) defined by them as well as allow placing wagers on event (Event 3 ) by bidders from the same country not known to them. Bidders 120 can place wager on events in multiple pools including those setup by the service provider (Event 5 ) with the same country or foreign countries too. Communities of bidders 130 within the same country can place their wager on pools for events setup by service provider.
Pool Service Provider 160 hosts additional logic to support 3 rd party payment service provider (PayPal) 170 allowing bidders to pay for their wagers on events associated with pools and to providers of premium services and content. Credit card or electronic funds transfer (EFT) processors 180 registered as partners will provide direct and indirect content and services to bidders. Content providers and service providers 190 - 200 can attract new clients through Pool Service Provider resulting in additional revenue from the content and service providers in the form of a referral fee.
Referring to FIG. 2 , a system for hosting and managing betting pools is illustrated. The system can include logic 210 to manage the life of the betting pool from inception to settlement based on methods and sub-methods of the Pool Manager. The Pool Manager will allow Host Bidder to setup betting pool associated with a pending event which is already setup by the Host Bidder or by Pool Service Provider. The Pool Manager also verifies bidder's eligibility to place a wager on the event related to the pool contingent upon bidder being accepted by the Host Bidder of the pool. The logic embedded in the Pool Manager will also verify bidder's payment for the wager is processed and credited to the pool account. Bidder can also place wager in multiples of base wager of up to a maximum of three-times the base wager. The base wager amount should be a minimum of USD 15 and cannot exceed 1,000 in base wager currency. The logic of the Pool Manager also allows Pool Service Provider or Host Bidder to associate a pre-defined event with the pool. Through the Pool Manager, an event established by a Host Bidder can be made accessible to other registered bidders not known to the Host Bidder. Logic in Pool Manager will also perform high-level data gathering required to support the logic and other logic modules based on the Pool Master schema shown below:
Key
Element
Attribute
Length
Values
Mandatory
Y
Pool ID
Num
20
Y
Y
Pool Name
AlphaNum
60
Y
Y
Open Date
Date
8
Y
Expiration
Date
8
Y
Date
Expiration
Time
6
Y
Time
Settlement
Date
9
Y
Date
Owner
Num
16
Y
Identifier
Number
Owner Name
AlphaNum
30
Partner (Bidder name)/Pool
Y
Service Provider Name, must
match ID and name from
PRM Table
Finite
Alpha
1
Y, N
Y
Outcome
Expected
Open Ended
Alpha
1
Y
Pool
Base Wager
Num
9
Base Wager
Alpha
3
Currency
Creation
Date
8
Y
Date
Creation
Time
6
Y
Time
Last Update
Date
8
Y
Date
Last Update
Time
6
Y
Time
Logic in Pool Manager 210 will also perform high-level data gathering required to support the logic and other logic modules based on the Pool Master Definition schema shown below:
Key
Element
Attribute
Length
Values
Mandatory
Y
Pool ID
Num
20
Y
Y
Pool Name
AlphaNum
60
Y
Y
Date
Date
8
Y
Y
Time
Time
6
Y
Y
Transaction
AlphaNum
3
001 - New Wager, 002 - Wager
Y
Type
Payment From Bidder Processed,
003 - Settlement Payment To
Winning Bidders Processed, 004 -
Adjustment Debit, 005 - Adjustment
Credit, 999 - Pool closed prematurely
Y
Partner
Num
16
Derived from Partner Relationship
Y
Identifier
Table
Number
Partner IP
Hex
32
Address
Y
Sequence
Num
3
Auto-increment starting from 001
Y
Number
through 999
Transaction
Num
9
Y
Amount in
local
currency
Transaction
Alpha
3
Currency codes - ISO 4217,
Y
Currency
http://www.iso.org/iso/en/prods-
code
services/popstds/currencycodeslist.html
The Event Manager 230 includes the logic for allowing Pool Service Provider or Host Bidder to establish an event based on no pre-defined outcome or pre-defined outcome. These events could be setup using feed from external sources or Host Bidder defined events either with or without projected probabilities for each possible outcome of the event. The Event Manager also includes the logic for assigning outcome of an event defined by Host Bidder. The logic module supports required data gathering based on the Pool Event Master definition schema shown below:
Key
Element
Attribute
Length
Values
Mandatory
Y
Pool ID
Num
20
Y
Y
Pool Name
AlphaNum
60
Y
Y
Set-up Date
Date
8
Y
Y
Set-up Time
Time
6
Y
Y
Sequence
Num
3
Auto-increment starting from 001
Y
Number
through 999
Sub-
Num
3
Auto-increment starting from 001
Y
sequence
through 999
Number
Outcome
AlphaNum
60
Y
Name
Outcome
AlphaNum
1
Boolean - “B”, Numeric - “N”,
Y
Type
Ranking - “R”
Projected
Num
10
For Boolean store either 0 for
Y
Outcome
FALSE or 1 for TRUE. For
Value
numerical outcome, absolute
numerical value must be
assigned. For ranking, assign
ascending rank beginning with 1
Actual
Num
10
For Boolean store either 0 for
Y
Outcome
FALSE or 1 for TRUE. For
Value
numerical outcome, absolute
numerical value must be
assigned. For ranking, assign
ascending rank beginning with 1
The Billing module 220 has the logic to process payments of bidders placing wagers on pools, settlement payment to bidders in the pool as determined, payments from service providers for referring bidders to service providers' services and content. The Billing module's logic also performs the function of data to support the logic of the billing module and other modules.
The Billing module interfaces with third-party payment service providers 170 (example: PayPal) and other 180 local EFT service providers. The Billing module also sends payment confirmation status to the Pool Manager for confirming acceptance of bidders' wager on the pool. If the Billing Manager is unable to verify payment through third-party payment service provider, then the logic of the Pool Manager will reject bidder's wager on the pool. Interaction between all logic modules is implemented using standard service oriented architecture (SOA) based on enterprise service bus (ESB).
The Payout Settlement module 310 has the logic to determine which bidders qualify for payout and how much based on the algorithm below:
IF <Pool Master.Finite Outcome Expected> = “Y”
VAR <SUMMARY WAGER> = 0;
VAR <WINNING OUTCOME SEQUENCE> = 0;
INITIALIZE ARRAY <Pool Transactions Preliminary Settlement>;
LOOP TABLE <Pool Event Master> UNTIL <Pool Master.Pool ID> = <Pool
Event Master.Pool ID>
IF <Pool Event Master.Projected Outcome Value> = <Pool Event
Master.Actual Outcome Value>
<WINNING OUTCOME SEQUENCE> = <Pool Event
Master.Sequence Number>;
ELSE
IF <WINNING OUTCOME SEQUENCE> != 0
<WINNING OUTCOME SEQUENCE> = 0;
ENDIF
ENDIF
ENDLOOP
LOOP TABLE <Pool Transactions> UNTIL <Pool Transactions.Pool ID> =
<Pool Master.Pool ID> AND <Pool Transactions.Transaction Type> = “002”
VAR <SUMMARY WAGER> = <Pool Transactions.Transaction
Amount in local currency> + <SUMMARY WAGER>;
IF <Pool Transactions.Sequence Number> = <WINNING OUTCOME
SEQUENCE>
WRITE TO ARRAY <Pool Transactions Preliminary
Settlement>
Pool ID, Pool Name, Partner Identifier Number, Sequence
Number, Transaction Amount in Local Currency, Transaction
Currency Code, Payout in Local Currency = 0 /* write partial
record so at the end actual settlement amount can be calculated */
ENDIF
END LOOP TABLE
/* If payout settlement needs to be done, write-out payout settlement transactions for
further processing*/
IF ARRAY <Pool Transactions Preliminary Settlement> is NOT EMPTY
VAR <TOTAL PAYOUT> = 0.75 * <SUMMARY WAGER>;
LOOP ARRAY <Pool Transactions Preliminary Settlement> TILL
NULL
<Payout Amount> = (<Pool Transactions Preliminary
Settlement.Transaction Amount in local currency[n]>/
<SUMMARY WAGER>) * <TOTAL PAYOUT>;
WRITE to TABLE <POOL TRANSACTIONS>
Pool ID, Pool Name, Date, Time, Transaction Type =
“003”, Partner Identifier Number, Sequence Number,
Transaction Amount in Local Currency = <Payout
Amount>, Transaction Currency Code /* write settlement
record */
n++ ;
END LOOP ARRAY
ELSE /* Process Payout to bidder with bet closest to the actual outcome
*/
VAR <SUMMARY WAGER> = 0;
VAR <Payout Amount> = 0;
INITIALIZE ARRAY <Pool Transactions Preliminary Settlement>;
INITIALIZE ARRAY <Nearest Bidder>;
LOOP TABLE <Pool Transactions> UNTIL <Pool Transactions.Pool
ID> = <Pool Master.Pool ID> and <Pool Transactions.Transaction
Type> = “002”
LOOP TABLE <Pool Event Master> UNTIL <Pool
Transactions.Pool ID> = <Pool Event Master.Pool ID> AND
<Pool Transactions.Sequence Number> = <Pool Event
Master.Sequence Number>
<Proximity Rate> = <Pool Event Master.Projected Outcome
Value> / <Pool Event Master.Actual Outcome Value>
WRITE TO ARRAY <Nearest Bidder>
Pool ID, Pool Name, Partner Identifier Number, Sequence
Number, Proximity Rate/* write partial record so at the
end actual settlement amount can be calculated */
ENDLOOP
<SUMMARY WAGER> = <Pool Transactions.Transaction
Amount in local currency> + <SUMMARY WAGER>;
ENDLOOP
SORT ARRAY <Nearest Bidder> DESCENDING <Proximity
Rate>
<Payout Amount> = <SUMMARY WAGER> * 0.70
WRITE to TABLE <POOL TRANSACTIONS>
Pool ID[1], Pool Name[1], Date, Time, Transaction Type =
“003”, Partner Identifier Number[1], Sequence
Number[1], Transaction Amount in Local Currency =
<Payout Amount>, Transaction Currency Code /* write
settlement record */
ENDIF
/* Complete Payout through payment service provider */
INIT AUDIT_CHECK PARM (Pool ID) /* Verify total payout does not exceed the
75% threshold of total wagered amount in the pool /*
LOOP TABLE <Pool Transactions> UNTIL <Pool Transactions.Transaction Type> =
“003” AND <Pool Transactions.Payment Date> = NULL
INIT EXTRNAL_SECURED_PAYMENT_SERVICE /* Paypal or EFT
Processor*/
IF ACKNOWLEDGMENT is “OK”
UPDATE TABLE <Pool Transactions>
<Pool Tranactions.Payment Date> = SYSTEM DATE, <Pool
Transactions.Payment Time> = SYSTEM TIME;
INIT WINNER_NOTIFICATION /* Notify Winners via preferred email
address */
ENDIF
ENDLOOP
Logic in module 330 Audit Controller maintains a log of all interactions between partners and the Pool Service Provider. In an event of a dispute arising between partners and the Pool Service Provider or between partners, the Audit Controller can provide activity insight based on date, time, financial transactions, partner identification and authentication. The logic in module 330 also provides control point for both inbound (accounts receivable) and outbound payments (accounts payable). For outbound payments, the logic in module 330 checks that total payment to pool participants does not exceed predetermined thresholds (75% of total wagered amount for the pool in case the outcome of the event matches exactly with wager's predicted outcome for the event associated with the pool or else 70% of total wagered amount for the pool for wager with nearest outcome to the actual outcome of the event).
Logic in module 340 Concierge allows partners to buy and sell products or services from each other including third-party service and content providers, buy gift vouchers which can be redeemed by other members with the pool service provider.
Logic in module 350 Analytics aggregates, sorts and presents data related to open events such as number of wagers and total wager per event; data related to closed events such as number of wagers, total wager, number of winners and total payout per event, number of wagers and total wager per pool; number of winners and total payout per pool, other daily and monthly statistics.
Those of ordinary skill in the art understand that data, information and signals may be represented in a number of different ways, using various technologies and techniques. The logical blocks in the flow charts, circuits, and components described in connection with the various embodiments may be implemented as hardware, software, firmware, or some combination thereof. Those of ordinary skill in the art would know to implement the described embodiments using various design options, depending upon the particular constraints and considerations of the situation. Such design choices are not a departure from the scope of the present invention.
The various logical blocks depicted in the flow charts, circuits, and components may be implemented using a personal computer, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), using discrete or integrated circuitry, or a combination of these. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, microcontroller, or state machine.
The method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a DVD/CD, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
The various steps and activities in the embodiments described herein may be performed in the exemplary order illustrated in the figures, or another order, depending upon the particularities of the implementation. Various other activities and steps may be performed in a sequence other than that illustrated in the figures.
The disclosure of the various embodiments is provided so as to enable those of ordinary skill in the art to make and use the present invention. Design choices and modifications to the various embodiments will occur to practitioners of ordinary skill in the art without departing from the spirit or scope of the invention. The present invention is not intended to be limited only to those specific versions which are discussed herein for the sake of illustration, but is to be accorded the widest scope for the features and aspects of the invention enabled herein and recited in the appended claims.
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Methods and systems for hosting a betting pool are disclosed. The betting pool can be hosted by a lead participant. Pool participants can be maintained through a partner relationship module. The betting pool lead participant manages events associated with the betting pool through an event manager and through a pool manager. Winning participants in the betting pool are determined and payouts can be processed.
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TECHNICAL FIELD
The present invention relates to a method for producing 1,2-benzisothiazol-3-one compounds useful as antimicrobial agents, antifungal agents, etc.
BACKGROUND ART
1,2-Benzisothiazol-3-one compounds are useful as antimicrobial agents, antifungal agents, etc. Patent Literature 1 listed below discloses a production method therefore comprising reacting a 2-(alkylthio)benzonitrile compound with a halogenating agent in the presence of water. In this method, after mixing a 2-(alkylthio)benzonitrile compound with water, a halogenating agent is added thereto and then reacted. This method achieves a relatively high yield, but there is room for further improvement.
CITATION LIST
Patent Literature
PTL 1: JP8-134051A
SUMMARY OF INVENTION
Technical Problem
A major object of the present invention is to provide a simple and economical method for producing highly pure 1,2-benzisothiazol-3-one compound at a high yield.
Solution to Problem
The present inventors conducted extensive studies to achieve the above object and found that, among methods for producing a 1,2-benzisothiazol-3-one compound by reacting a 2-(alkylthio)benzonitrile compound with a halogenating agent in the presence of water, a method wherein a halogenating agent and water are simultaneously and gradually added to a reaction system that contains a 2-(alkylthio)benzonitrile compound as a starting material to conduct the reaction allows a highly pure 1,2-benzisothiazol-3-one compound to be produced at a high yield while preventing a side reaction and a hydrolysis reaction of the product. The present invention has been accomplished based on this finding.
The present invention provides a method for producing a 1,2-benzisothiazol-3-one compound described below.
Item 1. A method for producing a 1,2-benzisothiazol-3-one compound represented by formula (2):
wherein R 1 is a hydrogen atom, C 1-4 alkyl group, C 1-4 alkoxy group, nitro group, carboxyl group, alkoxycarbonyl group, or halogen atom,
the method comprising reacting a 2-(alkylthio)benzonitrile compound represented by formula (1):
wherein R 1 is as defined above and R 2 is a C 1-4 alkyl group, with a halogenating agent in the presence of water,
wherein the halogenating agent and water are gradually and simultaneously added to a reaction system containing the 2-(alkylthio)benzonitrile compound to proceed the reaction.
Item 2: The method according to Item 1, wherein the halogenating agent and water are simultaneously added to the reaction system in such a manner that the amount of water added falls within the range of 0.5 times less to 0.5 times more in an amount by mol than the amount by mol of the halogenating agent added to the reaction system.
Item 3: The method for producing a 1,2-benzisothiazol-3-one compound according to Item 1 or 2, wherein the halogenating agent is chlorine or sulfuryl chloride.
The method for producing the 1,2-benzisothiazol-3-one compound of the present invention is explained in detail below.
Starting Material
(1) Described below are the groups R 1 in the 2-(alkylthio)benzonitrile compound used as the starting material in the present invention and represented by formula (1):
wherein R 1 is a hydrogen atom, C 1-4 alkyl group, C 1-4 alkoxy group, nitro group, carboxyl group, alkoxycarbonyl group, or halogen atom, and R 2 is a C 1-4 alkyl group. Specifically, examples of C 1-4 alkyl groups include linear or branched C 1-4 alkyl groups, such as a methyl group, an ethyl group, an n-propyl group, an isopropyl group, an n-butyl group, an isobutyl group, a sec-butyl group, and a tert-butyl group. Examples of C 1-4 alkoxy groups include a methoxy group, an ethoxy group, an n-propoxy group, an isopropoxy group, an n-butoxy group, an isobutoxy group, a sec-butoxy group, and a tert-butoxy group. Examples of alkoxycarbonyl groups include those having a C 1-4 linear or branched alkyl group, such as a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, and a butoxycarbonyl group. Examples of halogen atoms include a chlorine atom and a bromine atom.
Among these groups or atoms represented by R 1 , a hydrogen atom, a methyl group, an ethyl group, a tert-butyl group, a methoxy group, a methoxycarbonyl group, an ethoxycarbonyl group, a propoxycarbonyl group, a chlorine atom, a nitro group, and the like are particularly preferable.
Examples of C 1-4 alkyl groups represented by R 2 are the same as those mentioned as the examples of alkyl groups represented by R 1 . Among these, a methyl group, an ethyl group, an n-propyl group, a tert-butyl group, and the like are preferable.
Specific examples of 2-(alkylthio)benzonitrile compounds represented by formula (1) include 2-(methylthio)benzonitrile, 2-(ethylthio)benzonitrile, 2-(n-propylthio)benzonitrile, 2-(tert-butylthio)benzonitrile, 3-methyl-2-(methylthio)benzonitrile, 5-tert-butyl-2-(methylthio)benzonitrile, 4-methoxy-2-(methylthio)benzonitrile, 3-nitro-2-(methylthio)benzonitrile, 3-nitro-2-(tert-butylthio)benzonitrile, 4-chloro-2-(methylthio)benzonitrile, 4-carboxy-2-(methylthio)benzonitrile, and 4-methoxycarbonyl-2-(methylthio)benzonitrile. Among these, 2-(methylthio)benzonitrile, 3-methyl-2-(methylthio)benzonitrile, 5-tert-butyl-2-(methylthio)benzonitrile, 4-methoxy-2-(methylthio)benzonitrile, 3-nitro-2-(tert-butylthio)benzonitrile, 4-chloro-2-(methylthio)benzonitrile, and 4-methoxycarbonyl-2-(methylthio)benzonitrile are preferable because they are readily available and can render high antimicrobial activity to the product.
In the present invention, any 2-(alkylthio)benzonitrile compound represented by formula (1) produced by any method may be used. For example, it is possible to use a 2-(alkylthio)benzonitrile compound obtained by, as disclosed in Patent Literature 1 (JP8-134051A), reacting a 2-halobenzonitrile compound represented by formula (3):
wherein R 1 is the same as R 1 in formula (1) and X is a chlorine or bromine atom, with an alkanethiol represented by formula (4):
R 2 SH (4)
wherein R 2 is the same atom or group as R 2 in formula (1), in the presence of a base in a heterogeneous system.
Among the starting materials used in the present invention, examples of usable halogenating agents include chlorine, bromine, sulfuryl chloride, and sulfuryl bromide. Among these, chlorine, and sulfuryl chloride are preferable from an economical viewpoint.
Production Method of 1,2-benzisothiazol-3-one Compound
The method for producing a 1,2-benzisothiazol-3-one compound according to the present invention comprises:
reacting a 2-(alkylthio)benzonitrile compound represented by formula (1):
wherein R 1 is a hydrogen atom, C 1-4 alkyl group, C 1-4 alkoxy group, nitro group, carboxyl group, alkoxycarbonyl group, or halogen atom, and R 2 is a C 1-4 alkyl group, with a halogenating agent in the presence of water to produce a 1,2-benzisothiazol-3-one compound represented by formula (2):
wherein R 1 is the same as defined above.
In this method, the halogenating agent is preferably used in an amount of about 0.8 to 3 mol, and more preferably about 1 to 2 mol, per mol of 2-(alkylthio)benzonitrile compound. When the amount of the halogenating agent is less than the above range, the amount of unreacted 2-(alkylthio)benzonitrile compound tends to increase, and the yield may be undesirably lowered. When the amount of the halogenating agent is unduly large, a side reaction easily occurs and the yield may be lowered.
Water is preferably used in an amount of about 0.8 to 3 mol, and more preferably about 1 to 2 mol, per mol of 2-(alkylthio)benzonitrile compound. When the amount of water falls outside this range, a side reaction easily occurs and the yield may be undesirably lowered.
Water may be used in the form of an aqueous solution of mineral acid by adding a mineral acid to water. Examples of mineral acids include hydrochloric acid, sulfuric acid, and nitric acid. The concentration of the aqueous solution of mineral acid is not particularly limited. In the case of hydrochloric acid, the preferable range generally employed is from 10% by weight to a saturated concentration. In the case of sulfuric acid or nitric acid, 10 to 50% by weight is preferably employed. The addition of mineral acid to water improves selectivity during reaction and suppresses the generation of by-products.
In the method of the present invention, the use of a reaction solvent is not always necessary; however, a reaction solvent may be used if necessary. The use of a reaction solvent can often help the reaction to proceed more smoothly.
The reaction solvent is not particularly limited and any nonaqueous solvent can be used as long as it is inactive to the reaction. Specific examples of such reaction solvents include hydrocarbons, such as n-hexane, cyclohexane, and n-heptane; halogenated hydrocarbons, such as dichloroethane, dichloromethane, and chloroform; aromatic hydrocarbons, such as benzene, toluene, xylene, and monochlorobenzene; N,N-dimethylformamide; dimethyl sulfoxide; and the like. Among these, toluene and monochlorobenzene are preferable.
When a reaction solvent is used, the amount may be generally about 20 to 3,000 parts by mass relative to 100 parts by mass of 2-(alkylthio)benzonitrile compound. When the amount of the reaction solvent is unduly small, the effect of adding the reaction solvent cannot be satisfactorily achieved. When the amount of the reaction solvent is unduly large, the volume efficiency may be undesirably lowered.
The reaction of the 2-(alkylthio)benzonitrile compound represented by formula (1) with a halogenating agent and water is generally conducted at a temperature of about −20 to 170° C., preferably about 0 to 150° C., and more preferably about 20 to 100° C. An unduly low reaction temperature may undesirably slow down the reaction speed and prolong the necessary reaction time. In contrast, an unduly high reaction temperature may easily cause side reactions. Therefore, reaction temperatures that are either unduly low or unduly high are undesirable.
The reaction time depends on the reaction temperature, etc.; however, it is generally about 0.5 to 40 hours.
In the present invention, when a 2-(alkylthio)benzonitrile compound represented by formula (1) is reacted with a halogenating agent under the conditions described above, it is essential to gradually and simultaneously add a halogenating agent and water to a reaction system containing a 2-(alkylthio)benzonitrile compound to proceed the reaction.
By conducting the reaction while gradually and simultaneously adding a halogenating agent and water, the occurrence of a side reaction and a hydrolysis reaction of the product can be suppressed. This makes it possible to obtain, in high purity and at a high yield, the 1,2-benzisothiazol-3-one compound represented by formula (2):
wherein R 1 is the same as defined above.
There is no limitation to the method for adding a halogenating agent and water; however, in order to reduce side reactions and/or hydrolysis reactions so as to maintain a high yield, it is preferable that a halogenating agent and water be added simultaneously in such an amount that both the halogenating agent and water have almost the same amounts by mol. Generally, it is preferable that water be added in an amount that falls within the range of 0.5 times less to 0.5 times more in an amount by mol, more preferably within the range of 0.2 times less to 0.2 times more in an amount by mol, and even more preferably within the range of 0.1 times less to 0.1 times more in an amount by mol, than the amount by mol of the halogenating agent added to the reaction system.
When the amount of water is unduly small relative to the amount of the halogenating agent added, a side reaction easily occurs. In contrast, when the amount of water is unduly large relative to the amount of the halogenating agent added, a decomposition reaction of the product is promoted. Such cases both undesirably lower the yield.
The speed for adding the halogenating agent and water cannot be generalized because it depends on the reaction temperature, etc. The halogenating agent and water may be added continuously or intermittently depending on the specific reaction temperature within the time required to react.
For example, 1/10 or more and preferably ½ or more of the total reaction time may be allotted as the time for adding a halogenating agent and water. The halogenating agent and water may be added intermittently or continuously as evenly as possible within this time. More specifically, a halogenating agent and water may be simultaneously and gradually added to the reaction system within the total reaction time. Alternatively, after simultaneously and gradually adding the halogenating agent and water to the reaction system, the mixture may be further heated continuously within the reaction temperature range described above, preferably in a temperature range higher than that at which the halogenating agent and water were added. Note that some water may be contained in the reaction system beforehand within the addable water range. In this case, the amount of water that may be contained in the reaction system in advance may be suitably selected as long as it is about 1 mol or less, preferably about 0.5 mol or less, and more preferably about 0.2 mol or less, per mol of 2-(alkylthio)benzonitrile compound.
The method described above makes it possible to obtain, for example, a highly pure target product (with purity exceeding about 99%) at a high yield of 99% or more depending on the specific reaction conditions and addition conditions.
The 1,2-benzisothiazol-3-one compound thus obtained can be easily isolated and purified, for example, by directly crystallizing from a reaction mixture containing the compound, or extracting and recrystallizing, etc.
Specific examples of the 1,2-benzisothiazol-3-one compounds represented by formula (2), which is the target compound obtained as described above, include 1,2-benzisothiazol-3-one, 7-methyl-1,2-benzisothiazol-3-one, 5-tert-butyl-1,2-benzisothiazol-3-one, 6-methoxy-1,2-benzisothiazol-3-one, 7-nitro-1,2-benzisothiazol-3-one, 6-chloro-1,2-benzisothiazol-3-one, 6-carboxy-1,2-benzisothiazol-3-one, and 6-methoxycarbonyl-1,2-benzisothiazol-3-one.
Advantageous Effects of Invention
The method of the present invention makes it possible to simply and economically produce 1,2-benzisothiazol-3-one compounds, which are useful as antimicrobial agents, antifungal agents, etc., as highly pure compounds at a high yield.
DESCRIPTION OF EMBODIMENTS
The present invention is explained in further detail below with reference to a Production Example, Examples, and a Comparative Example. However, the scope of the present invention is not limited to these Examples.
Production Example 1
Synthesis of 2-(methylthio)benzonitrile
2-Chlorobenzonitrile (27.5 g, 0.2 mol), monochlorobenzene (30.0 g), and a 50% by weight aqueous solution (1.0 g) of tetra-n-butyl ammonium bromide were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, a dropping funnel, and a condenser under a nitrogen atmosphere to give a mixture. A 30% by weight aqueous solution (51.4 g) of sodium salt of methanethiol (0.22 mol) was added dropwise to the mixture at 60 to 65° C. over a period of 5 hours under stirring. After completion of the dropwise addition, the mixture was allowed to react at the same temperature for 12 hours.
After completion of the reaction, the reaction mixture was cooled to room temperature. The solvent was distilled off, and then the reaction mixture was distilled under a reduced pressure to give 29.5 g of 2-(methylthio)benzonitrile (boiling point: 139 to 140° C./931 Pa). The yield of the target product relative to 2-chlorobenzonitrile was 99%.
Example 1
2-(Methylthio)benzonitrile (29.8 g, 0.2 mol) obtained in Production Example 1, monochlorobenzene (50.0 g), and water (0.7 g, 0.04 mol) were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, and a condenser to give a mixture. Chlorine (15.6 g, 0.22 mol) was blown into the mixture over a period of 2 hours at 45 to 50° C. under stirring. Water (3.6 g, 0.2 mol) was added to the mixture dropwise over a period of 2 hours at the same time with blowing the chlorine. After completion of blowing chlorine and the dropwise addition of water, the mixture was further heated to 65 to 70° C. and then allowed to react for 1 hour.
After completion of the reaction, a 20% by weight aqueous solution (41.0 g) of sodium hydroxide was added thereto at the same temperature, and the mixture was cooled to room temperature. The precipitated crystal was collected by filtration, washed with monochlorobenzene, and dried to obtain 1,2-benzisothiazol-3-one (29.9 g, 0.198 mol). The yield of the target product relative to 2-(methylthio)benzonitrile was 99%. The purity of the obtained 1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 99.8%.
Example 2
2-Chlorobenzonitrile (27.5 g, 0.2 mol), monochlorobenzene (30.0 g), and a 50% by weight aqueous solution (1.0 g) of tetra-n-butyl ammonium bromide were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, a dropping funnel, and a condenser under a nitrogen atmosphere to obtain a mixture. A 30% by weight aqueous solution (51.4 g) of sodium salt of methanethiol (0.22 mol) was added dropwise to the mixture at 60 to 65° C. over a period of 5 hours under stirring. After completion of the dropwise addition, the mixture was further allowed to react at the same temperature for 12 hours. By this operation, 2-(methylthio)benzonitrile was obtained.
After completion of the reaction, the reaction mixture was cooled to room temperature. An organic layer was obtained by liquid separation. Water (0.7 g, 0.04 mol) was added to the resulting organic layer. Chlorine (15.6 g, 0.22 mol) was blown into the organic layer at 45 to 50° C. over a period of 2 hours under stirring. Water (3.6 g, 0.2 mol) was added dropwise thereto over a period of 2 hours at the same time with blowing the chlorine. After completion of blowing chlorine and the dropwise addition of water, the mixture was further heated to 65 to 70° C. and allowed to react for 1 hour.
After completion of the reaction, a 20% by weight aqueous solution (41.0 g) of sodium hydroxide was added at the same temperature and the mixture was cooled to room temperature. The precipitated crystal was collected by filtration, washed with monochlorobenzene, and dried to obtain 1,2-benzisothiazol-3-one (29.9 g, 0.198 mol). The yield of the target product relative to 2-chlorobenzonitrile was 99%. The purity of the obtained 1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 99.8%.
Example 3
7-Methyl-1,2-benzisothiazol-3-one (31.7 g, 0.192 mol) was prepared in the same manner as in Example 1, except that 3-methyl-2-(ethylthio)benzonitrile (35.4 g, 0.2 mol) was used instead of 2-(methylthio)benzonitrile (29.8 g, 0.2 mol). The yield of the target product relative to 3-methyl-2-(ethylthio)benzonitrile was 96%. The purity of the obtained 7-methyl-1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 99.6%.
Example 4
5-tert-Butyl-2-(methylthio)benzonitrile (41.0 g, 0.2 mol), monochlorobenzene (50.0 g), and water (0.7 g, 0.04 mol) were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, and a condenser to give a mixture. Both sulfuryl chloride (29.7 g, 0.22 mol) and water (3.6 g, 0.2 mol) were simultaneously added dropwise to the mixture over a period of 2 hours at 45 to 50° C. under stirring. After completion of the dropwise addition, the mixture was heated to 65 to 70° C. and allowed to react for 1 hour.
After completion of the reaction, a 20% by weight aqueous solution (41.0 g) of sodium hydroxide was added thereto at the same temperature. The mixture was cooled to room temperature. The precipitated crystal was collected by filtration, washed with monochlorobenzene, and dried to obtain 5-tert-butyl-1,2-benzisothiazol-3-one (40.2 g, 0.194 mol). The yield of the target product relative to 5-tert-butyl-2-(methylthio)benzonitrile was 97%. The purity of the obtained 5-tent-butyl-1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 99.5%.
Example 5
4-Chloro-2-(methylthio)benzonitrile (36.7 g, 0.2 mol), monochlorobenzene (50.0 g), and 35% by weight hydrochloric acid (1.1 g, water: 0.04 mol) were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, and a condenser to give a mixture. Chlorine (15.6 g, 0.22 mol) was blown into the mixture at 45 to 50° C. over a period of 2 hours under stirring and 35% by weight hydrochloric acid (5.5 g, water: 0.2 mol) was added dropwise thereto over a period of 2 hours at the same time with blowing the chlorine. After completion of blowing chlorine and the dropwise addition of water, the mixture was further heated to 65 to 70° C. and allowed to react for 1 hour.
After completion of the reaction, a 20% by weight aqueous solution (41.0 g) of sodium hydroxide was added thereto at the same temperature and the mixture was cooled to room temperature. The precipitated crystal was collected by filtration, washed with monochlorobenzene, and dried to obtain 6-chloro-1,2-benzisothiazol-3-one (36.0 g, 0.194 mol). The yield of the target product relative to 4-chloro-2-(methylthio)benzonitrile was 97%. The purity of the obtained 6-chloro-1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 99.7%.
Comparative Example 1
2-(Methylthio)benzonitrile (29.8 g, 0.2 mol), monochlorobenzene (50.0 g), and water (4.3 g, water: 0.24 mol) were placed in a 500-ml four-necked flask equipped with a stirrer, a thermometer, and a condenser to give a mixture. Chlorine (15.6 g, 0.22 mol) was blown into the mixture at 45 to 50° C. over a period of 2 hours under stirring. The mixture was further heated to 65 to 70° C. and allowed to react for 1 hour.
After completion of the reaction, a 20% by weight aqueous solution (41.0 g) of sodium hydroxide was added at the same temperature and the mixture was then cooled to room temperature. The precipitated crystal was collected by filtration, washed with monochlorobenzene, and dried to obtain 1,2-benzisothiazol-3-one (29.0 g, 0.192 mol). The yield of the target product relative to 2-(methylthio)benzonitrile was 96%. The purity of the obtained 1,2-benzisothiazol-3-one measured with high-performance liquid chromatography was 97.1%.
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The present invention provides a method for producing 1,2-benzisothiazol-3-one compounds by reacting a 2-(alkylthio)benzonitrile compound with a halogenating agent in the presence of water, the method being characterized in that the reaction proceeds while the halogenating agent and water are gradually and simultaneously added to a reaction system containing the 2-(alkylthio)benzonitrile compound. The invention allows the simple and economical production of highly pure 1,2-benzisothiazol-3-one compounds, which are useful as antimicrobial agents, antifungal agents, etc.
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FIELD OF INVENTION
[0001] The present invention relates generally to surveillance system, and more particularly to remote control video and audio surveillance network system.
BACKGROUND OF THE INVENTION
[0002] Surveillance security system has played a very important role in today's world. Since the attack of the World Trade Center, all civilized societies demand for more and more security control in both government and private sectors. Video and audio surveillance are the most basic and are the biggest demand in the industries. Furthermore, much more sophisticated network systems are also required to satisfy today and future needs.
[0003] Quality video surveillance equipments are also very expensive. The security surveillance industries need a line of low cost but high quality video equipment such that the users can have more choices.
[0004] Thus there is a need for a complete line of low cost surveillance video and audio system with a lot of choices to satisfy every user's requirement. These equipments must be easy to be integrated into both basic and sophisticated surveillance systems. In addition there is an urgent need of video/audio surveillance network such that this network system is low cost, massive, easy to access, easy to control, fast in communication, global and secure from theft and hackers.
[0005] All the video, audio and control signals are bundled together and transmitted through data channels and lines. This is much more cost effective than coaxial video and audio cables in most of the surveillance systems.
[0006] Furthermore, most remote surveillance systems are static. Users can only watch picture data submitted by the video capturing stations and cannot demand for continuous changing of view or focus and receive the image feedback instantly. This invention provides the dynamic instant control capability and responses to the users.
[0007] The present invention provides such a dynamic video/audio global surveillance network system.
CROSS REFERENCE TO RELATED APPLICATIONS Field of Search International Class: H04N 007/14, 007/18; H04M 011/00 US Class 348/14.01, 14.05, 14.09, 143, 211.8, 211.11, 211.12 U.S. Patent Documents 6462774 Oct. 8, 2002 Bildstein 384/143 This patent is of a surveillance system monitoring local signals. 6166763 Dec. 26, 2000 Rhodes 348/143 This patent is of a local video security system with recording management. 5774569 Jun. 30, 1998 Waldenmaier 382/100 This patent is of a surveillance component to be used in optical system. 5517236 May 14, 1996 Sergeant 348/143 This patent is a local surveillance system working with a specific camera and not any generic camera available in the market. 5886738 Mar. 23, 1999 Hollenbeck 348/151 This patent is a local surveillance system working with a specific camera and not any generic camera available in the market. 6151490 Nov. 21,2000 Schultheiss 455/403 This patent is not a video on demand teleconferencing system. 5835130 Nov. 10, 1998 Read 348/14.11 This patent is a static on hold feature add-on to a telephone system. 5936945 Aug. 10, 1999 Shibata 370/260 This patent is not a video on demand teleconferencing system. 20020097322 Jul. 25, 2002 Monroe 343/159 This patent application is of system with static cameras and not dynamic video on demand method.
SUMMARY OF THE INVENTION
[0008] An universal video/audio surveillance network system that utilizes the latest technology of remote-control utility mounting device, remote-control generic video camera device, compressed bundle signal transmission technique via Internet communication and advance software development of multimedia computer display and control programs.
[0009] The unique feature of this invention is the utilization of available generic video camera to perform the video data taking and the built in microphone of the video camera to capture the audio signals. External microphone can also be used to adapt to the video camera. The available handheld video cameras in the market are much more cost effective than industrial line of surveillance camera and with much better features such as high zoom power, fast auto focusing response, low light intensity filming, digital data recording and stereo sound and so on.
[0010] The system is comprised of the component stage, (NS) node system stage, (LAVSN) local area video surveillance network stage, Internet stage, (WC) web computer stage and security protection stage.
[0011] The component stage consists of the robotic video station system, the bundled signal transmitter and the signal receiver.
[0012] The (NS) node system stage includes all the component stage equipment connected to the computer with specially developed software.
[0013] The (LAVSN) local area video surveillance network stage includes one or more node system linked together. This can also be a video surveillance network resided in an Intranet system.
[0014] The Internet stage consists of at least one LAVSN connecting to a server station, a WC or another LAVSN via the Internet.
[0015] The security protection stage consists of all the components of the Internet stage or LAVSN stage with a security protection server also connected to the Internet or the particular LAVSN. The security protection server will verify each user before authorizing the communication processes between node systems; and can also enhance the system by serving as the centralized data storage and backup system.
[0016] This basic video retrieval surveillance system allows the user to be able to control and retrieve data from a robotic video camera system through the internet. The user can control his video surveillance system installed at home by virtually using a computer connecting to Internet from any place in the world. Furthermore, he can watch the video picture and listen to the audio sound of his home in the multimedia screen display in his present computer instantly. He can also perform rotate and tilt of the camera mounting stage and zooming function of the video camera by keyboard input to his present computer.
[0017] The global video on demand surveillance system allows multiple users to perform the basic video retrieval system at the same time via Internet or Intranet. It can also be used as a video conferencing system with the users can control the camera in every meeting room such that the users can focus and zoom in at wish to watch whatever is in any of the attending conference room plus any NS in the community network system.
[0018] The high security system protects the data by providing backup, access authorization check, hacker and theft deterrent to all the above video surveillance systems.
[0019] Other features and advantages of the invention will appear from the following description in which the preferred embodiments have been set forth in detail, in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is the overall diagram of the complete Universal Dynamic Video On Demand Surveillance Network System. It depicts the three LAVSN systems, the Internet connection, server, and web computer systems according to present invention.
[0021] [0021]FIG. 2 is the illustration of a conventional computer station setup with special software installed and showing the multimedia screen, keyboard and pointing devices.
[0022] [0022]FIG. 3 is the illustration of a Web computer of PC handheld, PDA or dash mounted type setup showing the multimedia screen with hard keys, virtual soft keys and pointing devices. A pair of speakers is connected to the system.
[0023] [0023]FIG. 4 is the illustration diagram of a typical NS node system according to present invention.
[0024] [0024]FIG. 5 is the illustration diagram of a typical LAVSN local area video surveillance network system according to present invention.
[0025] [0025]FIG. 6 is the illustration diagram of the communication between 2 LAVSN systems, a server and a web computer system through Internet connection according to present invention.
[0026] [0026]FIG. 7 is the retrieval process flow chart of direct communication between a Web computer (WC) system and node station (NS) system.
[0027] [0027]FIG. 8 is the retrieval communication flow chart between two node station (NS) systems within a LAVSN system.
[0028] [0028]FIG. 9 is the retrieval communication flow chart between two node station (NS) systems of 2 LAVSN systems via Internet.
[0029] [0029]FIG. 10 is the signal communication flow chart between the video camera, remote control camera mount and the computer I/O data connector via the IR (infrared) transmission method.
[0030] [0030]FIG. 11 is the signal communication flow chart between the video camera, remote control camera mount and the computer I/O data connector via the RF (radio frequency) transmission method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0031] [0031] Nomenclature LAVSN = Local Area Video Surveillance Network NS = Node Station VBCS = Video Base Computer Station VS = Video Station TNS = Terminal Node Station MW = Multimedia Window Display WC = Web Computer Connecting System 28 = This is the connecting system between VBCS systems. It can be direct cable connection, fiber optic connection, wireless connection, Infrared connection or any other connection system which can facilitate the data connection mean between the VBCS systems. Connecting System 29 = This is the connecting system from VBCS, WC, Server, Main frame computer to the Internet. It can be dial up modem, DSL, cable, T1, ISDN,fiber optic, satellite,wireless or any other connection system which can facilitate as the connection means to the Internet from each station. Software 15 = This is the computer program specially designed for this overall system 1. It is to be installed in all NS, VBCS, TNS, WC systems to allow these systems to perform accordingly.
[0032] [0032]FIG. 1 is the overall system 1 of the complete Universal Dynamic Video On Demand Surveillance Network System. As shown in the drawing the system is consisted of LAVSN 2 , LAVSN 3 and LAVSN 4 all are connected to Internet 5 . In practice the number of LAVSN systems 2 , 3 and 4 are infinite. Any LAVSN system can link to each other via Internet 5 . The overall system 1 also comprises of the server system 66 , Web computer station 68 , Portable Web computer station 70 , Handheld PC Web computer station 71 , Equipment Mounted Web computer station 73 and Mobile Web computer station 75 and all are connected to the Internet 5 via connecting system 29 .
[0033] LAVSN 2 , which can be an Intranet system or LAN (local area network) system, includes NS 6 and NS 7 . The number of NS 6 and NS 7 systems within the LAVSN 2 is users' choice. In practice at least one NS (node station) system is present in the LAVSN 2 .
[0034] NS 6 comprises of a VBCS 10 , which is connected to VS 16 via the IR signals bundler, receiver & transmitter 12 , the IR signals converter, receiver & transmitter 11 and a connecting cable 19 . The VBCS 10 is also connected to VS 17 via the signal bundler & converter 18 by a connecting cable 19 . In practice, it is users' choice to determine the quantity of video station (VS) systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IR signals bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS 10 . The operation software 15 is installed in VBCS 10 to provide the VBCS 10 the necessary control and computing capability as node system computer.
[0035] NS 7 comprises of a VBCS 27 , which is connected to VS 20 via the RF signals bundler, receiver & transmitter 21 , the RF signals converter, receiver & transmitter 24 and a connecting cable 19 . The VBCS 27 is also connected to VS 22 via the signal bundler & converter 18 by a connecting cable 19 . In practice, it is users' choice to determine the quantity and types of video station VS systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IR signals bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS 27 . The operation software 15 is installed in VBCS 27 to provide the VBCS 27 the necessary control and computing capability as node system computer.
[0036] VBCS 10 is connected to VBC 2 27 by connecting system 28 and also to the Internet 5 via the connecting system 29 .
[0037] LAVSN 3 , which can be an Intranet system or LAN (local area network) system, includes NS 8 and NS 9 . The number of NS 8 and NS 9 systems within the LAVSN 3 is users' choice. In practice at least one NS (node station) system is present in the LAVSN 3 .
[0038] NS 8 comprises of a VBCS 32 , which is connected to VS 39 via the RF signals bundler, receiver & transmitter 21 , the RF signals converter, receiver & transmitter 24 and a connecting cable 19 . The VBCS 32 is also connected to VS 37 via the signal bundler & converter 18 by a connecting cable 19 . In practice, it is users' choice to determine the quantity and types of video station (VS) systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IR signals bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS 32 . The operation software 15 is installed in VBCS 32 to provide the VBCS 32 the necessary control and computing capability as node system computer.
[0039] NS 9 comprises of VBCS 46 , which is connected to VS 43 via the IR signals bundler, receiver & transmitter 12 , the IR signals converter, receiver & transmitter 11 and a connecting cable 19 . The VBCS 46 is also connected to VS 42 via the signal bundler & converter 18 by a connecting cable 19 . In practice, it is users' choice to determine the quantity of video station (VS) systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IR signals bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS 46 . The operation software 15 is installed in VBCS 46 to provide the VBCS 46 the necessary control and computing capability as node system computer.
[0040] VBCS 46 is connected to VBCS 32 by connecting system 28 and is also connected to the Internet 5 via the connecting system 29 .
[0041] LAVSN 4 , which can be an Intranet system or LAN (local area network) system, includes a main frame computer system 61 with terminal node station TNS 60 , TNS 62 and computer terminal 59 connected together. The number of TNS 60 , TNS 62 and computer terminal 59 systems within the LAVSN 4 is users' choice. In practice at least one TNS Terminal node station is present in the LAVSN 4 .
[0042] TNS 60 comprises of a VBCS 64 , which is connected to VS 55 via the IR signals bundler, receiver & transmitter 12 , the IR signals converter, receiver & transmitter 11 and a connecting cable 19 . The VBCS 64 is also connected to VS 52 via the signal bundler & converter 18 by a connecting cable 19 . In practice, it is users' choice to determine the quantity of video station VS systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IR signals bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS system 64 .
[0043] TNS 62 comprises of a VBCS 47 , which is connected to VS 49 via the RF signals bundler, receiver & transmitter 21 , the RF signals converter, receiver & transmitter 24 and a connecting cable 19 . In practice, it is users' choice to determine the quantity and types of video station VS systems, RF signals bundler, receiver & transmitter 21 , RF signals converter, receiver & transmitter 24 , IRs signal bundler, receiver & transmitter 12 , IR signals converter, receiver & transmitter 11 and signal bundler & converter 18 to be connected to the VBCS system 47 .
[0044] The TNS 60 , TNS 62 and computer terminal 59 are all connected to the main frame computer 61 by connecting system 58 , which can be cable connection system or wireless connection system; or any connection system which can facilitate the connection mean to the main frame computer 61 . The main frame computer 61 is connected to the Internet 5 via the connecting system 29 . It is the users' choice to determine the quantity of computer terminal 59 , TNS 60 and TNS 62 to be connected to the main frame computer 61 .
[0045] The operation software 15 is installed in the main frame computer 61 to provide the main frame computer 61 the necessary control and computing capability to allow its TNS 1 60 , TNS 2 62 and computer terminal 59 to function as node system computer and data retrieval computer. The operation software 15 can also be installed to TNS 1 60 , TNS 2 62 and computer terminal 59 if necessary.
[0046] The server system 66 is equipped with server software 23 , which provides the overall system 1 with system security and data storage capability. The operation software 15 provides lower level security system to each stand alone station while the server software 23 provides high level security system for the overall system 1 .
[0047] The Web computer (WC) 68 and portable Web computer (WC) 70 are equipped with operation software 15 and connected to the Internet 5 with connecting system 29 .
[0048] The PC handheld Web computer (WC) 71 , which also includes handheld PC computer, PDA, wearable computer, headset computer, mobile phone combined computer, is equipped with operation software 15 and connected to the Internet 5 with connecting system 29 .
[0049] The equipment mounted Web computer (WC) 73 , which also includes computer system installed or mounted to any equipment, is equipped with operation software 15 and connected to the Internet 5 with connecting system 29 .
[0050] The mobile Web computer (WC) 75 , which also includes computer system installed or resided in boats, automobiles, airplanes and spacecraft, is equipped with operation software 15 and connected to the Internet 5 with connecting system 29 .
[0051] During operation the users at all Web computers (WC) 68 , 70 , 71 , 73 and 75 , VBCS stations 10 , 27 , 32 , 46 , 47 and 64 , computer terminal 59 are eligible to control and retrieve data from the video station (VS) 16 , 17 , 20 , 22 , 37 , 39 , 42 , 43 , 49 , 52 and 55 . A pre-determined seniority system defines the access authorization of each user such that there will be no conflict if more than one users attempt to control a particular VS at the same time. The overall system 1 also allows the users to retrieve data from more than one video system (VS) and display them on the users' monitor screen simultaneously as multimedia display. The overall system 1 also allows the data of any video system (VS) to be sent to more than one users simultaneously; in results that more than one users can watch and hear the video and audio data taken by any particular video system simultaneously.
[0052] Further detail illustrations and explanations are shown in FIG. 2 to FIG. 11.
[0053] [0053]FIG. 2 is the illustration of a conventional computer station setup. The conventional computer station represents VBCS stations 10 , 27 , 32 , 46 , 47 and 64 , computer terminal 59 , Web computer station 68 and portable Web computer station 70 . However, equipment mounted Web computer station 73 and mobile Web computer station 75 can also be a conventional computer station. VBCS 10 is illustrated in the FIG. 2.
[0054] The VBCS 10 is equipped with software 15 and is supported by the monitor 83 , speakers 142 , keyboard 148 , mouse 146 and joystick 147 . The monitor shows multimedia display with window MW 143 , MW 144 and MW 145 . The software 15 allows the VBCS 10 to perform multimedia function of retrieving data from more than one video station (VS) systems and displays them on the monitor screen simultaneously. Software 15 also allows the VBCS 10 to receive input data via the keyboard 148 , mouse 146 and joystick 147 as the input device to perform remote-control functions of video station (VS) systems which VBCS 10 is communicating with. Furthermore, touch screen, capacitance probe, inductance probe, writing pad, wireless mouse, wireless keyboard, wireless joy stick and any other data inputting device which can facilitate as input device can also be used as data input device to the VBCS 10 . The speakers 142 provide high quality audio sound simulating the ambient audio sound data captured at the video station (VS) systems. It is users' choice to determine the number of multimedia display windows (MW 13 , 14 and 15 ) to be shown simultaneously. The users also can choose to broadcast the audio data from different VS systems at the speaker 142 together or just one at a time.
[0055] [0055]FIG. 3 is the illustration of a small handheld Web computer 71 , which also includes the PC handheld type, PDA and combined system of mobile phone and computer units. However, equipment mounted Web computer station 73 and mobile Web computer station 75 can also be a handheld computer station.
[0056] The handheld Web computer 71 is equipped with software 15 and is supported by the LCD monitor display with touch screen 152 , key pad 159 and speakers 142 , which is connected to the handheld Web computer 71 by connecting cable 150 . As shown in FIG. 3, the monitor shows multimedia display with MW 151 , MW 154 and MW 155 . The software 15 allows the handheld Web computer 71 to perform multimedia function of retrieving data from more than one video station (VS) systems and displays them on the monitor screen simultaneously. A virtual keypad 158 is also shown in the LCD monitor display with touch screen 152 . The stylus pen 157 is used by user for activating the virtual keypad 158 as input device for the handheld Web computer 71 .
[0057] Software 15 also allows the handheld Web computer 71 to receive input data via the keypad 159 and virtual keypad 158 as the input device to perform remote-control functions of video station (VS) systems which the handheld Web computer 71 is communicating with. Furthermore, capacitance probe, inductance probe, writing pad, wireless mouse, wireless keyboard, wireless joy stick and any other data inputting device which can facilitate as input device can also be used as data input device to the handheld Web computer 71 . The speakers 142 provide high quality audio sound simulating the ambient audio sound data captured at the video station (VS) systems. It is users' choice to determine the number of multimedia display windows to be shown simultaneously. The users also can choose to broadcast the audio data from different VS systems at the speaker 142 together or just one at a time.
[0058] [0058]FIG. 4 illustrates node station (NS) system 6 , which also represents the basic video on demand surveillance system. VBCS 10 is a conventional computer station with software 15 and is supported by a keyboard 148 and a monitor 83 . An external intercom system is setup with the microphone 109 at the NS 6 and intercom speaker 80 at the video station (VS) area. Three video stations 16 , 17 and 100 are connected to NS 6 .
[0059] Video Station (VS) 16 comprises of a video camera 94 installed in a remote-control camera activator system 92 mounted on a remote-control equipment mounting device 96 . Remote-control equipment mounting device 96 can perform vertical tilt motion and horizontal rotational motion as described in prior art disclosed in patent application Ser. No. 10/201,092 (Remote-control utility equipment mounting apparatus). The remote-control activator system 92 is described in prior art disclosed in patent application Ser. No. 10/142,069 (Remote-control device for video camera). This remote-control activator system 92 can control all the mechanical switches on the video camera body and the handheld controller provided with generic video camera. The video and audio signals captured by the video camera 94 are transmitted to IR signals bundler & transmitter 12 by cable 93 . The remote-control activator system 92 and the remote-control equipment mounting device 96 are connected to the IR signals bundler, receiver & transmitter 12 by cable 105 . The IR signals bundler, receiver & transmitter 12 bundles up the video and audio signals, the control signal feedback from remote-control function of activator system 92 and the control signal feedback from remote-control function of equipment mounting device 96 together and encodes them into a combined signal function 38 . The IR signals bundler, receiver & transmitter 12 then emits the combined signal function 38 out with the built-in IR transmitter. The IR signals converter, receiver & transmitter 11 , which has built-in IR signals receiver, receives the combined signal function 38 and decodes the combined signal function 38 into decoded signal function 40 , which includes the video and audio signals, the control signal feedback from remote-control function of activator system 92 and the control signal feedback from remote-control function of equipment mount 96 respectively, and then sends all the signals to VBCS 10 via the signal cable 19 . The decoded signal function 40 can be digital signals, analog signals or combination of digital and analog signals. The video signals of the decoded signal function 40 can be of NTSC, PAL, MPEG, VCD, DVD or any other video signal formats; and they can be compressed or non-compressed data signals. The audio signals of the decoded signal function 40 can be of WAV, MP3 format or any other audio signal formats; and they can be compressed or non-compressed data signals.
[0060] In operation, user 81 can use the keyboard 148 to control the pan and tilt functions of the video camera 94 ; and all the functions of the video camera 94 . As VBCS 10 picks up an input signal from the keyboard 148 , the software 15 will generate a corresponding signal function 78 . This signal function 78 will then be sent to IR signals converter, receiver & transmitter 11 through cable 19 . This signal will be converted into signal function 38 and emitted out. The IR signals bundler, receiver & transmitter 12 detects the signal function 38 and generates corresponding electrical driving functions to the designated electrical components of the remote-control camera activator system 92 and the remote-control equipment mounting device 96 respectively. In results, the video camera 94 will be tilted, rotated, instructed to perform zooming functions or other specific functions according to the input instruction from the user 84 . The video and audio signals are also sent back to the VBCS 10 and the software 15 will show the video picture in the multimedia window 143 of the monitor 83 . The audio will also be sent to the speakers 142 and user 84 can listen to all the sound or conversation which the video camera 94 has captured.
[0061] As shown in FIG. 4, User 91 is in front of VS 16 and is reporting to user 81 . The speech of user 91 is captured by the built in microphone system of the video camera 94 and sent to the speaker 142 of VBCS 10 while user 91 can listen to user 81 via the microphone 109 and intercom speaker system 80 . As a result, user 81 and user 91 can communicate verbally without interference. Furthermore, user 81 can see user 91 in the multimedia window 82 of the monitor 83 .
[0062] Video Station (VS) 17 and 100 comprise of the same component elements of 94 , 92 , 96 , 93 and 105 as VS 16 . VS 17 is connected to signals bundler & converter 18 , which is connected to VBCS 10 by cable 19 . As shown in FIG. 4, User 95 is in front of VS 17 and is reporting to user 81 . The speech of user 95 is captured by the built in microphone system of the video camera 94 and sent to the speaker 142 of VBCS 10 while user 95 can listen to user 81 via the microphone 109 and intercom speaker system 80 . As a result, user 81 and user 95 can communicate verbally without interference. Furthermore, user 81 can see user 91 in the multimedia window 84 of the monitor 83 .
[0063] VS 100 is connected to RF signals bundler, receiver & transmitter 21 through cable 93 and cable 105 . The video and audio signals captured by the video camera 94 are transmitted to RF signals bundler & transmitter 21 by cable 93 . The remote-control activator system 92 and the remote-control equipment mounting device 96 are connected to the RF signal bundler, receiver & transmitter 21 by cable 105 . The RF signals bundler, receiver & transmitter 21 bundles up the video and audio signals, the control signal feedback from remote-control function of activator system 92 and the control signal feedback from remote-control function of equipment mounting device 96 together and encodes them into combined signals function 38 . The RF signals bundler, receiver & transmitter 21 then emits the combined signals function 38 out with the built-in RF transmitter. The RF signals converter, receiver & transmitter 24 , which has built-in RF signals receiver, receives the combined signal function 38 and decodes the combined signal function 38 into decoded signal function 40 , which includes the video and audio signals, the control signal feedback from remote-control function of activator system 92 and the control signal feedback from remote-control function of equipment mounting device 96 respectively, and then sends all the signals to VBCS 10 via the signal cable 19 . The decoded signal function 40 can be digital signals, analog signals or combination of digital and analog signals. The video signals of the decoded signal function 40 can be of NTSC, PAL, MPEG, VCD, DVD or any other video signal formats; and they can be compressed or non-compressed data signals. The audio signals of the decoded signal function 40 can be of WAV, MP3 format or any other audio signal formats; and they can be compressed or non-compressed data signals.
[0064] As shown in FIG. 4, Machine 99 is in front of VS 100 . The ambient noise is captured by the built in microphone system of the video camera 94 and sent to the speaker 142 of VBCS 10 . As a result, user 81 can listen to the machining sound and visualize if the process is normal or not in the multimedia window 108 of the monitor 83 . User 81 can also conference in user 91 and user 95 together and all three user 81 , 91 and 95 can listen and discuss about the processing noise of machine 99 together. This is a great tool for manufacturing processes control especially user 81 can perform rotate and tilt, zoom in or out functions of the video camera 94 with the keyboard 148 in front of him. VBCS 10 can also be connected to other node systems (NS) via the connecting system 28 or to the Internet via the connecting system 29 .
[0065] [0065]FIG. 5 is showing a local area video surveillance network system (LAVSN) 2 with NS 6 and NS 7 linked together by connecting system 28 . FIG. 5 also represents a basic dynamic video on demand teleconferencing system. NS 6 comprises of the same setup and components as in FIG. 4 except without the VS 100 system. User 131 is controlling the VBCS 10 and is in front of VS 17 . Remote video site 133 comprises of VS 16 , IR signals bundler, receiver & transmitter 12 and IR signals converter, receiver & transmitter 11 is connecting to VBCS 10 via the cable 19 .
[0066] NS 7 comprises of the same setup and components as NS 6 (in FIG. 5) without the remote video site 133 . User 130 is controlling the VBCS 140 and is in front of VS 128 .
[0067] In practice, initial conditions require both VBCS 10 and VBCS 140 have software 15 installed and activated; user 131 uses VBCS 10 to send request to VBCS 140 to establish the proper handshake between the two VBCS 10 and 140 . After the software 15 handshake is completed at both VBCS 10 and 140 , both user 131 and user 130 can control both VS 128 and VS 17 . As a result, both users can demand and retrieve the particular video images, focusing, magnification (zoom quality) etc. from VS 128 and VS 17 . They can also hear each other via the built in microphones of the video cameras 94 from the speakers 142 of the VBCS 10 and 140 respectively. Thus, this system represents a dynamic video on demand teleconferencing system. Two user video base computer stations (VBCS 10 and VBCS 140 ) are shown in the drawing; in practice, it is users' choice to determine the number of user video base computer stations to be in the teleconferencing system. The software 15 also provides the users a choice to set an user authority list with pre-defined seniority table for the users so that there will be no conflicts when two or more users try to control the same VS at the same time.
[0068] As the remote video site 133 is connected to VBCS 10 , both users 131 and 130 can access the control of VS 16 of remote video site 133 . VS 16 is a surveillance camera system installed at a specific location. As a result, both users 131 and 130 can watch the video and audio data captured by VS 16 instantly and remotely control all the functions of the video camera 94 of the VS 16 and the image capturing direction as well. Thus, this present invention represents the dynamic video on demand surveillance system with multiple users. In practice, it is users' choice to determine the quantity of remote video site 133 to be in the system and the authorization of access right to users.
[0069] [0069]FIG. 6 shows the universal dynamic video on demand surveillance system including the universal dynamic video on demand teleconferencing system. The NS 6 of LAVSN 2 comprises of the same setup and components as NS 6 shown in FIG. 5 and is connected to Internet 5 via the connecting system 29 . The NS 9 of LAVSN 3 comprises of the same setup and components as NS 7 shown in FIG. 5 and is connected to Internet 5 via the connecting system 29 . Both Web computer 73 and server 66 are connected to Internet 5 via connecting systems 29 .
[0070] In operation, initial conditions require all involved systems in the community network, which is defined as all the equipments in the surveillance system shown in FIG. 6, have the software 15 installed and activated. VBCS 10 connects to the VBCS 46 address through the Internet 5 and initiates the software handshaking processes between the software 15 of both systems. This handshake also includes authorization verification by both VBCS systems. Upon the completion of handshaking processes, user 44 at VBCS 10 and user 41 at VBCS 46 will communicate the way same as user 130 and user 131 of FIG. 5. As user 45 initiates the connection to VBCS 10 with Web computer (WC) 73 , the software 15 of both systems will go through the same software handshaking processes with WC 73 . Upon the completion of handshaking processes user 45 will join in and communicate with user 44 and user 41 through their VBCS and Web computer systems. Furthermore, they also can remotely control all the VS in the overall system (community network). Thus, this system represents the universal dynamic video on demand teleconferencing system.
[0071] In practice, an user can communicate to all the VBCS systems as he gets connected with access approval to any one of the VBCS systems which is already in the communication community, which represents the universal dynamic video on demand teleconferencing system. It is users' choice to define the number of users in the overall communication community.
[0072] As the remote video site 133 is connected to VBCS 10 , all users in the communication community can access the control of VS 16 of remote video site 133 . VS 16 is a surveillance camera system installed at a specific location. As a result, all users can watch and listen to the video and audio data captured by VS 16 instantly and remotely control all the functions of the video camera 94 of the VS 16 and the image capturing direction as well. Thus, this present system represents the universal dynamic video on demand surveillance system with multiple users. In practice, it is users' choice to determine the quantity of remote video site 133 to be in the system and the authorization of access right to users.
[0073] The server 66 equipped with server software 23 is connected to the Internet 5 via connecting system 29 . It can serve as the data center such that it can store data when requested by users from any VBCS in the communication community. It can also function as the centralized authorization center for all users to have connection authorization verified before gaining access to the communication community. This provides security to all users from data contamination, hacking and theft. Thus this system represents the universal dynamic video on demand surveillance system with security protection.
[0074] [0074]FIG. 7 is the retrieval process flow chart of direct communication by a Web computer (WC 68 ) system on requesting and retrieving data from VBCS 27 of node station 7 . Video station 128 is the video station of node station 7 . The initial condition requires VBCS 27 has the software 15 up and running and is linked to the Internet 5 ; and the identity and password of the Web computer 68 is already in VBCS 27 's data record. The Web computer 68 is also required to have the software 15 up and running and is linked to the Internet 5 . Through the Internet connection WC 68 connects to VBCS 27 and sends request for communication to VBCS 27 . VBCS 27 will then check for verification of WC 68 's identity and password. If failed, request from Web computer 68 will be rejected. Otherwise, VBCS 27 will activate video station 128 after verification and approval of WC 68 's identity and will wake up VS 128 if it is in sleep mode. Through the Internet 5 connection, VBCS 27 communicates with WC 68 and enables WC 68 to submit controlling input requests for VS 128 ; and VBCS 27 will act accordingly to control the VS 128 as per WC 68 's request. VBCS 27 will collect the result data, which also includes the video and audio signals from VS 128 and then sends the data back to WC 68 via the Internet 5 connection. Upon receipt of the data, WC 68 will display the video data on the monitor screen. This data display window can also be a multimedia window. WC 68 can also broadcast the audio data through the speakers 142 .
[0075] Web computer 68 can stay on working with VBCS 27 as long as it needs and receives instant responding video and audio data from video station 128 . Web computer 68 will log off from VBCS 27 after completion. Thus, this represents a basic dynamic video on demand surveillance system.
[0076] [0076]FIG. 8 is the dynamic video on demand communication flow chart between two node station (NS) systems within a LAVSN system. FIG. 8 illustrates the process of VBCS 10 of NS 6 initiates the connection to VBCS 27 of NS 7 and then establishes the communication between the two systems. Initial conditions require that the two systems VBCS 10 and VBCS 27 are linked together with connection system 28 and both systems have software 15 running. The overall process is composed of (a) the demand and retrieval process of request made by VBCS 10 and (b) the verification of authorization and supporting process of VBCS 10 in response to request from VBCS 27 .
[0077] The demand and retrieval process of VBCS 10 is similar to the process for Web computer 68 as stated in FIG. 7 description except without connecting to the Internet 5 . Process begins with VBCS 10 sends request for communication to VBCS 27 . VBCS 27 will then check for verification of VBCS 10 's identity and password. If failed, request from VBCS 10 will be rejected. Otherwise, VBCS 27 will activate video station 128 after verification and approval of VBCS 10 's identity. If video station 128 is in sleep mode when not being used; VBCS 27 will wake up and activate video station 128 . VBCS 27 communicates with VBCS 10 and enables VBCS 10 to submit controlling input requests for video station 128 and VBCS 27 will act accordingly to control the video station 128 as per VBCS 10 's request. VBCS 27 will collect the result data, which also includes the video and audio signals from video station 128 and then send the data back to VBCS 10 . Upon receipt of the data, VBCS 10 with the software 15 will display the video data on the monitor screen. This data display window can also be a multimedia window. VBCS 10 can also display the audio data through the speakers 142 . It is VBCS 27 's user choice to display the data from video station 128 on the multimedia window screen of VBCS 27 .
[0078] VBCS 10 can stay on working with VBCS 27 as long as it needs and receives instant responding video and audio data from video station 128 . VBCS 10 will log off from VBCS 27 after completion.
[0079] The verification of authorization and supporting process of VBCS 10 in response to request from VBCS 27 begins with VBCS 10 receives authorization request from VBCS 27 . VBCS 10 searches through its databases to verify if VBCS 27 is a registered user and if the password is correct. Process will stop if results are negative. Otherwise VBCS 10 will activate video station 16 after verification and approval of VBCS 27 's identity. If video station 16 is in sleep mode when not being used; VBCS 10 will wake up and activate video station 16 . VBCS 10 communicates with VBCS 27 and enables VBCS 27 to submit controlling input requests for video station 16 and VBCS 10 will act accordingly to control the video station 16 as per VBCS 27 's request. VBCS 10 will collect the result data, which also includes the video and audio signals from video station 16 and then send the data back to VBCS 27 . Upon receipt of the data, VBCS 27 with the software 15 will display the video data on the monitor screen. This data display window can also be a multimedia window. VBCS 27 can also display the audio data through the speakers 142 . It is VBCS 10 's user choice to display the data from video station 16 on the multimedia window screen of VBCS 10 .
[0080] VBCS 10 will stay on supporting VBCS 27 as long as it receives request from VBCS 27 and send instant responding video and audio data from video station 16 to VBCS 27 until VBCS 27 logs off from VBCS 10 after completion.
[0081] This represents dual channels dynamic video on demand communication with multimedia window display at the VBCS 10 and 27 . In practice, it is users' choice to determine how many users VBCS systems can join together at the same time and how many multimedia windows to be display at the same time. All the processes of (a) the demand and retrieval process of requesting to VBCS 10 and (b) the verification of authorization and supporting process in response to request from VBCS 10 will be automatically initiated as another VBCS or Web computer connects to VBCS 10 . Upon approval, all the processes of (a) the demand and retrieval process of requesting to other VBCS systems in the community and (b) the verification of authorization and supporting process in response to request from VBCS in the community will be automatically initiated. Since software 15 is installed in all computer systems therefore they are all capable of multimedia functions, the process of new system introduction can run in parallel with other current supporting functions. The new arrival VBCS or Web computer will join, request and retrieve data from the community system upon approval of authorization from all present VBCS in the community system.
[0082] [0082]FIG. 9 is the dynamic video on demand communication flow chart between two node station (NS) systems of two LAVSN systems. FIG. 9 illustrates the process of VBCS 10 of NS 6 initiates the connection to VBCS 27 of NS 7 via Internet 5 and then establishes the communication between the two systems. Initial conditions require that the two systems VBCS 10 and VBCS 27 are both connected to Internet 5 with connection system 29 and both systems have software 15 running. The overall process is composed of (a) the demand and retrieval process of request from VBCS 10 to VBCS 27 and (b) the verification of authorization and supporting process of VBCS 10 in response to request from VBCS 27 .
[0083] The demand and retrieval process of VBCS 10 begins with VBCS 10 sends request for communication to VBCS 27 via Internet 5 . VBCS 27 will then check for verification of VBCS 10 's identity and password. If failed, request from VBCS 10 will be rejected. Otherwise, VBCS 27 will activate video station 128 after verification and approval of VBCS 10 's identity. If video station 128 is in sleep mode when not being used; VBCS 27 will wake up and activate video station 128 . VBCS 27 communicates with VBCS 10 through the Internet 5 thereafter. VBCS 27 enables VBCS 10 to submit controlling input requests for video station 128 and will act accordingly to control the video station 128 as per VBCS 10 's request. VBCS 27 will collect the result data, which also includes the video and audio signals from video station 128 and then send the data back to VBCS 10 . Upon receipt of the data, VBCS 10 with the software 15 will display the video data on the monitor screen. This data display window can also be a multimedia window. VBCS 10 can also display the audio data through the speakers 142 . It is VBCS 27 's user choice to display the data from video station 128 on the multimedia window screen of VBCS 27 .
[0084] VBCS 10 can stay on working with VBCS 27 through the Internet 5 connection as long as it needs and receives instant responding video and audio data from video station 128 . VBCS 10 will log off from VBCS 27 after completion.
[0085] The verification of authorization and supporting process of VBCS 10 in response to request from VBCS 27 begins with VBCS 10 receives authorization request from VBCS 27 through the Internet 5 . VBCS 10 searches through its databases to verify if VBCS 27 is a registered user and if the password is correct. Process will stop if results are negative. Otherwise VBCS 10 will activate video station 16 after verification and approval of VBCS 27 's identity. If video station 16 is in sleep mode when not being used; VBCS 10 will wake up and activate video station 16 . VBCS 10 communicates with VBCS 27 through the Internet 5 thereafter. It enables VBCS 27 to submit controlling input requests for video station 16 and will act accordingly to control the video station 16 as per VBCS 27 's request. VBCS 10 will collect the result data, which also includes the video and audio signals from video station 16 and then send the data back to VBCS 27 . Upon receipt of the data, VBCS 27 with the software 15 will display the video data on the monitor screen. This data display window can also be a multimedia window. VBCS 27 can also display the audio data through the speakers 142 . It is VBCS 10 's user choice to display the data from video station 16 on the multimedia window screen of VBCS 10 .
[0086] VBCS 10 will stay on supporting VBCS 27 as long as it receives request from VBCS 27 and will send instantly responding video and audio data from video station 16 to VBCS 27 until VBCS 27 logs off from VBCS 10 after completion.
[0087] This represents dual channels dynamic video on demand communication with multimedia window display via Internet 5 connection at the VBCS 10 and 27 . In practice, it is users' choice to determine how many user VBCS systems can join together at the same time and how many multimedia windows to be display at the same time. All the processes of (a) the demand and retrieval process of requesting to VBCS 10 and (b) the verification of authorization and supporting process in response to request from VBCS 10 will be automatically initiated as another VBCS or Web computer connects to VBCS 10 via Internet 5 . Upon approval, all the processes of (a) the demand and retrieval process of requesting to other VBCS in the community by the new comer and (b) the verification of authorization and supporting process in response to request from all VBCS systems in the community will be automatically initiated. Since software 15 is installed in all computer systems therefore they are all capable of multimedia functions, the process of new system introduction can run in parallel with other current supporting functions. The new arrival VBCS or Web computer will join, request and retrieve data from the community system upon approval of authorization from all present VBCS systems in the community system.
[0088] [0088]FIG. 10 is the signal communication flow chart from the video system (VS) 16 , which includes the video camera, remote control camera mount, remote control device for video camera; the IR (infrared) signals bundler, receiver, & transmitter 12 and IR signals converter, receiver & transmitter 11 to the input/output data connector 13 , which is to be connected to VBCS 10 of the NS 6 computer system.
[0089] Video Station (VS) 16 comprises of a video camera 94 installed in a remote-control camera activator system 92 mounted on a remote-control equipment mounting device 96 . Remote-control equipment mounting device 96 can perform vertical tilt motion and horizontal rotational motion as described in prior art disclosed in patent application Ser. No. 10/201,092 (Remote-control utility equipment mounting apparatus). The remote-control activator system 92 is described in prior art disclosed in patent application Ser. No. 10/142,069 (Remote-control device for video camera).
[0090] Process begins at the I/O data connector 13 . As soon as I/O data connector 13 receives input signals for the control of remote-control activator system 92 and the equipment-mounting device 96 from the VBCS 10 , it will pass all the input signals to the IR signals converter, receiver, & transmitter 11 , where all signals will be encoded or encrypted into signals function 38 and emitted out through the built in IR electronic components. IR signals bundler, receiver, & transmitter 12 will detect and receive the signals function 38 and decode it into driver functions to drive the camera remote-control activator system 92 and the remote control equipment mounting device 96 respectively. The feedback signals from camera remote-control activator system 92 and the remote-control equipment-mounting device 96 are sent to the IR signals bundler, receiver, & transmitter 12 . The video and audio signals captured by the video camera 94 are also sent to the IR signals bundler, receiver, & transmitter 12 , where all the signals will be encoded or encrypted together as signal function 38 and then emitted out through the built in IR electronic components. The IR signals converter, receiver, & transmitter 11 will detect and receive the signal function 38 ; and decode it into camera remote-control activator system 92 feedback output signals, equipment-mounting device 96 remote control feedback signals, video data signals and audio data signals functions, and all these signals will be passed to the I/O data connector 13 . Thus, the signals function 38 is the bundled signals, which also includes video and audio signals being transmitted and received between IR signals bundler, receiver, & transmitter 12 and IR signals converter, receiver, & transmitter 11 wirelessly.
[0091] [0091]FIG. 11 is the signal communication flow chart from the video system (VS) 20 , which includes the video camera, remote control equipment mounting device 96 , remote control activator system 92 for video camera; the RF signals bundler, receiver, & transmitter 21 and RF signals converter, receiver & transmitter 24 to the input/output data connector 13 , which is to be connected to VBCS 27 of the NS 7 computer system.
[0092] Video Station (VS) 20 comprises of a video camera 94 installed in a remote-control camera activator system 92 mounted on a remote-control equipment mounting device 96 . Remote-control equipment-mounting device 96 can perform vertical tilt motion and horizontal rotational motion as described in prior art disclosed in patent application Ser. No. 10/201,092 (Remote-control utility equipment mounting apparatus). The remote-control activator system 92 is described in prior art disclosed in patent application Ser. No. 10/142,069 (Remote-control device for video camera).
[0093] Process begins at the I/O data connector 13 . As soon as I/O data connector 13 receives input signals for the control of the remote-control activator system 92 and the equipment-mounting device 96 , it will pass all the input signals to the RF signals converter, receiver, & transmitter 24 , where all signals will be encoded or encrypted as signal function 38 and emitted out through the built in RF electronic components. RF signals bundler, receiver, & transmitter 21 will detect and receive the signal function 38 and decode it into driver functions to drive the camera remote-control activator system 92 and the remote control equipment mounting device 96 respectively. The feedback signals from camera remote-control activator system 92 and the remote-control equipment-mounting device 96 are sent to the RF signals bundler, receiver, & transmitter 21 . The video and audio signals captured by the video camera 94 are also sent to the RF signals bundler, receiver, & transmitter 21 , where all the signals will be encoded or encrypted together as signal function 38 and then emitted out through the built in RF electronic components. The RF signals converter, receiver, & transmitter 24 will detect and receive the signal function 38 ; and decode it into camera remote-control activator system 92 feedback output signals, equipment-mounting device 96 remote control feedback signals, video data signals and audio data signals functions and all these signals will be passed to the I/O data connector 13 . Thus, the signals function 38 is the bundled signals, which also includes video and audio signals being transmitted and received between RF signals bundler, receiver, & transmitter 21 and RF signals converter, receiver, & transmitter 24 wirelessly.
[0094] It will be appreciated that the sizes and shapes and dispositions of various node systems, camera remote-control activator system, equipment mounting device, generic video camera, handheld PC systems, computer systems, server computer, pointing devices, IR transceivers, IR receivers, RF transceivers, RF receivers and signals bundlers can be varied, without departing from the spirit and scope of the invention. Similarly, the sizes and colors of the multimedia window display, and the like may be varied. While the method of connection to networks, Intranet, the Internet has been described with respect to current available technology, other future connecting means may instead (or in addition) be used. While the computers, servers, handheld computers has been described with current available equipment, other future advance computers, faster CPUs, microprocessors and other computing devices may instead ( or in addition) be used. While the surveillance system and the teleconferencing system have been described with respect to application with video cameras with capability of audio capturing, the described system may be applied to other video cameras including without limitation to use digital cameras.
[0095] Modifications and variations may be made to the disclosed embodiments without departing from the subject and spirit of the invention as defined by the following claims.
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An Universal Dynamic Video On Demand Surveillance System is a mass video surveillance system with affordable price. It allows users to have global access to the installed sites and with multiple users at the same time. Users can use generic personal video camcorder or camera instead of expensive industrial surveillance camera. Users can have full control of the camera pan and tilt positions and all the features of the video camera from any part in the world as long as Internet access is available. Furthermore, the users can retrieve the video and audio data and watch it on the monitor screen instantly.
This new invention is also a dynamic video on demand video-telephone conferencing system. It allows the users to search, zoom and focus around all the meeting rooms at wish.
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FIELD OF THE INVENTION
[0001] The present invention relates to a system and method for the application of differential pressure indicating transmitters in conjunction with pressure sensors, pressure transmitters and position switches to monitor and control a flowline protection system (FPS) at a remote wellhead. The system communicates with a local control panel in proximity to the wellhead, as well as to a central control room at the processing plant supplied by the well. The system provides a “black box” data recorder function that documents every system test, valve closure and ability of independent protection layers to contain the well topside pressure.
BACKGROUND OF THE INVENTION
[0002] In the oil and gas industry, production fluid pipelines downstream of the wellhead are designed to minimize the cost of the pipeline and the cost of a conventional downstream pressure relief valve and flare system. It is therefore necessary that such pipelines be protected against excessive pressure that might rupture the pipe or lift pressure relief devices, which could result in excess flaring or environmental pollution. A design approach used to protect pipelines from over-pressure applies a short-section of thick-walled pipe close to the wellhead, with a dual layer of protection comprising an emergency shutdown (ESD) valve and a high integrity protection system (HIPS). The ESD valve is designed to provide a safe and orderly shutdown of the pipeline in the event process parameters require it. HIPS is typically an automated electro-hydraulic system employing pressure sensors to control the closure of valves to isolate a rapid build-up of pressure in order to protect the downstream pipe from an overpressure which may exceed the pipeline's pressure rating. A HIPS unit is preferably provided with standardized design and integrally constructed as a modular, factory-assembled unit.
[0003] Prior art valve control techniques rely upon valve limit switches or valve stem position sensors to offer feedback during functional valve testing of the ESD valve and the HIPS valves. In some cases, differential pressure is also checked to confirm valve closure. However, the prior art does not disclose the use of differential pressure measurements across each of the safety systems independent protection layers within an assembled flowline protection system to provide useful and actional feedback of the status of each of the systems and to identify failures.
[0004] It would be desirable to provide a wellhead flowline protection system that includes differential pressure transmitters across each of the safety systems independent protection layer and that incorporates those measurements within expert, state-based logic, local to the wellsite.
[0005] It is therefore an object of the present invention to provide a wellhead flowline protection system and a method for the application of differential pressure indicating transmitters in conjunction with pressure sensors, pressure transmitters and position switches to monitor and control the integrated protection systems at remote wellheads.
SUMMARY OF THE INVENTION
[0006] The above objects, as well as other advantages described below, are achieved by the method and apparatus of the invention which provides a flowline protection system comprising an emergency shutdown valve and a high integrity protection system (HIPS). The ESD valve is designed to provide a safe and orderly shutdown of the pipeline in the event process parameters require it. The HIPS offers an additional layer of protection to limit pressure exerted on the piping system connected to a wellhead. The HIPS of the present invention has an inlet for connection to the wellhead and an outlet for connection to the downstream piping system and, in a preferred embodiment, is constructed as a skid-mounted integral system for transportation to the site where it is to be installed.
[0007] The ESD valve is monitored by a valve stem position switch, a downstream pressure switch, and an upstream pressure indicating transmitter, with a differential pressure indicating transmitter measuring differential pressure across the ESD valve. The instruments provide their measurements to a local control panel located at the wellsite. The HIPS comprises at least one set of two valves in series, each valve monitored by a valve stem position switch, and at least one dedicated set of redundant pressure switches located downstream of the valves and by an additional pressure indicating transmitter. In addition, a differential pressure indicating transmitter is placed across each of the HIPS valves, and another differential pressure indicating transmitter is placed across each of the at least one set of two valves that make up the assembled HIPS unit. These instruments also provide their measurements to the local control panel located at the wellsite. The local control panel provides a wellsite “black box” data recorder function that documents and time stamps valve movement and system performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will be further described below and in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is a schematic diagram of a wellhead flowline protection system in accordance with the invention; and
[0010] FIG. 2 is a process flow diagram of steps carried out in monitoring and controlling a wellhead flowline protection system, using the system and method of the present invention; and
[0011] FIG. 3 is a block diagram of a component of a system for implementing the invention, according to one preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Referring to FIG. 1 , a flowline protection system 1 is installed at a petroleum wellhead 2 to protect the integrity of flowline 3 , prevent the loss of petroleum product and prevent environmental damage, as well as reducing the occurrence of activation (lifting) of conventional pressure relief systems. Flowline protection system (FPS) 1 comprises an emergency shutdown (ESD) system 4 , a high integrity protection system (HIPS) 5 , and local control panel 10 .
[0013] ESD 4 includes an ESD valve 20 , monitored by position switch 30 , a pressure transmitter 40 that is tapped from flowline 3 downstream of valve 20 , and a differential pressure indicating transmitter 50 that is placed across valve 20 . The instrumentation interfaces with local control panel 10 . The actuator for valve 20 is not shown, but also interfaces with local control panel 10 .
[0014] HIPS 5 includes redundant inline valves 21 and 22 , each monitored by a valve stem position switch, 31 and 32 , respectively. Redundant pressure transmitters 41 , 42 are tapped from flowline 3 downstream of valves 21 and 22 . Differential pressure indicating transmitters 51 and 52 are placed across valves 21 and 22 , respectively, and differential pressure indicating transmitter 53 is placed across both valves 21 and 22 . The instrumentation interfaces with local control panel 10 . The actuators for valves 21 and 22 are not shown, but also interface with local control panel 10 .
[0015] ESD 4 is placed upstream of HIPS 5 . ESD 4 has a lower trip setting than HIPS 5 . Pressure indicating transmitter 60 is tapped off flowline 3 upstream of ESD 4 , while pressure indicating transmitter 61 is tapped off flowline 3 downstream of HIPS 5 . Pressure indicating transmitters 60 , 61 also interface with local control panel 10 . A specification break 6 is placed in flowline 3 downstream of HIPS 5 , at a junction between high-pressure upstream piping and lower-pressure downstream piping.
[0016] Downstream of specification break 6 is a conventional pressure relief and flare system 7 . Pressure relief and flare system 7 includes a pressure relief valve that will have a setpoint above that of FPS 1 . That is, ESD 4 and HIPS 5 will activate before pressure relief and flare system 7 activates.
[0017] During normal operation, all valves 20 , 21 , 22 will be open and position switches 30 , 31 , 32 will correctly identify that. Pressure transmitters 40 , 41 , and 42 will all indicate a consistent normal pressure, such as 500 psig, and the differential pressure indicating transmitters 50 , 51 , 52 , 53 will indicate 0 psig (i.e., no difference between the upstream and downstream pressures they are monitoring). Local control panel 10 will indicate safe and normal operation.
[0018] In the event of an overpressure at the well due to downstream blockage, the ESD system should trip first on increasing pressure, as it has a lower trip setting than the FPS. If it trips, then ESD valve 20 should close, which should be indicated by valve stem position switch 30 . Pressure transmitter 40 will indicate the pressure downstream of valve 20 , and differential pressure indicating transmitter 50 shall indicate the pressure difference between the upstream and downstream sides of valve 20 . If valve 20 correctly trips and closes, the downstream flowline 3 shall be pressurized at a level below the HIPS or the pressure relief valve setpoint. The differential pressure indicating transmitter 50 will indicate a differential of the wellhead shut-in pressure and the downstream flowline pressure. Local control panel 10 will indicate trip of ESD 4 , that it requires reset, and will record the time and date of the event.
[0019] If ESD 4 fails to trip in response to an overpressure, such as 800 psig, then the pressure will rise until the blockage results in a HIPS 5 trip, which will close valves 21 and 22 , and which closure will be indicated by position switches 31 , 32 . Pressure transmitters 41 , 42 will indicate the pressure downstream of valves 21 , 22 , and differential pressure indicating transmitters 51 , 52 , 53 will indicate the pressure difference each is experiencing. If valve 21 correctly closes, then pressure transmitters 41 , 42 will indicate the pressure within the downstream flowline 3 , differential pressure indicating transmitter 51 (across valve 21 ) will indicate a differential of the wellhead shut-in pressure and the pressure of downstream flowline 3 . Differential pressure indicating transmitter 52 (across valve 22 ) will not indicate any differential pressure, as the upstream overpressure will be sealed off by valve 21 . Differential pressure indicating transmitter 53 (across both valves 21 and 22 ) will indicate a differential of the wellhead shut-in pressure and the pressure of downstream flowline 3 . If valve 21 fails to close but valve 22 does close, then differential pressure indicating transmitter 51 would not indicate a differential, but differential pressure indicating transmitter 52 would indicate the full differential, as would differential pressure indicating transmitter 53 . In either case, local control panel 10 will indicate failure of ESD 4 to trip, will indicate that HIPS 5 has tripped and requires reset, and will record the date and time of all valve responses. There can also be cases where the downstream pressure exceeds the pressure setpoints of ESD 4 and HIPS 5 for a short period that reaches the downstream pressure relief valve lift setting. This does not change the operation of the ESD or HIPS layers of protection.
[0020] The black box function of local control panel 10 tracks the maximum upstream to downstream pressure rise during a high pressure event.
[0021] In the event of an overpressure in the downstream piping, followed by failure of both ESD 4 and HIPS 5 , the pressure indicating transmitters 60 , 61 would both indicate the pressure relief valve setting, and the differential pressure indicating transmitters 50 , 51 , 52 , 53 would not indicate any differential. Local control panel 10 would indicate a failure of ESD 4 and HIPS 5 , and that manual isolation of wellhead 2 is required. Local control panel 10 would also timestamp occurrences of downstream pressure exceeding the setting of pressure relief and flare system 7 , so as to document the venting of the well.
[0022] In an alternate embodiment, not shown, HIPS 5 can include two sets of redundant inline valves, the two sets being assembled in parallel, such that for testing purposes one of the sets can be isolated and the valves closed while the other set of valves remains open to allow uninterrupted flow from the wellhead. All valves within the parallel flow paths would be monitored by local control panel 10 , as described above.
[0023] In another embodiment, local control panel 10 supports functional testing of ESD 4 and HIPS 5 systems. Furthermore, the black box functions of the local control panel include time stamping all ESD 4 and HIPS 5 valve movements, whether they occur as part of a functional test, or through a safety demand.
[0024] In another embodiment, local control panel 10 is configured to monitor for leaks in the flowline, emergency shutdown system, or high integrity protection system, and to timestamp and record any detected leaks, in support of a leak detection and repair reporting program.
[0025] FIG. 2 shows a process flow diagram of a method 200 of monitoring and controlling a wellhead flowline protection system. In step 205 , local control panel 10 monitors normal conditions, confirming that position switches indicate that the ESD valve 20 and HIPS valves 21 and 22 are open, and confirming that the pressure switches, pressure transmitters, and differential pressure transmitters are reporting numbers that are within tolerance. If the conditions remain normal, method 200 advances to step 210 , in which local control panel 10 indicates that conditions are normal, such as via a green pilot light on local control panel 10 . As long as conditions remain normal, method 200 will continue to loop back through step 205 .
[0026] If local control panel 10 notes an overpressure condition, method 200 advances to step 215 , in which local control panel 10 signals for a trip of ESD valve 20 . The method 200 advances to step 220 , monitoring valve stem position switch 30 , the pressure switches, pressure transmitters, and differential pressure transmitters to confirm that ESD valve 20 has tripped. If ESD valve 20 is confirmed as tripped, method 200 advances to step 225 , in which local control panel 10 confirms the trip of ESD valve 20 , such as via a red pilot light on local control panel 10 . Method 200 then awaits a reset by an operator or maintenance personnel.
[0027] If a trip of ESD valve 20 is not confirmed, method 200 advances to step 230 , in which local control panel 10 signals for a trip of HIPS valves 21 and 22 . The method 200 advances to step 235 , monitoring position switches 31 , 32 , the pressure switches, pressure transmitters, and differential pressure transmitters to confirm that at least one of HIPS valves 21 and 22 have tripped. If HIPS valve 21 or 22 is confirmed as tripped, method 200 advances to step 240 , in which local control panel 10 confirms which HIPS valves have tripped, such as via red pilot lights on local control panel 10 . Method 200 then awaits a reset by an operator or maintenance personnel.
[0028] If neither of HIPS valves 21 and 22 trip, method 200 advances to step 245 , in which local control panel 10 indicates that the downstream pressure reached the pressure relief valve setting and that manual isolation is required.
[0029] If a reset is required as a result of steps 225 , 240 , or 245 , this is accomplished by step 250 . The method 200 will continue to loop back through step 250 until a reset is accomplished. When an operator or maintenance personnel conducts the appropriate actions, ensuring that the pressures are within tolerance, and all equipment and instrumentation is in working condition, the valves are reopened, and the system reset to step 205 .
[0030] FIG. 3 shows an exemplary block diagram of a computer system 400 installed in local control panel 10 . Computer system 400 includes a processor 420 , such as a central processing unit, an input/output interface 430 and support circuitry 440 . Optionally, a display 410 and an input device 450 such as a keyboard, mouse or pointer are also provided. The display 410 , input device 450 , processor 420 , and support circuitry 440 are shown connected to a bus 490 which also connects to a memory 460 . Memory 460 includes program storage memory 470 and data storage memory 480 . Note that while computer 400 is depicted with direct human interface components display 410 and input device 450 , programming of modules and exportation of data can alternatively be accomplished over the interface 430 , for instance, where the computer 400 is connected to the central control room at the processing plant supplied by the wells, or via a detachable input device as is known with respect to interfacing programmable logic controllers.
[0031] Program storage memory 470 and data storage memory 480 can each comprise volatile (RAM) and non-volatile (ROM) memory units and can also comprise hard disk and backup storage capacity, and both program storage memory 470 and data storage memory 480 can be embodied in a single memory device or separated in plural memory devices. Program storage memory 470 stores software program modules and associated data, and in particular stores a first software program module 310 that monitors for normal pressure and calls for the trip of the ESD valve in the event of overpressure; a second software program module 320 that monitors whether the ESD valve has tripped when called to do so, and if not, that calls for the HIPS valves to trip; a third software program module 330 that monitors whether at least one of the HIPS valves have tripped when called to do so, and if not, signals that manual isolation is required; and a fourth software program module 340 that monitors for a manual reset of tripped valves. Software program modules 310 - 340 incorporate the logic recited above in the paragraphs that describe FIG. 1 . Local control panel 10 includes black box data recorder functions, monitoring the performance of the well and associated ESD and HIPS systems.
[0032] In a preferred embodiment, support circuitry 440 of local control panel 10 includes a fully self-contained battery backup. The battery backup integrates with solar charging panel 445 that provides power at wellsites that are not supplied with utility power. Solar charging panel 445 is preferably mounted remotely from local control panel 10 .
[0033] Thus, it can be seen that with this combination of isolation valves, position switches, pressure transmitters, pressure indicating transmitters, and differential pressure indicating transmitters, local control panel 10 will be able to recognize whether conditions are normal, or whether there is a high pressure demand with proper response by ESD 4 , or whether there is a high pressure demand with a failure of ESD 4 but with a proper response by HIPS 5 , or whether there is a high pressure demand with a failure of both ESD 4 and HIPS 5 that resulted in activation of pressure relief and flare system 7 .
[0034] Another feature of the invention is that pressure indicating transmitter 61 works with local control panel 10 to identify the maximum pressure experienced by flowline 3 during a high pressure event, because even if the ESD and/or HIPS function as required at their setpoints, it is important to know the maximum downstream pressure reached to assess the likelihood of damage to flowline 3 downstream of specification break 6 and to determine if the pressure relief valve lifted, resulting in release of hydrocarbons.
[0035] The system and method can be used for new construction, or can be retrofitted to existing construction at wellsites with reliable power or at remote wellsites without a reliable power supply.
[0036] Although various embodiments that incorporate the teachings of the present invention have been illustrated in the figures and described in detail, other and varied embodiments will be apparent to those of ordinary skill in the art and the scope of the invention is to be determined by the claims that follow.
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A system and method for the application of differential pressure indicating transmitters in conjunction with pressure sensors, pressure transmitters and position switches to monitor and control the flowline protection systems at remote wellheads. The system communicates with a local control panel in proximity to the wellhead, as well as to a central control room at the processing plant supplied by the wells. The system provides a black box data recorder function that documents every system test, valve closure, and the ability of the independent protection layers to contain the wellhead topside pressure. In addition, the system provides a means to limit release of hydrocarbons via a conventional pressure relief and flare system, and documents high pressure events when pressure relief valve setpoints are reached.
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BACKGROUND OF THE INVENTION
The present invention relates to a soil tilling device with at least one tool holder that is connected to a support frame or a swivel arm whereby the tool holders are rotatably drivable and are provided with soil tilling tools.
Soil tilling devices of the aforementioned kind are known in various embodiments. The tool holder is usually provided with a soil tilling tool in the form of a disk that is provided with a vertically extending prong whereby the disk is fixedly connected to the tool holder. The tool holder is generally drivable by a pulling vehicle or tractor to which the soil tilling device is connected.
With forcedly driven tools of the aforementioned kind an intensive soil tilling is possible; however, the prongs often tear up the soil to an undesirably great extent and furthermore, a tilling of a uniform depth is not possible. Another disadvantage is that when using such soil tilling devices with the aforementioned tools the rotatingly driven prongs throw rocks and pieces of soil in the air. Also, the roots of cultivated plants between which the soil is tilled are often damaged. Furthermore, driving such a tool holder requires a great drive power. When working with the aforementioned soil tilling devices the danger of having accidents is therefore quite great, and extensive constructive measures must be taken, especially to prevent rocks and soil parts from being thrown in the air, and to prevent accidents due to the prongs rotating at a high speed. Furthermore, it is disadvantageous that the forcedly driven prongs are often damaged when hitting a rock or any other obstacle so that the operation of the tilling device must be interrupted in order to repair respective damages. Furthermore the aforementioned tilling devices are usually very tall and tilling soil under trees with low branches is often impossible. Also, when the soil to be tilled is grown over with weeds a clogging of the machine due to weeds pulled from the soil is inevitable. A satisfactory operation, especially under changing working conditions to which such tilling devices are usually exposed, is thus impossible.
It is therefore an object of the present invention to provide a soil tilling device for multiple applications which allows a high working speed without pulling rocks and soil parts from the soil to be tilled and throwing them into the air, and without the necessity of providing special measures to prevent accidents. Furthermore, a satisfactory and uniform tilling of soil of various soil conditions should be possible. The soil should not be torn up and removed, and roots of cultivated plants between which the soil is to be tilled should not be damaged, and it is desired that the soil surface in one working step is cut and also smoothed so that weeds are reliably removed. Furthermore, it should be possible to feed grass which is directly adjacent to trees or other obstacles into the soil tilling device so that grass may be mowed. Also, shoots that are growing at lower portions of a tree should be removable with the soil tilling device.
The required constructive expenditures should be low, and an economic manufacture should be provided. The drive power required for driving the soil tilling device should be low. It should be impossible that during the tilling process in tall grass a clogging within the area of the tool holder occurs. The soil tilling device should be universally applicable and a high operational safety with a long life span of the tools should be ensured. Furthermore, the tilling depth should be adjustable and uniform.
SUMMARY OF THE INVENTION
The soil tilling machine according to the present invention is primarily characterized by at least one tool holder that is supported at a supporting element and is rotatably drivable; at least two circular disk-shaped tools connected to a respective one of the tool holders and uniformly distributed over a circumference of the tool holder, with each one of the soil tilling tools being connected to a shaft, whereby the shaft is supported at a support of the tool holder, the soil tilling tools being rotatable about an axis of rotation thereof that corresponds to the shaft; and the shaft is slanted relative to an axis of rotation of the tool holder such that the soil tilling tools have an angle of 20° to 40° to a surface of the soil to be tilled, with circumferential sections of the soil tilling tools forming tilling surfaces. The supporting element may be in the form of a support frame or a swivel arm.
It is preferable that the tool holder has an axis of rotation that is tilted in the direction of travel or against the direction of travel of the soil tilling device. The tilting of the tool holder, in a simple manner, may be achieved by providing a support frame that is pivotable about a pivoting axis which is essentially horizontal and extends perpendicularly to a direction of travel of the soil tilling device, whereby the pivoting axis is in the form of a bolt that is provided at guiding elements of a frame of the tractor vehicle, the guiding elements being connected to the support frame. For pivoting the support frame, a servo device may be provided at the guiding elements.
The soil tilling tools of a soil tilling device may be connected to a common support which is fastened to the tool holder and may be provided in the form of a truncated pyramid or a truncated cone. However, it is also possible to connect each of the soil tilling tools to a respective support, whereby the support is connected to the tool holder and is adjustable about a horizontal pivotable axis in the form of a bolt. The support may be adjustable against the force of a spring, and the respective end positions of the support are determined by respective abutments. Furthermore, it is expedient that the supports are adjustable at different angles of tilt relative to one another.
In a preferred embodiment the support is provided with respective carrier elements to which the soil tilling tools are connected, whereby the carrier elements are pivotably connected to the support so that the soil tilling tools are laterally pivotable relative to the support. The carrier elements may be angled. It is furthermore expedient that the soil tilling tools are connected to the carrier elements by a respective shaft, whereby vertically above the carrier element the shaft may be provided with a supporting means, for example, in the form of a wheel that is rotatably supported at the shaft.
In another embodiment the soil tilling tools have varying diameters. Furthermore, it is preferable that the soil tilling tools that are connected to the tool holder are arranged at different levels of the soil tilling device. The soil tilling tools may be arranged above and below the support at a same distance or at varying distances. It is also possible that the soil tilling tools are arranged below the support at a same or varying distances, or that the soil tilling tools are arranged above the support at a same or varying distances.
In a preferred embodiment six of the soil tilling tools are provided at the tool holder whereby diametrically oppositely arranged ones of the soil tilling tools are provided at different levels of the soil tilling device.
It is expedient to provide the underside of the tool holder with an abutment for adjusting an engagement depth of the soil tilling tools with the soil to be tilled.
When the support frame is provided with a plurality of tool holders, the tool holders, in a direction of travel, should be staggered such that a respective tilling range of the soil tilling tools of the respective tool holders overlap one another. The abutment is preferably in the form of a gliding disk that is height-adjustable.
The disk-shaped soil tilling tools may be in the form of a toothed disk, a disk-shaped knife, a disk provided with spring prongs, or a disk provided with brushes.
In another embodiment of the soil tilling device grass that is positioned between obstacles or is located close to obstacles may be fed into the soil tilling tools in order to be mowed; for this purpose, the soil tilling tools are provided with a cleaning tool that is arranged vertically above the soil tilling tools and may be provided in the form of a wheel brush that is rotatably driven about a vertically extending axis, with brush elements of the wheel brush extending with at least one portion thereof beyond a tilling range of the soil tilling tools. Instead of a wheel brush, a brush roller may be provided as a cleaning tool, which is rotatably driven about a horizontally extending axis. The brush elements of the brush roller preferably extend with at least one portion thereof beyond a tilling range of the tools.
It is preferable that the wheel brush and the tool holder are drivable in a same direction of rotation. Furthermore, it is expedient that the wheel brush is arranged concentrically to the tool holder and is directly connected thereto. It is also possible that the wheel brush is arranged at a supporting device coordinated with the tool holder. The supporting device may be in the form of a pivoting arm. It is furthermore expedient that the wheel brush is arranged at a lever that is supported at the pivoting arm, whereby the lever as pivotable in a controlled manner by a servo device. The lever may be pivotable about an axis in the form of a shaft of the tool holder. It is also possible that the wheel brush is arranged at a slide that is supported at the pivoting arm whereby the slide is adjustable in a controlled manner by a servo device. The slide is preferably radially outwardly adjustable.
The tool holder may be supported at the pivotable arm and may be provided with a sensor, whereby the wheel brush is arranged such that brush elements thereof extend outwardly beyond a working range of the sensor. The sensor may be connected to a control device for actuating the servo device such that when a displacement of the sensor occurs the wheel brush assumes an operating position.
It is expedient that the wheel brush is fixedly connected to the tool holder. The brush elements of the wheel brush may be arranged parallel to the soil tilling tools.
In another embodiment it is possible that the wheel brush is arranged eccentrically relative to the tool holder at an outer portion thereof in a rotatable manner and is drivingly connected to the tool holder.
For the driving connection between the wheel brush and the tool holder a chain drive or a belt drive may be provided.
In a preferred embodiment the wheel brush is a disk to which at least one radially extending rod or strip is connected to form the brush elements, whereby the rod or strip is elastically deformable in a circumferential direction of the disk and is made of a whether-resistant plastic material. It is expedient that the rod or strip is bent in the circumferential direction.
When a brush roller is provided it is expedient that the brush roller is connected to a shaft that is tilted in an outward direction relative to a direction of travel of the tilling machine. The shaft of the brush roller may be driven by a hydraulically actuatable rotation motor.
It is furthermore possible that the brush roller is directly connected to the tool holder or is arranged at a supporting device connected to the tool holder. The supporting device may be in the form of a pivotable arm.
In a preferred embodiment the brush roller is arranged at a lever that is supported at the pivoting arm, whereby the lever is pivotable in a controlled manner by a servo device. The lever may be pivotable about an axis in the form of a shaft of the tool holder. Furthermore, it is possible that the brush roller is arranged at a slide that is supported at the pivoting arm, whereby the slide is adjustable in a controlled manner by a servo device and is radially outwardly adjustable.
It is preferable that the tool holder is supported at the pivoting arm and is provided with a sensor, whereby the brush roller is arranged such that brush elements thereof extend outwardly beyond a working range of the sensor. The sensor is connected to a control device for actuating the servo device such that when a displacement of the sensor occurs the brush roller assumes an operating position.
It is expedient that the brush roller is formed by a plurality of rubber flaps that are connected with one end thereof to a drivable shaft.
With a soil tilling machine according to the present invention in which disk-shaped at least two soil tilling tools are provided at a driven tool holder and are arranged on a shaft tilted relative to the soil to be tilled, a clean and efficient soil tilling is possible without tearing or pulling out soil parts and rocks and throwing them into the air. The soil tilling tools are rotating about the axis of rotation of the tool holder and are also freely rotatable about their own shafts so that an intensive and uniform tilling of the soil at a constant tilling depth is ensured. The soil tilling tools rotate against the direction of rotation of the tool holder along the soil so that soil parts and rocks are not carried away with the soil tilling tools. The soil surface is thus cut open by the soil tilling tools in their respective working range so that weeds to be removed are cut below the soil surface in a reliable manner without roots of cultivated plants being damaged. Within the rear portion of the tilling machine the soil is smoothed by the soil tilling tools.
Since the disk-shaped soil tilling tools are not forcedly driven their wear is very low. Due to the rolling movement on the soil surface different sections of the tools are engaged by the soil so that the wear is thus evenly distributed over the circumference of the tool, respectively, the tool is actually automatically sharpened. Furthermore, damages to the tools are almost entirely prevented since the tools are rolling along rocks or similar obstacles so that an uninterrupted operation over an extended period of time may be ensured.
Furthermore it is advantageous that due to the tilt of the tool holder in the direction of travel the tools exert a pulling force so that thereby they will dig into the soil to thereby further improve the soil tilling. Since the soil tilling tools themselves are not driven rocks and soil parts may not be torn from the soil and thrown into the air so that no particular measures must be taken to prevent accidents caused by flying rocks or soil parts. It is especially advantageous that the drive power of the tool holder is substantially reduced, although, high tilling speeds, even under differing soil conditions, are still possible. Furthermore, root sections, weeds and grass are not carried along by the soil tilling tools so that clogging within the tool holder is prevented. The inventive soil tilling device thus provides, despite a minimal constructive expenditure and a low drive power, a simple handling and a sufficient soil tilling, especially within orchards and vegetable cultivations as well as in berry plantations.
When in the inventive embodiment a cleaning tool in the form of a wheel brush or a brush roller is provided it is furthermore possible within a single working process to perform the soil tilling and, at the same time, to feed grass, which is located between tree trunks or other obstacles or is positioned close to obstacles, to the soil tilling device and to thereby mow the grass. Furthermore shoots that are growing within the lower sections of a tree may be removed with the aid of the cleaning tools. Thus any manual follow-up labor is entirely eliminated. Since the cleaning tool may be installed and used only when needed it is not subjected to a high wear.
BRIEF DESCRIPTION OF THE DRAWINGS
This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying drawings, in
FIG. 1 shows a tractor with a connected soil tilling device in a plan view;
FIG. 2 shows the soil tilling device according to FIG. 1 in an enlarged side view;
FIGS. 3-5 show an axial cross-sectional view of the tool holder of the soil tilling device according to FIG. 1 in various embodiments;
FIG. 6 shows a tool holder with pivotably connected soil tilling tools in a plan view;
FIG. 7 shows a detail of the tool holder according to FIG. 6 in a side view;
FIG. 8 shows a tool holder with soil tilling tools at various rotational levels of the tilling device;
FIG. 9 shows a cross-sectional view along the line IX--IX of FIG. 8;
FIG. 10 shows a soil tilling machine having a plurality of laterally staggered tool holders in a plan view;
FIG. 11 shows a soil tilling device that is usable as a lawn mower in a longitudinal cross-sectional view;
FIGS. 12-16 represents various embodiments of the soil tilling tools in a plan view;
FIG. 17 shows, in a plan view, a tool holder that is connected to a pivoting arm and is provided with soil tilling tools, further having a wheel brush as a cleaning tool;
FIG. 18 shows a soil tilling device according to FIG. 17 in an axial cross-sectional view; and
FIG. 19-20 show the soil tilling device according to FIG. 17 with a pivotably arranged wheel brush, respectively, a radially adjustable brush roller as cleaning tools.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention will now be described in detail with the aid of several specific embodiments utilizing FIGS. 1 through 20.
The soil tilling device 1 represented in FIG. 1 is connected to the rear end of a pulling vehicle 2 in the form of tractor, or as can be seen in the dash-dotted lines of the figure, at its front end and serves to till the soil B intensively and uniformly. A support frame 21 is supported at the tractor 2 by a holding means 4 which may be laterally displaced by a cylinder 9. The support frame 21 is provided with the tool holder 22 which carries the soil tilling tools 25. The tool holder 22 is driven by the gear box 7 and drive shaft 6 of the tractor 2 and is drivingly connected via a belt drive 8 which drives a pulley 15 that is positioned on a shaft 11. Via a further belt drive 30 the drive power is transmitted to a pulley 29 which is positioned at the tool holder 22 and is in a driving connection therewith. Assisted by a cylinder 10 the soil tilling device 1 which is connected to the vehicle frame 3 of the tractor 2 and which is supported by a wheel 5 may be pivoted sideways to a varying degree.
The soil tilling device 1, as can be seen in detail in the FIGS. 3 to 5, is comprised of two or more soil tilling tools 25 that are distributed over the circumference of the tool holder 22 at a uniform distance. The soiling tilling tools 25 are disk-shaped and are supported at a respective shaft 24 which is tilted relative to the axis of rotation A of the tool holder 22. A pyramid-shaped support 23 is provided for supporting the shafts 24 and is welded to the tool holder 22. The shafts 24 are provided with a respective collar 34 and are supported in a rotatable manner by a bearing 36 at a housing 33, whereby between the housing 33 and the collar 34 a respective soil tilling tool 25 is clamped. The shafts 24 which penetrate the support 23 are secured by snap rings 35.
The tool holder 22 is drivable about its axis of rotation A and is supported in a rotatable manner by a shaft 27, which carries the pulley 29, and ball bearings 28 at the housing 26. The housing 26 is fixedly connected by screw 39 to the support frame 21. Furthermore, the tool holder 22 is provided with a flange 31 to which the support 23 is welded, and a sleeve 32 as a protective measure which is supported at the flange 31. The outer areas of the support frame 21 are provided with chains 37 for covering the soil tilling tools 25. A cover 38 is provided at the support frame 21 for protecting the pulley 29 and the belt drive 30. In order to ensure soil engagement of the tilling tools 25 at a uniform depth of the soil B, an abutment in the form of a gliding disk 42 (see FIGS. 4 and 5) is provided at the tool holder 22. This abutment is height-adjustable and may optionally be in contact with the soil B.
With the embodiment according to FIG. 3, the support 23 is rigidly connected to the tool holder 22 so that the soil tilling tools 25 may not change their position. According to FIG. 4 the individual soil tilling tools 25 are each supported at a respective support 23' which is supported, pivotable about its axis, via a joint bolt 43 at a strap 42 provided at the tool holder 22. When the soil tilling tools 25 hit an obstacle the individual tool 25, as can be seen in the dash-dotted lines of FIG. 4, may optionally give way to the obstacle in an upward direction.
For returning the support 23' into its starting position pressure springs 46 are provided which are supported, on the one hand, at a crosspiece 45 provided at the tool holder 22 and, on the other hand, at the support 23', so that the support 23' is forced towards an abutment 42 provided at the tool holder 22 due to the force of the pressure spring 46 and thereby assumes a defined position.
The soil tilling tools 25 may also be arrested at different angles of tilt relative to the axis of rotation A of the tool holder 22. For this purpose plates 47 are provided at the supports 23' (see FIG. 5) and at the housing 26 of the tool holder 22 laterally extending plates 48 are provided. The plates 47, 48 have corresponding recesses 49. The arresting of the tool 25 in a desired position is simply achieved by inserting a pin 50 into two congruent recesses 49.
When the tool holder 22 of the soil tilling device 1 is driven by the tractor and is thus in rotation, the soil tilling tools 25 which due to the tilted arrangement of the shafts 24, have in their outer sections a respective tilling surface essentially cut the soil surface B without soil parts or rocks being thrown into the air. The soil tilling tools 25 which are rotatably supported at the shafts 24 are moved about the axis of rotation A of the tool holder 22, however, at the soil surface B they roll against the rotating movement of the tool holder so that roots of weeds to be removed are cut below the soil surface, but the loosened soil remains in place and is not removed. Furthermore the loosened soil may be additionally broken into smaller pieces and smoothed by the soil tilling tools 25 which are guided over the loosened soil. An intensive and uniform soil tilling at a uniform tilling depth is thus ensured.
Furthermore, the support frame 21 of the tractor 2 may be tilted in the travel direction F so that, as can be seen in the dash-dotted line in FIG. 2, the axis of rotation A of the tool holder 22 in the direction of travel F (axis A') or against the direction of travel F (axis A") of the tractor 2. For this purpose the vehicle frame 3 is adjustable via two bolts 14 at the guide elements 13 of the tractor 2 and is pivotable about a horizontal axis and adjustable via a servo device 12.
The tool holder 62 according to the FIGS. 6 and 7 is provided with soil tilling tools 65 that are laterally pivotably supported at a support 63. For this purpose an angled carrier element 66 is provided which is pivotable against the force of a spring 68 about a shaft 67 provide at the support 63.
The shafts 64 which support the soil tilling tools 65 are tilted relative to the axis of rotation of the tool holder 62 so that the soil tilling tools 65 form tilling surfaces at their outer areas. Above the carrier elements 66 supporting means in the form of a rotatably supported wheel are provided so that when an obstacle appears within the tilling range of the tool holder 62 the soil tilling tools 65 may be pivoted inwardly due to the pivotable support at the carrier elements 66, as can be seen in the dash-dotted line of FIG. 6
The tool holder 82 represented in FIGS. 8 and 9 is provided with six soil tilling tools 85, 85' whereby diametrically oppositely arranged soil tilling tools are arranged in different levels so that they work in different rotation planes. Thus, three soil tilling tools 85 are in a common rotation plane and three soil tilling tools 85' are in a common rotation plane, with the arrangement of the tools 85 rotated by 60° relative to the arrangement of the tools 85' about the central shaft 87. The housings 86, 86' which receive the shafts 84 thus have a different height so that the distance between the support 83 and the soil tilling tools 85, 85' vary.
According to the embodiment represented in FIG. 10 the support frame 91 is provided with a plurality of tool holders 92, 92', 92", and 92"' which are laterally staggered relative to one another such that their tilling ranges overlap. The soil tilling tools 95 which are connected to a support 93 and are rotatable about a shaft 94 that is tilted relative to the axis of rotation of the tool holders 92, 92', 92", and 92"' are commonly drivable. For this purpose a drive pulley 96 is provided which is drivingly connected to the tractor 2 and is connected via belt drives 97 and 97' with the tool holders 92 and 92". The tool holders 92 and 92" are in return connected via belt drives 98 and 98' with the tool holders 92' and 92"'.
The soil tilling machine 101 which is represented in FIG. 11 may be used as a lawnmower and is essentially comprised of a tool holder 102 to which a pyramid-shaped support 103 is connected which is provided with a plurality of soil tilling tools 105 that are supported on respective shafts 104. The shafts 104, in this embodiment, are tilted relative to the axis of rotation of the tool holder 102 so that the outer sections of the tools form respective tilling surfaces.
The tool holder 102 which is positioned in a housing 106 is driven by a motor 108 that is connected to the housing 106. Furthermore, the housing 106 is provided with a handle 109 and a wheel 110. The tool holder 102 has an abutment in the form of gliding disk 107. The soil tilling device 101 may thus be moved over the soil surface B manually in order to cut grass with the soil tilling tools 105 that are rotatably driven by the tool holder 102, or, when set to a respective tilling depth, may loosen the soil.
FIGS. 12 to 15 show embodiments of the soil tilling tools that may be used with the soil tilling devices according to FIGS. 1 through 11. According to FIGS. 12 and 13 the soil tilling tools 121 respectively 121' are embodied as toothed disks 122 respectively 122', and according to FIG. 14 the soil tilling tool 123 is provided in the form of a disk-shaped knife 124. According to the representations of FIGS. 15 and 16 it is also possible to provide the soil tilling tool 125 respectively 125' in the form of disks 126 to which outwardly extending brushes 127, respectively, spring prongs 128 are fastened.
FIGS. 17 and 18 represent a mower 201 which may be used especially for trimming edges. Here a support frame 202 is provided and has connected thereto a pivoting arm 203 which is provided with a tool holder 204 that has connected thereto disk-shaped soil tilling tools 205. The tool holder 204 is rotatably supported at a shaft 208 and is drivable about an axis A in the direction of the arrow P by a motor 206 and a corresponding belt drive 207.
The pivoting arm 203 is further provided with a sensor 210 that is arranged outwardly of the tool holder 204 and is connected to a control device 211. When the sensor 210 contacts an obstacle H, for example, a tree trunk, it is pivoted towards the center so that the control device 211 activates a servo device 209 via which the pivoting arm 203 and therewith the soil tilling tools 205 of the tool holder 204 are also pivoted inwardly so that damages to the tools 205 resulting from the obstacle may be avoided.
In order to be able to cut the grass between the obstacles H and grass that is located immediately adjacent to those obstacles, a cleaning tool in the form of a wheel brush 221 is provided vertically above the soil tilling tools 205 with which the grass may be fed into the soil tilling tools 205. The brushes 223 of the wheel brush 221 are in the form of elastically deformable rods or straps made from weather-resistance plastic material which are, as can be seen in FIG. 18, connected to a disk 222.
Since the wheel brush 221 is fixedly connected to the tool holder 204 and accordingly rotates together with the tool holder 204 in the direction of the arrow P the grass which is gripped by the brushes 223 is guided in the direction of the disk-shaped soil tilling tools 205 and accordingly may be cut by the tools 205. With a soil tilling device 201 according to the above described embodiment, within one working step the soil tilling within the area designated by the letter C may be activated, and, simultaneously, the cleaning of the area between the obstacles H, designated by the line D, may be cleaned.
The soil tilling device according to FIGS. 19 and 20 represents a mulching device 231 which guides the grass that is positioned between the obstacles H to the soil tilling tools 235 connected to the tool holder 234. For this purpose a wheel brush 251 or a brush roller 261 are provided. The tool holder 234 is connected to a pivoting arm 233 which is fastened in a pivotable manner at the housing 232 of the mulching device 231 and is driven by a belt drive 237. The drive power is transmitted by a rotatably driven shaft 236 to the shaft 238 which is fixedly connected to the tool holder 234 so that the tool holder 234 is drivable in the direction of the arrow P. With the aid of a servo device 239 the pivotable arm 233 is adjustable.
The wheel brush 252 is rotatably supported at a lever 242 which is pivotably arranged at the shaft 238. The pivoting action of the lever 242 is achieved by a servo device 243 which is actuated by a control device 241. The control device 241 is furthermore connected to a sensor 240.
When the sensor 240 is pivoted inwardly due to contact with an obstacle H then the servo device 243 is actuated by the control device 241 so that the lever 242 together with the wheel brush 252 is pivoted into the position indicated as a dash-dotted line in the drawing. The brushes 252 extend beyond the working area C of the tool holder 234 so that with the aid of the belt drive 253 the rotatably driven wheel brush 251 catches the grass that is positioned between the obstacles H and feeds it into the soil tilling tools 235 so that the grass may be cut.
According to FIG. 20 the cleaning tool is in the form of a brush roller 261 which is drivable about a horizontally extending axis b by a motor 263 which is actuatable by a pressure medium, i.e., a well-known rotary motor such as a multi-cell motor or vane-type motor operated by a pressure medium such as hydraulic oil or compressed air is provided. The brush roller 261 is outwardly movable by a servo device 246 in the form of a piston/cylinder arrangement operated by a hydraulic medium. The motor 263 which is connected to the shaft 264, on which the brush elements 262 are fastened, is in the form of a slide 244, whereby at the pivoting arm 233 a guide 245 is provided for receiving the motor 263. The servo device 246 thus can move the slide-shaped motor 263 along the guide 245 into a desired position. A sensor 240 is connected to a control device 241 which upon pivoting of the sensor 240 moves the brush roller 261 with the aid of the servo device 246 into the represented operational position. The brush elements 264 are, in a manner known per se, int he form of flaps made of strips of rubber, leather, or similar materials. The flaps, due to the centrifugal forces generated by rotation, are "stiffened" and provide for a gentle working of the soil.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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A soil tilling device that is pulled by a tractor vehicle comprises at least one tool holder that is supported at a supporting element and is rotatably drivable. At least two circular disk-shaped soil tilling tools are connected to a respective one of the tool holders and are distributed over a circumference of the tool holder at a uniform distance from one another. Each one of the soil tilling tools is connected to a shaft whereby the shaft is supported at a support that is connected to the tool holder. The soil tilling tools are rotatable about an axis of rotation thereof corresponding to the shaft. This shaft is slanted relative to an axis of rotation of the tool holder such that the soil tilling tools have an angle of 20° to 40° to a surface of soil to be tilled whereby circumferential sections of the soil tilling tools form tilling surfaces. With this embodiment it is possible to achieve a clean soil tilling without soil parts or rocks being pulled from the soil and thrown into the air. With the soil tilling tools, which are rotating about the axis of rotation of the tool holder, but are freely rotatable about their shafts, an intensive and uniform soil tilling at a uniform tilling depth is ensured. The soil surface is cut and smoothed by the soil tilling tools which roll on the soil surface opposite to the direction of rotation of the tool holder without damaging roots of cultivated plants.
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BACKGROUND
The present invention relates to devices for securing objects such as utility racks to structures such as vehicles.
Carrying devices are often attached to the exteriors of vehicles for carrying large, bulky, or otherwise awkward objects. Examples of such objects include canoes, kayaks, surf boards, skis and poles, toboggans, snow boards, wheelchairs, bicycles, clam-shell containers for loose objects, and the like. These objects are lashed, clamped, or otherwise affixed to the carrying devices.
Common means of carrying bulky objects include racks, such as utility racks, which are mounted on the roof, side, trunk or bumper of the vehicle. Typically, these racks are removable; i.e., they are not permanently mounted on the vehicle. Vehicles usually do not have any special permanent attachment points or other devices to which a rack may be secured. In fact, owners of vehicles generally do not prefer permanent attachment points or devices because such devices detract from the vehicle's appearance when the rack is removed from the vehicle.
Roof racks are typically releasably attached by hooks or clamps to rain gutters near the edges of the vehicle roof, instead of to permanent attachment points. However, many modern vehicles employ streamlined "Aero Doors" which eliminate the rain gutters commonly found in earlier vehicles. These vehicle designs remove a convenient attachment point. As a result, specially shaped hooks which fit over the edge of the roof of the vehicle and in between the door jamb and the door of the vehicle have been developed. However, many hooks having different sizes and shapes must be provided because of the large variety of vehicle designs. Vehicle designs also change from year to year. Wholesalers and retailers thus have to maintain a large inventory of different kinds of hooks which is updated annually. This usually results in high administrative and engineering costs, and in substantial quantities of unmarketable excess inventory in various kinds of obsolete hooks.
Carriers or racks can also be attached to the trunks of vehicles. These kinds of racks typically carry wheelchairs or bicycles. Their lower position with respect to the ground makes these carriers much more convenient for persons without considerable upper body strength. Such carriers are usually anchored by at least one hook that fits around the edge of the trunk lid. Naturally, the hook must conform to the particular design of the vehicle trunk lid.
A concern of many vehicle owners is that the hooks not scratch the paint finish of the roof, trunk lids, side or bumper of the vehicle. In addition, an installed hook should not allow rain water to leak past the trunk lid or door of the vehicle. The hooks should also be tough enough to be good anchors and to offer theft resistance.
Accordingly, a need exists for a detachable anchor for attachment to structures such as vehicles which: (1) has sufficient strength to secure the carrying device to the vehicle for objects of varying loads; (2) can conform to various shapes of anchor sites on vehicles such as door jambs or the edges of trunk lids; (3) is nondestructive to the vehicle; (4) is streamlined and does not leak water under wet weather conditions; (5) is easily removed from or attached to the vehicle; (6) is inexpensive to manufacture; (7) is easily attachable to a utility rack or other carrying exists for a "universal" anchor that fits a wide variety of vehicle configurations.
SUMMARY
The above-identified needs are met by the present invention. The invention is an anchor for detachably securing utility racks to structures such as vehicles. The anchor comprises a plate which is initially flexible to conform to a desired anchor site, and then subsequently becomes rigid or hardens to retain the shape of the anchor site.
An anchor according to the invention comprises a plate that is conformable from a first configuration into an anchoring configuration which fits snugly into the anchor site. The anchor has attaching means for attaching the utility rack to the anchor, and rigidifying means for
PATENT rendering the anchor substantially rigid and non-pliable in its anchoring configuration.
The rigidifying means can comprise an absorbent layer for receiving hardening material to make the plate rigid. The plate can comprise a plurality of perforated sheets. The perforations allow the hardening material to pass through the plate to better permeate the absorbent layer.
The anchor can have a layer of cushioning material adjacent the vehicle to protect against vehicle damage. It can also have a protective layer between the absorbent layer and the cushioning layer to prevent the hardening material from chemically reacting with the cushioning layer.
The rigidifying means can further comprise preplaced hardening material permeating the absorbent layer and a burstable bladder containing a curing agent adjacent the absorbent layer. When the bladder bursts and the curing agent is released into contact with the hardening material, the anchor becomes rigid. An alternative rigidifying means comprises an opening in the anchor for receiving an injection instrument which injects activated hardening material into the anchor through the opening to permeate and harden the absorbent layer.
The attaching means can comprise a slot formed in the plate. If the utility rack is attached to the anchor by a strap, the strap can be connected to the anchor by passing the strap through the slot.
An anchor according to the present invention is installed by conforming the anchor from its initial pliable configuration into an anchoring configuration which fits snugly into the anchor site. The anchor is then hardened by injecting activated hardening material into the anchor while the anchor is in its anchoring configuration, or by bursting a bladder filled with the catalyst hardening chemical to mix it with the hardenable material to form the hardening material. The anchor can also be hardened by exposing a suitable hardening material to heat or ultra violet light. The anchor then becomes substantially rigid and non-pliable in its anchoring configuration.
Important features of the invention have been outlined very broadly. Additional features of the invention will be set forth below.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a perspective view of the roof of a vehicle on which is mounted two utility racks attached to anchors constructed according to one embodiment of the invention;
FIG. 2 is a perspective view of the rear portion of an automobile with a bicycle carrier held in position by straps attached to anchors constructed according to a second embodiment of the invention;
FIG. 3 is a plan view of a utility rack mounted on the roof of an automobile (shown in phantom) and attached to anchors constructed according to the embodiment of the invention shown in FIG. 1;
FIG. 3A is a vertical cross-section of an anchor constructed according to the embodiment of the invention shown in FIG. 1 attached to the roof of an automobile of the type having "Aero Doors";
FIG. 4 is a perspective view of an anchor constructed according to the embodiment of the invention shown in FIG. 1;
FIG. 5 is a cross-sectional view of the anchor shown in FIG. 4 taken along line 5--5 in FIG. 4;
FIG. 6 is an exploded view of the anchor shown in FIG. 4;
FIG. 7 is a cross-sectional view of the anchor shown in FIG. 4 taken along line 7--7 in FIG. 5;
FIG. 8 is a perspective view of a hardened anchor according to the embodiment of the invention shown in FIG. 4;
FIG. 9 is a perspective view showing one means for hardening an anchor such as the anchors shown in FIGS. 1 and 2;
FIG. 10 is another perspective view showing an alternate means of hardening an anchor such as the anchors shown in FIGS. 1 and 2;
FIG. 11 is a perspective view showing a third means for hardening an anchor such as the anchors shown in FIGS. 1 and 2; and
FIG. 12 is a cross-sectional view of the anchor and a roller as shown in FIG. 11 taken along line 12--12 in FIG. 11.
DESCRIPTION
Referring now to FIG. 1 in the drawings, two utility racks 10 are attached to the roof 150 of a vehicle 20. Each utility rack 10 has a carrier bar 30 extending substantially across the roof 150 of the vehicle 20. The vehicle 20 can be an automobile, truck, watercraft, aircraft or the like, although the description below will be given in the context of the automobile 20 shown in the drawings (particularly FIGS. 1 and 2). Indeed, this invention permits the attachment of utility racks to almost any structure having access means for opening and closing the structure, such as a door, hatch or trunk lid. A "utility rack" generally is any device used for supporting objects on such a structure.
Straps 50 secure the carrier bars 30 to anchors 60. The straps 50 are preferably constructed of a flexible but tough and difficult to cut material such as webbing made of an aromatic polyamide fiber (such as KEVLAR® aromatic polyamide fiber available from DuPont de Nemours and Co.), stainless steel strips, aluminum alloy strips or the like. The anchors 60 wrap around and gain a purchase on the rim 154 of the roof 150 of the vehicle 20.
The anchors 60 are initially flexible strips which fit between doors 70 and the corresponding door jambs 72 of the vehicle and are hardened in place, as described below.
FIG. 2 shows another application of an embodiment of the invention. A bicycle rack 80 rests on the trunk lid 110 of an automobile. The bicycle rack 80 is secured by the straps 52 to the anchors 62. The anchors 60 bend around the edge of the trunk lid 110 and therefore fit between the trunk lid 110 and a seat (not shown) for the trunk lid 110. A tightener 100 shortens one of the straps 52 in order to hold the bicycle rack 80 in place against the trunk lid 110.
FIG. 3 shows the utility rack 10 in position on the roof 150 of the vehicle 20. The vehicle 20 is shown in phantom. The anchors 60, after being hardened in place, conform to the shape of the juncture between the door jamb 122 on the one side and the door frame 120 and the door seal 140 on the other side. The snug fit of the anchors 60 to the door frame 120 provides a secure attachment to the vehicle. In addition, the anchors 60 are sufficiently thin to not interfere with the functioning of the seal 140 or the door frame 120, and do not cause leaks of water under wet weather conditions or wind noises. The anchors 60 are also easily removed from the vehicle when the doors are opened and the tension in the straps 50 is released.
FIG. 3A shows how the anchor 60 is mounted on a vehicle having "Aero Doors." Such vehicles do not have external rain gutters; instead, a soft elastic seal 142 containing a trough 143 is attached to the door jamb 122 of the vehicle 20. The door 70 fits against the seal 142. The trough 143 in the seal 142 carries rain water away from the door 70.
The anchor 60 conforms to the seal 142 and wraps far enough around the door jamb 122 to gain a solid purchase, even though the anchor 60 does not touch any solid parts of the roof 150 or the door jamb 122.
FIG. 4 is a perspective view of an anchor of the embodiment of the invention shown in FIG. 1. FIGS. 5, 6, and 7 show details of its construction. A flexible plate 160 is formed from at least two plate sheets 162 of strong and flexible material such as KEVLAR® aromatic polyamide fiber webbing, soft aluminum alloy, brass shim stock, or flexible stainless steel. Two or more sheets are provided in this embodiment of the invention in order to provide the resulting laminated structure with sufficient strength to secure the anchor to the vehicle when the anchor 60 is hardened into its final shape. In some applications, a single plate sheet, or even the absence of a plate sheet, can work where the plate and/or the hardening agent in the anchor 60 provide sufficient rigidity. A generally rectangular slot 170 perforates a first end 166 of the flexible plate 160 in order to provide a means for attachment to the strap 50, which is connected in turn to the utility rack 30. The straps 50 also can be attached to the flexible plate 160 by D-rings, rivets, hooks, and the like. The flexible plate 160 can be formed as an integral extension of a strap 50, in which case the strap 50 is inherently attached to the flexible plate 160.
Most of the flexible plate 160 is sandwiched in two cushion sheets 180 in order to protect the anchor site from damage and to cooperate with vehicle door and hatch seals, as described below. The cushion sheets 180 are preferably formed of a soft and resilient cushioning material, such as neoprene synthetic elastomer. This material is usually available in stores carrying marine products because it is often used in patching rubber wet suits. Other acceptable materials for the cushion sheets include soft synthetic or natural rubber or similar material. The desired properties for a cushion sheet material are abrasion resistance, water tightness, flexibility, and the ability to easily conform to a variety of shapes.
The cushion sheets 180 are sealed to each other or to the flexible plate 160 to form a cushioning layer around the anchor. The region of the seal in FIG. 4 is indicated by reference numeral 182 and the interior boundary of the seal is indicated by reference numeral 184. The seal is formed by the use of an adhesive, such as rubber cement available at many hardware stores under the trademark SUPER 77 from 3M Company in Minneapolis, Minn. Other rubber cements sold under the 3M trademark by the 3M Company can also be used. It is also possible to form an appropriate seal by a heating process which melts the sheets 180 together, but this method is usually more expensive than applying an adhesive.
An absorbent layer or strip of matting 200 is doubled and folded through a slot 202 which perforates the flexible plate 160 perpendicular to the main dimension of the plate and close to slot 170 in the first end 166 of the plate 160. The doubled matting strip 200 is therefore double-layered on both sides of the flexible plate 160. The purpose of the absorbent layer or matting strip 200 is to serve as a matrix for hardening material. The matting 200 thus comprises a rigidifying means for the anchor 60. The matting strip 200 can be made of woven fiberglass cloth, but can be made of other kinds of fibers having sufficient tensile strength and which can be woven or pressed into batts. Woven fiberglass cloth sold by the Owens Corning Fiberglass Company under the trademark WOVEN ROVING can be used. Such material can be found at many boat repair shops and at many marine and automotive body shops. The hardening material is preferably epoxy resin, as discussed below.
Protective sheets 190 are located between a matting strip 200 and the cushion sheets 180. A useful material for the protective sheets 190 is polyethylene. The purpose of the protective sheets 190 is to prevent hardening material in the matting strip 200 from contacting and having an unfavorable chemical reaction with the material of the cushion sheets 180.
The layers 160, 180, 190 and 200 of the anchor 60 together form a support 204 for supporting the rack 10 on the vehicle 20. The support 204 in its first configuration is sufficiently pliable, flexible and thin to change shape to conform to an anchoring configuration (for example, the shape shown in FIG. 8) in which the anchor 60 hardens so as to form a substantially rigid and non-pliable anchor support for the rack 10.
FIGS. 5, 6, and 7 depict the laminated construction of the anchor 60. The cushion sheets 180 surround as much of the flexible plate 160 as needed to prevent damage to the finish of the anchor site and any adjacent components such as doors or trunk lids. The flexible plate 160 itself is constructed of three plate sheets 162. Two plate sheets can also be provided, instead of three as shown in FIG. 6. However, the use of three sheets usually provides greater rigidity for the hardened anchor 60. The plate sheets 162 are not attached to each other except at the end 166 of the flexible plate 160 which contains the slot 170.
The plate sheets 162 are perforated by a plurality of holes 164. The purpose of the holes 164 is to permit hardening material to penetrate the plate sheets 162 and to spread throughout interior portions of the anchor 60.
Once the hardening material has hardened, the flexible plate sheets 162 are fixed together, providing a laminated rigid structure which has the strength properties of the combined thicknesses of the metal plates 162 plus the matting strip 200 and the hardening material. The completed anchor 60 thus has the rigidity and strength to be a good anchor, while having an anchoring configuration fitting the anchor site, as described below.
In an alternative structure of the anchor 60, the support normally provided by the plate sheets 162 can be formed solely by the matting 200 having suitable tensile strength to secure the anchor to the anchor site after the anchor hardens. Hardening material could then be added to the matting 200 in order to rigidify the anchor 60. Hardening material can be injected into the matting 200 or previously incorporated into the matting 200 at the time of manufacture to be activated later as described below.
Useful approximate dimensions for the anchor 60 are a length of 8 inches, a width of 2 inches, and a thickness of not more than 1/4 inch. The matting strip 200 is approximately slightly less than 24 inches long. The strip 200 is folded once to double it and then inserted half way through the slot 202 in the flexible plate 160 and folded again at the slot 202. The total length of the flexible plate 160 contacted by the matting strip 200, on either side, is about 6 inches.
In the embodiment of the invention shown in FIG. 6, the cushion sheets 180 form approximately fifty percent of the thickness of the anchor 60, or approximately 1/8 inch in total thickness. The total thickness of the plate sheets 162 forms less than about ten percent of the thickness of the anchor 60. The remaining thickness of the anchor 60 is provided by the combined thicknesses of the matting strip 200 and the protective sheets 190.
The anchor 60 is initially flexible so that it can conform to the contours of the door jamb, hatch, trunk lid, or other component (anchor site) of the vehicle or other structure that the anchor 60 is to hook against. Thus, a user can place the anchor 60 between a door 70 and a door jamb 122 of a vehicle and simply shut the door, as shown in FIGS. 1, 3, and 3A The anchor 60, because of its flexibility, conforms to the juncture between the door and the door jamb. The anchor 60 is sufficiently thin so as not to disrupt the seals between the door and door jambs of the vehicle, thus avoiding water leaks and wind noises.
FIG. 8 shows the anchor 60 already formed into the shape it might have to assume in order to fit between a door 70 and a door jamb 122 of the vehicle. Another possible site for the anchor is the lid 110 of a trunk, as shown in FIG. 2. The anchor 60 is placed around the edge of the lid 110 and the trunk lid 110 is closed, trapping the anchor 60 between the lid of the trunk and its seat.
The anchor 60 must then be hardened so as to retain the appropriate shape. In one embodiment of the invention, epoxy resin or a similar hardening material impregnates the matting strip 200 and penetrates between the plate sheets 162 via the plate sheet holes 164. An acceptable epoxy resin is made by the Devcon Company and is sold under the trademark DEVCON Five-Minute Epoxy, in many hardware and auto supply stores. When this material is hard, the anchor 60 is permanently hardened into whatever shape the anchor 60 had at the time of hardening.
The hardening means for hardening the anchor can be provided by alternative means. Activated resin or other activated hardening material can be injected into the matting strip 200 when the anchor 60 is to be hardened. Alternatively, non-activated hardenable material, such as non-activated resin, can be added to the matting strip 200 when the anchor 60 is first constructed, and later activated so that it will cure and harden. In this case, some activating means, such as one of those illustrated by FIGS. 9 and 11, must be provided for subsequently activating the resin.
In FIG. 9, the anchor 60 is manufactured with the hardening material (e.g., resin) already impregnating the matting strip 200. This kind of hardening material hardens upon exposure to heat. In one application, the user simply dips the anchor 60 in hot water (contained in pot 210). This activates the hardening material in the anchor 60 and the material gradually becomes rigid. The anchor 60 is immediately placed in an appropriate anchor site on the vehicle, whether between a door and a door jamb, between a trunk lid and the trunk lid seat or some other location, as shown in FIGS. 1, 2, 3, and 3A. One end of the anchor is folded over a hard point or ridge of the anchor site in order to provide positive anchoring later on. The user then waits for the material in the anchor 60 to harden as it cools.
The hardening material can also be of the kind which hardens upon exposure to ultra violet (UV) light. The non-activated hardening material is pre-placed in the anchor when it is manufactured and UV light is applied to the anchor for sufficient time to harden the anchor in its anchoring configuration. This alternative has the disadvantage of not being as practical for those lacking a UV light source.
In FIG. 10, the hardening material is epoxy resin which is injected by an injection instrument such as a syringe 140 into the opening 192 in the anchor 60 between the protective sheets 190 and the cushion sheets 180. An opening 192 of about one-quarter inch can be used. As explained above, DEVCON Five-Minute Epoxy resin, which comes in a package containing two chemicals which are mixed together to create the hardening resin, can be used as the hardening material. Other hardening materials, such as those which harden upon exposure to air, can also be used. However, air-activated hardening materials tend to cure more slowly than hardening materials which are combined with a chemical curing agent. The anchor 60 is massaged to spread the resin through the holes 164 in the plates 162 (see FIG. 6) and into the fiberglass matting 200 on both sides of the plates 102. The anchor 60 is then pressed into its position on the vehicle and allowed to harden. The anchor 60 can be covered with a plastic covering, such as a bag made of polyurethane, before the anchor 60 is pressed into position on the vehicle so that excess resin does not ooze from the anchor 60 onto the vehicle when it is conformed to the anchoring configuration. After the anchor 60 hardens, the plastic covering can be peeled off the anchor 60, and any excess resin extending from the opening 192 can be cut away.
In FIG. 11, an anchor 60 is illustrated with the same layers of material as the anchor 60 shown in FIG. 6, except the absorbent layer 200 is impregnated with a non-activated epoxy resin or other hardening material when the anchor 60 is manufactured. As is best seen in FIG. 12, bladders 260 containing a curing agent such as a catalyst hardening chemical 250 are placed on either side of the anchor 60 between the doubled matting strip 200 and the protective sheet 190. Later, a roller 220 is pressed against the anchor 60 and rolled back and forth in order to burst the bladder 260 on either side of the anchor 60. This releases the curing agent 250 from the bladders 260 so that it mixes with the resin in the matting strip 200, thereby forming activated resin or hardening material which eventually hardens the strip 200. The user then places the anchor 60 into its position on the vehicle or other structure and allows the anchor 60 to harden. The kind of curing agent that can be injected, as described above in connection with FIG. 10, can be used. For example, the catalyst hardening chemical included with the product sold under the name DEVCON Five-Minute Epoxy resin can be placed in the bladder 260 with the non-hardened, non-activated resin pre-placed in the matting strip 200.
No matter how activated resin is introduced into the anchor 60, the process is essentially the same: the anchor 60 hardens after the anchor is shaped to conform to the selected anchoring site. This results in an anchor that is suitably shaped to the appropriate anchoring position on the vehicle.
The invention, therefore, provides an anchor that is initially flexible, conforms to any vehicle seal and door configuration, permanently hardens in the desired shape easily and quickly, is strong enough to securely hold the utility rack to a vehicle, is streamlined and does not leak water under wet weather conditions, is non-destructive and does not require permanent installation means in the vehicle, is easily removed or attached to the vehicle, is inexpensive to manufacture, offers theft resistance, and is easily attached to the rack.
Thus, an anchor for a utility rack for a vehicle is provided. Those skilled in the art will appreciate that an anchor according to the present invention may be designed using other structures. The claims, therefore, should be regarded as including equivalent constructions as do not depart from the spirit and the scope of the invention, which is intended to be defined by the appended claims.
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An anchor for detachably securing utility racks to vehicles is provided. A plate made of a strong and flexible material such as stainless steel, aluminum, or synthetic aromatic polyamide is slotted on one end or otherwise provided with means for attachment to the utility rack. A substantial part of the plate is surrounded by fiberglass cloth sheeting contained within a cushioning neoprene envelope and an intermediate polyethylene resin barrier. A thin cushioning layer of neoprene rubber envelops the plate, fiberglass cloth sheeting and polyethylene barrier. Activated resin is introduced into the fiberglass cloth sheeting or a hardening material already in the fiberglass sheeting is activated. The activated resin in the anchor is allowed to harden while the anchor is in a configuration which conforms to an anchor site between a door and a jamb of the vehicle, or at some other location on the vehicle. A permanent, hardened, custom-fitted, and cushioned anchor is provided.
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FIELD OF INVENTION
[0001] The invention is related to the wireless communication engineering, and more particularly related to the technique for automatically selecting a communication band and mode in the field of mobile communication.
BACKGROUND OF THE INVENTION
[0002] For a wireless communication device, like a portable or handheld communication device, such as a mobile phone, Personal Digital Assistants (PDA) or smart phone, manufacturers usually have to emphasize the “standby time” and “talk time” of their products to attract the potential buyers. This is because the space the batteries occupy is indirectly affected as mobile communication devices reducing their sizes for portability. Therefore, besides developing new-typed batteries how to reduce the power dissipation becomes very important with limited battery space.
[0003] Referring to FIG. 1 , it illustrates a block diagram of a conventional communication device 100 . The communication device 100 comprises an antenna 102 , a Radio Frequency (RF) transceiver 104 , an analog base band processor 106 , an application processor 108 , a memory 110 and an I/O interface 112 . Taking a Global System for Mobile communications (GSM) mobile phone for example, the application processor 108 generates a registration signal passing through the analog base band processor 106 , the RF transceiver 104 and the antenna 102 in turn and then transmitted to a base station nearby to perform the location registration procedure when a user pushes the power-on button on the I/O interface 112 . The registration signal is subsequently forwarded to a Visitor Location Register (VLR) via the Base Station Controller (BSC), so that the communication network system can acquire the current location information of the communication device 100 , and then the talk function of the communication device 100 is able to work.
[0004] For multi-band, multi-mode wireless communication devices, such as dual-band, tri-band or quad-band mobile phones that advertised for international roaming convenience, they scan operable bands and modes first to find an available service network and perform the location registration procedure. Referring to FIG. 2 that states the operating processes when a conventional tri-band mobile phone is powered on. After the mobile phone is powered on (step 202 ), the mobile phone searches for the first frequency band first (step 204 ), and if the searching succeeds (step 206 ), the mobile phone sends a network registration signal by using the first frequency band (step 208 ), and if the network registration succeeds (step 210 ), the talk function of the mobile phone is enabled (step 212 ) and then ends (step 232 ). Backing to the blocks (step 206 ) and (step 210 ), if the searching or registration doesn't succeed, the mobile phone searches for the second frequency band (step 214 ), and if the searching succeeds (step 216 ), the mobile phone sends a network registration signal by using the second frequency band (step 218 ), and if the network registration succeeds ( 220 ), the talk function of the mobile phone is enabled (step 212 ) and then ends (step 232 ). Backing to blocks (step 216 ) and (step 220 ), if the searching or registration doesn't success, the mobile phone searches the third frequency band (step 224 ), and if the searching successes (step 226 ), the mobile phone sends a network registration signal by using the third frequency band (step 228 ), and if the network registration successes (step 230 ), the talk function of the mobile phone is enabled (step 212 ) and then ends (step 232 ). Backing to block (step 226 ) and (step 230 ), if the searching or registration doesn't succeed, the mobile phone stops the network searching since no service network is available (step 222 ) and then ends. It is noted from above recitations, when a communication device is scanning available service network, it consumes more power than other common operation from the processes above, that is, comparing to making a call if the mobile phone has already connected to the service network, the searching processes may consume much more battery power.
[0005] Furthermore, the scanning processes may be skipped if the user sets up the communication bands and modes used in that communication region the user located by himself/herself, but it requires the user to have knowledge of the communication bands and modes used in that region first. For example, 900 MHz and 1800 MHz are used in Europe region while 850 MHz and 1900 MHz are used in North America for GSM system. Besides, 2100 MHz is used in Europe and pan-Asia region while 850 MHz and 1900 MHz are used in North America, and 1700 MHz will be used in Japan in the future for WCDMA system. Asking users to memorize these complicated system specifications is unfriendly.
[0006] Therefore, there is a need for a device and method for automatically helping users select a communication band and mode without scanning the bands and modes.
SUMMARY OF THE INVENTION
[0007] One aspect of the present invention provides a wireless communication device for automatically selecting a communication band and mode, comprising: a Global Positioning System (GPS) module for obtaining a position of the wireless communication device; a memory module having a database, the database storing a plurality of regions, each with a corresponding communication band and mode; a processing module in connection with the GPS module and the memory module, the processing module utilizing the position and the database to select a band and a communication mode used in that position; and a mobile telecommunication module in connection with the processing module, the mobile telecommunication module utilizing the selected communication band and mode to send a registration signal.
[0008] Another aspect of the present invention provides a method for a wireless communication device automatically selecting a communication band and mode, the wireless communication device supporting a GPS system and having a database, this method comprising the following steps: (a) obtaining a position of the wireless communication device from the GPS system; (b) querying the database based on the position to select a communication band and mode used in the position; (c) utilizing the selected communication band and mode to send a registration signal of the wireless communication device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 shows a block diagram design of a conventional communication device.
[0010] FIG. 2 shows the operating processes of a tri-band mobile phone when the mobile phone is powered on.
[0011] FIG. 3 illustrates a wireless communication device for automatically selecting a communication band and mode in accordance with one embodiment of present invention.
[0012] FIG. 4 illustrates a method for a wireless communication device automatically selecting a communication band and mode in accordance with one embodiment of present invention.
DETAILED DESCRIPTION
[0013] A device and method for automatically selecting a communication band and mode is disclosed. In the following, the present invention can be further understood by referring to the exemplary, but not limiting, description accompanied with the drawings in FIG. 3 and FIG. 4 .
[0014] Referring to FIG. 3 , a wireless communication device 300 for automatically selecting a communication band and mode in accordance with one embodiment of present invention is disclosed. The wireless communication device 300 includes a GPS module 302 , a memory module 308 with a database 310 , a processing module 306 , and a mobile communication module 304 . The GPS module 302 can receive signals from satellites in the space. When receiving signals from three different satellites, the GPS module 302 can get the longitude and latitude (2D) position by calculation, and when receiving a signal from a fourth satellite, it can further get the altitude (3D), and when receiving signals form the 5 th , 6 th satellites and so on, the precision of the position is enhanced. Generally speaking, whenever and wherever on earth at least four satellites provide GPS signals in the space at the same time, so when the wireless communication device 300 is powered on, the GPS module 302 can be used to provide the current position of the wireless communication device 300 . In addition to obtaining the position of the wireless communication device 300 , it still needs to know what band and mode to be used in this position. Thus the invention also provides a database 310 within the memory module 308 , and the database 310 stores a plurality of communication regions, each with a corresponding communication band and mode. That is, after the GPS module 302 obtains the position of the wireless communication device 300 and notifies the processing module 306 , the processing module 306 selects a band and mode used in this position by querying the database 310 . Thus the mobile communication module 304 , such as the structure shown in FIG. 1 , may send a registration signal by using the selected band and mode. However, it should be noticed that the processing module 306 is expressed as one module just for simplicity, and in other embodiments, the processing module 306 may be integrated or incorporated into the mobile communication module 304 or the GPS module 302 .
[0015] In some embodiments, the memory module 308 further includes a function of recording the positions at which the wireless communication device 300 had roamed. For example, the wireless communication device 300 can use the last position or previous times positions where the wireless communication device 300 is powered on as references for querying the database 310 to facilitate various algorisms application. And, in some embodiments, the database 310 not only stores bands and modes used in different regions but also stores bands and modes used by different service network providers in the same region. Moreover, in some embodiments, the wireless communication device 300 further includes a function of updating the database 310 .
[0016] Referring to FIG. 4 , it illustrates a method for a wireless communication device automatically selecting a communication band and mode in accordance with one embodiment of present invention. First, a wireless communication device is powered on (step 402 ), and then the GPS obtains the position of the wireless communication device (step 404 ), and the wireless communication device queries a database to select a band and mode used in this position subsequently (step 406 ), and the wireless communication sends a registration signal by using the selected band and mode (step 408 ), and then ends (step 410 ).
[0017] The present invention has been described above with reference to preferred embodiments. However, those skilled in the art will understand that the scope of the present invention need not be limited to the disclosed preferred embodiments. On the contrary, it is intended to cover various modifications and equivalent arrangements within the scope defined in the following appended claims. The scope of the claims should be accorded the broadest interpretation so as to encompass all such modifications and equivalent arrangements.
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A wireless communication device and method for automatically selecting a band and mode is provided. Utilizing the global positioning system to obtain the position of the wireless device for simplifying the process of searching service networks and reducing power consumption. Furthermore, a method for a wireless communication device to automatically select a band and mode is also provided.
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FIELD
The present invention relates to illumination. In particular, the invention relates to devices for producing a light pattern with an even color distribution. More specifically, the invention relates to an optical surface according to the preamble portion of claim 1 .
BACKGROUND
Light emitting diodes, i.e. LED's, have become an increasingly popular source of light for illuminators. The recent developments in LED technology have radically improved the output of the diodes, whereby new application areas have emerged. Indeed, the use of LED's has expanded from the traditional indication purposes to more demanding indoor and outdoor lighting apparatuses.
The improved light output has revealed problems newly associated with LED's. One particular issue is the color distribution in the produced light patter. Color distribution was never considered an issue with traditional LED's because they had relatively low light output. With modern LED's with high light output, however, the distribution of color is a concern as LED's are used to illuminate large areas in indoor lighting, for example. The issue is emphasized when using separate LED's for particular wavelength bandwidths. In indoor lighting applications, for example, it is common to use one LED for each primary color, i.e. three LED's for red, green and blue, respectively. In such a multi-source illuminator it is common that the colors are clearly distinguishable in the light pattern produced, which is not desirable when pursuing light with uniform color.
For managing the color distribution, various solutions have been proposed. An established solution for managing the color distribution of illuminators with an LED light source is to use a plurality special lenses, the incident surfaces of which have been treated such to mix different wavelengths produced by the LED into a light pattern which contains all wavelengths evenly distributed across the pattern.
Another solution is proposed by US 2011/0018016 A1 which discloses an optical surface for producing a desired color pattern. The optical surface according to US 2011/0018016 A1 features a plurality of bulges which extend from an otherwise planar emission surface of a lens. The bulges are used to converge light beams refracting from the emission surface of the lens for controlling the color pattern produced.
The optical surface as proposed by US 2011/0018016 A1 is mainly suitable for controlling the angular color distribution pattern, which does not address the issue of mixing different wavelengths produced by the LED into a light pattern which contains all wavelengths evenly distributed across the pattern.
It is therefore an aim of the present invention to provide an optical surface which when used as an emission surface or as a portion thereof—is able to mix different wavelengths produced into a light pattern which contains all wavelengths evenly distributed across the pattern.
SUMMARY
The aim of the present invention is achieved with aid of a novel optical surface which extends in at least two Cartesian base dimensions. A cross-section of the surface taken in either of said two Cartesian base dimensions features a first plurality of protuberances which extend to the same direction in a third Cartesian dimension. The cross-section of the optical surface also features a second plurality of protuberances which extend to the opposite direction as the first plurality of protuberances in the third Cartesian dimension. The pluralities of protuberances form converging and diverging optical shapes for mixing different wavelengths scattering from the optical surface.
More specifically, the optical surface according to the present invention is characterized by the characterizing portion of claim 1 .
The aim of the invention is on the other hand achieved with a novel a lens which has such an optical surface, preferably as the emission surface.
Considerable benefits are gained with aid of the present invention. Because the optical surface is provided with both converging and diverging deviations from a planar shape, the light beams exhibiting a certain wavelength are effectively mixed thus producing a light pattern which contains all wavelengths evenly distributed across the pattern. By equipping a lens or a reflector with such a novel optical surface, different colors resulting from defects in a single light source or emitted by a plurality of light sources emitting different wavelengths are effectively mixed thus producing a solid light pattern.
BRIEF DESCRIPTION OF DRAWINGS
In the following, exemplary embodiments of the invention are described in greater detail with reference to the accompanying drawings in which:
FIG. 1 presents a cross-sectional view of an illuminator featuring a lens which has been provided with an optical surface according to embodiments of the present invention,
FIG. 2 presents a detailed top elevation view of an optical surface according to one embodiment of the invention featuring alternating converging and diverging protuberances,
FIG. 3 presents a schematic isometric view of the arrangement of converging and diverging protuberances according to the embodiment of FIG. 2 in a mathematical plane,
FIG. 4 a presents a schematic cross-sectional view of the arrangement of converging and diverging protuberances according to the embodiment of FIG. 2 in a mathematical plane,
FIG. 4 b presents the path of light beams travelling through the arrangement of FIG. 4 a,
FIG. 5 presents a top elevation view of an optical surface according to a second embodiment of the invention featuring converging and diverging protuberances as shown in FIGS. 3 and 4 arranged as alternating groups of three,
FIG. 6 presents a top elevation view of an optical surface according to a third embodiment of the invention featuring converging and diverging protuberances arranged as alternating groups of three without a planar section in between said protuberances,
FIG. 7 presents a schematic isometric view of the embodiment of FIG. 6 in a mathematical plane,
FIG. 8 presents a schematic cross-sectional view of the embodiment of FIG. 6 in a mathematical plane, and
FIG. 9 presents a schematic view of the formation of the base plane according to one approach.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The optical surface 200 herein described may be used to scatter light beams transiting from a lens or a reflector. In this context optical surface is meant to refer to a surface which reflects or refracts light beams without substantial absorption of said beams. In this context the term transit is meant to refer to such interference in the path of radiation which causes the radiation to reflect or refract. FIG. 1 demonstrates an example in which light beams 101 a , 101 b produced by an artificial light source, such as an LED (not shown) travel through an incidence surface of a lens and thus experience a first refraction. The reflected light beams 102 a , 102 b then exit the lens through an emission surface which has been provided with a novel optical surface 200 for producing scattered light beams 103 with mixed wavelengths. Considering the lens example shown in FIG. 1 and the following elucidation about the particulars of the optical surface, one may conceive a respective reflector application for such an optical surface.
FIG. 2 shows a top detail view of the optical surface 200 which features alternating converging and diverging protuberances 201 , 202 . The converging protuberances 201 project from the base surface 203 toward the main radiation direction and are indicated by a downward opening curve. The diverging protuberances 202 are project from the base surface 203 in a direction opposing the main radiation direction and are indicated by an upward opening curve. As is further apparent from FIG. 2 , the protuberances 201 , 202 alternate without overlapping each other and without forming groups of neighboring protuberances of the same orientation, whereby each protuberance 201 , 202 is at least partly separated by a section of the base surface 203 . The separation of each protuberance by a patch of base surface is more visible from FIG. 3 . The protuberances 201 , 202 have a circular or oval shape when examined from an elevated plan view.
The concept of base surface 203 is specified by FIG. 3 which shows a schematic isometric view of the arrangement of converging and diverging protuberances of FIG. 2 . The base surface 203 may be seen as a mathematical plane formed by two Cartesian axes which form the base dimension X, Y of the base surface 203 . Because the base surface 203 has been provided with the deviations discussed here after, the resulting surface is not planar. Nevertheless, in order to be able to describe the reference from which the protuberances are deviating, the term base surface 203 is used as the starting point for said deviations.
That said, the base surface 203 may also be curved (not shown), whereby the resulting optical surface is both curved and provided with protuberances in mutually opposing directions. In this respect, the base surface 203 may be defined as mainly extending in the two main base Cartesian dimensions X, Y while extending to the third Cartesian dimension Z. By mainly extending is meant that the extent to which the base surface 203 extends in the third Cartesian dimension Z is substantially smaller than the two main base Cartesian dimensions X, Y. More specifically, the extension of the base surface 203 in the third Cartesian dimension Z in a given portion of the surface is at most half of that of either extension in the two main base dimensions X, Y. Where the base surface 203 is provided with an equal amount of opposing protuberances 201 , 202 having an equal extension, the base surface 203 may be defined as the continuous surface which would result if the opposing protuberances 201 , 202 would cancel each other out. More specifically, if each protuberance shape extending in one direction would be reverted by a corresponding protuberance extending in the opposing direction, the resulting shape would represent the base surface 203 .
Alternatively, the base surface 203 is defined by a surface continuously connecting the center points of the radii of the protuberances 201 , 202 , which is demonstrated by FIG. 9 . The protuberances 201 , 202 are defined by a radius or radii which has/have a center point. In FIG. 9 said center points are connected by a dashed line. When the dashed connecting lines connected, the resulting surface represents the base surface 203 of the optical surface.
The optical surface depicted in FIGS. 2 and 3 is further clarified by FIGS. 4 a and 4 b which show a schematic cross-sectional view of the optical surface 200 . More specifically, the cross-section of FIGS. 4 a and 4 b is taken along the second base direction Y of FIG. 3 . From the Figures it may be seen that the arrangement of converging and diverging protuberances projecting in opposite directions from the base surface 203 . In the illustrated example the base surface 203 is planar. As described above, the base surface 203 may alternatively be curved (not shown). Projecting from the base surface 203 of FIG. 4 a , namely from the first base dimension X, is a first plurality of protuberances 201 which extend to one direction in the third Cartesian dimension Z, which direction is upward in FIG. 4 . While the first plurality of protuberances 201 are shown to occupy the base surface 203 in the first base direction X, the first plurality of protuberances 201 also occupy the base surface 203 in the second base direction Y as illustrated by FIG. 2 . The same applies to the second plurality of protuberances 202 which extend to the opposing direction in the third Cartesian dimension Z, which direction is downward in FIG. 4 a . FIG. 4 b shows how the upward projecting protuberances 201 converge the light beam 102 , whereas the downward projecting protuberances 202 diverge the light beam 102 , which results in a mixed light pattern 103 .
In the example shown in FIGS. 2 to 4 , the protuberances 201 , 202 projecting to opposite directions from the base surface 203 , are arranged somewhat sporadically in an alternating fashion. It is, however, possible to group up sub-pluralities of protuberances extending in one direction to create a structure demonstrated by FIG. 5 . In the illustrated example protuberances 201 , 202 extending in opposing directions are arranged in groups of three. In such an arrangement each protuberance is directly surrounded by two similar protuberances and four opposing protuberances. By grouping similar protuberances has the additional benefit of avoiding repetitive patterns in the resulting protuberance arrangement. The optical surface 200 preferably includes a similar amount of converging and diverging protrusions 201 , 202 for avoiding aberration in the resulting light pattern.
Another embodiment of arranging the protuberances to the base surface 203 is shown in FIG. 6 . Firstly it may be noted that the protuberances of said embodiment are grouped similarly as presented with reference to FIG. 5 . Secondly it may be noted that in the example of FIG. 6 neighboring protuberances are not separated by a section of the base surface. Such a pattern may be accomplished by providing the protuberances 201 , 202 with polygonal shape. Because similar protuberances are grouped in groups of three, a pattern without separating base surface sections is enabled by a hexagonal shape when examined from an elevated plan view.
A modified embodiment featuring interconnected protuberances 201 , 202 is demonstrated by FIGS. 7 and 8 . Said Figures depict a pattern of circular protuberances 201 , 202 which are interconnected such that the curvature of a previous protuberance is continued by a following protuberance extending in the opposite direction. The benefit of merged protuberances is that all light beams emitted from the optical surface are refracted thus achieving maximum mixing of wavelengths.
The protuberances 201 , 202 capable of achieving the desired effect through converging and diverging refractions or reflections may be provided with various different specifications. The desired effect may be achieved with a variety of different size of lenses and corresponding protuberances. For example, an optical surface having the diameter of 20 mm may be provided with protuberances having a diameter of 0.01 to 1.5 mm. However, if the diameter of the optical surface is enlarged to 100 mm, the diameter of the protuberances could be of the order of 0.01 to 2 mm. In this respect, the mutual size difference of the optical surface and the protuberance may vary greatly. Generally speaking, it is preferably to provide the protuberances as dense as possible of improving the mixing effect. The distance between two neighboring protuberance is therefore preferably less than twice the diameter of the protuberance. The depth of the protuberances is dictated by the reflective properties of the optical surface. Accordingly, the depth of the protuberances ranges from almost planar to a depth which corresponds to the critical angle for total internal reflection. If this depth were to be exceeded, the light beam would reflect to an undesirable direction thus failing to achieve the desired mixing effect.
The optical surface 200 as described above is preferably manufactured in a molding process. The protuberances are therefore established by laser machining the mold surface.
The optical surface 200 may be applied to any structure which transits a light beam. Particular applications for such an optical surfaces are the emission surfaces of lenses and the reflective surfaces of reflectors. It is also to be noted that a combination of optical surfaces in a device may be provided with the protuberances herein described. For example, in a system including two lenses arranged successively, both emission surfaces may be provided with such protuberances, whereas only one TIR surface, i.e. lateral or flanking surface, may be provided with protuberances. The TIR surface—i.e. total internal reflection surface—connects the incidence surface of the lens to the emission surface thereof in an outwardly flaring manner. The idea behind the TIR surface is that the artificial light beam arriving scattered from the reflector and reflecting through the incidence surface is reflected efficiently by the TIR surface for minimizing radiation energy losses.
It is therefore advantageous to use a TIR surface on the flank of the lens. Alternatively, the TIR surface may be parabolic.
Indeed, any of the optical surfaces may be provided with such protuberances; it may be the light incidence surface, TIR surface or the emission surface. Also it is to be noted that the shape of the protuberance need not conform to a mathematical shape but the cross-sectional shape of the protuberance may also be a so called free-form line being sculptured freely.
The optical surface may also or alternatively be a reflecting surface in a reflector.
The novel optical surface may be used to mix wavelengths originating from a single artificial light source, such as an LED, or from a plurality of artificial light source, such as a compound LED having individual LED's for each primary color or a cluster of LED's, for example.
Alternatively or additionally, only a portion of the optical surface may be provided with such color mixing protuberances.
TABLE 1
LIST OF REFERENCE NUMBERS.
Number
Part
101a
first emitted light beam
101b
second emitted light beam
102a
first reflected light beam
102b
second reflected light beam
103
scattered light beam with mixed wavelengths
200
emission surface
201
first plurality of protuberances, converging protuberances
202
second plurality of protuberances, diverging protuberances
203
base surface
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The present invention provides an optical surface which is able to mix different wavelengths into a light pattern which contains all wavelengths evenly distributed across the pattern. The novel optical surface extends in at least two Cartesian base dimensions (X, Y), whereby a cross-section of the surface taken in either of said two Cartesian base dimensions (X, Y) features a first plurality of protuberances which extend to the same direction in a third Cartesian dimension (Z). The cross-section of the optical surface also features a second plurality of protuberances which extend to the opposite direction as the first plurality of protuberances in the third Cartesian dimension (Z). The pluralities of protuberances form converging and diverging optical shapes for mixing different wavelengths scattering from the optical surface.
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FIELD OF THE INVENTION
This invention relates to a method and apparatus for mounting a forklift on a carrier vehicle.
BACKGROUND OF THE INVENTION
Forklifts are commonly used for loading and unloading pallets which are stacked with various goods from tractor trailers and other carrier vehicles. Often a carrier vehicle arrives at a site where no forklift vehicles are available. The accompanying manual labor necessary for unloading as would be required under those circumstances is often unavailable and always expensive. Similarly, it may be uneconomic to keep a forklift at all the places where it might be used. Thus, various apparatus have been suggested for transporting a forklift with the carrier.
One obvious solution to this problem is to load the forklift on the bed of the carrier. That is not a practical solution because it takes up space which may otherwise be filled with cargo.
A solution suggested by several patents is to provide a pair of pockets on the trailing end of the carrier vehicle into which the forks of the forklift are inserted. The hydraulic system is then used to lift the frame of the forklift to a suitable level above the ground to allow its transportation with the carrier vehicle. The forklift projects from the trailing end of the carrier. The weight of the forklift is borne by the forks, carriage and mast.
An example of this type of structure is illustrated in U.S. Pat. No. 3,799,379 and it includes a cable 158 mounted on a shaft 154 on the trailing end of the carrier. The cable has an eye 160 at one end and it slides over a hook 162 mounted on the frame of the forklift. The cable is then tightened and maintained in tension by a ratchet 156. Thereby the forklift is prevented from separating from the carrier due to bumps and bounces during transportation from one site to another. One problem which this patent does not solve is the bending, flexing and constant tension of the forks mounted on the mast and carriage of the forklift.
A similar structure is illustrated in U.S. Pat. No. 4,396,341 which includes vertically displaced cross bars on the end of a carrier for the forks. The forklift is lifted in the same way as described in the paragraph above. However, there is a significant difference in that the carrier structure of this patent includes a pair of wheel pockets 78 transversely located on each side of the fork supporting cross bars to house the forward wheels of the forklift. The wheel pockets 78 restrict the movement of forward wheels 24 of the forklift in forward, upward and downward directions. To a certain extent this relieves the problem of strain on the carriage, mast and forks. The patent provides for links 106 extending between the carrier frame and the forklift frame to hold the forklift in position to prevent accidental release due to bounces and the like.
Two commonly owned U.S. Pat. Nos. 4,921,075 and 5,174,415 illustrate other means for mounting forklifts on the trailing end of a carrier vehicle. Neither discloses the problem of relieving strain on the forks, carriage, and mast.
The problems which exist in the industry are strain on the forks, carriage and mast as described above and providing a secure lock to hold the forklift on the carrier vehicle. This invention solves these problems.
SUMMARY OF THE INVENTION
This invention includes the conventional structure of a forklift comprising a frame supported by front and rear wheels and including a vertically extending mast combined with a carriage and pair of forks which project forwardly.
A pair of pockets mounted on the frame of a carrier are configured to receive the forks of the forklift which may be driven into the pockets and the forklift raised from the supporting substrate by the hydraulic fluids used by the forklift for moving the carriage and driving the wheels. Abutments are mounted beneath the carrier frame for abutting the forward wheels of the forklift.
Two embodiments serve to latch the forklift to the carrier frame in a manner to prevent the forklift from disengaging from the carrier due to impacts and bounces during transportation and also allow the hydraulic system to be depressurized and thereby remove any strain on the forks, carriage and mast during transportation. Said latch structure is in addition to conventional cables or bars attached to both the carrier frame and the forklift frame.
One embodiment to accomplish this added latch result comprises a pair of upwardly facing hooks projecting rearwardly from the carrier frame which engage a pair of horizontally extending bars mounted above the forklift frame, a pivotable latch swings into position above the open hooks after the bars are in position to thereby prevent vertical disengagement by bumps or dips in the road traveled by the carrier vehicle. This structure allows the hydraulic system to be depressurized and the forklift is held in place by the bars, latches and hooks in combination. With depressurization, the forklift pivots marginally about the bars such that the forward wheels engage the wheel abutments extending downwardly from the frame of the carrier. Thus, two point support is provided for the forklift on each side of the carrier.
An alternative embodiment for supporting the wheels and allowing depressurization of the hydraulic system comprises a strap hooked on the forward side of each wheel abutment or elsewhere on the carrier frame. One strap extends around the lower side of each of the forward wheels of the forklift and the distal end of each strap is secured in position at the trailing end of the carrier by a winch and ratchet combination which may be used to tighten each strap to pull the frame of the forklift against a bracket or support block on each side of the carrier.
Objects of the invention not clear from the above will be fully understood upon a review of the drawings and the description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a carrier and forklift according to this invention;
FIG. 2 is a side elevational view of the combination of FIG. 1 with the forklift raised to the locked transport position;
FIG. 3 is a fragmentary elevational view of the latching elements of the carrier and forklift in unlatched condition and with the carriage retracted and raised above latching position;
FIG. 4 is a fragmentary schematic perspective view of the latching elements of FIG. 3;
FIG. 5 is a fragmentary sectional view taken along line 5--5 of FIG. 2; and
FIG. 6 is a fragmentary side elevational view, of an alternative embodiment for mounting the forklift on a carrier.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking now to FIG. 1, a forklift 10 is supported above a substrate 12 by a pair of front wheels 14 and rear castor wheel 16. It includes a conventional hydraulic motor system 18 to provide hydraulic fluid to drive the wheels 14, advance and retract the mast 20 on the U-shaped frame 22 by piston and cylinder combination 23, raise and lower carriage 24 on mast 20, and tilt mast 20 by hydraulic piston and cylinder combinations 26. A pair of conventional forks or prongs 28 are mounted to reciprocate with carriage 24 and mast 20.
Forklift 10 is shown behind a carrier 30 having a frame 32 supported by wheels 34 on substrate 12. A pair of wheel abutments 36 having rear faces generally perpendicular to substrate 12 are mounted beneath carrier frame 32. It will be observed that abutments 36 are reinforced by gusset plates 38 of generally triangular shape.
Projected rearwardly from the rear of carrier 30 are a set of upwardly facing hooks 40 as best seen in FIG. 4. In each case, a pair of hooks 40 are located on each side of the carrier and a pivotal latch 42 is mounted on a shaft 44 projecting transversely outwardly from the outermost set of hooks on each side.
Looking to FIGS. 2 and 3, a bracket 46 is secured to the outer edge on each side of the U-shaped frame 22 of forklift 10 and projects upwardly therefrom. At its upper end, bracket 46 is penetrated by a transversely extending bar 48, see FIG. 5, and the pairs of hooks 40 on each side of carrier 30 are So located with respect to forklift frame 22 that each bracket 46 slides between a pair of hooks.
Also mounted on the underside of frame 32 of the carrier are a pair of pockets or generally rectangular tubes 50 aligned parallel with each other to receive the parallel forks 28 of the forklift. The pair of pockets 50 illustrated could be a single, wider pocket if desired.
The structure illustrated in FIG. 4 is a retrofit kit which may be mounted on any carrier frame for purposes of mounting the forklift 10 on the rear or side of a carrier, tractor trailer or the like. The critical dimensions are the spacing between the sides of the U-shaped frame 22 on the forklift and the requirement that the pair of hooks 40 on each side of the carrier frame 32 be so located and secured in place that upstanding brackets 46 from each side of forklift frame 22 will slide between the two hooks 40 as seen in FIG. 5. After this dimension is established, a plurality of spacer brackets 52 accurately locate the pockets 50 beneath the frame and abutments 36 and gusset plates 38 are then secured in place on the framework. Indeed all of these elements may be preassembled as a pair of units for mounting beneath the frame of a carrier where the only dimension to be measured is the spacing between the pair of hooks 40 on each side of the frame. However, the preferred procedure is to provide the unassembled parts because it is less bulky.
It will be clear that the hooks 40 may be inverted and mounted on an upstanding bracket on the forklift frame 22. In that case, the support bars 48 would be mounted on the rear of carrier frame 32. An automatic latch may be incorporated into the combination without departing from the spirit of the invention.
In operation, forklift 10 is located behind a carrier 30 and the carriage 24 is raised to a proper level so that forks 28 are aligned with the openings in pockets 50 and with the carriage 24 and mast 20 advanced slightly toward carrier 30 as illustrated in FIG. 3.
With the forks 28 projecting into pockets 50, carriage 24 is lowered on mast 20, thereby lifting forklift 10 from the substrate 12 to an elevation such that bars 48 are above hooks 40. Piston and cylinder combinations 26 tilt mast 20 backward toward the operator. Next, mast 20 and carriage 24 are retracted toward the operator to thereby move frame 22, bracket 46 and bar 48 toward carrier frame 32 until the bars 48 are above the cavities 53 formed by the upwardly facing hooks 40. Then the frame 22 is lowered to allow bars 48 to settle into cavity openings 53.
Note the general location of wheels 14 of the forklift with respect to the face of abutments 36 before carrier 24 is retracted as illustrated in FIG. 3. After the bars 48 settle into cavities 53 of hooks 40, the hydraulic system is depressurized allowing forklift frame 22 to pivot counterclockwise about bars 48 and front wheels 14 of the forklift to engage abutments 36. Thereby, the forklift is supported on the carrier frame 32 by a two point support or contact on each side, namely, the engaging surface of each front wheel 14 with abutment 36 and the surface of hooks 40 engaging the bars 48. Note in FIG. 2 that mast 20 has a front side nearest the front wheels 14 and a rear side nearest the rear wheel 16, the hook 40 contact being the sole upward force on U-shaped frame 22 and it is forward of the rear side of said mast 20. What this accomplishes is taking the tension and pressure off the forks 28, mast 30 and carriage 24 to support the forklift on the carrier. Thereby, impacts due to bumps and other obstructions in the route taken by the carrier will not be transmitted to the forks, carrier, mast etc. which comprise the critical operating elements of the forklift. All such impacts are partially absorbed by the resilience of the front wheels 14 and the easy pivoting about bars 48.
In order to prevent bumps in the roadway and the like from accidentally disengaging the forklift from the trailer 30, which could jar the bars 48 above the cavities 53 and allow the forklift to fall, the pivotal latch 42 is pulled into place by a bar, tie or the like 54. Tie 54 connects through an opening 56 in latch 42 and is secured into a connector 58 secured to frame 22 on the forklift. In the illustrated embodiment, a tie 54 is merely shown as a line and it could be flexible or rigid. The connector 58 is shown as an eyelet which could in fact be of some other shape. Any particular shape is of no significance. What is of significance is that a biasing means holds latch 42 in place during transportation of the forklift such that it is not accidentally bounced out of position by bumps or the like, thereby raising bar 48 above opening or cavity 53 in hook 40. The pair of ties 54 also serve as a backup securing means to hold the forklift in transport position.
In an alternative embodiment illustrated in FIG. 6, the forklift 10 is mounted in similar fashion to the mounting of the forklift discussed above in FIGS. 1 through 5. In the FIG. 6 embodiment there is no hook or latch on the rear of the frame 32 of the carrier. What holds the forklift resiliently in place is a hook-like arrangement 60 connected to a strap 62 which encircles each front wheel 14 of the forklift after it is raised in position and in engagement with abutment 36. Hook-like arrangement 60 is shown connected to the forward side of abutment 36 but other connection locations may be appropriate. In this instance, frame 22 of the forklift is raised into engagement with support blocks 64 mounted on the lower surface of a bracket 66 secured to the underside of carrier frame 32. Note that the supporting surface for support blocks 64 is inclined downwardly toward the front of the carrier 30. The reason for the inclination is to allow the support blocks 64 and abutment 36 to engage the wheel 14 and frame 22, respectively, when the hydraulic system is depressurized and the frame pivots counterclockwise as illustrated in FIG. 6. Further, inclined support blocks 64 minimize rocking of forklift 10 during transportation. This depressurization occurs after the ratchet and pawl combinations 68 are used With lever 70 to cinch the remote end of strap 62 tightly against the peripheral surface of wheel 14.
A similar tie 54 and connector 58 are used in this case but with the FIG. 6 embodiment it is more likely that tie 54 will be a relatively rigid bar which may be adjusted in length by turnbuckle or the like, such that the counterclockwise pivoting takes place between the tie connection to the rear of frame 32 rather than about the bar 48 of FIG. 3.
The straps 62 serve as a lock to hold the carrier and forklift together as do the hooks 40 and bars 48 of the FIGS. 1-5 embodiment.
Having thus described the apparatus in its preferred embodiments, it will be clear that modifications may be made to the apparatus and the procedure for mounting the same without departing from the spirit of the invention. It is not intended that the invention be limited by the drawings, nor the words used to describe the same, rather it is intended that the invention be limited only by the scope of the appended claims.
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A forklift having a frame supported by front and rear wheels is mounted on a carrier by inserting its forks into pockets mounted on the frame of the carrier vehicle and lifting the wheels of the forklift off the ground. A pair of wheel abutments on the underside of the carrier serve as abutments for the front wheels of the forklift to prevent its forward movement. A combined lock and support structure connected to the frame of the carrier prevents separation of the forklift from the carrier after the hydraulic system of the forklift is neutralized and all pressure on the forks, carriage, and mast are relieved of support forces.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of International Patent Application No. PCT/JP03/010623, filed on Aug. 22, 2003, and claims priority to Japanese Patent Application No. 2002-243823, filed on Aug. 23, 2002, both of which are incorporated herein by reference in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to crystals of alanine alkyl ester sulfonates, which exhibit low hygroscopicity and low corrosiveness, and which are useful as intermediates for the production of pharmaceutical compounds having an alanine skeleton or as an alanine-containing peptide synthetic reagent. The present invention also relates to methods of producing such a crystal of an alanine alkyl ester sulfonate.
[0004] 2. Discussion of the Background
[0005] Alanine lower alkyl ester compounds are useful as intermediates for the production of pharmaceutical compounds having an alanine skeleton or as alanine-containing peptide synthetic reagents. Generally, alanine lower alkyl esters are distributed in the form of a hydrochloride salt, and, for example, alanine methyl ester hydrochloride (hereinafter sometimes to be abbreviated as “Ala-OMe HCl salt”), alanine ethyl ester hydrochloride (hereinafter sometimes to be abbreviated as “Ala-OEt HCl salt”), and the like are commercially available. However, these hydrochlorides are hygroscopic and highly deliquescent, which makes handling thereof difficult. In addition, due to moisture absorption and deliquescence, the ester moiety such as alanine methyl ester (hereinafter sometimes to be abbreviated as “Ala-OMe”), alanine ethyl ester (hereinafter sometimes to be abbreviated as “Ala-OEt”) and the like is hydrolyzed into methanol, ethanol and the like, and the purity becomes low. Particularly, when a synthetic reaction is carried out using such a compound, the alanine resulting from the decomposition reacts to produce a substance other than the desired product. Therefore, an extremely serious problem occurs when such compounds are used as starting materials for a pharmaceutical product required to have high purity.
[0006] As a substance other than hydrochloride, alanine ethyl ester hydrobromide, alanine ethyl ester p-toluenesulfonate (4-methylbenzenesulfonate) and the like are known. However, hydrohalides such as hydrochloride, hydrobromide, and the like exhibit a high corrosiveness to metals, and an industrial process using such a compound requires the use of equipment having a high resistance to corrosion.
[0007] In the case of p-toluenesulfonate, Kato et al. ( Nippon Kagaku Kaishi, vol. 83, p. 1151 (1962)) obtained various amino acid ethyl ester p-toluenesulfonates as crystals by a method comprising an azeotropic dehydration treatment of p-toluenesulfonic acid and various amino acids in ethanol in the presence of carbon tetrachloride to effect esterification. However, Kato et al. reported that alanine ethyl ester p-toluenesulfonate became oily and failed to crystallize. On the other hand, DJ. Collins et al. ( Aust. J. Chem., 1999, vol. 52, pp. 379-385) reported that they obtained a crystal of alanine ethyl ester p-toluenesulfonate by transesterification using ethyl p-toluenesulfonate. However, when the present inventors tried to obtain L-alanine ethyl ester p-toluenesulfonate by transesterification, the reaction took a considerably long time and this method was found to be not entirely sufficient as an industrial production method.
[0008] Thus, there remains a need for crystals of alanine lower alkyl esters salts. There also remains a need for crystals of alanine lower alkyl esters salts, which exhibit reduced hygroscopicity. There also remains a need for crystals of alanine lower alkyl esters salts, which exhibit reduced corrosiveness. There also remains a need for a method for conveniently preparing such crystals.
SUMMARY OF THE INVENTION
[0009] Accordingly, it is one object of the present invention to provide novel crystals of alanine lower alkyl esters salts.
[0010] It is another object of the present invention to provide novel crystals of alanine lower alkyl esters salts, which exhibit reduced hygroscopicity.
[0011] It is another object of the present invention to provide novel crystals of alanine lower alkyl esters salts, which exhibit reduced corrosiveness.
[0012] It is another object of the present invention to provide novel crystals of alanine lower alkyl ester salts which exhibit reduced hygroscopicity (deliquescence) and low corrosiveness.
[0013] It is another object of the present invention to provide novel crystals of alanine lower alkyl esters salts, which can be produced efficiently on an industrial scale.
[0014] It is another object of the present invention to provide novel methods for the production of such crystals.
[0015] These and other objects, which will become apparent during the following detailed description, have been achieved by the inventors' discovery that a crystal of a particular sulfonic acid salt has markedly reduced hygroscopicity and corrosiveness as compared to Ala-OEt HCl salt and Ala-OMe HCl salt. Furthermore, they have found that this substance can be industrially produced easily.
[0016] Accordingly, the present invention provides the following:
[0017] (1) A crystal of alanine alkyl ester sulfonate, which is represented by formula (1):
wherein R 1 is a methyl group or an ethyl group, provided that when R 1 is a methyl group, R 2 is an ethylphenyl group or a dimethylphenyl group; and when R 1 is an ethyl group, R 2 is a methyl group, a phenyl group, a chlorophenyl group, an ethylphenyl group, or a dimethylphenyl group.
[0018] (2) The crystal of the aforementioned (1), wherein, when R 1 is a methyl group, R 2 is a 4-ethylphenyl group, a 2,4-dimethylphenyl group, or a 2,5-dimethylphenyl group; and when R 1 is an ethyl group, R 2 is a methyl group, a phenyl group, a 4-chlorophenyl group, a 4-ethylphenyl group, a 2,4-dimethylphenyl group, or a 2,5-dimethylphenyl group.
[0019] (3) The crystal of the aforementioned (1), wherein R 1 is an ethyl group.
[0020] (4) The crystal of the aforementioned (1), wherein R 1 is a methyl group.
[0021] (5) The crystal of the aforementioned (1)-(4), wherein the alanine alkyl ester is an L form.
[0022] (6) A crystal of alanine alkyl ester methanesulfonate.
[0023] (7) A crystal of L or D-alanine alkyl ester methanesulfonate.
[0024] (8) A crystal of L-alanine ethyl ester methanesulfonate.
[0025] (9) A crystal of L-alanine ethyl ester benzenesulfonate.
[0026] (10) A crystal of L-alanine ethyl ester 4-chlorobenzenesulfonate.
[0027] (11) A crystal of L-alanine ethyl ester 4-ethylbenzenesulfonate.
[0028] (12) A crystal of L-alanine ethyl ester 2,4-dimethylbenzenesulfonate.
[0029] (13) A crystal of L-alanine ethyl ester 2,5-dimethylbenzenesulfonate.
[0030] (14) A crystal of L-alanine methyl ester 4-ethylbenzenesulfonate.
[0031] (15) A crystal of L-alanine methyl ester 2,4-dimethylbenzenesulfonate.
[0032] (16) A crystal of L-alanine methyl ester 2,5-dimethylbenzenesulfonate.
[0033] (17) A method of preparing a crystal of alanine alkyl ester sulfonate represented by formula (1):
wherein R 1 is a methyl group or an ethyl group, provided that when R 1 is a methyl group, R 2 is an ethylphenyl group or a dimethylphenyl group; and when R 1 is an ethyl group, R 2 is a methyl group, a phenyl group, a chlorophenyl group, an ethylphenyl group, or a dimethylphenyl group,
[0034] wherein the method comprises:
[0035] (a) contacting an alanine alkyl ester represented by formula (2):
wherein R 1 is a methyl group or an ethyl group, with a sulfonic acid, to obtain an alanine alkyl ester sulfonate; and
[0036] (b) crystallizing the alanine alkyl ester sulfonate.
[0037] (18) The method of the aforementioned (17), wherein, when R 1 is a methyl group, R 2 is a 4-ethylphenyl group, a 2,4-dimethylphenyl group, or a 2,5-dimethylphenyl group; and when R 1 is an ethyl group, R 2 is a methyl group, a phenyl group, a 4-chlorophenyl group, a 4-ethylphenyl group, a 2,4-dimethylphenyl group, or a 2,5-dimethylphenyl group.
[0038] (19) The method of the aforementioned (17), wherein R 1 is an ethyl group and R 2 is a methyl group.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same become better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
[0040] FIG. 1 is a chart of the infrared (IR) spectrum of the L-alanine ethyl ester methanesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt MsOH salt”) obtained in Example 1;
[0041] FIG. 2 is a powder X-ray diffraction pattern of the L-Ala-OEt MsOH salt obtained in Example 1;
[0042] FIG. 3 is a powder X-ray diffraction pattern of the L-alanine ethyl ester benzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt BsOH salt”) obtained in Example 6;
[0043] FIG. 4 is a powder X-ray diffraction pattern of the L-alanine ethyl ester 4-chlorobenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt 4-CBS salt”) obtained in Example 7;
[0044] FIG. 5 is a powder X-ray diffraction pattern of the L-alanine ethyl ester 4-ethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt 4-EBS salt”) obtained in Example 8;
[0045] FIG. 6 is a powder X-ray diffraction pattern of the L-alanine ethyl ester 2,4-dimethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt 2,4-DMBS salt”) obtained in Example 9;
[0046] FIG. 7 is a powder X-ray diffraction pattern of the L-alanine ethyl ester 2,5-dimethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OEt 2,5-DMBS salt”) obtained in Example 10;
[0047] FIG. 8 is a powder X-ray diffraction pattern of the L-alanine methyl ester 4-ethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OMe 4-EBS salt”) obtained in Example 11;
[0048] FIG. 9 is a powder X-ray diffraction pattern of the L-alanine methyl ester 2,4-dimethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OMe 2,4-DMBS salt”) obtained in Example 12;
[0049] FIG. 10 is a powder X-ray diffraction pattern of the L-alanine methyl ester 2,5-dimethylbenzenesulfonate (hereinafter sometimes to be abbreviated as “L-Ala-OMe 2,5-DMBS salt”) obtained in Example 13;
[0050] FIG. 11 is a graph of the results presented in Table 1;
[0051] FIG. 12 is a graph of the results presented the values in Table 2;
[0052] FIG. 13 is a graph of the results presented the values in Table 4;
[0053] FIG. 14 is a graph of the results presented the values in Table 5; and
[0054] FIG. 15 is a graph of the results presented the values in Table 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] The present invention is explained in detail in the following.
[0056] Alanine, alanine methyl ester, alanine ethyl ester, and alanine alkyl ester sulfonates such as alanine ethyl ester methanesulfonate and the like in this specification encompass a D form, an L form, racemic mixutes, racemates, and mixtures which exhibit enantiomeric enrichment between 0% and 100%, unless otherwise specified. By “L form,” it is meant that the asymmetric carbon atom in the salt has the same configuration as in L-alanine, regardless of the actual direction of rotation of polarized light by the salt. Similarly, by “D form,” it is meant that the asymmetric carbon atom in the salt has the same configuration as in D-alanine, regardless of the actual direction of rotation of polarized light by the salt.
[0057] Preferred examples of the crystal of alanine alkyl ester sulfonate represented by formula (I) include the following compounds:
[0058] crystal of alanine ethyl ester methanesulfonate,
[0059] crystal of alanine ethyl ester benzenesulfonate,
[0060] crystal of alanine ethyl ester 4-chlorobenzenesulfonate,
[0061] crystal of alanine ethyl ester 4-ethylbenzenesulfonate,
[0062] crystal of alanine ethyl ester 2,4-dimethylbenzenesulfonate,
[0063] crystal of alanine ethyl ester 2,5-dimethylbenzenesulfonate,
[0064] crystal of alanine methyl ester 4-ethylbenzenesulfonate,
[0065] crystal of alanine methyl ester 2,4-dimethylbenzenesulfonate, and
[0066] crystal of alanine methyl ester 2,5-dimethylbenzenesulfonate.
[0067] As for the the alanine alkyl ester sulfonate of the present invention, the L form is particularly preferable.
[0068] The alanine alkyl ester sulfonate of the present invention can be easily obtained by methods generally used for producing amino acid ester. In the following, alanine ethyl ester methanesulfonate is taken as an example for the explanation of the specific production method. However, the method is not limited to those shown below. Moreover, other alanine alkyl ester sulfonates of the present invention can be easily produced by similar methods, or a method analogous thereto.
[0000] Production Method 1. Method of esterifying alanine in ethanol in the presence of methanesulfonic acid.
[0069] This esterification is generally conducted at a reaction temperature of 15 to 80° C. for a reaction time of 30 minutes to 24 hours. For sufficient progress of the esterification reaction, the reaction solution is heated to about 90° C., and the reaction may be further carried out by adding ethanol while distilling away the same amount of ethanol.
[0000] Production Method 2. Method of obtaining the object methanesulfonate by contacting salt of volatile acid of alanine ethyl ester with methanesulfonic acid and removing liberated volatile acid to effect salt exchange.
[0070] As used herein, as the volatile acid, hydrochloric acid, hydrogen bromide, hydrogen fluoride, and the like can be mentioned, with preference given to hydrochloric acid and hydrogen bromide.
[0071] The reaction for contacting a salt of volatile acid of alanine ethyl ester with methanesulfonic acid is generally carried out at a reaction temperature of 0 to 80° C. for a reaction time of 1 minute to 24 hours.
[0072] As a method of removing the liberated volatile acid, evaporation, concentration under reduced pressure, and the like can be mentioned.
[0000] Production Method 3. Method of forming methanesulfonate by esterification of alanine in ethanol in the presence of an acid catalyst, adding methanesulfonic acid to the reaction mixture, and evaporating the existent volatile substance.
[0073] As the acid catalyst to be used for the esterification, hydrogen chloride gas, thionyl chloride, hydrogen bromide gas, thionyl bromide, and the like can be mentioned, and the esterification is generally carried out at a reaction temperature of 0 to 80° C. for a reaction time of 30 minutes to 24 hours.
[0074] As a method of evaporating a volatile substance, evaporation, concentration under reduced pressure, and the like can be mentioned.
[0000] Production Method 4. Method of forming methanesulfonate by esterification of alanine N-carboxyanhydride in ethanol containing methanesulfonic acid.
[0075] The esterification is generally carried out at a reaction temperature of !50 to 80° C. for a reaction time of 1 minute to 3 hours.
[0076] Production Method 5. Method of forming methanesulfonate by neutralization-extraction of alanine ethyl ester hydrochloride or hydrobromide in water containing an organic solvent immiscible with water and a basic substance, and adding methanesulfonic acid to the organic layer containing the alanine ethyl ester.
[0077] As the organic solvent immiscible with water to be used for this method, acetic acid esters such as ethyl acetate, isopropyl acetate, and the like; aromatic hydrocarbons such as toluene, xylene, and the like; hydrocarbons such as hexane, heptane, and the like; ethers such as diethyl ether, methyl tert-butyl ether, and the like, and halogenated hydrocarbons such as methylene chloride, chloroform, and the like, and the like can be mentioned.
[0078] As the basic substance, sodium hydrogencarbonate, sodium carbonate, sodium hydroxide, potassium hydroxide, ammonia, triethylamine, and the like can be mentioned.
[0079] As used herein, the neutralization-extraction means neutralizing a hydrochloric acid or hydrogen bromide moiety of alanine ethyl ester hydrochloride or hydrobromide with a basic substance, while extracting the liberated alanine ethyl ester with the organic solvent
[0080] Production Method 6. Method of forming methanesulfonate by esterifying alanine in ethanol in the presence of mineral acid, neutralizing-extracting the reaction mixture with water containing an organic solvent immiscible with water and a basic substance, and adding methanesulfonic acid to the organic layer containing the alanine ethyl ester.
[0081] As used herein, as the mineral acid, hydrochloric acid, sulfuric acid, oxalic acid, phosphoric acid, and the like can be mentioned, and the esterification is generally carried out at a reaction temperature of 15 to 80° C. for a reaction time of 30 minutes to 24 hours. The organic solvent immiscible with water and the basic substance are the same as those in Production Method 5.
[0082] Of these Production Methods, Production Method 4 is difficult to handle, because alanine N-carboxyanhydride is unstable to heat, moisture, and the like, as well as expensive; and Production Methods 5 and 6 are hardly considered to be industrial production methods, because the extraction rate of alanine ethyl ester (or alanine methyl ester) with an organic solvent is not very high and the yield is low. In contrast, Production Methods 1, 2 and 3, wherein alanine alkyl ester is contacted with sulfonic acid, are industrially suitable and preferable production methods, because they use comparatively economical starting materials alone and afford high yields.
[0083] Since alanine alkyl ester sulfonates such as Ala-OEt MsOH salt and the like obtained by the aforementioned method show comparatively high solubility in a highly polar solvent such as water, alcohol and the like, they are not easily crystallized. They are not crystallized even by the methods of Production Methods 5 and 6, because teh extracted organic layer contains water or alcohol, and they tend to become oily substances. To obtain crystals, therefore, crystallization is desirably performed by substitution of a solvent to one that decreases the solubility of Ala-OEt MsOH salt, or removing water contained therein by distillation and the like.
[0084] As a solvent that lowers the solubility, acetic acid esters such as ethyl acetate, isopropyl acetate, butyl acetate, and the like; aromatic hydrocarbons such as toluene, xylene, and the like; hydrocarbons such as hexane, heptane, and the like; and the like are used. Of these, acetic acid esters having the effect of suppressing the hydrolysis of Ala-OEt (or Ala-OMe) by competitive hydrolysis caused by moisture in the air are preferable. Particularly preferred is ethyl acetate (or methyl acetate) free of transesterification.
[0085] As a crystallization method, the following methods can be mentioned, but the method is not limited to those shown below.
[0000] Crystallization Method 1. Method of crystallization by adding a poor solvent to a solution wherein the alanine ethyl ester sulfonate, such as Ala-OEt MsOH salt and the like, has been formed (e.g., applied to Production Methods 1, 2, 3, and 4).
[0086] As the poor solvent to be used for this method, hydrocarbons such as hexane, heptane, and the like; aromatic hydrocarbons such as toluene, xylene, and the like; acetic acid esters such as ethyl acetate, isopropyl acetate, and the like; ethers such as diethyl ether, methyl tert-butyl ether, and the like; and the like can be mentioned.
[0087] Crystallization Method 2. Method of crystallization by concentrating or cooling a solution wherein the alanine ethyl ester sulfonic, acid salt such as Ala-OEt MsOH salt and the like, has been formed, thus affording a concentration of not less than the solubility (e.g., applied to Production Methods 5 and 6).
[0000] Crystallization Method 3. Method of crystallization by adding sulfonic acid such as methanesulfonic acid and the like to a state wherein Ala-OEt (or Ala-OMe) is dissolved in an organic solvent (e.g., applied to Production Methods 5 and 6).
[0088] For crystallization, a seed crystal may be added. The compound obtained by crystallization is separated by sedimentation, filtration, centrifugal separation, or the like, and washed, and dried, as necessary. Crystallization may be performed by adding the aforementioned solvent such as water, alcohol, and the like and a poor solvent as appropriate to the residue obtained by evaporating a solvent from a solution, wherein a salt has been formed, and drying to give a slurry, and then cooling the slurry without sufficiently dissolving the solid therein, and the like. In this case, however, the purity tends to become low. Therefore, it is preferable to perform crystallization after sufficiently dissolving the residue.
[0089] The hygroscopicity (deliquescence) of the crystals of alanine alkyl ester sulfonates of the present invention thus obtained was evaluated. As a result, the hygroscopicity was substantially absent under low humidity conditions, hygroscopicity was low even under high humidity conditions as compared to that of Ala-OEt HCl salt and Ala-OMe HCl salt, and no practical problem was found. In regard to corrosiveness, Ala-OEt HCl salt and Ala-OMe HCl salt showed corrosiveness against stainless, but the crystals of the alanine alkyl ester sulfonates of the present invention did not show corrosiveness.
[0090] Other features of the invention will become apparent in the course of the following descriptions of Examples, Comparative Examples, and Experimental Examples, which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLES
[0091] The measurement equipment and conditions are shown in the following.
[0092] NMR: BRUKER AVANCE 400 (400MHz) melting point: BUCHI 535 (Examples 1-5), precision micromelting point measurement apparatus, Ishiishouten Co., Ltd. (Examples 6-13)
[0093] HPLC: (Examples 1-5)
column: Inertsil ODS-2 4.6 mmφ×150 mm detection wavelength: 210 nm column temperature: 40° C. injection volume: 20 μl flow: 1.0 ml/min mobile phase: SOLUTION A 0.05M potassium dihydrogen phosphate (pH 2.0) 0.01M aqueous sodium octanesulfonate solution SOLUTION B methanol gradient conditions: 0 min A/B=82/18→15 min A/B=60/40
[0106] HPLC: (Examples 6-13)
column: Inertsil ODS-3 4.6 mmφ×250 mm detection wavelength: 210 nm column temperature: 40° C. injection volume: 50 μl flow: 1.5 ml/min mobile phase: {0.1M potassium dihydrogen phosphate (pH 2.3)+0.005M sodium octanesulfonate}/acetonitrile=90/10
[0114] IR: Perkin Elmer Spectrum One
Measurement method ATR method (total reflection measurement method)
[0116] XRD (X ray diffraction): PHILIPS X-ray generator PW1710 (Examples 1-5), PHILIPS X-ray generator PW3050 (Examples 6-13)
[0117] MS: Electrospray ionization mass spectrometer TSQ700, Thermoquest
Example 1
[0118] Methanesulfonic acid (5.72 g, 59.52 mmol) was added to a slurry obtained by adding L-alanine (4.46 g, 50.06 mmol) to ethanol (25 ml) and dissolved therein. This solution was heated overnight at 70° C. to allow esterification. To complete the esterification reaction, triethyl orthoacetate (11 ml, 60 mmol) was added, and the mixture was stirred at 70° C. for 8 hours. Thereafter, the solvent was evaporated under reduced pressure, and ethyl acetate (15.96 g) was added to the obtained concentrated solid residue (12.14 g) to give a slurry. This slurry was filtered by suction, and the crystals were washed with ethyl acetate (3 ml). The obtained crystals (wet weight 12.33 g) were dried in vacuo to give dry crystals (10.01 g, 46.0 mmol).
[0119] As a result of HPLC analysis using L-Ala-OEt HCl salt as a standard product, the L-Ala-OEt MsOH salt content was 97.9 wt % (yield 91.9%).
[0120] 1 H-NMR (400MHz, DMSO-d 6 ): 1.24 (3H, O—CH 2 —C H 3 , t, J=7.1Hz), 1.39 (3H, CH—C H 3 , d, J=7.2Hz), 2.32 (3H, C H 3 —SO 3 , s), 4.09 (1H, N—C H —CO, q, J=7.2Hz), 4.21 (2H, O—C H 2 —CH 3 , q, J=7.1Hz), 8.28 (3H, N H 3 , bs) mp: 119° C. IR: 1750cm −1 (ester C═O) XRD (2θ, CuKα rays): 7.4°, 11.2°, 12.9°, 15.3°, 18.2°, 21.3°, 22.1°, 24.0°, 28.0°, 29.7° ESI-MS: 118 (MH+; Ala-OEt), 191 ([2M−H]−; MsOH) The results of IR and XRD are shown in FIG. 1 and FIG. 2 .
Example 2
[0121] L-Ala-OEt HCl salt (161.6 g, 1.053 mol) was suspended in ethyl acetate (400 ml), and methanesulfonic acid (69 ml, 1.063 mol) was added to allow dissolution. The solution was concentrated under reduced pressure to give a concentrate (278 g). Thereto was added ethyl acetate (200 ml), and the mixture was concentrated under reduced pressure to allow crystallization. Ethyl acetate (200 ml) was added to the obtained slurry (350 g), and the mixture was concentrated again under reduced pressure. Ethyl acetate (200 ml) was added to the obtained slurry (325 g), and the mixture was stirred at 8° C. for 5.5 hours. This slurry was filtered by suction, and the obtained wet crystals (225 g) were dried in vacuo to give L-Ala-OEt MsOH salt dry crystals (179 g, 0.839 mmol). yield 79.8% (L-Ala-OEt MsOH salt content 99.9%, yield 79.7%).
Example 3
[0122] Ethanol (302 L) was maintained at not higher than 15° C., and thionyl chloride (87 kg) was added over 4 hours. L-alanine (54.6 kg) was added, and the mixture was heated at 50° C. for 2 hours to allow esterification. A portion (10 ml, containing L-Ala-OEt HCl salt (2.559 g, 16.67 mmol) was taken from the obtained reaction mixture (370 L), and methanesulfonic acid (1.1 ml, 16.95 mmol) was added. The obtained solution was concentrated under reduced pressure. Ethyl acetate (30 ml) was added to the oily residue, and the mixture was concentrated again under reduced pressure. The oil concentrate (5.174 g) was dissolved in ethyl acetate (30 ml), and a small amount of L-Ala-OEt MsOH salt crystals was added to allow crystallization. The resulting crystals were preserved overnight in a refrigerator, collected by suction filtration, and washed with ethyl acetate (10 ml). The obtained wet crystals (3.566 g) were dried in vacuo to give L-Ala-OEt MsOH salt dry crystals (2.681 g, 12.58 mmol). yield 75.5% (L-Ala-OEt MsOH salt content 99.4%, 12.51 mmol, 75.0%).
Example 4
[0123] Methanesulfonic acid (0.795 ml, 12.25 mmol) was added to ethanol (50 ml), and L-alanine-N-carboxyanhydride (1.41 g, 12.25 mmol) was added with stirring. This reaction mixture was concentrated under reduced pressure, ethyl acetate (20 ml) was added to the obtained oil concentrate (2.785 g), and a small amount of L-Ala-OEt MsOH salt was added as a seed crystal to allow crystallization. The crystals were preserved in a refrigerator for 3 days, collected by suction filtration, washed with ethyl acetate (10 ml), and dried in vacuo to give L-Ala-OEt MsOH salt dry crystals (1.959 g, 9.19 mmol). yield 75.0%.
Example 5
[0124] L-Ala-OEt HCl salt (2.054 g, 13.38 mmol) was suspended in ethyl acetate (100 ml), and aqueous 6M NaOH solution (2.5 ml) and water (5 ml) were added. The mixture was stirred and extracted. The obtained ethyl acetate layer (88.3 g) was concentrated to 43.2 g under reduced pressure. Methanesulfonic acid (0.87 ml, 13.41 mmol) was added to allow crystallization. The crystals were preserved overnight in a refrigerator, collected by suction filtration, and washed with ethyl acetate (15 ml). The obtained wet crystals (1.995 g) were dried in vacuo to give L-Ala-OEt MsOH salt dry crystals (1.695 g, 7.95 mmol). yield 59.4% (L-Ala-OEt MsOH salt content 83.4%,6.63 mmol, yield 49.6%).
Example 6
[0125] L-alanine (1.50 g, 16.84 mmol) and benzenesulfonic acid monohydrate (BsOH H 2 0) (3.56 g, 20.20 mmol) were added to ethanol (10 ml), and the mixture was heated overnight at 70° C. to perform esterification. To complete the esterification reaction, the mixture was heated to 90° C. and ethanol (200 ml) was added over 3.5 hours while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure. Ethanol (0.5 ml) and diethyl ether (30 ml) were added to partially crystallize an oily residue, and the mixture was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 4.55 g of L-alanine ethyl ester benzenesulfonate (L-Ala-OEt BsOH salt) dry crystals (L-Ala-OEt BsOH salt content 87.6%, (14.47 mmol), yield 86.0%).
[0126] 1 H-NMR (400MHz, CD 3 OD): 1.29 (3H, O—CH 2 —C H 3 , t, J=7.2Hz), 1.51 (3H, CH—C H 3 , d, J=7.3Hz), 4.06 (1H, N—C H —CO, q, J=7.3Hz), 4.26 (2H, O—C H 2 —CH 3 , q, J=7.2Hz), 4.89 (N H 3 , bs), 7.39-7.45 (3H, benzene, m), 7.81-7.84 (2H, benzene, m) ESI-MS: 118 (MH+; Ala-OEt), 159 (MH+; BsOH), 157 (MH−; BsOH) mp: 92° C. XRD (2θ, CuKα rays): 6.2°, 7.3°, 8.0°, 13.4°, 23.8°, 25.0° The results of XRD are shown in FIG. 3 .
Example 7
[0127] L-alanine (1.50 g, 16.84 mmol) and 4-chlorobenzenesulfonic acid (4-CBS) (3.89 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70 EC to perform esterification. To complete the esterification reaction, the mixture was heated to 90 EC, and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure. Ethanol (1 ml) and diethyl ether (60 ml) were added to partially crystallize an oily residue and the mixture was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator and the crystals were separated and dried to give 3.52 g of L-alanine ethyl ester 4-chlorobenzenesulfonate (L-Ala-OEt 4-CBS salt) dry crystals (L-Ala-OEt 4-CBS salt content 93.6%, 10.64 mmol, yield 63.2%).
[0128] 1 H-NMR (400MHz, CD 3 OD): 1.29 (3H, O—CH 2 —C H 3 , t, J=7.2Hz), 1.52 (3H, CH—C H 3 , d, J=7.3Hz), 4.08 (1H, N—C H —CO, q, J=7.3Hz), 4.26 (2H, O—C H 2 —CH 3 , q, J=7.2Hz), 4.91 (N H 3 , bs), 7.42-7.45 (2H, benzene, m), 7.78-7.81 (2H, benzene, m) ESI-MS: 118 (MH+; Ala-OEt), 191 (MH−; 4-CBS) mp: 133° C. XRD (2θ, CuKα rays): 6.0°, 6.7°, 11.2°, 11.9°, 13.0°, 20.1°, 22.4°, 28.5° The results of XRD are shown in FIG. 4 .
Example 8
[0129] L-alanine (1.50 g, 16.84 mmol) and 4-ethylbenzenesulfonic acid (4-EBS) (3.76 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70 EC to perform esterification. To complete the esterification reaction, the mixture was heated to 90 EC, and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure. The obtained oily residue was cooled in a refrigerator to allow partial crystallization. Diethyl ether (5 ml) and ethyl acetate (5 ml) were added, the residue was completely dissolved at 40° C., and the mixture was stirred at room temperature. Since crystallization occurred when a vessel containing the reaction solution was immersed in ice water, ethyl acetate (15 ml) was further added, and the mixture was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 2.98 g of L-alanine ethyl ester 4-ethylbenzenesulfonate (L-Ala-OEt 4-EBS salt) dry crystals (L-Ala-OEt 4-EBS salt content 98.5%, 9.67 mmol, yield 57.4%).
[0130] 1 H-NMR (400MHz, CD 3 OD): 1.23 (3H, CH 2 —C H 3 , t, J=7.6Hz), 1.29 (3H, O—CH 2 —C H 3 , t, J=7.2Hz), 1.51 (3H, CH—C H 3 , d, J=7.2Hz), 2.67 (2H, C H 2 —CH 3 , q, J=7.6Hz), 4.06 (1H, N—C H —CO, q, J=7.2Hz), 4.26 (2H, O—C H 2 —CH 3 , q, J=7.2Hz), 4.84 (N H 3 , bs), 7.26 (2H, benzene, d, J=8.1Hz), 7.73 (2H, benzene, d, J=8.1Hz) ESI-MS: 118 (MH+; Ala-OEt), 185 (MH−; 4-EBS) mp: 85° C. XRD (2θ, CuKα rays): 7.6°, 13.4°, 16.4°, 19.3°, 22.8° The results of XRD are shown in FIG. 5 .
Example 9
[0131] L-alanine (1.50 g, 16.84 mmol) and 2,4-dimethylbenzenesulfonic acid (2,4-DMBS) (3.76 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70 EC to perform esterification. To complete the esterification reaction, the mixture was heated to 90 EC, and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure. The obtained oily residue was cooled in a refrigerator to allow partial crystallization. Diethyl ether (2.5 ml) and ethyl acetate (17.5 ml) were added, and the residue was dissolved almost entirely at 50° C. The mixture was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 3.00 g of L-alanine ethyl ester 2,4-dimethylbenzenesulfonate (L-Ala-OEt 2,4-DMBS salt) dry crystals (L-Ala-OEt 2,4-DMBS salt content 99.6%, 9.84 mmol, yield 58.4%).
[0132] 1 H-NMR (400MHz, CD 3 OD): 1.28 (3H, O—CH 2 —C H 3 , t, J=7.2Hz), 1.51 (3H, CH—C H 3 , d, J=7.3Hz), 2.30 (3H, C H 3 , s), 2.61 (3H, C H 3 , s), 4.05 (1H, N—C H —CO, q, J=7.3Hz), 4.25 (2H, O—C H 2 —CH 3 , q, J=7.2Hz), 4.84 (N H 3 , bs), 7.00 (1H, benzene, d, J=8.0Hz), 7.06 (1H, benzene, s), 7.77 (1H, benzene, d, J=8.0Hz) ESI-MS: 118 (MH+; Ala-OEt), 185 (MH−; 2,4-DMBS) mp: 104° C. XRD (2θ, CuKα rays): 7.4°, 10.5°, 14.7°, 19.1°, 22.2°, 24.2° The results of XRD are shown in FIG. 6 .
Example 10
[0133] L-alanine (1.50 g, 16.84 mmol) and 2,5-dimethylbenzenesulfonic acid (2,5-DMBS) (3.76 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70° C. to perform esterification. To complete the esterification reaction, the mixture was heated to 90° C., and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure. The obtained oily residue was cooled in a refrigerator to allow partial crystallization. Ethyl acetate (7 ml) was added, and the residue was dissolved almost entirely at 50° C. The mixture was stirred at room temperature, diethyl ether (40 ml) was further added, and the mixture was stirred at room temperature to give a slurry. The obtained slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 3.77 g of L-alanine ethyl ester 2,5-dimethylbenzenesulfonate (L-Ala-OEt 2,5-DMBS salt) dry crystals (L-Ala-OEt 2,5-DMBS salt content 95.6%,11.88 mmol, yield 70.5%).
[0134] 1 H-NMR (400MHz, CD 3 OD): 1.29 (3H, O—CH 2 —C H 3 , t, J=7.2Hz), 1.51 (3H, CH—C H 3 , d, J=7.2Hz), 2.31 (3H, C H 3 , s), 2.60 (3H, C H 3 , s), 4.06 (1H, N—C H —CO, q, J=7.2Hz), 4.26 (2H, O—C H 2 —CH 3 , q, J=7.2Hz), 4.84 (N H 3 , bs), 7.12 (2H, benzene, s), 7.74 (1H, benzene, s) ESI-MS: 118 (MH+; Ala-OEt), 185 (MH−; 2,5-DMBS) mp: 132° C. XRD (2θ, CuKα rays): 7.6°, 12.8°, 15.1°, 16.8°, 17.8°, 18.4°, 19.7°, 22.7° The results of XRD are shown in FIG. 7 .
Example 11
[0135] L-Ala-OMe HCl salt (1.00 g, 7.16 mmol) was suspended in methyl acetate (15 ml). 4-Ethylbenzenesulfonic acid (4-EBS) (1.60 g, 8.57 mmol) was added, and the mixture was stirred for dissolution. This solution was concentrated under reduced pressure, methyl acetate (15 ml) was added, and the mixture was concentrated twice under reduced pressure. The obtained concentrate was cooled in a refrigerator. Since partial crystallization occurred, methyl acetate (15 ml) was added to dissolve the crystals at 50° C. This solution was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator and the crystals were separated and dried to give 1.04 g of L-alanine methyl ester 4-ethylbenzenesulfonate (L-Ala-OMe 4-EBS salt) dry crystals (L-Ala-OMe 4-EBS salt content 100%, 3.42 mmol, yield 47.8%).
[0136] 1 H-NMR (400MHz, CD 3 OD): 1.23 (3H, CH 2 —C H 3 , t, J=7.6Hz), 1.51 (3H, CH—C H 3 , d, J=7.3Hz), 2.67 (2H, C H 2 —CH 3 , q, J=7.6Hz), 3.81 (3H, O—C H 3 , s), 4.09 (1H, N—C H —CO, q, J=7.3Hz), 4.84 (N H 3 , bs), 7.25-7.27 (2H, benzene, m), 7.71-7.74 (2H, benzene, m) ESI-MS: 104 (MH+; Ala-OMe), 185 (MH−; 4-EBS) mp: 105° C. XRD (2θ, CuKα rays): 8.1°, 8.5°, 14.2°, 21.7°, 22.2°, 24.4° The results of XRD are shown in FIG. 8 .
Example 12
[0137] L-Ala-OMe HCl salt (0.68 g, 4.87 mmol) was suspended in methyl acetate (15 ml). 2,4-Dimethylbenzenesulfonic acid (2,4-DMBS) (1.09 g, 5.85 mmol) was added, and the mixture was stirred for dissolution. This solution was concentrated under reduced pressure, methyl acetate (15 ml) was added, and the mixture was concentrated twice under reduced pressure. The obtained concentrate was cooled in a refrigerator. Since partial crystallization occurred, methyl acetate (5 ml) and diethyl ether (15 ml) were added to dissolve the crystals by stirring at room temperature. This solution was stirred under ice-cooling to give a slurry. This slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 1.18 g of L-alanine methyl ester 2,4-dimethylbenzenesulfonate (L-Ala-OMe 2,4-DMBS salt) dry crystals (L-Ala-OMe 2,4-DMBS salt 92.9%, 4.11 mmol, yield 84.4%).
[0138] 1 H-NMR (400MHz, CD 3 OD): 1.51 (3H, CH—C H 3 , d, J=7.1Hz), 2.31 (3H, C H 3 , s), 2.61 (3H, C H 3 , s), 3.81 (3H, O—C H 3 , s), 4.09 (1H, N—C H —CO, q, J=7.1Hz), 4.84 (N H 3 , bs), 7.00 (1H, benzene, d, J=8.0Hz), 7.06 (1H, benzene, s), 7.77 (1H, benzene, d, J=8.0Hz) ESI-MS: 104 (MH+; Ala-OMe), 185(MH−; 2,4-DMBS) mp: 78° C. XRD (2θ, CuKα rays): 9.1°, 9.8°, 10.8°, 12.1°, 16.4°, 20.1°, 22.2°, 26.5° The results of XRD are shown in FIG. 9 .
Example 13
[0139] L-Ala-OMe HCl salt (1.00 g, 7.16 mmol) was suspended in methyl acetate (15 ml). 2,5-Dimethylbenzenesulfonic acid (2,5-DMBS) (1.60 g, 8.59 mmol) was added, and the mixture was stirred for dissolution. This solution was concentrated under reduced pressure, methyl acetate (15 ml) was added, and the mixture was concentrated twice under reduced pressure to allow crystallization. Methyl acetate (15 ml) was added to dissolve the obtained slurry almost entirely at 50° C. This solution was stirred at room temperature to give a slurry. This slurry was cooled overnight in a refrigerator, and the crystals were separated and dried to give 1.87 g of L-alanine methyl ester 2,5-dimethylbenzenesulfonate (L-Ala-OMe 2,5-DMBS salt) dry crystals (L-Ala-OMe 2,5-DMBS salt content 98.9%, 6.23 mmol, yield 87.0%).
[0140] 1 H-NMR (400MHz, CD 3 OD): 1.51 (3H, CH—C H 3 , d, J=7.3Hz), 2.31 (3H, C H 3 , s), 2.60 (3H, C H 3 , s), 3.80 (3H, O—C H 3 , s), 4.09 (1H, N—C H —CO, q, J=7.3Hz), 4.85 (N H 3 , bs), 7.13 (2H, benzene, s), 7.73 (1H, benzene, s) ESI-MS: 104 (MH+; Ala-OMe), 185 (MH−; 2,5-DMBS) mp: 165° C. XRD (2θ, CuKα rays): 7.6°, 12.8°, 15.2°, 16.8°, 17.8°, 18.4°, 19.7°, 22.7° The results of XRD are shown in FIG. 10 .
Comparative Examples 1 -5
[0141] The same operation as in Examples 1-5 was performed except that methanol, methyl acetate, and L-Ala-OMe HCl salt were used instead of ethanol, ethyl acetate and L-Ala-OEt HCl salt, respectively, but L-alanine methyl ester methanesulfonate(L-Ala-OMe MsOH salt) was obtained only as an oily substance and did not crystallize.
Comparative Example 6
[0142] Acetyl bromide (4.75 ml, 64.2 mmol) was added dropwise to ethanol (30 ml) cooled to −5° C. to allow generation of hydrogen bromide. L-alanine (4.46 g, 50.06 mmol) was added to this solution, and the mixture was heated at 50° C. for 12 hours. Then, triethyl orthoacetate (10 ml, 54.6 mmol) was added and the mixture was heated at 70° C. for 7 hours to perform esterification. Thereafter, the mixture was concentrated under reduced pressure. Ethyl acetate (10 ml) was added to the obtained oily residue, and the mixture was concentrated again under reduced pressure. Ethyl acetate (20 ml) was added to the obtained oily residue (10.2 g), and the mixture was stored overnight in a refrigerator. However, the solution remained unchanged and crystallization did not occur.
Comparative Example 7
[0143] L-Ala-OEt HCl salt (1.04 g, 6.78 mmol) was suspended in ethyl acetate (10 ml), and triethyl orthoacetate (0.5 ml, 2.73 mmol) and 97% sulfuric acid (0.38 ml, 6.92 mmol) were added. The mixture was concentrated under reduced pressure. Ethyl acetate was added to the obtained oily residue, but the oily substance did not dissolve, and crystallization did not occur. Toluene and methyl tert-butyl ether were similarly added to the oily residue, but crystallization did not occur.
Comparative Example 8
[0144] L-alanine (2.29 g, 25.67 mmol) was added to methanol (5 ml), and methyl orthoformate (5 ml, 45.7 mmol) was added thereto. Methanesulfonic acid (2 ml, 30.82 mmol) was added, and the mixture was heated at 55° C. for 21 hours to perform esterification. A portion (1 ml) was taken from the obtained esterification reaction mixture (11.3 g) and concentrated under reduced pressure. Cyclohexane was added to the obtained oily residue, but crystallization did not occur. Similarly, a portion was taken from the esterification reaction mixture and concentrated under reduced pressure. Toluene, acetonitrile and methyl acetate were added to the residue, but crystallization did not occur.
Comparative Example 9
[0145] L-Ala-OMe HCl salt (1.00 g, 7.16 mmol) was suspended in methyl acetate (15 ml), and benzenesulfonic acid monohydrate (BsOH H 2 O) (1.51 g, 8.57 mmol) was added. The mixture was stirred for dissolution. This solution was concentrated under reduced pressure, and methyl acetate (15 ml) was added. The mixture was concentrated twice under reduced pressure, and the obtained concentrate was cooled in a refrigerator. Since partial crystallization occurred, diethyl ether (3 ml) and methyl acetate (15 ml) were added to dissolve the crystals almost entirely at 40° C. This solution was stirred at room temperature and cooled overnight in a refrigerator. The crystals were separated and dried to give L-alanine methyl ester benzenesulfonate (L-Ala-OMe BsOH salt) crystals. The crystals were left standing at room temperature for a while. As a result, the crystals were liquefied and failed to provide stable crystals.
Comparative Example 10
[0146] L-alanine (1.50 g, 16.84 mmol) and 98% phosphoric acid (2.02 g, 20.20 mmol) were added to ethanol (10 ml), and the mixture was heated at 65° C. to perform esterification reaction. L-alanine was once dissolved, but crystals gradually precipitated. Therefore, the crystals were separated 8 hours later. The obtained crystals were L-alanine. The mother liquor was analyzed by HPLC and found to show almost no progress of the reaction.
Comparative Example 11
[0147] L-alanine (1.50 g, 16.84 mmol) and citric anhydride (3.88 g, 20.20 mmol) were added to ethanol (10 ml), and the mixture was heated at 65 EC to perform esterification reaction. L-alanine did not dissolve, but the mixture was stirred overnight as it was. The slurry was separated and confirmed to be L-alanine. The mother liquor was analyzed by HPLC and found to show almost no progress of the reaction.
Comparative Example 12
[0148] L-alanine (1.50 g, 16.84 mmol) and ethyl p-toluenesulfonate (ethyl 4-methylbenzenesulfonate (3.71 g, 18.52 mmol) were added to ethanol (10 ml), and the mixture was heated at 65 EC to perform esterification reaction. After 72 hr, the reaction was completed (reaction yield 90%), and the reaction mixture was concentrated under reduced pressure. Ethyl acetate (15 ml) was added to the obtained concentrate, and the mixture was stirred. The insoluble materials were removed by filtration, the mixture was concentrated again under reduced pressure, and ethyl acetate (15 ml) was added. Cooling in a refrigerator did not lead to crystallization.
Comparative Example 13
[0149] L-alanine (1.50 g, 16.84 mmol) and 4-methylbenzenesulfonic acid monohydrate (3.84 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70 EC to perform esterification reaction. To complete the esterification reaction, the mixture was heated to 90 EC, and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure, and cooled in a refrigerator, but crystallization did not occur.
Comparative Example 14
[0150] L-alanine (1.50 g, 16.84 mmol) and 4-hydroxybenzenesulfonic acid (3.52 g, 20.20 mmol) were added to ethanol (15 ml), and the mixture was heated overnight at 70 EC to perform esterification reaction. To complete the esterification reaction, the mixture was heated to 90 EC, and ethanol (200 ml) was added over 3.5 hours, while distilling away almost the same amount of ethanol. Thereafter, the solvent was evaporated under reduced pressure, and the residue was dried under reduced pressure, and cooled in a refrigerator, but crystallization did not occur.
Comparative Example 15
[0151] L-alanine (1.50 g, 16.84 mmol) and methanesulfonic acid (1.94 g, 20.20 mmol) were added to ethanol (10 ml), and the mixture was heated at 65 EC for 5.5 hr to perform esterification reaction. Thereafter, the solvent was evaporated under reduced pressure, and methyl acetate (6 ml) was added to the obtained concentrate. The mixture became cloudy upon stirring. Cooling in a refrigerator did not result in crystallization.
Comparative Example 16
[0152] L-alanine (1.15 g, 12.91 mmol) and 4-methylbenzenesulfonic acid (2.66 g, 15.45 mmol) were added to methanol (18 ml), and the mixture was heated overnight at 65 EC to perform esterification reaction. Thereafter, the solvent was evaporated under reduced pressure, and methyl acetate (8 ml) was added to the obtained concentrate. The mixture was cooled in a refrigerator, but crystallization did not occur.
Comparative Example 17
[0153] L-alanine (1.00 g, 11.22 mmol) and benzenesulfonic acid (2.13 g, 13.47 mmol) were added to methanol (20 ml), and the mixture was heated overnight at 65 EC to perform esterification reaction. Thereafter, the solvent was evaporated under reduced pressure, and methyl acetate (10 ml) was added to the obtained concentrate. The mixture was stirred to give an oily substance. The obtained oily substance was cooled in a refrigerator, but crystallization did not occur.
Comparative Example 18
[0154] L-alanine (1.50 g, 16.84 mmol) and 4-hydroxybenzenesulfonic acid (3.52 g, 20.21 mmol) were added to methanol (20 ml), and the mixture was heated overnight at 65 EC to perform esterification reaction. Thereafter, the solvent was evaporated under reduced pressure, and methyl acetate (10 ml) was added to the obtained concentrate. The mixture was stirred to give an oily substance. Then, methanol (3 ml) was added to dissolve the oily substance. The solution was cooled in a refrigerator, but crystallization did not occur.
Experimental Example 1
Comparison of Hygroscopicity Between the L-Ala-OEt HCl Salt and the L-Ala-OEt MsOH Salt
[0155] L-Ala-OEt HCl salt and L-Ala-OEt MsOH salt were measured into in a glass container in an amount of 1.6 g each, dried in vacuo at 30° C. for 5 hours, left under conditions of temperature: 22 to 24° C., humidity: 44 to 45% RH, and then the hygroscopicity was compared based on the weight gain over the lapse of time. The L-Ala-OEt HCl salt showed liquefaction of a part of the crystals in 60 minutes. The liquefied portion increased with the lapse of time, and the entire salt became liquid 750 minutes later with no observable crystal. In contrast, the L-Ala-OEt MsOH salt showed almost no change in weight with the lapse of time, and liquefaction was not observed. The results are shown in Table 1 and FIG. 11 .
TABLE 1 Comparison of hygroscopicity between L-Ala-OEt HCl salt and L-Ala-OEt MsOH salt. weight increase rate (% relative to initial weight) Time (minutes) L-Ala-OEt HCl salt L-Ala-OEt MsOH salt 0 0.00 0.00 1 1.63 0.08 2 1.67 0.11 3 1.72 0.17 4 1.73 0.17 6 1.80 0.23 10 1.95 0.36 15 2.07 0.41 25 2.29 0.48 35 2.55 0.56 50 2.88 0.58 60 3.09 0.59 (partly liquefied) 75 3.38 0.63 90 3.63 0.57 120 4.10 0.58 150 4.41 0.58 180 4.89 0.61 750 14.37 1.16 (whole liquid)
Experimental Example 2
Comparison of Hygroscopicity Between L-Ala-OEt MsOH Salt and L-Ala-OMe HCl Salt.
[0156] In the same manner as in Experimental Example 1, L-Ala-OEt MsOH salt and L-Ala-OMe HCl salt were measured into a glass container in an amount of 0.6 g each, left under conditions of temperature: 24° C., humidity: 62 to 64% RH, and then the hygroscopicity was compared based on the weight gain with the lapse of time. The L-Ala-OMe HCl salt showed liquefaction of a part of the crystals in 20 minutes. The liquefied portion increased with the lapse of time and the entire salt became liquid 155 minutes later with no observable crystal. In contrast, the L-Ala-OEt MsOH salt showed not much change in weight with the lapse of time, and liquefaction was not observed. The results are shown in Table 2 and FIG. 12 .
TABLE 2 Comparison of hygroscopicity between L-Ala-OEt MsOH salt and L-Ala-OMe HCl salt. weight increase rate (% relative to initial weight) Time (minutes) L-Ala-OEt MsOH salt L-Ala-OMe HCl salt 0 0.00 0.00 10 0.18 0.11 20 0.26 0.54 (partly liquefied) 35 0.39 1.04 50 0.53 1.67 65 0.55 2.27 (whole sherbet) 80 0.63 2.83 95 0.70 3.36 110 0.78 3.97 125 0.94 4.54 140 1.01 5.13 155 1.00 5.48 (whole liquid) 170 1.13 6.02 185 1.26 6.56 200 1.32 7.03
Experimental Example 3
Ccomparison of Corrosiveness
[0157] A small amount of crystals of each of L-Ala-OEt HCl salt, L-Ala-OEt MsOH salt, and L-Ala-OMe HCl salt was placed on a stainless plate (SUS 316 L), stored under an atmosphere at 22° C., 30% RH, and the corrosion state of the stainless plate was observed. When one day passed, the L-Ala-OEt HCl salt and the L-Ala-OMe HCl salt caused a brown rust on the stainless plate, and at day 7, the rust increased. After the lapse of 7 days, the plate was moved to at atmosphere at 24° C., 65% RH. After 9 hours, the L-Ala-OEt HCl salt became a brown liquid with the color of the rust, and the L-Ala-OMe HCl salt became a colorless liquid. On the other hand, the L-Ala-OEt MsOH salt showed no change during this period, and no rust was found on the stainless plate. The results are show in Table 3.
TABLE 3 Comparison of corrosiveness of L-Ala-OEt HCl salt, L-Ala-OEt MsOH salt and L-Ala-OMe HCl salt to stainless. L-Ala-OEt L-Ala-OEt L-Ala-OMe HCl No. of days HCl salt MsOH salt salt Day 1 development of No change development of brown rust on a brown rust on a part of stainless part of stainless plate plate Day 7 enlarged brown No change enlarged brown rust on stainless rust on stainless plate plate (smaller than L-Ala-OEt HCl salt) Day 8 brown liquid No change of colorless liquid (after standing crystal at 24° C., No change of 65% RH) stainless plate
Experimental Example 4
Comparison of Hygroscopicity
[0158] The L-Ala-OEt HCl salt, L-Ala-OEt MsOH salt, L-Ala-OEt BsOH salt, L-Ala-OEt 4-CBS salt, L-Ala-OEt 4-EBS salt, L-Ala-OEt 2,4-DMBS salt, and L-Ala-OEt 2,5-DMBS salt were measured in an amount of about 0.3 g each, left standing in a thermostatic chamber at a temperature of 24° C. and a humidity of 40 to 46% RH, and the hygroscopicity was compared based on the weight gain with the lapse of time. A part of the crystal of the L-Ala-OEt HCl salt was liquefied in 30 minutes, and the liquefied portion increased thereafter with the lapse of time. After 100 minutes, the whole mass became like a sherbet. In contrast, the other salts showed almost no change in weight with the lapse of time, and liquefaction was not observed. The results are shown in Table 4 and FIG. 13 .
TABLE 4 weight increase rate (%) L-Ala-OEt Time MsOH BsOH 4-CBS 4-EBS 2,4-DMBS 2,5-DMBS (minutes) HCl salt salt salt salt salt salt salt 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 15 2.63 0.03 0.66 1.55 0.00 0.00 0.00 30 4.56 0.03 0.63 1.51 0.00 0.00 0.00 (partly liquefied) 45 6.42 0.00 0.75 1.48 0.00 0.00 0.06 60 7.76 0.19 0.93 1.81 0.13 0.03 0.10 75 8.82 0.35 1.05 2.01 0.19 0.03 0.16 90 9.53 0.35 1.08 2.14 0.22 0.06 0.19 (sherbet state) 120 9.89 0.42 1.23 2.30 0.41 0.06 0.26 150 10.39 0.39 1.02 2.17 0.54 0.06 0.32 180 10.69 0.55 1.08 2.27 0.36 0.06 0.32
Experimental Example 5
Comparison of Hygroscopicity
[0159] The L-Ala-OMe HCl salt, L-Ala-OEt MsOH salt, L-Ala-OEt BsOH salt, L-Ala-OEt 4-CBS salt, L-Ala-OEt 4-EBS salt, L-Ala-OEt 2,4-DMBS salt, and L-Ala-OEt 2,5-DMBS salt were measured in an amount of about 0.3 g each, left standing in a thermostatic chamber at a temperature of 24 EC and a humidity of 60 to 66% RH, and the hygroscopicity was compared based on the weight gain with the lapse of time. A part of the crystal of the L-Ala-OMe HCl salt was liquefied in 35 minutes, and the liquefied increased thereafter with the lapse of time. After 125 minutes, the whole mass like a sherbet. In contrast, the other salts showed almost no change in weight with the lapse of time, and liquefaction was not observed. The results are shown in Table 5 FIG. 14 .
TABLE 5 weight increase rate (%) L-Ala- L-Ala-OEt Time OMe MsOH BsOH 4-CBS 4-EBS 2,4-DMBS 2,5-DMBS (minutes) HCl salt salt salt salt salt salt salt 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 10 3.03 0.32 1.46 2.26 0.09 0.00 0.00 20 4.85 0.35 1.80 2.83 0.09 0.00 0.03 35 7.30 0.38 1.97 3.38 0.15 0.00 0.03 (partly liquefied) 50 8.84 0.38 2.11 3.77 0.15 0.00 0.09 65 10.42 0.41 2.22 4.10 0.15 0.00 0.06 80 11.65 0.44 2.25 4.31 0.15 0.03 0.06 95 12.77 0.44 2.28 4.46 0.15 0.00 0.06 110 13.69 0.48 2.22 4.58 0.18 0.03 0.12 125 14.74 0.44 2.22 4.70 0.15 0.03 0.06 (sherbet state) 140 15.46 0.48 2.22 4.76 0.18 0.03 0.09 155 16.23 0.48 2.22 4.82 0.18 0.03 0.09 170 16.88 0.51 2.28 4.94 0.18 0.06 0.09 185 17.43 0.48 2.25 4.94 0.15 0.06 0.09 200 17.77 0.51 2.25 5.03 0.21 0.06 0.12
Experimental Example 6
Corrosiveness Evaluation
[0160] A small amount of each of the L-Ala-OMe HCl salt, L-Ala-OEt HCl salt, L-Ala-OEt MsOH salt, L-Ala-OEt BsOH salt, L-Ala-OEt 4-CBS salt, L-Ala-OEt 4-EBS salt, L-Ala-OEt 2,4-DMBS salt, and L-Ala-OEt 2,5-DMBS salt was placed on a stainless plate (SUS 316 L), left standing in a thermostatic chamber at a temperature of 22 EC and a humidity of 30% RH, and the corrosion state of the stainless plate was observed. When one day passed, the L-Ala-OEt HCl salt developed a brown rust on the stainless plate. After 6 days, the L-Ala-OEt HCl salt developed more rust, and the L-Ala-OMe HCl salt developed a rust. After the lapse of 7 days, the plate was moved to the atmosphere at 24° C. and 65% RH. The rust expanded in 6 hours. The L-Ala-OEt MsOH salt was liquefied in its entirety, and the L-Ala-OEt BsOH salt and L-Ala-OEt 4-CBS salt were partly liquefied, though without rust. The other salts showed no change, and the stainless plate had no rust. The results are shown in Table 6.
TABLE 6 Evaluation of corrosiveness Days lapsed 8 days later 1 day later 6 days later 7 days later (24° C., 65% RH) L-Ala-OMe No change Development No change Expansion of rust HCl salt of rust on a part from 6 on stainless plate of stainless days later (entire sherbet) plate L-Ala-OEt HCl salt Development Expansion of No change Expansion of rust of rust on a rust on from 6 on stainless plate part of stainless plate days later (entirely stainless plate (entirely liquefied) (partly liquefied) liquefied) MsOH salt No change No change No change No rust (entirely liquefied) BsOH salt No change No change No change No rust (partly liquefied) 4-CBS salt No change No change No change No rust (partly liquefied) 4-EBS salt No change No change No change No change 2,4-DMBS No change No change No change No change salt 2,5-DMBS No change No change No change No change salt
Experimental Example 7
Evaluation of Hygroscopicity
[0161] The L-Ala-OMe HCl salt, L-Ala-OMe 4-EBS salt, L-Ala-OMe 2,4-DMBS salt, and L-Ala-OMe 2,5-DMBS salt were measured in an amount of about 0.3 g each, left standing in a thermostatic chamber at temperature of 24 EC and a humidity of 60 to 66% RH, and the hygroscopicity was compared based on the weight gain with the lapse of time. A part of the crystal of the L-Ala-OMe HCl salt was liquefied in 10 minutes, and the entirety became a sherbet in 20 minute. The liquefied portion increased thereafter with the lapse of time. After 80 minutes, the whole was liquefied. In contrast, the other salts showed almost no change in weight with the lapse of time, and liquefaction was not observed. The results are shown in Table 7 and FIG. 15 .
TABLE 7 weight increase rate (%) Time L-Ala-OMe (min) HCl salt 4-EBS salt 2,4-DMBS salt 2,5-DMBS salt 0 0.00 0.00 0.00 0.00 10 6.74 0.06 0.33 0.06 (partly liquefied) 20 10.06 0.06 0.37 0.06 (sherbet state) 35 12.52 0.06 0.37 0.06 50 14.31 0.06 0.37 0.03 65 15.69 0.03 0.37 0.03 80 17.16 0.06 0.37 0.03 (entirely liquefied) 95 18.31 0.06 0.37 0.00 110 19.42 0.03 0.40 0.03 125 20.54 0.06 0.43 0.06 140 21.66 0.06 0.40 0.00 155 22.62 0.06 0.43 0.00 170 23.55 0.06 0.47 0.03 185 24.41 0.06 0.50 0.03 200 25.14 0.06 0.50 0.06
Industrial Applicability.
[0162] Crystals of alanine alkyl ester sulfonates, which are useful as intermediates for the production of pharmaceutical compounds which having an alanine skeleton or as an alanine-containing peptide synthetic reagent, and which exhibit low hygroscopicity and low corrosiveness, can be obtained by the method of the present invention. The sulfonic acid to be used in the present invention can be either obtained industrially economically or can be easily produced. In addition, the alanine alkyl ester sulfonates of the present invention can be easily produced industrially.
[0163] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
[0164] All patents and other references mentioned above are incorporated in full herein by this reference, the same as if set forth at length.
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The present invention provides a novel crystal of alanine alkyl ester sulfonate having low hygroscopicity and low corrosiveness, which can be produced industrially economically. The present invention provides crystals of alanine alkyl ester sulfonates represented by formula ( 1 ):
wherein R 1 is a methyl group or an ethyl group, provided that when R 1 is a methyl group, R 2 is an ethylphenyl group or a dimethylphenyl group; and when R 1 is an ethyl group, R 2 is a methyl group, a phenyl group, a chlorophenyl group, an ethylphenyl group, or a dimethylphenyl group.
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This is a continuation of application Ser. No. 08/469,704 filed Jun. 6, 1995, now abandoned which is a continuation of application Ser. No. 08/097,506, filed on Jul. 27, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates in general to systems and methods for monitoring the activities of computers. More particularly, the invention is directed to systems and methods for selectively and contemporaneously monitoring the states of client application type processes executing in a multiprocess server of a client-server network.
The client-server processing model has been widely adopted in the definition of distributed computing type networks. In the context of such networks, better performance with higher degrees of service concurrence have been exhibited by server operating systems which execute multiple client application programs through multiple processes. Examples are the OS/2® and AIX® operating system programs commercially available from IBM Corporation. In contrast, single process operating systems require the server to await the completion of a current client's application program before commencing any aspect of a new client's application program.
The present concept of multiprocessing from the software perspective should not be confused with classical multiprocessing from the hardware perspective. From the hardware perspective, microprocessors such as the Intel Corp. models 80386 and 80486 incorporate time sharing features which accomplish multiprocessing through a time allocation for the different instructions being processed. In contrast, microprocessors such as the Intel Corp. model 80286 do not provide such a hardware capability, requiring that software manage any concurrent execution of multiple application programs. Operating system software which accomplishes this task for a 80286 type processor, and equally for the 80386 and 80486 microprocessors, is the aforementioned OS/2 operating system program. The present invention is directed to process management in the context of such an operating system, and not in the context of management by the microprocessor hardware.
The client-server network architecture is generally well known. With the advent of multiprocessing operating system capabilities in the servers, associating the activities occurring in the server to specific client application program processes has proven to be a significant challenge not only for the user clients but even for network administrators. Though operating systems, such as the aforementioned AIX program, provide resources for monitoring the state of a composite operating system on a server workstation, no contemporaneous information is provided about the states of the individual client application processes executing on the server. This level of information is particularly important to developers of client-server application programs. For example, presently available operating system monitors do not provide users with information regarding the server's work on a specific application program, or why a specific application program is hung up, or the identity of a semaphore delaying an application process. This deficiency is attributable to the fact that present operating system monitors do not link to the individual application processes, but rather, reflect the state of the composite of all server processes, viewed from the level of the operating system. Though trace log data could be generated in sufficient detail, the volume of the data requires storage to disk and time consuming analysis.
Therefore, a need exists for a monitoring system which provides contemporaneous information about the status of individual client application processes undergoing execution on a multiprocessing server in a client-server network.
SUMMARY OF THE INVENTION
The present invention provides systems and methods for monitoring individual server processes at the granularity of the client's application program. Information regarding the status of each client application program as reflected by a server process is acquired and made available to the network administrator or client. In one form, the invention is directed to a monitoring system of a multiprocess server in a client-server network and comprises, a means for creating multiple control blocks of a server process monitor on a server processor, means for relating server application processes to control blocks in a server processor, means for storing the control blocks in memory shared by the different server application processes, and means for indicating the status of a server application process responsive to a server process monitor access of a control block. In other forms, the invention relates to program products executable on server processor workstations and methods for accomplishing such application process selective monitoring.
In a preferred form, the invention involves a server process monitor program for creating control blocks and descriptors in a shared range of a server workstation memory. The control blocks are linked to and accessed by every server process executing a client application. In addition, every process running on the server has associated therewith synchronization object descriptors, defining semaphore or message queue states, which are similarly stored in shared memory. The control blocks and descriptors are registered with the server process monitor program upon creation and are accessed by the server process monitor program to derive, and subsequently indicate on a video display or the like, the status of one or more of the server processes which are executing client applications.
The server process monitor function can also be performed by an operating system deamon process, which deamon process periodically reads the server process status information from the control blocks or descriptors in shared memory and displays the status on a dedicated window of a video display.
Irrespective of the particular form chosen, the information provides network administrators, software developers or field engineers with management, performance and diagnostic information at the granularity of each client process within a complex client server network.
These and other features of the invention will be more clearly understood and appreciated upon considering the particulars of the detailed embodiment described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram depicting a client server network.
FIG. 2 is a schematic diagram depicting server processes and the server operating environment.
FIG. 3 is a schematic diagram depicting a composite flow diagram for the processes of the system.
FIGS. 4-11 are schematics with the individual flow diagrams of those depicted in FIG. 3.
FIG. 12 is a schematic depicting the video operation display flow diagram.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is particularly useful in the context of a client-server network of the form depicted in FIG. 1. FIG. 1 shows a network 1 with a number of clients 2 and a server 3. Representative examples of the clients 1 and servers 3 would be PS/2 or RISC System/6000 workstations as are commercially available from IBM Corporation. A representative choice for network 1 in the context of PS/2 workstations would be Netbios and in such context include OS/2 Lan Server client code on respective workstations 2 and OS/2 Lan Server server code executing on server workstation 3. These operating systems are also commercially available from IBM Corporation. In the context of the RISC System/6000 workstation implementation, a preferred choice for the network would be TCP/IP and accordingly include in client 2 and server 3 workstations AIX type TCP/IP Server code, also commercially available from IBM Corporation.
Client workstations 2 transmit over network 1 requests that server 3 execute certain application program code responsive to commands issued by the client. In particular, the invention is directed to the server 3 executing in the multiprocessing mode of the aforementioned OS/2 or AIX operating systems, so that the various requests from the multiple clients timeshare the resources of server 3. The purpose of the server monitor is to determine and display, such as by way of video display 4, the status of each process associated with each individual application program invoked by a respective client. This is in contrast to presently available operating system monitors which merely describe the overall state of the server and not the states of the individual processes. Those differences become crucial when a client, network administrator, software developer or field engineer needs to know the specific state of a client's process, not only in ascertaining its momentary status, but also in identifying, when, where and in what code and under what conditions process execution is temporarily or permanently interrupted.
FIG. 2 schematically depicts the functional relationships between the processes and system elements needed to implement the present invention. Server workstation 3 executes multitasking operating system code 6, a code suitable to manage by software processes the relatively concurrent execution of application program code 7 and related application processes 8 of the multiple clients 2 (FIG. 1) served by workstation 3. The present invention provides systems and methods for monitoring individual server processes at the granularity of the application program in contrast to the network or server operating system. Information regarding the status of individual server processes is acquired and made available for system administrator or user consideration.
An example of a multiprocessing server application program for which the present server process monitor has particular relevance is the IBM Parallel Database Manager Server program, commercially available from IBM Corporation. The Parallel Database Manager Server program is composed of multiple server processes, which include a pool of database manager agent processes, a deadlock detector process, a parallel database communication process, client communication processes, host gateway communication processes, and high availability processes. These server processes cooperate to provide the database manager service to the individual applications invoked by the clients. The process synchronization among the server processes is implemented through the process concurrence services of the base operating system, in this case the earlier noted OS/2 or AIX operating system. Semaphores, signals, and locks are examples of process concurrence services. The server processes also communicate among each other by sending information through shared memory or message queues.
These server processes can be forced into a wait states, which states can be induced by a number of different reasons. For example, an agent process might wait for a reply message from a parallel database communication process, or for a new application request. Similarly, two agent processes might attempt to access the same database record at the same time, or a group of processes might be trapped into a deadlock situation. With so many server processes working concurrently in the system, a system level, but process specific, tool to monitor the server processes is needed by software developers, network administrators or service engineers when diagnosing malfunctions in a multiprocessing server.
The present server process monitor differs from the operating system process monitor. The process monitor of the base operating system describes the states of each process in terms of operating system parameters. For instance, the "PS" command in the AIX operating system causes the display of the user id, the process id, the parent process id, the start time, and the execution command of each AIX process. In contrast, the present server process monitor describes the server processes in terms of the state of each client's application process. Examples of valuable state information about the progress of an "agent" type process for the Parallel Database Manager Server are as follows:
in free agent queue
waiting on the database manager queue
waiting on the parallel database queue
processing database manager requests
processing parallel database requests
waiting on buffer queue services connection: token=xxxx, sid=x,
waiting on closing buffer queue services connection: token=xxxx
waiting on buffer distribution services message: token=xxxx, sid=x, rid=x
waiting on buffer queue services data: token=xxxx, sid=x, rid=x
waiting on fast communication manager memory request
waiting on parallel database agent shared information
waiting on table access: table token=xxxx
waiting on access to data management services database control block
waiting on access to data protection services database control block
waiting to access to data protection services read buffer
waiting to write a log
deadlock detector waiting for time out
waiting for log I/O done
From the examples of the states identified above it becomes apparent that the server process monitor provides state particulars about each individual server application process in contrast to merely identifying the presence of an application process.
Multiprocessing server 3 depicted in FIG. 2 includes within its memory 9 a shared memory region 11. Server process control blocks 5 and synchronization object descriptors/blocks 10 are defined within shared memory 11. The placement of the control blocks and descriptors within the shared range of the memory addresses ensures that all the processes are accessible to all of the control blocks of the process monitor. The common access also applies to server process monitor code 12, which defines a distinct server process status utility process 13. Control block and descriptor information is extracted and visually depicted on video display 4 by the utility process.
A server process is described in shared memory 11 by a server process control block. Such a block is created when a server process is generated and registered with the server process monitor. The server process control block preferably contains four fields:
proc -- id: the process id of the server process.
proc-type: by the nature of the server process, the server processes can be grouped into different process types. A server process can be a database agent process, communication process, a deadlock detector, et cetera. New process types can be created by the applications.
proc -- state: a process is either in "runnable" or "waiting" state.
syn -- obj -- handle: the handle of the synchronization object which associates with the server process. The handle of the synchronization object is the address of the synchronization object descriptor.
When a new server process type is created, a server process type record is also created. Each server process type record contains the following fields:
proc -- type: the server process type identification.
proc -- desc: a text string that describes the function of the server process.
Synchronization objects such as latches, semaphores, wait post areas, or message queues are described by synchronization object descriptors in the server process monitor. Each synchronization object descriptor preferably contains the following data fields:
syn -- obj -- type: the types of the synchronization objects, including latch, wait post area, or message queue.
syn -- obj -- id: each synchronization object type has its own unique identifier. Latches are identified by latch handles, wait post areas are identified by wait post area handles, and message queues are referenced to message queue descriptors.
syn -- obj -- desc: a text string that describes the purpose of the synchronization object.
A set of application program interfaces suitable to use the data structures and described above is defined through a combination of a description, pseudocode, and correspondence to a flow diagram of those depicted in the drawings.
The first application program interface (API) is to create a new server process type.
The input is:
proc -- desc: a text string that describes the function of the server process.
The output is:
proc -- type: the server process type identification.
Pseudocode defining the creation of a new server process type is as follows:
create a new server process type.
allocate a new server process type record.
define the server process type identification.
initialize the server process type record with the server process type identification and the server process description.
return the server process type identification to the application program caller.
The flow diagram corresponding to the steps necessary to create a new server process type appears in FIG. 4, which figure relates to the process composite in FIG. 3.
After a new server process is created, it must register with the server process monitor. In that situation the input is:
proc -- id: the process id of the server process.
proc -- type: the server process type identification.
The registration process identified as reg -- svr -- proc has its output:
ret -- sta: return status.
Pseudocode corresponding to the registration of a server process is as follows:
create a server process control block for the server process.
initialize the server process control block with the process id and the server process type.
return control to the caller of the application program.
The flow diagram corresponding to the registration of a server process appears in FIG. 5, which is likewise a part of the composite depicted in FIG. 3.
The next application program interface (API) involves a change of the process type: chg -- svr -- proc. The change of the server process type from one to another involves an input of:
proc -- id: the process id of the server process
proc -- type: the new server process type identification.
The output of the application program interface is:
ret -- sta: return status
Pseudocode for changing a server process is as follows:
update the server process control block of the server process with the new server process type.
return control to the caller in the application program.
The corresponding flow diagram is depicted in FIG. of the drawings.
The application programming interface (API) reg -- syn -- obj registers a synchronization object such as a latch, semaphore, or message queue. The registration must be accomplished before it is referenced by a server process. The registration involves an input of:
syn -- obj -- type: the types of synchronization objects can be latches, wait post areas, or message queues. The synchronization object type identifications are defined by the server process monitor.
syn -- obj -- id: each synchronization object type has its unique identifier. The synchronization object identifiers are defined by the base operating system when they are created.
syn -- obj -- desc: a text string to describe the function of the synchronization object.
As an output the API provides:
syn -- obj -- handle: the address of the synchronization object descriptor.
Pseudocode for implementing the API is set forth below in correspondence to FIG. 7 of the drawings.
Create a synchronization object descriptor.
Update the synchronization object descriptor with a synchronization object type, synchronization object id, and the synchronization object description.
Return the synchronization object handle to the caller in the application program.
Before the server process calls the base operating system services to operate the synchronization object, the server process must call the wait -- syn -- obj to associate itself with the synchronization object. The API involves an input of:
proc -- id: the process id of the server process
syn -- obj -- handle: the address of the synchronization object descriptor.
As an output of the API there is provided:
ret -- sta: return status
Pseudocode corresponding to the flow diagram in FIG. 8 of the drawings is set forth below:
use the process id of the server process to locate the server process control block.
change the process state of the server process control block from the: "runnable" to the "waiting" state.
update the synchronization object handle of the server process control block.
return control to the caller in the application program.
When the server process returns from the executing operations on the synchronization object, the server process calls run -- svr -- proc to change the server process state from "waiting" to "runnable".
The input is:
proc -- id: the process id of the server process.
The output is:
ret -- sta: return status.
The corresponding pseudocode, is depicted by flow diagram in FIG. 9, involves the follows:
Change the server process from "waiting" to "runnable" in its server process control block.
Return control to the caller in the application program.
A server process can be deregistered with the server process monitor by calling the dereg -- svr -- proc API. The server process control block of the server process will thereupon be freed. When a server process is terminated, by convention or otherwise, the server process exit routine calls dereg -- svr -- proc to deregister it from the server process monitor. The input to the API is:
proc -- id: the process id of the server process. The output is:
ret -- sta: return status.
Pseudocode corresponding to the flow diagram in FIG. 10 is as follows:
free the server process control block of the server process.
return control to the caller in the application program.
A synchronization object is deregistered from the server process monitor by calling an API identified as dereg -- syn -- obj. The syn -- obj -- type in the synchronization object in descriptor is changed to invalid -- obj. The corresponding syn -- obj -- id in the synchronization object descriptor is changed to zero. The syn -- obj -- desc in the corresponding synchronization object descriptor is changed to a null string pointer.
The input to the API is:
syn -- obj -- handle: the address of the synchronization object descriptor.
The output the of the API is:
ret -- sta: return status.
The flow diagram for this API appears in FIG. 11 and corresponds to the following pseudocode:
change syn -- obj -- type in the synchronization object descriptor to invalid -- obj.
change syn -- obj -- id in the synchronization object descriptor to zero.
change syn -- obj -- desc in the synchronization object descriptor to null.
return control to the caller in the application program.
An API utility suitable to convey server process status information to the video display, such as video display 4 in FIG. 2, is presented by flow diagram in FIG. 12. The server process status utility can be issued from any window of the base operating system. The utility spawns a process, process 13 in FIG. 2, which has read access to the server process monitor residing in shared memory 11 of server workstation 3, as depicted in FIG. 2. The utility reads the server process control block and synchronization object descriptor information and provides that information to video display terminal 4 in the format selected by the user. In a preferred form, the utility provides the user with options for selecting the server process status by process type, process state or the process id.
The utility includes resources for interpreting the synchronization object descriptor on which a process is waiting in those situations where the server process is in a waiting state.
Pseudocode to display the server process status, corresponding to the flow diagram in FIG. 12, is set forth as follows:
read all the server process control blocks.
if the server is runable.
display the server process status.
else.
read the synchronization object descriptor.
endif.
return control to the caller in the server process status program.
Though the invention has been described and illustrated by way of a specific enbodiment, the methods, systems and programs encompassed by the invention should be interpreted consistent with the breadth of the claims set forth hereinafter.
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A system, method and program product for determining and displaying the status of client application programs executing on a multiprocessing server. Server process control blocks and synchronization object descriptors are created in the shared memory of the server. Application program interfaces APIs are linked to the control blocks and descriptors during the execution of the various multiprocessing application programs. A status utility related to the service process monitor selectively accesses information from the control blocks and descriptors to determine the status of the individual multiple processes executing on the server workstation. In a preferred form, the status information is conveyed to and displayed on a video display associated with the service process monitor. In contrast to operating system monitors which disclose the status of all processes as a whole, the present server process monitor particularizes the information to the specific client process. Thereby, the information is of a granularity to identify processes which are hung up on semaphores, message queues, or the like. The information is at the level used by a system administrator or software developer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generaly relates to a resuscitation process of animal fibers, more particularly, to a process for resuscitating natural crimps inherent in the animal fibers, retaining and recovering fluffy and soft touch, removing foul odor peculiar to the animal fibers, and preventing parasitism of insects and growth of mold.
2. Description of the Prior Art
Animal fibers such as feather, wool and mohair have long been for use in bedding, clothings, carpets and the like. Above all, feather and wool have excellent heat retaining property, lightweight, soft touch and the like and therefore have been in widespread use for high-grade bedding in recent years. Wool has natural crimps having superior heat retaining property and soft touch, but is normally subjected to a crimp processing then supplied for practical use. Although the crimp processing is attained by physical or chemical treatment, it involves a fatal drawback of injuring fibers per se and thus damaging durability.
Moreover, the animal fibers contain protains such as keratin as a major ingredient so that they emit foul odor inherent in proteins when ventilation is poor. For deodorization and degreasing, surface active agents are used in greater amounts but those not only damage fibers, but require a great quantily of water for washing to thus raise problems in equipment and cost. Still worse, waste water after washing leads to environmental pollution.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a process for resuscitating natural crimps inherent in animal fibers whereby fluffy volume and soft feeling are retained and restored.
It is another object of the present invention is to provide a process for eliminating foul odor inherent in animal fibers and for preventing parasitism of insects as well as growth of mold.
It is a further object of the present invention to provide a process for extending the life of animal fibers.
These and other objects of the present invention together with the advantages thereof will become apparent to those skilled in the art from the detailed disclosure of the present invention as set forth hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation showing deodorization test by use of a negative ion generator.
FIG. 2 is a schematic representation in which a head space gas is taken out for the measurement by a gaschromatography.
FIG. 3 and FIG. 4 are chromatograms for feathers subjected to the treatment by a negative ion generator and for non-treated feathers, respectively.
The present invention has been completed after a series of studies on the discovery that the foregoing drawbacks can be solved by charging fibers with negative ions, with a further result that parasitism of harmful insects and the like is prevented.
DETAILED DESCRIPTION OF THE INVENTION
The present invention encompasses a process for resuscitating animal fibers which comprises charging with negative ions animal fibers such as feather, wool, mohair, alpaca, cashmere, camel, vicugna and the like containing keratin as a main ingredient.
The charging of negative ions may be achieved using or not using an electroconductive board, through an electroconductive operation stand, internal walls of an equipment, pipe lines, conveyers and the like in at least one step selected from a package-opening steps, a defibering step, a carding step, a mixing step, a resin-coating step, a drying step, a stock step, a producing step of beddings, carpets and the like, a storage step of products or the like. The charging of negative ions may also be effected in an exclusive treating equipment.
When the treating equipment is used, the temperature is preferably between 20° C. and 35° C. and the humidity is preferably between 60% and 90%. Moreover, it is very effective to charge the animal fibers with negative ions while blowing off steam onto the animal fibers. Moreover, it is also effective to use water containing negative ions in a washing step. It is possible to effect concentrated charging of negative ions only to the side of the animal fibers by providing an insulating sheet at the backside of the electroconductive board.
The animal fibers are normally charged positive and therefore it is possible to remove dust more effectively by charging the dust positive to thus cause electric repulsion between the fibers and the dust in a dust-removal step. In this case, a dust-collecting effect is enhanced by charging a dust collector itself and/or air negative because of electric attracitve action of the collector and air.
Hereinafter, the present invention will be explained in more detail by away of experimental examples that follow, to which examples the invention is in no way limited.
EXPERIMENT 1
As was illustrated by FIG. 1, about 12 g of bedding feathers (1) were wrapped in a polyester net (2) and those were surrounded by a negative ion generator (3). Those were placed in a vinyl bag (4) and an inlet (5) was fastened to isolate the external atmosphere. Electric power was supplied to generate negative ions with which the feathers were charged for one month. As a negative ion generator, "ION ROLL (tradename, manufactured by RAKKASAN Co., Ltd.)" generators having an output of 1.5 W and 0.2 W were served.
For comparison, a similar experiment was carried out with the exception that the feathers were not subjected to the treatment by the negative ion generator.
After one month, as shown by FIG. 2, 5 g of treated and non-treated feathers were placed in 500-ml conical flasks (6), respectively, which were sealed with silicone rubber corks (8) having a hole (7) for samping, then the flasks (6) were placed in a thermostat and heated at 60° C. for 3 hours, then gas in a space of the flasks (head space gas) was subjected to the measurement by a gaschromatography.
The obtained results were given in FIG. 3 (non-treated feathers) and FIG. 4 (feathers treated with an output of 1.5 W). In these figures, the outstanding two pearks are hydrogen sulfide (H 2 S) and methyl mercaptan (CH 3 SH) and the small peak adjacent thereto appears to be methyl sulfide (CH 3 SCH 3 ).
As clear from the comparison of the two, an unexpectedly outstanding deodorization effect was admitted by subjecting feathers to the treatment by the negative ion generator. With the output of 0.2 W, the deodorization effect could hardly be obtained.
EXPERIMENT 2
As was shown by FIG. 2, 10 g of wool were placed in two conical flasks with humidity of about 90%. The one was sealed tightly with a silicone rubber cork and subjected to the treatment by the negative ion generator with an output of 1.5 W, while the other was isolated from the external atmosphere. The both flasks were left to stand for two months.
After the lapse of two months, the wool treated with negative ions are free of odor, whereas the wool non-treated emitted disagreeable odor inherent in protein. Gases in the flasks were subjected to the measurement by a gaschromatography, the main ingredients were hydrogen sulfide, methyl mercaptan and methyl sulfide.
EXPERIMENT 3
10 g of Wool were taken from a quilt which were being used actually and placed in two 100-ml neasuring cylinders to adjust the level to 50 ml. The humidity in the flasks was controlled to about 75% and isolated from the external atmosphere by seal with a polyethylene film. The one flask was treated with negative ions while the other was left to stand without such treatment.
The difference in volume between the two starts to be observed after 15 days. After three months, the level of negative ion-treated wool increased up to 64 ml, i.e., raising the volume by 30% approximately, whereas non-treated wool retained the original level.
As is apparent from foregoing, the present invention is capable of not only producing surprising deodorization effect, but retaining and reviving voluminous, fluffy and soft feel and touch inherent in the animal fibers. Still further, it was also ascertained that parasitism of harmful insects and growth of mold are effectively impeded by the charging of negative ions. The reasons why such marked effects can be provided are not made clear, but presumably the animal fibers are always held fresh by electric stimulation resulting from negative electric potential so that the fibers which lost crimps are not only recovered, but the fibers are kept from harmful insects. Accordingly, the present invention may also be applied to beddings during actual use. For instance, when the present invention is applied to quilts containing wool which are being actually used, release of foul odor and loss of crimps are prevented, while, in the case of quilts which lost crimps to be masses of fibers, emitting disagreeable odor, the fibers are resuscitated to result in possessing confortable soft touch, heatretaining property and lightweight.
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Disclosed is a process for resuscitating animal fibers which comprises charging animal fibers such as feather and wool with negative ions. The present invention not only permits the animal fibers to keep or revive fluffy and soft touch inherent therein, prevents harmful insects from parasitism, but removes foul odor peculiar to protein.
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RELATED APPLICATIONS
[0001] The present application is based upon and claims priority to U.S. Provisional Patent Application Ser. No. 61/234,462, filed on Aug. 17, 2009.
BACKGROUND
[0002] Those suffering from lymphatic and/or circulatory disorders are commonly prescribed a compression garment for wear to help in the reduction and management of swelling and circulation in their extremities. For example, compression garments configured to surround one's arm or leg are typically used to treat lymphedema. Lymphedema is an accumulation of lymphatic fluid resulting from impairment of the lymphatic transport system. Lymphatic fluid can build up in different affected areas of the body, especially in the arms and legs. Lymphedema can cause pain, chronic inflammation, fibrosis, and reduced mobility. In this regard, compression garments are typically placed over the affected extremity in order to counteract fluid build-up.
[0003] Compression garments, such as compression sleeves, compression gauntlets, and compression stockings, are typically made from an elastic material. The elastic material, for instance, may comprise an elastic knitted woven material.
[0004] In order for the compression garments to function properly, the garments are typically designed to cover substantially the entire extremity. For example, compression sleeves typically cover the entire arm extending from the wrist to the shoulder of the wearer. Similarly, compression stockings typically extend from the foot to the hip of the wearer although knee-high stockings are also available. Selecting a compression garment with the appropriate amount of compression is critical to successfully treating lymphedema or other circulatory diseases. If the garment provides too little compression, for instance, the garment may be ineffective in preventing fluid build-up. Too much compression exerted by the garment, on the other hand, can damage the tissues.
[0005] Compression garments are typically not worn while sleeping. If worn while sleeping, for instance, the garment may provide too much compression when the body is inactive. Most compression garments also need to be replaced every four to six months since the elastic properties of the garments tend to degrade. Thus, compression garments normally have to be removed and applied at least once during the day. Unfortunately, most patients prescribed these highly elastic garments find it difficult to don them. While donning the arm sleeve, one arm is rendered useless while the opposite arm is left to pull on the garment. Not only is the individual trying to use one arm for a traditionally two arm event, the patient may be further compromised by skin integrity, immobility, inflexibility, obesity, weakened from a medical condition or suffer from limited mobility or other condition limiting their ability to properly don the extremity compression garment.
[0006] In order to improve and facilitate the donning of compression garments, in the past, it was recommended to apply a thin layer of cornstarch or powder to the extremity prior to placing the compression garment on the extremity. Some manufacturers also recommend wearing rubber or vinyl gloves while putting on the compression garment to provide a better grip on the fabric and to prevent one's fingernails from damaging the fabric or one's skin.
[0007] In view of the above problems experienced in donning compression garments, however, a need currently exists for a device and a method for facilitating application of a compression garment onto one's extremities.
SUMMARY
[0008] In general, the present disclosure is directed to an extremity garment donning assist device that is designed to assist an individual in donning a compression garment onto an extremity, especially a stocking or other leg garment. The garment donning assist device of the present disclosure is particularly well suited to providing assistance to those who may be suffering from a medical condition and lack flexibility or suffer from limited mobility.
[0009] In one embodiment, for instance, the present disclosure is directed to an extremity garment donning assist device that includes a rigid structure having a top edge, a bottom edge, and a pair of opposing side walls. The side walls extend outwardly to define an open cylindrical configuration that extends from the top to the bottom of the rigid structure. In one embodiment, for instance, the side walls are curved such that the rigid structure has an arcuate-shaped cross section. For instance, the arcuate-shaped cross section can form an open channel that has walls extending from about 120° to about 210°, such as from about 150° to about 175°.
[0010] In one embodiment, the top edge of the rigid structure can be rounded in order to facilitate application of the compression garment. The bottom edge, however, can be flat for maintaining the rigid structure in an upright configuration when used on an adjacent surface. In addition, the rigid structure can include an interior surface that is relatively smooth in comparison to an exterior surface. The rougher exterior surface, for instance, may facilitate holding a compression garment in place, while the smooth interior surface may facilitate application of the garment to an extremity, such as one's leg or foot. Overall, the rigid structure has a size such that a compression garment can be slid over the top edge leaving an outstretched opening. The outstretched opening is for receiving a users' extremity for donning the compression garment.
[0011] In one embodiment, the rigid structure can include a flattened area located adjacent the bottom edge. For instance, the flattened area can be located in between the two side walls. The flattened area can extend the entire length of the rigid structure, can have a length that is less than ½ the length of the rigid structure, or can have a length that is less than ¼ the length of the rigid structure. In one particular embodiment, for instance, the flattened area can have a width of from about 1.5 inches to about 2.5 inches and can have a length of from about 0.75 inches to about 1.75 inches. In one embodiment, an anti-skid member can be located on the flattened area on the exterior surface of the rigid structure. The anti-skid member, for instance, can be made from a compressible material, such as an elastomeric material. The anti-skid member can prevent the device from slipping on a surface, such as a floor, when an extremity such as a foot, is being inserted into a compression garment.
[0012] In one embodiment, the rigid structure can also define an indentation opposite the flattened area. The indentation can project outwardly from the interior surface of the rigid structure. The indentation can form part of the bottom edge of the rigid structure and can have a size so as to allow the rigid structure to stand upright when placed on a flat surface.
[0013] The present disclosure is also directed to a process for donning a compression garment. The process includes the steps of placing a compression garment over the extremity garment donning assist device as described above. The compression garment is placed over the top edge of the rigid structure, turned partially inside-out, and pulled down onto the device so as to form an outstretched opening. The device is then placed on a flat surface such that the outstretched opening is perpendicular to the surface.
[0014] An extremity, such as a foot, is inserted into the outstretched opening of the compression garment. With a forward and downward motion, the foot can be used to pivot the extremity garment donning assist device into an upright configuration. During this motion, the compression garment is caused to slide up and over the foot of the user. If any part of the compression garment is remaining on the extremity garment donning assist device, the remainder can be slid off the device and onto the calf or leg of the user.
[0015] Other features and aspects of the present disclosure are discussed in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
[0017] FIG. 1 is a front perspective view of one embodiment of an extremity garment donning assist device made in accordance with the present disclosure;
[0018] FIG. 2 is a bottom plan view of the donning assist device illustrated in FIG. 1 ;
[0019] FIG. 3 is a top plan view of the donning assist device illustrated in FIG. 1 ;
[0020] FIG. 4 is a back perspective view of the donning assist device illustrated in FIG. 1 ;
[0021] FIG. 5 is a side view of the donning assist device illustrated in FIG. 1 ;
[0022] FIG. 6 is a side view of one embodiment of a garment donning assist device made in accordance with the present disclosure illustrating a compression garment loaded on the device;
[0023] FIGS. 7 through 9 are side views of one embodiment of an extremity garment donning assist device made in accordance with the present disclosure showing one embodiment of a process for donning a garment using the device; and
[0024] FIG. 10 is a front perspective view of another embodiment of an extremity garment donning assist device made in accordance with the present disclosure.
[0025] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
DETAILED DESCRIPTION
[0026] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.
[0027] In general, the present disclosure is directed to a garment donning assist device that is particularly well suited for applying compression garments, such as compression sleeves, compression gauntlets, and compression stockings onto the extremities of a wearer. Such compression garments are typically prescribed to those suffering from lymphedema or circulatory disorders. The compression garments are intended to provide compression to an extremity, such as an arm or leg, for preventing fluids from accumulating within the treated region. Compression garments, in order to provide the needed therapy, are highly elastic and somewhat difficult to place over one's arm or leg without the assistance of a caregiver. Further, since many individuals using compression garments suffer from lymphedema or circulatory diseases, the problems associated with donning the garments become exacerbated due to the health state of the wearer. For instance, individuals suffering from the above conditions are often in pain and suffer from chronic inflammation, reduced mobility and may also even suffer from skin ailments.
[0028] In this regard, the present disclosure is directed to a garment donning assist device that not only assists an individual in placing a compression garment on an extremity, such as an arm or leg, but also serves to ensure that the garment is properly located and positioned on the extremity to be treated. For example, referring to FIGS. 1 through 5 , one embodiment of a compression garment donning assist device 10 is shown. As illustrated, the garment donning assist device 10 includes a rigid structure 12 .
[0029] The rigid structure 12 includes a top edge 16 , a bottom edge 18 , a pair of extending side walls 20 and 22 and a back wall 21 . The side walls 20 and 22 extend in a manner that forms a cylindrical configuration, such as an open channel 24 as shown in FIG. 1 .
[0030] In the embodiment illustrated in FIGS. 1 and 2 , the side walls 20 and 22 are curved such that the rigid structure 12 has an arcuate-shaped cross section. It should be understood, however, that the open channel 24 can have various other shapes and configurations. For example, in an alternative embodiment, the side walls 20 and 22 may extend along a more linear path. In this embodiment, for instance, the rigid structure 12 may have more of a polygon-like cross sectional shape. For example, in one embodiment, the rigid structure 12 may have an open rectangular cross sectional shape.
[0031] In general, the cross sectional shape of the rigid structure 12 is intended to partially encircle an individual's extremity, such as an arm or leg. As will be described in greater detail below, the shape is also used to form an opening in a compression garment for insertion of an extremity.
[0032] The amount the side walls 20 and 22 of the rigid structure 12 are extended may vary depending upon the particular application and various factors. When the rigid structure 12 has an arcuate-shaped cross section, for instance, the side walls may extend from about 120° to about 210°, such as from about 150° to about 175°. In the embodiment illustrated in FIG. 1 , for instance, the rigid structure 12 forms a substantially open half cylindrical configuration.
[0033] The rigid structure 12 can be made from various different materials as long as the structure has sufficient rigidity to hold a compression garment. For instance, the rigid structure 12 can be made from a solid material. For example, the rigid structure can be made from a single piece of metal or from a structural plastic material. When formed from a plastic material, the rigid structure can be made from any suitable polymer. For instance, the rigid structure can be made from a polyolefin, a polyester, a polyamide, a polycarbonate, a polystyrene, a copolymer thereof, or mixtures thereof. In one embodiment, for instance, the rigid structure 12 can be made from a single continuous piece of plastic comprised of a copolyester, such as PETG.
[0034] Alternatively, the rigid structure 12 , instead of being made from a continuous solid piece of material, may have a grid-like structure or apertured structure.
[0035] In one embodiment, the rigid structure 12 can include a first, interior surface that defines the open channel and a second, exterior and opposite surface. In one configuration, the first surface can be relatively smooth, while the opposite second surface can be textured. The second surface can be textured so as to better hold a compression garment in place while the garment is being donned by a user. The second side of the rigid structure 12 can be textured using any suitable technique. For instance, the mold used to form the plastic material may include undulations that create a textured surface on the second side.
[0036] In the embodiment illustrated in FIG. 1 , the open channel 24 formed by the rigid structure 12 generally has the same dimensions or size from the top edge 16 of the structure to the bottom edge 18 . In other embodiments, however, the open channel 24 may taper in one direction. For instance, the open channel 24 may decrease in size from the top edge 16 to the bottom edge 18 . The dimensions of the rigid structure 12 can vary dramatically depending upon the size of the user and the type of compression garment being donned. For exemplary purposes, when designed to don stockings, for instance, the rigid structure can have a length of from about 6 inches to about 10 inches, such as from about 7 inches to about 7.5 inches. The diameter of the open channel 24 , on the other hand, can generally be from about 3 inches to about 6 inches. For instance, in one embodiment, the diameter of the open channel can be from about 3.75 inches to about 4.25 inches.
[0037] As shown in FIGS. 1 , 2 and 3 , in one embodiment, the top edge 16 can have a different shape than the bottom edge 18 . For instance, the top edge 16 can have a rounded shape. Having a rounded shape allows for a compression garment to slide over the device without being snagged on any sharp edges. The bottom edge 18 , on the other hand, can be flat to provide stability. For instance, as will be described in greater detail below, the garment donning assist device 10 during use is typically placed upright on a flat surface, such as a table or floor. Having a flat bottom edge 18 makes the device more stable when placed upright on an adjacent surface, especially when pressure is applied to the device.
[0038] As shown particularly in FIGS. 1 , 2 , 4 and 5 , the garment donning assist device 10 can further include a flattened area 30 . When present, the flattened area 30 can serve several functions. The flattened area 30 , for instance, provides stability to the garment donning assist device 10 when either placed in a vertical position as shown in FIG. 1 on a surface or when placed in a horizontal position as shown in FIG. 7 on a surface. The flattened area 30 can also receive an anti-skid member 34 as shown in particularly in FIGS. 2 and 4 that prevents the donning assist device 10 from slipping or sliding on a surface when pressure is applied to the device and the device is pivoted as will be described in greater detail below.
[0039] In the embodiment illustrated, the flattened area projects outwardly from the exterior surface of the rigid structure 12 . In an alternative embodiment, however, the flattened area may be flush with the exterior surface of the side walls. In this embodiment, the side walls would extend from the flattened area 30 .
[0040] When the flattened area 30 extends outwardly out from the exterior surface of the rigid structure 12 , as shown in FIGS. 1 and 2 , an indentation 32 can also be formed along the interior surface of the rigid structure. As shown in the figures, the indentation 32 corresponds in size and shape to the flattened area 30 . Having an indentation as shown creates a tab along the bottom edge 18 that maintains the garment donning assist device 10 in an upright configuration when placed on a surface, such as a floor. The indentation 32 can also have a size and shape so as to facilitate a foot or arm during donning of a garment as the foot or arm is brought down through the open channel 21 . For instance, when inserting a foot through the open channel of the garment donning assist device, the foot will generally descend vertically through the channel and then begin to horizontally emerge from the channel. During this transition from vertical to horizontal motion, the indentation may provide extra space for the heel.
[0041] In the embodiment illustrated in FIGS. 1 and 2 , the flattened area 30 is located adjacent to the bottom edge 18 and only extends over a portion of the length of the rigid structure 12 . It should be understood, however, that the flattened area 30 (and corresponding indentation 32 ) may extend along the entire length of the rigid structure 12 . In other embodiments, the flattened area 30 may have a length that is less than about ½ the length of the rigid structure, such as by having a length that is less than ¼ length of the rigid structure. In one particular embodiment, for instance, the flattened area 30 and the corresponding indentation 32 may have a width of from about 1.5 inches to about 2.5 inches and have a length from about 0.75 inches to about 1.75 inches.
[0042] As shown in FIGS. 2 and 4 , the anti-skid member 34 is attached to the flattened area 30 . The anti-skid member may cover the entire flattened area 30 or only a portion of the flattened area 30 . in addition, the anti-skid member may terminate at the bottom edge 18 of the rigid structure or may wrap around the bottom edge of the rigid structure.
[0043] The anti-skid member 34 can be made from any suitable material that will increase the friction of the rigid structure against an adjacent surface. In one embodiment, for instance, the anti-skid member 34 may be made from a compressible material, such as an elastomeric material. The elastomeric material, for instance, may be a natural rubber or may be formed from a synthetic polymer.
[0044] In operation, the garment donning assist device 10 can be used to don a compression garment to an upper or lower extremity. The device aides in donning compression garments where strength or medical conditions inhibit the compliance of donning because of the difficulty in pulling the garment completely up one's arm or over one's leg. One method of using the garment donning assist device 10 is illustrated in FIGS. 6 through 9 . In FIGS. 6 through 9 , a compression garment or stocking is shown being positioned over a user's foot and calf.
[0045] In one embodiment, in order to use the garment donning assist device 10 , as shown in FIG. 6 , the device is first placed vertically on a surface, such as a floor. A compression garment 50 is then prepared for application to the device. As shown in FIG. 6 , for instance, the compression garment 50 is draped through the inside open channel of the device. The outer edge of the garment 50 is then draped over the top edge of the rigid structure 12 . In particular, the garment 50 is partially folded inside out and folded over the top of the rigid structure. Depending upon the size of the compression garment 50 , the garment 50 can be pulled over the entire length of the rigid structure 12 or only over a portion of the rigid structure. As shown, once the compression garment 50 is positioned on the donning assist device 10 , an outstretched opening 52 is formed at the top that is then ready to receive a user's foot.
[0046] Compression sleeves, for instance, can be formed from various materials. Desirably, the compression sleeve stretches in at least two different directions. Materials that may be used to form the compression sleeve include, for instance, elastic foam materials, woven materials, knitted materials, films, and combinations thereof. For example, in one embodiment, the compression sleeve comprises a knitted fabric containing elastic threads, yarns or filaments. Alternatively, the compression sleeve may comprise a woven fabric containing elastic yarns. In still another embodiment, the compression sleeve may comprise an elastic film alone or in combination with various woven and nonwoven materials. For example, in one embodiment, the compression sleeve may comprise an elastic film bonded to a stretchable fabric.
[0047] As shown in FIG. 7 , once the compression garment 50 is properly loaded onto the donning assist device 10 , the device can be placed horizontally on a surface, such as on the floor. A user's foot is then inserted into the outstretched opening 52 . The open channel formed by the rigid structure 12 can have a shape and size designed to produce an outstretched opening having dimensions that facilitate insertion of the foot.
[0048] Once the foot is inserted into the outstretched opening, with a forward and downward motion, the foot is pivoted until the device is in a vertical upright position as shown in FIGS. 7 through 9 . As also shown in the figures, during this motion, the entire foot is inserted into the compression garment 50 . Thus, in one motion, the foot is inserted into the compression garment while the donning assist device pivots from a horizontal position to a vertical position.
[0049] Once the donning assist device 10 is in a vertical position as shown in FIG. 9 , the remainder of the compression garment 50 can then be pulled up the leg of the wearer and off the donning assist device 10 . The open channel formed by the rigid structure 12 allows the foot and leg of the wearer to be released from the donning assist device once the garment is properly positioned on the wearer.
[0050] Referring now to FIG. 10 , an alternative embodiment of a donning assist device 110 made in accordance with the present disclosure is shown. In this embodiment, the donning assist device 110 includes a rigid structure 112 comprising a pair of curved side walls 120 and 122 . The side walls 120 and 122 form an open cylindrical configuration defining an open channel 124 extending along the length of the rigid structure. The rigid structure further includes a top edge 116 and a bottom edge 118 . As shown, the top edge 116 can have a rounded configuration, while the bottom edge 118 can be generally flat.
[0051] In the embodiment illustrated in FIG. 10 , the donning assist device 110 does not include any indentation or flattened area on the interior or exterior surface of the rigid structure. Depending upon the material used to form the rigid structure, the other features described above with respect to FIG. 1 may be eliminated while still attaining a very functional product.
[0052] These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.
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An extremity garment donning assist device, includes a rigid structure that, in one embodiment, contains no handles or other extending members. The device has an open cylindrical configuration that is well suited to placing compression garments on a user or patient. For instance, the device is well suited to placing a stocking on the foot of a wearer. When using the device, a compression garment is turned partially inside out over a top edge of the device forming an outstretched opening. A user then inserts one's foot into the outstretched opening. In a pivoting motion, the foot is then pushed down through the device causing the compression garment to at least partially or entirely release from the device for placement on a person's foot and leg. In order to assist in the pivoting motion, the garment donning assist device can include a flattened area, an indentation and/or an anti-skid member.
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BACKGROUND OF THE INVENTION
[0001] For purification of exhaust emissions from a car (a vehicle) having a diesel engine, an emission control system is used in which a adsorption type NOx catalyst, a selective reduction type NOx catalyst and a diesel particulate filter are combined together to prevent the emission of NOx (oxides of nitrogen) and PM (particulate matter) which are contained in exhaust emissions from a diesel engine to the atmosphere
[0002] An emission control system like this adopts a construction in which a catalyst referred to as a pre-stage catalyst such as an oxidation catalyst, a NOx trap catalyst or a selective reduction type NOx catalyst is provided in an interior of an exhaust pipe portion which expels exhaust gases discharged from the engine to the outside thereof, and a fuel injection valve (such as one for adding a reducing agent) which injects a fuel required for reaction of the catalyst to an upstream side of the catalyst, for example, the oxidation catalyst.
[0003] In the emission control system, for efficient reaction of the pre-stage catalyst, it becomes important that the injected fuel is sufficiently mixed with the exhaust gases before the fuel flows into the pre-stage catalyst.
[0004] For this to happen, a sufficient fuel spray travel needs to be secured in a segment from the fuel adding valve to the catalyst.
[0005] However, as it is required that a location where a catalyst is installed is secured in the vicinity of an exhaust side of an engine in order to meet the recent tendency of enhancing the exhaust emission purifying efficiency at the time of cold start, it becomes difficult to ensure such a sufficient fuel spray travel. An example of an engine adopting the aforesaid construction is disclosed in JP-A-2005-127260.
[0006] Namely, in order to make full use of the catalyst installation design described above, as is disclosed in JP-A-2005-127260, a fuel injection valve has to be provided at a part of an exhaust pipe which lies directly upstream of the catalyst, that is, for example, at a bent portion of the exhaust pipe. To make this happen, it becomes difficult to ensure a long enough fuel spray travel for mixture of fuel with exhaust gases between the fuel injection valve and the catalyst.
[0007] From the reasons regarding the installation of the fuel injection valve and the catalyst, the situation in which the fuel spray travel for mixture of fuel with exhaust gases becomes difficult to be ensured is seen not only the emission control system in which the bent portion is provided in the exhaust pipe but also in an emission control system in which no such bent portion is provided.
[0008] To cope with this, as is disclosed in JP-A-2004-44483, an emission control system is proposed which has a construction in which a fuel injection valve is disposed in a position lying far apart from an exhaust pipe portion so that fuel is injected from the position which lies far away from the flow of exhaust gases.
[0009] However, even with this proposed emission control system, from the limitations on the installation of the fuel injection valve and the catalyst, which are similar to the aforesaid one, there still remains the situation in which the fuel spray travel for mixture of fuel with exhaust gases is difficult to be ensured.
[0010] Due to this, in an emission control system, it remains difficult to mix injected fuel with exhaust gases sufficiently. This has caused a problem that uniformly atomized fuel is difficult to be supplied to a catalyst and hence the catalyst cannot fulfill its function.
SUMMARY
[0011] It is therefore an object of the invention to provide an emission control system which enables a sufficient mixture of a reducing agent with exhaust gases even though a fuel spray travel necessary for the aforesaid mixture is not ensured between an additive injection valve and a catalyst.
[0012] In order to achieve the object, according to the invention, there is provided an emission control system, comprising;
[0013] an exhaust pipe portion, adapted to guide exhaust gas from an engine to outside;
[0014] a catalyst accommodated in the exhaust pipe portion;
[0015] an additive injection valve, provided at the exhaust pipe portion located at upstream side of the catalyst, and configured to inject additives to be supplied to the catalyst toward a flow of the exhaust gas in the exhaust pipe portion, wherein
[0016] the exhaust pipe portion has a flow path section located at upstream side of the catalyst, which intersects an injection flow of the additives injected by the additive injection valve, and
[0017] the flow path section is made to have substantially the same shape as an injection region of the injection flow which confronts the exhaust gas.
[0018] The flow path section may be an exhaust gas induction portion that is formed at the exhaust pipe portion located at upstream side of the catalyst, which intersects the injection flow of the additives injected by the additive injection valve, and that has a shape being identical with an injection region of the injection flow as viewed from a direction which intersects the flow of the exhaust gas.
[0019] The exhaust gas induction portion may have a shape that expands towards a leading end of the injection flow and that is shaped in such a manner that an upstream side of the injection flow is thin and a downstream side of the injection flow is thick.
[0020] The exhaust pipe portion located at upstream side of the catalyst may be formed in such a manner as to intersect the injection flow of the additives at an acute angle and to confront the catalyst. The exhaust gas induction portion may be formed from an upstream part of the exhaust pipe portion which intersects the injection flow of the additives.
[0021] The exhaust pipe portion located at upstream side of the catalyst may be formed in such a manner as to intersect the injection flow of the additives in a substantially normal direction and to confront the catalyst. The exhaust gas induction portion may be formed from an upstream part of the exhaust pipe portion which intersects the injection flow of the additives.
[0022] A release portion where a contact with the injection flow of the additives which is deflected as a result of collision with the exhaust gas is avoided, may be formed at a downstream part of the exhaust pipe portion which intersects the injection flow of the additives.
[0023] The exhaust gas induction portion may be formed in such a manner as to keep an area of a flow path from an upstream side of the exhaust pipe portion constant.
[0024] The exhaust pipe portion may be provided with: a bent portion, connected to an upstream side of the catalyst, and formed by bending the exhaust pipe portion; and a projecting portion, one end of which is opened to a wall surface of the bent portion, and which projects to an opposite side of the catalyst in a direction of a central axis of the catalyst. The additive injection valve may be provided at the other end of the projecting portion.
[0025] An additive mixing portion may be formed at the exhaust pipe portion located at upstream side of the catalyst, through which the injection flow of the additives injected by the additive injection valve passes, and have a shape being identical with a section of an injection region of the injection flow.
[0026] The additive mixing portion may be formed in such a manner as to keep an area of a flow path from an upstream side of the exhaust pipe portion constant.
[0027] An outlet of the additive mixing portion may be expanded into a bell mouth shape.
[0028] The exhaust pipe portion may be provided with: a bent portion, connected to an upstream side of the catalyst, and formed by bending the exhaust pipe portion; and a projecting portion, one end of which is opened to a wall surface of the bent portion, and which projects to an opposite side of the catalyst in a direction of a central axis of the catalyst. The additive injection valve may be provided at the other end of the projecting portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a partially sectional side view showing the construction of an emission control system according to a first embodiment of the invention.
[0030] FIG. 2 is a sectional view of an exhaust gas induction portion taken along the line A-A in FIG. 1 .
[0031] FIG. 3 is a schematic perspective view showing the exhaust gas induction portion.
[0032] FIG. 4 is a sectional side view showing the construction of an emission control system according to a second embodiment of the invention.
[0033] FIG. 5 is a sectional view taken along the line B-B in FIG. 4 .
[0034] FIG. 6 is a sectional side view showing in an enlarged fashion of the vicinity of an inlet of a catalyst of an emission control system according to a third embodiment of the invention.
[0035] FIG. 7 is a sectional view taken along the line C-C in FIG. 6 .
[0036] FIG. 8 is a side view showing an emission control system according to a fourth embodiment of the invention.
[0037] FIG. 9 is a sectional view taken along the line D-D in FIG. 8 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] Hereinafter, the invention will be described based on a first embodiment shown in FIGS. 1 to 3 .
[0039] FIG. 1 shows an exhaust system of an internal combustion engine, for example, a diesel engine. In FIG. 1 , reference numeral 1 denotes an engine main body of the diesel engine, 1 a an exhaust manifold (only part of which is shown) of the engine main body 1 of the diesel engine, and 2 a supercharger or, in this embodiment, a turbocharger connected to an outlet of the exhaust manifold 1 a.
[0040] An emission control system 3 is provided at an exhaust outlet of the turbocharger 2 . A system in which a NOx removing system 3 a for adsorbing NOx (oxides of nitrogen) contained in exhaust gases and periodically reduction removing the adsorbed NOx and a PM (particulate matter) capturing system 3 b for capturing PM are combined together is used for the emission control system 3 .
[0041] For example, used for the NOx removing system 3 a is a configuration in which a catalytic converter 6 , a catalytic converter 9 and a fuel addition valve (an additive injection valve) 23 are combined together. The catalytic converter 6 is coupled to the turbocharger 2 in such a manner as to extend downwards from the exhaust outlet of the turbocharger 2 and incorporates therein a pre-stage oxidation catalyst 5 (corresponding to the catalyst of the subject patent application). The catalytic converter 9 is coupled horizontally to the rear of the catalytic converter 6 and incorporates therein a NOx trap catalyst 8 . The fuel addition valve 23 supplies a catalyst reaction promoting fuel which constitutes additives to the oxidation catalyst 5 , which will be described later. In addition, a configuration is adopted for the capturing system 3 b in which a catalytic converter 12 which incorporates therein a particulate filter 11 is coupled to the catalytic converter 9 . An exhaust pipe portion 15 for inducing exhaust gases discharged from the diesel engine (the engine main body 1 ) to the outside thereof is made up of the catalytic converters 6 , 9 , 12 and connecting portions 13 which connect the catalytic converters.
[0042] In these catalytic converters, a cylindrical housing 17 of the catalytic converter 6 which accommodates therein the oxidation catalyst 5 is bent at an upper portion in such a way as is shown in FIG. 1 , so that an inlet portion 17 a is disposed horizontally for connection to the turbocharger 2 which is situated thereabove. In additions an outlet portion 17 b which communicates with the catalytic converter 9 lying therebelow is disposed in such a manner as to be oriented downwards. A bent portion 15 a of the exhaust pipe portion 15 is formed in such a manner as to be bent in a position lying directly after an exhaust side of the diesel engine by the housing 17 . A catalyst installation space is secured in a portion lying directly below the bent portion 15 a . The oxidation catalyst 5 is installed in a position lying in the vicinity of the exhaust side of the diesel engine.
[0043] The fuel addition valve 23 is made to inject a fuel required for catalyst reaction to the oxidation catalyst 5 and is provided in a position lying directly above the oxidation catalyst 5 , for example, on the bent portion 15 a or on an outer circumferential wall portion lying downstream of the bent portion 15 a to fulfill the aforesaid function. The fuel addition valve 23 has a fuel injecting portion for injecting the fuel at a distal end portion thereof. The fuel addition valve 23 is installed at an end of a cylindrical portion 24 which branches off at an outer circumferential portion of the exhaust pipe portion 15 which lies downstream of the bent portion 15 a in such a manner as to extend outwards by the use of a mounting flange 24 a and a base seat 25 . The cylindrical portion 24 is a projecting portion projecting to an opposite side of the oxidation catalyst 5 in a direction of a central axis of the oxidation catalyst 5 . One end of the projecting portion is opened to the wall portion of the bent portion 15 a and the fuel addition valve 23 is provided at the other end of the projecting portion. By this configuration, the fuel injecting portion at the distal end portion of the fuel addition valve 23 is made to face a fuel injection path 24 b which is formed by an interior space of the cylindrical portion 24 . The fuel injection path 24 b extends in such a manner as to be inclined to an opposite side to a direction in which the bent portion 15 a is bent, and an outlet end thereof is oriented towards a circumferential edge of an inlet end face of the oxidation catalyst 5 rather than towards a center thereof (that is, towards the inlet portion 17 a ). By this configuration, the fuel promoting the reaction of the oxidation catalyst 5 is made to be injected from the position lying far apart from a flow of exhaust gases to the oxidation catalyst 5 from a direction which intersects the flow of exhaust gases which passes through the bent portion 15 a . Specifically, the fuel is made to be injected downwards, that is, towards a mixing chamber 19 defined in front of the inlet end face of the oxidation catalyst 5 from a direction which intersects a flowing direction a of the flow of exhaust gases at an acute angle θ 1 as is shown in FIG. 1 . By this configuration, a downstream portion of a flow of injected fuel α where a spray penetration becomes weak is made to collide with exhaust gases in a position directly upstream of the oxidation catalyst 5 . In addition, reference numeral 25 a denotes a coolant channel formed in an interior of the base seat 25 .
[0044] On the other hand, on an exhaust pipe part which lies upstream of the oxidation catalyst 5 , an exhaust gas induction portion 28 is provided in a position where the exhaust pipe part intersects the flow of injected fuel α injected from the fuel addition valve 23 , that is, at an exhaust pipe part S which constitutes an area extending, for example, from the bent portion 15 a to the mixing chamber 19 . As is shown in a sectional view shown in FIG. 2 and a perspective view shown in FIG. 3 , the exhaust gas induction portion 28 is formed in such a manner that a sectional shape of a flow path of the exhaust pipe part S which intersects the flow of injected fuel α equates to a side view of an injection region of the flow of injected fuel α as viewed from a transverse direction in which the flow of injected fuel α intersects exhaust gases. Specifically, the exhaust gas induction portion 28 is formed in such a manner that the sectional shape of the flow path of the exhaust pipe part S is formed into a fan-like shape which is substantially the same shape as a shape of a downstream side of the flow of injected fuel α as projected from the transverse direction. By being formed in the way described above to thereby have the same shape as that of the flow of injected fuel α which expands towards the leading end thereof, the exhaust gas induction portion 28 is made to have a flow path whose sectional shape is such that a portion corresponding to an upstream side of the flow of injected fuel α becomes thin, whereas an opposite portion corresponding to the downstream portion of the flow of injected fuel α becomes thick. In FIG. 2 , reference numeral 28 a denotes one of the portions where the flow path section becomes thin, and 28 b denotes the other portion where the flow path section becomes thick. A flow of exhaust gases is made to be distributed uniformly over the flow of injected additives in the exhaust gas induction portion by the exhaust gas induction portion 28 being configured as has been described above, whereby an opportunity is given where the flow of injected additives is allowed to contact exhaust gases sufficiently.
[0045] A flow path area of the portion of the exhaust pipe portion 15 which extends from the inlet portion 17 a which constitutes an upstream end of the exhaust pipe portion 15 to the exhaust gas induction portion 28 is held constant to a predetermined flow path area. Of course, the sectional shape of the flow path is constructed in such a manner as to change gradually so as to follow the shape of the flow of injected additives α in the exhaust gas induction portion 28 , whereby the generation of an unnecessary passage resistance is prevented.
[0046] In addition, a portion of the exhaust pipe portion 15 which lies downstream of the exhaust gas induction portion 28 is formed in such a manner as to be expanded in a radial direction. The fuel and exhaust gases which have collided with each other completely are supplied to the inlet end face of the oxidation catalyst 5 while being expanded in the radial direction by an expanded portion 29 which results from the radial expansion of the portion of the exhaust pipe portion 15 . It is effective to form the expanded portion 29 into a flared shape (a bell mouth shape) as well as a conical shape in supplying the mixture of fuel and exhaust gases to the oxidation catalyst 5 under uniform distribution.
[0047] In addition, the fuel injected from the fuel addition valve 23 is used to generate a reducing agent as a result of reaction with the oxidation catalyst 5 , so as to reduce to remove NOx and SOx which are adsorbed on to the NOx trap catalyst 8 by the use of the reducing agent so generated or to obtain heat as a result of reaction with the oxidation catalyst 5 , so as to burn to remove PM captured by the particulate filter 11 . Because of this, the fuel addition valve 23 is controlled by a control unit for controlling the diesel engine, for example, an ECU (not shown) to inject the fuel when a catalytic reaction is required during operation of the diesel engine for reduction removal of NOx and SOx and burning removal of PM.
[0048] Next, the function of the emission control system 3 configured as has been described above will be described.
[0049] Exhaust gases discharged from the diesel engine during operation thereof are, as is shown in FIG. 1 , expelled to the outside air through the exhaust manifold 1 a , the turbocharger 2 , the bent portion 15 a , the exhaust gas induction portion 28 , the oxidation catalyst 5 , the NOx trap catalyst 8 and the particulate filter 11 .
[0050] NOx and SOx which are contained in exhaust gases are adsorbed on to the NOx trap catalyst 8 , and PM is similarly captured by the particulate filter 11 .
[0051] Assuming that the fuel addition valve 23 is activated as time has arrived to remove the adsorbed NOx and SOx and captured PM.
[0052] Then, the fuel for removing NOx, SOx and PM is injected from the fuel injecting portion of the fuel addition valve 23 from the acute angle direction through the fuel injection path 24 b to the flow of exhaust gases which is flowing in the exhaust pipe part S. By this action, the flow of injected fuel α and the flow of exhaust gases are made to collide with each other.
[0053] As this occurs, since the exhaust gas induction portion 28 , which has the flow path whose sectional shape is substantially the same as that of the injection region of the flow of injected fuel α as viewed from the transverse direction, is formed in the exhaust pipe part S which intersects the flow of injected fuel α at the portion directly upstream of the downstream portion of the flow of injected fuel α where the spray penetration becomes weak, the exhaust gases which have passed through the exhaust gas induction portion 28 pass over the flow of injected fuel α while being distributed uniformly thereover.
[0054] By this action, there is provided an opportunity where the exhaust gases in the flow of exhaust gases and the fuel in the flow of injected fuel α are allowed to contact each other sufficiently, whereby the exhaust gases and the fuel contact each other uniformly for sufficient mixture of the exhaust gases with the furl.
[0055] As this occurs, since the flow velocities of the fuel and the exhaust gases are such that fuel in the upstream part of the flow of injected fuel α which is near from the fuel addition valve 23 and in which the spray penetration is strong collides with exhaust gases of a high flow velocity whose flow velocity has been increased at the portion 28 a where the section of the flow path is narrow, while fuel in the downstream part of the flow of injected fuel α which is far away from the fuel addition valve 23 and in which the spray penetration is weak collides with exhaust gases of a low flow velocity whose flow velocity is reduced at the portion 28 b where the section of the flow path is wide, a further uniform mixture of additives and exhaust gases can be obtained. The fuel and exhaust gases which are mixed uniformly then flow downwards towards the oxidation catalyst 5 while expanding in the radial direction due to the expanded portion 29 .
[0056] Here, since the flow of exhaust gases and the flow of injected fuel α intersect each other at the acute angle to thereby suppress the deflection of the flow of injected fuel α that would otherwise be produced by the flow of exhaust gases, the fuel and exhaust gases which have been mixed with each other in the way described above are supplied to a predetermined position of the oxidation catalyst 5 , for example, to a substantially central portion of the inlet end face thereof.
[0057] Consequently, even though the necessary distance or fuel spray travel is ensured between the fuel addition valve 23 and the oxidation catalyst 5 , the fuel which is uniformly mixed with the exhaust gases can be supplied to the catalyst due to the formation of the exhaust gas induction portion 28 .
[0058] Therefore, the function of the oxidation catalyst 5 can be made to be exhibited sufficiently by the use of the exhaust gas induction portion 28 . Of course, when the expanded portion 29 is used in parallel, the fuel can be supplied to the oxidation catalyst 5 while being distributed more uniformly. On top of this, since the exhaust gas induction portion 28 is formed in such a manner that the flow path area is held constant to the predetermined flow path area from the upstream of the exhaust pipe portion 15 , there is caused no increase in flow path resistance in the exhaust pipe portion 15 , whereby a reduction in engine output can be suppressed.
[0059] In particular, in the event that the exhaust gas induction portion 28 is adopted in the fuel injection construction in which the flow of exhaust gases is made to intersect the flow of injected fuel α at the acute angle, the exhaust gases and the fuel can be mixed together sufficiently while enjoying the benefit of the method in which the fuel is injected to the predetermined position while suppressing the deflection of the flow of injected fuel α.
[0060] FIGS. 4 and 5 show a second embodiment of the invention. In FIGS. 4 and 5 , like reference numerals are imparted to like portions to those of the first embodiment, and the description thereof will be omitted.
[0061] In the second embodiment, the invention is applied to an emission control system in which a flow of exhaust gases does not intersect a flow of injected fuel α at an acute angle as done in the first embodiment but intersects the flow of injected fuel α at substantially right angles.
[0062] Specifically, in the emission control system of this embodiment, as with the first embodiment, an injecting direction of a fuel addition valve 23 is determined to lie in a position which is offset from an oxidation catalyst 5 . A path is formed in an exhaust pipe part lying upstream of the oxidation catalyst 5 in such a manner as to intersect a flow of injected fuel α injected from the fuel addition valve 23 in a substantially right angle direction so as to be directed towards the oxidation catalyst 5 . By this configuration, on the contrary to the first embodiment, a construction is realized in which the flow of injected fuel α is pushed by the flow of exhaust gases, so as to deflect the flow of injected fuel α from the initial offset position to a desired position, whereby the fuel is injected to a predetermined position. In addition, as with the first embodiment, an exhaust gas induction portion 28 whose flow path section at the exhaust pipe part, which is something like one shown in a sectional view of FIG. 5 , is made to have substantially the same shape as a side view of an injection region of the flow of injected fuel α is provided directly upstream of an exhaust pipe part S of the exhaust pipe part lying upstream of the oxidation catalyst 5 which intersects the flow of injected fuel α injected from the fuel addition valve 23 .
[0063] By this configuration, even with the emission control system in which the flow of injected fuel α is deflected by the flow of exhaust gases, which is opposite to or differs from the configuration of the first embodiment, so that the fuel is injected to the predetermined position, by enjoying the benefit of the method adopted therein, the exhaust gases can be mixed with the fuel sufficiently by the use of the exhaust gas induction portion 28 .
[0064] In particular, in the second embodiment, for example, a curved recessed portion 30 is formed as a release portion on a wall surface of a downstream side exhaust pipe part T which intersects the flow of injected fuel α in such a manner that nothing in the exhaust pipe portion 15 is affected by the flow of injected fuel α when it is deflected. By this recessed portion 30 , the contact of the flow of injected fuel α which is deflected with the wall portion of the exhaust pipe part T can be avoided, whereby a good mixture of the exhaust gases with the fuel can be promised. Moreover, since a wall portion of the recessed portion 30 causes exhaust gases which have come into contact with the recessed portion 30 to bounce back towards the flow of injected fuel α as is indicated by arrows b so as to cause the exhaust gases to collide with the fuel in the flow of injected fuel α, it can be expected that the mixture of the fuel with the exhaust gases is promoted further.
[0065] In addition, FIGS. 6 and 7 show a third embodiment of the invention. In FIGS. 6 and 7 , like reference numerals are imparted to like portions to those of the first embodiment, and the description thereof will be omitted.
[0066] As is shown in an enlarged fashion in FIG. 6 , a fuel mixing portion (an additive mixing portion) 38 is provided in a position of an exhaust pipe part lying upstream of an oxidation catalyst 5 where a flow of injected fuel α injected from a fuel addition valve 23 passes, specifically, an exhaust pipe part U on an outlet side of a bent portion 15 a which constitutes a portion where injected fuel and exhaust gases are made to collide with each other. This fuel mixing portion 38 is configured in such a manner that only a sectional shape of a flow path at the exhaust pipe part U is, as is shown in FIG. 7 , has substantially the same shape as a sectional shape of an injection region of the flow of injected fuel α which passes through the exhaust pipe part U, that is, that the sectional shape of the flow path has the same shape of the sectional shape of the injection region. Fuel injected is made to be given by the fuel mixing portion 38 an opportunity where the fuel is uniformly distributed in an interior of the exhaust pipe part so as to be brought into sufficient contact with exhaust gases directed to the oxidation catalyst 5 . In addition, a flow path area of a portion, including the fuel mixing portion 38 , of an exhaust pipe portion 15 extending up to an inlet portion 17 a which constitutes an upper end of the exhaust pipe portion 15 is held constant to a predetermined flow path area from upstream, so that an unnecessary passage resistance is not generated.
[0067] As is shown in FIG. 7 , a wall surface of an end of a housing 17 which continuously follows an outlet of the fuel mixing portion 38 is formed into a bell mouth shape which expands in a radial direction. Fuel injected from the fuel mixing portion 38 is made to be supplied to an inlet end face of the oxidation catalyst 5 while being allowed to expand in the radial direction by a bell mouth portion 39 formed at the outlet of the fuel mixing portion 38 .
[0068] An exhaust pipe part lying in a position where it collides with a flow of injected fuel α and exhaust gases is formed into the fuel mixing portion 38 which has the flow path section which is substantially identical in shape to the section of the injection region of the flow of injected fuel α joins the exhaust gases thereat. Because of this, when the flow of injected fuel α passes through the fuel mixing portion 38 , the flow of injected fuel α passes therethrough while being distributed uniformly thereover.
[0069] By this configuration, since an opportunity is given where exhaust gases in the flow of exhaust gases and fuel in the flow of injected fuel α are allowed to contact with each other sufficiently, the exhaust gases and the fuel are allowed to contact uniformly, and a sufficient mixture of the exhaust gases with the fuel occurs.
[0070] The fuel and exhaust gases which have emerged from the fuel mixing portion 38 are atomized while being allowed to expand in the radial direction by the bell mouth portion 39 , so as to be supplied to the inlet end face of the oxidation catalyst 5 while the fuel is being distributed uniformly.
[0071] Consequently, by the formation of the fuel mixing portion 38 , even though a required distance or fuel spray travel for mixture with exhaust gases is not ensured between the fuel addition valve 23 and the oxidation catalyst 5 , uniformly atomized fuel can be supplied to the catalyst. Needless to say, of course, in the event that this configuration is adopted in parallel with the construction in which fuel is injected from a position which lies far away from the flow of exhaust gases, a good mixture of exhaust gases with fuel can be achieved.
[0072] Consequently, the function of the oxidation catalyst 5 can be exhibited sufficiently. In particular, since exhaust gases from a turbocharger 2 are introduced into the exhaust pipe portion 15 while being swirled, a better mixture of exhaust gases with fuel can be expected due to the swirling flow of exhaust gases produced then.
[0073] Moreover, since the flow path area of the exhaust pipe part including the fuel mixing portion 38 is configured in such as to be held constant to the predetermined flow path area from the upstream portion of the exhaust pipe portion 15 , the flow path resistance in the exhaust pipe portion 15 is increased in no case, whereby a reduction in engine output can be suppressed.
[0074] On top of this, since the exhaust gases and fuel which have flowed out from the fuel mixing portion 38 are directed uniformly to the oxidation catalyst 5 (the catalyst) while being allowed to expand in the radial direction of the housing 17 due to the formation of the bell mouth portion 39 at the outlet of the fuel mixing portion 38 , the fuel can be supplied to the oxidation catalyst 5 while being distributed uniformly.
[0075] FIGS. 8 and 9 show a fourth embodiment of the invention. In FIGS. 8 and 9 , like reference numerals are imparted to like portions to those of the first embodiment, and the description thereof will be omitted here.
[0076] In this embodiment, the invention is applied to an emission control system 3 in which a fuel addition valve 23 and an oxidation 5 are installed in an exhaust pipe portion 15 without forming a bent portion 15 a.
[0077] Specifically, in the emission control system 3 of this embodiment, a straight-line exhaust pipe portion 15 is used, and an oxidation catalyst 5 is provided in the exhaust pipe portion 15 . In addition, a fuel addition valve 23 is provided directly upstream of the oxidation catalyst 5 . Additionally, a sectional shape of a flow path of a straight-line exhaust pipe part U of the exhaust pipe portion 15 where a flow of injected fuel α passes is made to equate to a sectional shape of an injection region of the flow of injected fuel α which passes through the exhaust pipe portion 15 t whereby a fuel mixing portion 31 is provided. FIG. 9 shows the sections of the fuel mixing portion 38 and the flow of injected fuel α.
[0078] Even with the emission control system 3 configured as has been described above, in the event that the fuel mixing portion 38 is formed, as with the first embodiment, even though a required distance of fuel spray travel for mixture is not ensured between the fuel addition valve 23 and the oxidation catalyst 5 , uniformly distributed atomized fuel can be supplied to the oxidation catalyst 5 (the catalyst).
[0079] Note that the invention is not limited to the embodiments that have been described heretofore, and hence, the invention may be modified variously without departing from the spirit and scope thereof. For example, in the embodiments, while the exhaust gases are described as being made to intersect the flow of injected fuel or additives at the acute angle or at right angles, the invention is not limited thereto. In addition, in the embodiments that have been described heretofore, while the invention is described as being applied to the emission control system in which the oxidation catalyst is used as a catalyst lying directly downstream of the bent portion and the NOx trap catalyst and the particulate filter are provided downstream of the oxidation catalyst, the invention is not limited thereto. Thus, the invention may be applied to emission control systems which adopt other exhaust gas purifying approaches. For example, the invention may be applied to an emission control system in which a NOx trap catalyst is used as a catalyst to be installed directly downstream of a bent portion, a particulate filter is provided downstream of the NOx trap catalyst, and an addition valve is provided upstream of the NOx trap catalyst, an emission control system in which a NOx trap catalyst is used as a catalyst to be installed directly downstream of a bent portion, a NOx trap catalyst, an oxidation catalyst and a particulate filter are provided downstream of the NOx trap catalyst, and an addition valve is provided upstream of the NOx trap catalyst, or an emission control system in which an addition valve is provided upstream of a selective reduction type catalyst and a particulate filter.
[0080] Furthermore, in the embodiments, while the fuel is described as being used as the additives, any substances may be adopted, provided that they can be supplied to catalysts. For example, as a reducing agent, substances may be used which include gas oil, gasoline, ethanol, dimethyl ether, natural gas, propane gas, urea, ammonia, hydrogen, carbon monoxide and the like. In addition, any substances other than reducing agents may be used, and these substances include, for example, air, nitrogen or carbon dioxide used to cool the catalyst, or air or ceria which promotes the burning removal of soot captured on to the particulate filter.
[0081] In addition, in the embodiments that have been described above, while the injecting configuration of the fuel addition valve 23 is described as being formed into a conical shape, a fuel addition valve having an injecting configuration which expands in a flat fan-shaped fashion or a fuel addition valve in which additives is injected from a plurality of injection holes may be adopted. In the case of a plurality of injection holes being provided, an outline of a plurality of flows of injected fuel constitutes an injection region.
[0082] According to an aspect of the invention, since the flow of exhaust gases is distributed uniformly over the flow of injected additives by the exhaust gas induction portion, the opportunity can be given where exhaust gases in the flow of exhaust gases and additives in the flow of injected additives are allowed to contact with each other sufficiently.
[0083] Consequently, the exhaust gases can be mixed with the additives sufficiently, and even though a required distance or fuel or additive spray travel for mixture is not ensured between the additive injection valve and the catalyst, the additives which is mixed with the exhaust gases uniformly can be supplied to the catalyst. As a result, the function of the catalyst can be exhibited sufficiently.
[0084] According to an aspect of the invention, the flow velocities of the additives and the exhaust gases after they have collided with each other are such that additives in the upstream part of the flow of injected additives in which the spray penetration is strong collides with exhaust gases of a high flow velocity whose flow velocity has been increased at the portion where the section of the flow path is narrow, while additives in the downstream part of the flow of injected additives in which the spray penetration is weak collides with exhaust gases of a low flow velocity whose flow velocity is reduced at the portion where the section of the flow path is wide, whereby a uniform mixture of additives and exhaust gases can be promoted, and the additives and exhaust gases which are mixed uniformly can be supplied to the oxidation catalyst 5 .
[0085] According to an aspect of the invention, furthermore, by enjoying the benefit of the method in which the additives are injected to the predetermined position by suppressing the deflection of the flow of injected additives, the exhaust gases and the additives can be mixed with each other sufficiently.
[0086] According to an aspect of the invention, furthermore, by enjoying the benefit of the method in which the additives are injected to the predetermined position by deflecting the flow of injected additives by the flow of exhaust gases, which is opposite to or different from the method described above, the exhaust gases and the additives can be mixed with each other sufficiently.
[0087] According to an aspect of the invention, even though the flow of injected additives is deflected by the flow of exhaust gases, the additives in the flow of injected additives which is so deflected are prevented from being brought into contact with the wall surface of the exhaust pipe part by the release portion, a good mixture of the additives with the exhaust gases can be promised.
[0088] According to an aspect of the invention, since the flow path area of the exhaust pipe portion is held constant from the upstream portion to the exhaust gas induction portion, the flow path resistance is increased in no case, whereby a reduction in engine output occurs in no case.
[0089] According to an aspect of the invention, the opportunity can be given by the additive mixing portion where the exhaust gases in the flow of exhaust gases and the additives in the flow of injected additives are allowed to contact with each other sufficiently upstream of the catalyst, whereby the exhaust gases and the additives can be mixed together to a sufficient level.
[0090] Consequently, even though a required distance or additive spray travel for mixture is not ensured between the additive injection valve and the catalyst, the uniformly distributed atomized additives can be supplied to the catalyst, whereby the function of the catalyst can be exhibited sufficiently.
[0091] According to an aspect of the invention, since the flow path area of the exhaust pipe portion is held constant from the upstream portion to the additive mixing portion, the flow path resistance is increased in no case, whereby a reduction in engine output occurs in no case.
[0092] According to an aspect of the invention, furthermore, in addition to the advantages that have been raised above, since the exhaust gases and the additives which have flowed out from the additive mixing portion are directed uniformly towards the catalyst while being allowed to expand in the radial direction by the bell mouth-shaped outlet of the additive mixing portion, the additives can be supplied to the catalyst while being distributed uniformly.
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An emission control system, includes: an exhaust pipe portion, adapted to guide exhaust gas from an engine to outside; a catalyst, accommodated in the exhaust pipe portion; an additive injection valve, provided at the exhaust pipe portion located at upstream side of the catalyst, and configured to inject additives to be supplied to the catalyst toward a flow of the exhaust gas in the exhaust pipe portion. The exhaust pipe portion has a flow path section located at upstream side of the catalyst, which intersects an injection flow of the additives injected by the additive injection valve, and the flow path section is made to have substantially the same shape as an injection region of the injection flow which confronts the exhaust gas.
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This application is a continuation-in-part of application Ser. No. 07/818,117, filed Jan. 8, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process in which a solid mineral hydrocarbonaceous material is treated by a chemical process to improve its value as a fuel and to the product resulting from such a process. 2. Description of Related Art
It is important to control the bulk density of coal used as feed in two important industrial applications: the manufacture of coke used in steel production, and as power plant and boiler fuel.
Coal is ground to achieve a dense packing. The coal is washed with water to remove excess sulfur and stored in exterior storage piles. Removal of sulfur is essential to preventing air pollution associated with consumption of high sulfur coal. Such coal commonly has a moisture content between 2 and 15% by weight. This addition of water reduces the packing density of the coal. Thus, the bulk density of wet coal is considerably less than that of dry coal ground to the same specification.
Coking is the destructive distillation of coal in the absence of air. This process is effected in large coke ovens or retorts commonly of the slot oven type. In these ovens, finely divided coal is poured through the top of the ovens, sealed, and heated until the distillates are driven off.
Power plants also use ground coal which has been washed with water to remove sulfur which contributes to air pollution. It is essential to maintain the bulk density of boiler feed coal in power plants within a narrow range independent of the moisture content. This minimizes the adjustment of firing controls and maintains peak boiler efficiency.
In order to improve the bulk density of wet coal, some coke oven installations use a preheating process. The wet coal is heated until the moisture is driven off and this dried coal is then placed in the oven where it forms a highly dense mass. This process is expensive in capital and operating costs.
A more common method of increasing the bulk density of wet coal is to add a bulk density control medium to the wet coal. Commonly used media include recycled oil, #2 fuel oil, fuel oil and a surfactant, or a surfactant alone.
U.S. Pat. No. 2,378,420 issued Jun. 19, 1945 to F. A. Lohr et al, "Regulating the Bulk Density of Coke Over Charges", teaches that moist coal containing more than 1% weight moisture can be coated with small quantities of an oil to increase the wet bulk density of the coal. Lohr et al also teach that the wet bulk density of coal can be adjusted by spraying the surfaces of the coal with a free flowing liquid containing a wetting agent.
U.S. Pat. No. 3,563,714, issued Feb. 16, 1971 to Arthur G. Brewer, teaches a composition of matter used for controlling the bulk density of coal with comprises a combination of petroleum oil, water and a surfactant or mixture of surfactants.
U.S. Pat. No. 4,214,875, issued Jul. 29, 1980 to Kromrey, teaches treatment of exposed coal piles with polymers including polyethylene in combination with wax tars or pitch and solid fillers. The coating protects coal piles from the physical loss of coal.
U.S. Pat. No. 4,304,636, issued Dec. 8, 1981 to Kestner et al, teaches a method for controlling the bulk density and throughput characteristics of coking coal by treating the coal with a surfactant and a combination of fuel oil and alcohol or a solid lubricant and water.
U.S. Pat. No. 4,331,445, issued May 25, 1982 to Burns, teaches prevention of spontaneous combustion of coal by treatment with an aqueous solution of polyethylene oxide of at least 2% by weight followed by drying of the coal.
U.S. Pat. No. 4,450,046, issued May 22, 1984 to Rice et al, teaches spraying the surface of the coal with an aqueous dispersion of a surfactant to increase the wet bulk density.
There has been a long-felt and unfilled need for low cost processes for increasing and controlling the bulk density of wet coal. The present invention met this need.
SUMMARY OF THE INVENTION
It has been discovered than effective and inexpensive bulk density control of wet coal may be accomplished by mixing the coal with bulk density control media comprised of aqueous solutions of polyacrylamide, polyethylene oxide, or solutions containing both of these polymers. These polymers have high molecular weights, are water soluble, and are non-polluting.
The mechanism of action of these polymer solutions in increasing the bulk density of wet coal is unknown, but is thought to be due to the interaction of the wet coal particles with lipophilic-hydrophilic groups in polyacrylamide, and with the general interfacial characteristics of polyethylene oxide.
It is an object of this invention to provide processes which increase the bulk density of coal used in making coke.
It is another object of this invention to provide processes which allow control of the coke coal bulk density.
It is another object of this invention to provide processes which increase the weight of coal which may be processed in a coke oven in a single batch.
It is another object of this invention to provide processes which increase the thermal conductivity of the coke oven charge by increasing the coal bulk density.
It is another object of this invention to provide processes which increase the throughput and efficiency of a coke oven.
It is another object of this invention to provide processes which increase coke stability by increasing the bulk density of the coal used in making coke.
It is another object of this invention to provide processes which increase the burden of iron and limestone which may be supported in a blast furnace by providing coke of increased stability.
It is another object of this invention to provide processes for preventing damage to a coke oven from excessive wall pressures associated with coal of excessive bulk density.
It is another object of this invention to provide processes for increasing the density of power plant and boiler feed coal.
It is another object of this invention to provide processes for maintaining peak boiler efficiency in power plants through provision of coal within a narrow range of bulk densities independent of the moisture content of the coal.
It is another object of this invention to provide processes for controlling coal bulk density using extremely small amounts of very low cost water soluble polymers.
It is a final object of this invention to provide processes which raise and control the bulk density of coal in a manner which is inexpensive, effective, and environmentally benign.
These and other objects of this invention will become readily apparent from the following specification in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the effects of addition of diesel fuel on the normalized bulk density of coal containing 5%, 10%, and 15% by weight water.
FIG. 2 shows the effects of addition of 0.1% by weight polyethylene oxide aqueous solution on the normalized bulk density of coal containing 5%, 10%, and 15% by weight water.
FIG. 3 shows the effects of addition of 0.2% by weight polyethylene oxide aqueous solution on the normalized bulk density of coal containing 5%, 10%, and 15% by weight water.
FIG. 4 shows the effects of addition of 0.1% by weight polyacrylamide aqueous solution on the normalized bulk density of coal containing 5%, 10%, and 15% by weight water.
FIG. 5 shows the effects of addition of 0.2% by weight polyacrylamide aqueous solution on the normalized bulk density of coal containing 5%, 10%, and 15% by weight water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The term "wet coal" in this application means coking coal or power plant and boiler feed coal which has been ground or pulverized and treated with water. The presence of water on the surface of the fine coal particles reduces the bulk density of the coal. Such wet coal has a water content between 2% and 15% by weight.
The bulk density of wet coal may be increased to desired levels in the range of 45 to 50 lbs./cu.ft. by treating the coal with aqueous solutions of polyacrylamide or of polyethylene oxide or of mixtures of these two polymers.
Acrylamide readily undergoes vinyl polymerization to give a large variety of homopolymers and copolymers of controllable molecular weights and performance characteristics. Polyacrylamide is a white solid soluble in water, and generally insoluble in organic solvents. Polyacrylamide is a linear polymer having a head-to-tail structure. A significant amount of branching results when acrylamide is polymerized at temperatures over 50° C.
Polyacrylamides are readily water soluble over a broad range of conditions. The polymers of acrylamide are unique in their strong hydrogen bonding, linearity, and very high molecular weights. Polymers which are predominantly acrylamide are generally classed as polyacrylamides. These polymers are usually sold as water solutions or powders. Polyacrylamides have found utility as dry strength resins, as flocculents in water clarification and mining application, as flooding aids in secondary oil recovery, and as binders for foundry sand.
The weight average molecular weights of polyacrylamide useful in this invention range from about 1.5×10 3 to 15×10 6 preferably from about 2×10 4 to about 7×10 6 . Aqueous solutions are useful in the range of about 0.01% to about 1.0% polyacrylamide by weight. Many factors are involved in choosing the exact aqueous concentration solution for use with any particular wet coal. Degree of wetness and particle size are factors. In general, lower concentrations are preferable because of lower viscosity and lower cost. A preferred concentration of polyacrylamide in aqueous solution is about 0.1% to about 0.2% by weight.
The aqueous polyacrylamide solution is added to wet coal at an amount equivalent to about 0.5 gram to about 120 grams polyacrylamide per metric ton of wet coal. It is desirable to use polyacrylamide solutions in the lower range to reduce costs. A preferred range of polyacrylamide is from about 4 grams to about 24 grams per metric ton of wet coal.
Polyethylene oxide resins are dry, free-flowing powders completely soluble in water at temperatures up to 98° C. They are non-ionic polymers. The major commercial uses for polyethylene oxide include adhesives, water soluble films, rheology control agents and thickeners, flocculents, dispersants, detergents, control of sewer discharges, and metal-forming lubricants.
The weight average molecular weights of polyethylene oxide useful in this invention range from about 1×10 5 to 8×10 6 , preferably from about 1×10 5 to about 6×10 5 . Aqueous solutions are useful in the range of about 0.01% to about 1.0% polyethylene oxide by weight. Many factors are involved in choosing the exact aqueous concentration solution for use with any particular wet coal. Degree of wetness and particle size are factors. In general, lower concentrations are preferable because of lower viscosity and lower cost. A preferred concentration of polyethylene oxide in aqueous solution is about 0.1% to about 0.2% by weight.
The aqueous polyethylene oxide solution is added to wet coal at an amount equivalent to about 0.5 gram to about 120 grams polyethylene oxide per metric ton of wet coal. It is desirable to use polyethylene oxide solution in the lower range to reduce costs. A preferred range of polyethylene oxide is from about 4 grams to about 24 grams per metric ton of wet coal.
Aqueous solutions containing both polyacrylamide and polyethylene oxide also are useful in this invention. The ratio by weight of polyacrylamide:polyethylene oxide found to be useful ranges from about 10:1 to about 1:10. The total concentration of both polymers in aqueous solution found to be useful ranged from about 0.01% to about 1.0% by weight. The proportions and concentrations of polymers used may be varied depending on the characteristics of the wet coal and the relative costs of the polymers.
The aqueous polymers may be sprayed, poured, or otherwise applied to the wet coal at any stage before the wet coal is placed in the coking oven or fed into the power plant boiler.
EXAMPLES
Examples 1-15 show the effect of fuel oil, aqueous solutions of polyacrylamide (a commercial product available from American Cyanamid Co. under the tradename Magnifloc) at 0.1 and 0.2% by weight, and aqueous solutions of polyethylene oxide (a commercial product available from Union Carbide Corp. under the tradename Polyox WSR 301) at 0.1 and 0.2% by weight as bulk density control media on the bulk density of wet coal containing various amounts of water. The following procedures were used in Examples 1-15.
The tests of the bulk density control methodology were performed using small quantities of coal in a laboratory setting. The coal was obtained from untreated coal storage piles from a local coke plant. The coal was first air dried by periodically turning the coal mass in the presence of forced air current for a minimum of 24 hours. The second step of the process was to pass the coal sample through a 1/4 inch screen.
One thousand five hundred grams of the sieved coal was weighed and mixed for 3 minutes in the dry state in a Hobart, Model N-50 mixer. Water was then added to bring the moisture content of the coal to the desired level, and the mixing was continued for an additional 3 minutes.
Previously prepared samples of bulk density control medium (fuel or polymer solutions) were then added to the coal sample in the proper proportions, and the mixing was continued for an additional 3 minutes. The mixing bowl containing the treated coal was then placed on a Soiltest, Model CT-164 vibrating table and a standard container of approximately 500 cc was placed in the mixing bowl. This container was filled with the treated coal sample to overflowing.
The vibrating table was then turned on at a standard setting for 40 seconds. After this period of vibration, the excess coal was removed from the top of the sample container using a straightedge. The sample container containing the vibrated and compacted coal was then weighed.
The volume and weight of the coal sample were obtained by subtracting the weight of the sample container from the weight of the container filled with compacted coal, and measuring the volume of the sample container using standard methods.
The dry bulk density was obtained using the above methodology but omitting the steps of water addition, mixing after the water had been added, and the addition of the bulk control density medium.
Bulk density control media were added to the wet coal at the level of 0, 4, 8, or 12 liters media per metric ton of wet coal.
The bulk density of the coal was computed by the following formula: ##EQU1##
The normalized bulk density was computed within each Example by dividing the bulk density of the experimental sample by the bulk density of the dry sample. FIGS. 1-5 depict the normalized bulk densities on the vertical axis and the sample status on the horizontal axis. The DRY status indicates dry coal to which neither moisture nor bulk density media were added. The WET status indicates coal to which the indicated moisture was added but to which no bulk density medium was added "X", "2X" and "3X" indicate 4, 8 and 12 liters bulk density control media per metric ton of wet coal, respectively. The % by weight added moisture was indicated as follows: 5%, open squares; 10%, closed diamonds; and 15% closed squares The Example number is indicated adjacent the appropriate lines in FIGS. 1-5.
Examples 1-3
Examples 1-3 show the effect of diesel fuel as bulk density control medium on the bulk density of wet coal containing 5%, 10%, or 15% by weight water. The results of Examples 1-3 are listed in Table 1 and shown in FIG. 1. The results of Example 1 indicate that the density of wet coal containing 5% moisture was increased by fuel oil at all concentrations tested. Example 2 shows the density of wet coal containing 10% moisture was lowered by fuel oil at 4 l/M. ton wet coal but raised by fuel oil at 8 and 12 l/M. ton wet coal. Example 3 shows the density of wet coal containing 15% moisture was lowered by fuel oil at 4 and 8 l/M. ton wet coal but raised by fuel oil at 12 l/M. ton wet coal.
Examples 4-6
Examples 4-6 show the effect of 0.1% by weight aqueous solution of polyethylene oxide as bulk density control medium on the bulk density of wet coal containing 5%, 10%, or 15% by weight water. The results of Examples 4-6 are listed in Table 2 and shown in FIG. 2. The results of Example 4 indicate that the density of wet coal containing 5% moisture was decreased by the medium at 4 and 8 l/M. ton wet coal and was restored to the initial value at 12 l/M. ton wet coal. Example 5 indicates that the density of wet coal containing 10% moisture was lowered by the medium at 4 l/M. ton wet coal but raised by the medium at 8 and 12 l/M. ton wet coal. Example 6 indicates that the density of wet coal containing 5% moisture was lowered by the medium at 4 and 8 l/M. ton wet coal but raised by the medium at 12 l/M. ton wet coal.
Examples 7-9
Examples 7-9 show the effect of 0.2% by weight aqueous solution of polyethylene oxide as bulk density control medium on the bulk density of wet coal containing 5%, 10%, or 15% by weight water. The results of Examples 7-9 are listed in Table 2 and shown in FIG. 3. The results of Example 7 indicate that the density of wet coal containing 5% moisture was increased by the medium at all concentrations tested. Example 8 indicates that the density of wet coal containing 10% moisture was increased by the medium at all concentrations tested. Example 9 indicates that the density of wet coal containing 15% moisture was lowered by the medium at 4 l/M. ton wet coal but restored by the medium at 8 l/M. ton wet coal, and raised by the medium at 12 l/M. ton wet coal.
Examples 10-12
Examples 10-12 show the effect of 0.1% by weight aqueous solution of polyacrylamide as bulk density control medium on the bulk density of wet coal containing 5%, 10%, or 15% by weight water. The results of Examples 10-12 are listed in Table 3 and shown in FIG. 4. The results of Example 10 indicate that the density of wet coal containing 5% moisture was unchanged by the medium at 4 l/M. ton wet coal and increased by the medium at 8 and 12 l/M. ton wet coal. Example 11 indicates that the density of wet coal containing 10% moisture was increased by the medium at all concentrations tested. Example 12 indicates that the density of wet coal containing 15% moisture was increased by the medium at all concentrations tested.
Examples 13-15
Examples 13-15 showed the effect of 0.2% by weight aqueous solution of polyacrylamide as bulk density control medium on the bulk density of wet coal containing 5%, 10%, or 15% by weight water. The results of Examples 13-15 are listed in Table 3 and shown in FIG. 5. The results of Example 13 indicate that the density of wet coal containing 5% moisture was unchanged by the medium at 4 l/M. ton wet coal and increased by the medium at 8 and 12 l/M. ton wet coal. Example 14 indicates that the density of wet coal containing 10% moisture was increased by the medium at all concentrations tested. Example 15 indicates that the density of wet coal containing 15% moisture was increased by the medium at all concentrations tested.
In both the polyethylene oxide and polyacrylamide tests the smaller the amount of moisture added, the larger the bulk density drop. In the polyethylene oxide tests, best results were obtained with both 0.1% and 0.2% by weight solutions and wet coal of 15% moisture by weight. In the polyacrylamide tests, best results were obtained with both 0.1% and 0.2% by weight aqueous solutions with wet coal of 15% by weight moisture. The lower concentration of medium is preferred because of less use of polymer. Polyacrylamide is slightly more effective than polyethylene oxide in terms of bulk density recovery.
It will be apparent to those skilled in the art that the examples and embodiments described herein are by way of illustration and not of limitation, and that other examples may be utilized without departing from the spirit and scope of the present invention, as set forth in the appended claims.
TABLE 1______________________________________Effect on coal bulk density of the addition of diesel fueladditive in the presence of various amounts of surface moisture Surface Bulk Moisture Additive Density NormalizedExample (% by Weight) (1/M. Ton) (lb/cu ft) Bulk Density______________________________________1 0 0 51.52 1.00 5 0 41.34 0.80 5 4 44.90 0.87 5 8 46.34 0.90 5 12 46.32 0.902 0 0 52.12 1.00 10 0 43.61 0.84 10 4 41.64 0.80 10 8 45.37 0.82 10 12 46.38 0.893 0 0 52.15 1.00 15 0 48.45 0.93 15 4 44.14 0.85 15 8 46.69 0.90 15 12 49.38 0.95______________________________________
TABLE 2______________________________________Effect on coal bulk density of the addition ofpolyethylene oxide solutions in the presenceof various amounts of surface moistureSurface Normal-Ex- Moisture Polymer Additive Bulk izedam- (% by Concentration (1/M. Density Bulkple weight) (% by Weight) Ton) (lb/cu ft) Density______________________________________4 0 0.1 0 51.95 1.00 5 0 42.68 0.82 5 4 42.11 0.81 5 8 42.03 0.81 5 12 42.56 0.825 0 0.1 0 51.48 1.0010 0 43.49 0.8410 4 42.95 0.8310 8 44.30 0.8610 12 44.58 0.876 0 0.1 0 52.09 1.0015 0 47.23 0.9115 4 46.18 0.8915 8 46.91 0.9015 12 48.68 0.937 0 0.2 0 50.70 1.00 5 0 42.32 0.83 5 4 42.44 0.84 5 8 42.59 0.84 5 12 42.55 0.848 0 0.2 0 51.84 1.0010 0 43.20 0.8310 4 45.29 0.8710 8 45.04 0.8710 12 44.69 0.869 0 0.2 0 50.77 1.0015 0 46.99 0.9315 4 46.15 0.9115 8 47.11 0.9315 12 49.04 0.97______________________________________
TABLE 3______________________________________Effect on coal bulk density of the addition ofpolyacrylamide solutions in the presenceof various amounts of surface moistureSurface Normal-Ex- Moisture Polymer Additive Bulk izedam- (% by Concentration (1/M. Density Bulkple weight) (% by Weight) Ton) (lb/cu ft) Density______________________________________10 0 0.1 0 51.99 1.00 5 0 41.44 0.80 5 4 41.77 0.80 5 8 42.13 0.81 5 12 43.04 0.8311 0 0.1 0 51.84 1.0010 0 42.83 0.8210 4 43.62 0.8410 8 44.66 0.8610 12 46.95 0.9112 0 0.1 0 51.61 1.0015 0 47.52 0.9215 4 49.46 0.9615 8 50.01 0.9715 12 50.58 0.9813 0 0.2 0 52.84 1.00 5 0 42.80 0.81 5 4 42.94 0.81 5 8 43.63 0.83 5 12 44.06 0.8314 0 0.2 0 51.63 1.0010 0 42.75 0.8310 4 43.98 0.8510 8 44.03 0.8510 12 45.00 0.8715 0 0.2 0 52.86 1.0015 0 46.77 0.8815 4 47.25 0.8915 8 49.62 0.9415 12 50.05 0.95______________________________________
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Methods and compositions are provided for increasing packed bulk density of coal, whose surface moisture varies from 2 to 15 weight percent, to desired levels in the range of 45 to 50 lbs./cu.ft., and for controlling and maintaining the improved bulk density. The method involves treating the coal with dilute water solutions (0.01 to 1.0 weight percent of solids) of water soluble, nontoxic polymers, belonging to the classes of polyethylene oxides and polyacrylamides, in amounts between 0.5 gram and 120 grams of polymer solids per metric ton of coal.
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